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4-cylinder injection engine (hybrid vehicles)

For Golf VII

Original Volkswagen repair manual


29,09 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

41.195 KB

383 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mounting, Motor cover, Cylinder block (pulley end), Camshaft, Toothed belt drive, Valve gear, Sump, oil pump, Crankcase ventilation, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Exhaust turbocharger, Injectors, Intake manifold, Lambda probe and High-voltage battery unit. Show more
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Repair manual Golf VII 4-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety precautions when working on a high-voltage system
    1
  • 1.2 Safety precautions when working in the vicinity of high-voltage components
    2
  • 1.3 Safety regulations for working on fuel supply
    2
  • 1.5 Safety precautions when working on ignition system
    3
  • 1.6 Safety precautions when working on the cooling system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 Repair notes
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 Foreign objects in engine
    6
  • 3.3 Contact corrosion
    6
  • 3.4 Pipe/wire routing and attachment
    7
  • 3.5 Fitting radiator and condensers
    7
  • 3.6 Checking vacuum system
    7
  • 4 Classification of dangers of the high-voltage system
    8
  • Removing and installing engine
    15
  • 1 Removing and installing engine
    15
  • 1.1 Removing engine
    15
  • 1.2 Separating engine and gearbox
    25
  • 1.3 Securing engine on engine and gearbox support
    27
  • 1.4 Installing engine
    29
  • 2 Assembly mounting
    34
  • 2.1 Assembly overview - assembly mountings
    34
  • 2.2 Supporting engine in installation position
    35
  • 2.3 Removing and installing motor mounting
    39
  • 2.4 Removing and installing gearbox mounting
    43
  • 2.5 Removing and installing pendulum support
    43
  • 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
    44
  • 2.7 Adjusting assembly mountings
    45
  • 3 Motor cover
    47
  • 3.1 Removing and installing engine cover
    47
  • Crankshaft group
    48
  • 1 Cylinder block (pulley end)
    48
  • 1.1 Assembly overview - sealing flange, vibration damper
    48
  • 1.2 Removing and installing engine support
    49
  • 1.3 Removing and installing vibration damper
    50
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    51
  • 1.5 Removing and installing sealing flange on pulley end
    53
  • 2 Cylinder block, gearbox end
    56
  • 2.1 Assembly overview - cylinder block, gearbox end
    56
  • 2.2 Removing and installing flywheel
    57
  • 2.3 Removing and installing sealing flange on gearbox side
    58
  • 3 Camshaft
    68
  • 3.1 Crankshaft dimensions
    68
  • 3.2 Measuring axial clearance of crankshaft
    68
  • 3.3 Renewing needle bearing in crankshaft
    69
  • 4 Pistons and conrods
    72
  • 4.1 Assembly overview - pistons and conrods
    72
  • 4.2 Removing and installing pistons
    74
  • 4.3 Removing and installing oil spray jets
    75
  • 4.4 Checking pistons and cylinder bores
    76
  • 4.5 Checking radial clearance of conrods
    77
  • Cylinder head, valve gear
    79
  • 1 Cylinder head
    79
  • 1.1 Assembly overview - cylinder head
    79
  • 1.2 Assembly overview - camshaft housing
    81
  • 1.3 Removing and installing cylinder head
    82
  • 1.4 Removing and installing camshaft housing
    86
  • 1.5 Checking compression
    95
  • 2 Toothed belt drive
    97
  • 2.1 Assembly overview - toothed belt cover
    97
  • 2.2 Assembly overview - toothed belt
    98
  • 2.3 Removing toothed belt from camshaft
    100
  • 2.4 Removing and installing toothed belt
    112
  • 3 Valve gear
    127
  • 3.1 Assembly overview - valve gear
    127
  • 3.2 Removing and installing inlet camshaft control valve 1 N205
    128
  • 3.3 Measuring axial play of camshaft
    128
  • 3.4 Removing and installing camshaft oil seal
    129
  • 3.5 Removing and installing valve stem seals
    134
  • 4 Inlet and exhaust valves
    142
  • 4.1 Checking valve guides
    142
  • 4.2 Checking valves
    142
  • 4.3 Valve dimensions
    143
  • Lubrication
    144
  • 1 Sump, oil pump
    144
  • 1.1 Assembly overview - sump/oil pump
    144
  • 1.2 Engine oil:
    148
  • 1.3 Removing and installing lower part of sump
    149
  • 1.4 Removing and installing upper part of sump
    153
  • 1.5 Removing and installing oil pump
    156
  • 1.6 Removing and installing oil level and oil temperature sender G266
    157
  • 2 Engine oil cooler
    159
  • 2.1 Assembly overview - engine oil cooler
    159
  • 2.2 Removing and installing engine oil cooler
    159
  • 3 Crankcase ventilation
    161
  • 3.1 Assembly overview - crankcase breather system
    161
  • 3.2 Removing and installing oil separator
    162
  • 4 Oil filter, oil pressure switch
    164
  • 4.1 Assembly overview - oil filter/oil pressure switch
    164
  • 4.2 Removing and installing oil pressure switch F22
    165
  • 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
    166
  • 4.4 Removing and installing oil pressure regulating valve N428
    168
  • 4.5 Checking oil pressure
    169
  • Cooling
    171
  • 1 Cooling system/coolant
    171
  • 1.1 Connection diagram - coolant hoses
    171
  • 1.2 Coolant hose schematic diagram, high-voltage system
    173
  • 1.3 Checking cooling system for leaks
    174
  • 1.4 Checking cooling system of high-voltage system for leaks
    176
  • 1.5 Draining and adding coolant
    185
  • 1.6 Draining and adding coolant, high-voltage system
    191
  • 1.7 Checking filling quality of cooling system, high-voltage system
    198
  • 2 Coolant pump, regulation of cooling system
    201
  • 2.1 Assembly overview - coolant pump, thermostat
    201
  • 2.2 Assembly overview - electric coolant pump
    204
  • 2.3 Assembly overview - coolant temperature sender
    205
  • 2.4 Removing and installing electric coolant pump
    205
  • 2.5 Removing and installing coolant pump
    211
  • 2.6 Removing and installing thermostat
    214
  • 2.7 Removing and installing toothed belt pulley for coolant pump
    218
  • 2.8 Removing and installing coolant temperature sender G62
    219
  • 2.9 Removing and installing radiator outlet coolant temperature sender G83
    220
  • 2.10 Removing and installing coolant valves
    221
  • 2.11 Removing and installing coolant temperature sender for heater G241
    227
  • 2.12 Removing and installing engine temperature sender 2 G652
    228
  • 2.13 Overview of fitting locations - electric coolant pumps
    229
  • 2.14 Assembly overview - coolant valves
    231
  • 3 Coolant pipes
    232
  • 3.1 Assembly overview - coolant pipes
    232
  • 3.2 Removing and installing coolant pipes
    232
  • 4 Radiator, radiator fan
    238
  • 4.1 Assembly overview - radiator, radiator fan
    238
  • 4.2 Assembly overview - radiator cowl and radiator fan
    240
  • 4.3 Removing and installing radiator
    240
  • 4.4 Removing and installing radiator cowling
    244
  • 4.5