Name: 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA 888, generation III)
Brand: Volkswagen
SKU: CDG01c4526908e2
Price: 29.21 EUR
Availability: InStock

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Repair manual Jetta 2-türig Rl / Jetta 4-türig Ll 4-cylinder injection engine PDF download has the following content:

Chapter overview

Technical data
1
1 Safety information
1
1.1 Safety regulations for working on fuel supply
1
1.2 Safety measures when working on vehicles with a start/stop system
1
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on ignition system
2
2 Identification
3
2.1 Engine number/engine data
3
3 Repair instructions
5
3.1 Rules for cleanliness
5
3.2 General notes
5
3.3 General repair notes
6
3.4 Checking vacuum system
6
Removing and installing engine
8
1 Removing and installing engine
8
1.1 Removing engine
8
1.2 Separating engine and gearbox
20
1.3 Securing engine on engine and gearbox support
22
1.4 Installing engine
24
2 Assembly mountings
28
2.1 Assembly overview - assembly mountings
28
2.2 Removing and installing engine mounting
31
2.3 Removing and installing gearbox mounting
33
2.4 Removing and installing pendulum support
34
2.5 Supporting engine in installation position
35
2.6 Adjusting assembly mountings
44
2.7 Checking adjustment of assembly mountings
46
3 Engine cover panel
47
3.1 Removing and installing engine cover
47
Crankshaft group
48
1 Cylinder block (pulley end)
48
1.1 Assembly overview - cylinder block (pulley end)
48
1.2 Removing and installing poly-V belt
50
1.3 Removing and installing tensioner for poly V-belt
52
1.4 Removing and installing vibration damper
52
1.5 Removing and installing bracket for ancillaries
60
1.6 Removing and installing engine support
64
2 Cylinder block, gearbox end
66
2.1 Assembly overview - cylinder block, gearbox end
66
2.2 Assembly overview - drive plate
67
2.3 Removing and installing drive plate
68
2.4 Removing and installing flywheel
70
2.5 Removing and installing sealing flange on gearbox side
72
3 Crankshaft
81
3.1 Assembly overview - crankshaft
81
3.2 Crankshaft dimensions
83
3.3 Allocation of main bearing shells
83
3.4 Renewing needle bearing in crankshaft
85
3.5 Measuring axial clearance of crankshaft
88
3.6 Measuring radial clearance of crankshaft
89
3.7 Removing and installing sender wheel
90
4 Balancer shaft
92
4.1 Assembly overview - balance shaft
92
4.2 Removing and installing balance shaft
93
4.3 Renewing oil seal for balance shaft (inlet side)
98
5 Pistons and conrods
100
5.1 Assembly overview - pistons and conrods
100
5.2 Removing and installing pistons
102
5.3 Checking pistons and cylinder bores
103
5.4 Separating new conrod
105
5.5 Checking radial clearance of conrods
106
Cylinder head, valve gear
108
1 Cylinder head
108
1.1 Assembly overview - cylinder head
108
1.2 Assembly overview - camshaft housing
111
1.3 Removing and installing cylinder head
113
1.4 Removing and installing vacuum pump
118
1.5 Checking compression
120
2 Cover for timing chain
123
2.1 Assembly overview - cover for timing chain
123
2.2 Removing and installing timing chain cover
126
2.3 Renewing seal for vibration damper
134
3 Chain drive
138
3.1 Assembly overview - camshaft timing chains
138
3.2 Assembly overview - drive chain for balance shaft
142
3.3 Removing and installing camshaft timing chain
145
3.4 Removing and installing drive chain for balance shaft
162
3.5 Checking timing chain
162
3.6 Checking valve timing
163
4 Valve gear
167
4.1 Assembly overview - valve gear
167
4.2 Removing and installing camshaft
169
4.3 Removing and installing camshaft control valve 1 N205
186
4.4 Removing and installing valve stem seals
187
5 Inlet and exhaust valves
200
5.1 Checking valve guides
200
5.2 Checking valves
201
5.3 Valve dimensions
201
Lubrication
202
1 Sump, oil pump
202
1.1 Assembly overview - sump/oil pump
202
1.2 Engine oil:
205
1.3 Removing and installing lower part of sump
205
1.4 Removing and installing upper part of sump
208
1.5 Removing and installing oil pump
213
1.6 Removing and installing oil level and oil temperature sender G266
215
2 Engine oil cooler
217
2.1 Assembly overview - engine oil cooler
217
2.2 Removing and installing engine oil cooler
217
2.3 Removing and installing mechanical switching valve
219
3 Crankcase ventilation
220
3.1 Assembly overview - crankcase breather system
220
3.2 Removing and installing oil separator
221
4 Oil filter, oil pressure switch
222
4.1 Assembly overview - oil filter
222
4.2 Assembly overview - oil pressure switches/oil pressure control
222
4.3 Removing and installing oil pressure switch F1
223
4.4 Removing and installing oil pressure switch for reduced oil pressure F378
225
4.5 Checking oil pressure and oil pressure switch
226
4.6 Removing and installing oil pressure regulating valve N428
229
Cooling
231
1 Cooling system/coolant
231
1.1 Connection diagram - coolant hoses
231
1.2 Checking cooling system for leaks
233
1.3 Draining and adding coolant
236
2 Coolant pump, regulation of cooling system
244
2.1 Assembly overview - coolant pump, thermostat
244
2.2 Assembly overview - electric coolant pump
246
2.3 Assembly overview - coolant temperature sender
247
2.4 Removing and installing continued coolant circulation pump V51
248
2.5 Removing and installing coolant pump
251
2.6 Removing and installing toothed belt for coolant pump
252
2.7 Removing and installing thermostat housing
255
2.8 Removing and installing coolant temperature sender G62
258
2.9 Removing and installing radiator outlet coolant temperature sender G83
259
3 Coolant pipes
261
3.1 Assembly overview - coolant pipes
261
3.2 Removing and installing coolant pipes
261
3.3 Removing and installing upper coolant pipes
263
4 Radiator, radiator fan
265
4.1 Assembly overview - radiator/radiator fan
265
4.2 Assembly overview – radiator cowl and radiator fan
266
4.3 Assembly overview - radiator blind
267
4.4 Removing and installing radiator
270
4.5 Removing and installing radiator cowl
271
4.6 Removing and installing radiator fan
272
4.7 Removing and installing auxiliary radiator
272
4.8 Removing and installing radiator blind
274
4.9 Removing and installing radiator blind control motor V544
276
Turbocharging/supercharging
282
1 Turbocharger
282
1.1 Assembly overview - turbocharger
282
1.2 Removing and installing turbocharger
288
2 Charge air system
298
2.1 Assembly overview - charge air system
298
2.2 Removing and installing charge air cooler
300
2.3 Removing and installing charge pressure sender G31
302
2.4 Checking charge air system for leaks
302
Mixture preparation - injection
305
1 Injection system
305
1.1 Overview of fitting locations - injection system
305
2 Injectors
309
2.1 Assembly overview - fuel rail with injectors
309
2.2 Removing and installing fuel rail
311
2.3 Removing and installing injectors
312
2.4 Renewing seals on injectors
314
2.5 Cleaning injectors
317
3 Air filter
320
3.1 Assembly overview - air filter housing
320
3.2 Removing and installing air filter housing
322
4 Intake manifold
324
4.1 Assembly overview – intake manifold
324
4.2 Removing and installing intake manifold
326
4.3 Removing and installing throttle valve module GX3
332
4.4 Cleaning throttle valve module GX3
333
5 Senders and sensors
335
5.3 Removing and installing fuel pressure sender G247
337
5.4 Checking fuel pressure sender G247
339
5.5 Removing and installing intake manifold sender GX9
342
6 Engine control unit
343
6.1 Removing and installing engine control unit J623
343
7 High-pressure pump
347
7.1 Assembly overview - high-pressure pump
347
7.2 Removing and installing high-pressure pump
349
8 Lambda probe
353
8.1 Assembly overview - Lambda probe
353
8.2 Removing and installing Lambda probe 1 before catalytic converter GX10
353
8.3 Removing and installing Lambda probe 1 after catalytic converter GX7
355
Exhaust system
357
1 Exhaust pipes and silencers
357
1.1 Assembly overview – silencers
357
1.2 Removing and installing rear silencer
358
1.3 Aligning exhaust system free of stress
360
1.4 Checking exhaust system for leaks
361
1.5 Installation position of clamp
361
2 Emission control
364
2.1 Assembly overview – emission control
364
2.2 Removing and installing catalytic converter
364
3 Secondary air system
369
3.1 Assembly overview - secondary air system
369
3.2 Removing and installing secondary air pump motor V101
371
3.3 Removing and installing secondary air inlet valve N112
371
Ignition system
373
1 Ignition system
373
1.1 Assembly overview - ignition system
373
1.2 Test data, spark plugs
374
1.3 Removing and installing ignition coils with output stage
375
1.4 Removing and installing knock sensor 1 G61
376
1.5 Removing and installing Hall sender
378
1.6 Removing and installing engine speed sender G28
378

Manufacturer's designation	4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA 888, generation III)
Manufacturer	Volkswagen
Suitable for	Jetta 2-türig Rl (1980 - 1984) / Jetta 4-türig Ll (1980 - 1984)
Suitable car types	162, 163
Engine code	CPPA, CPKA, CPRA
Category	Reparaturanleitung

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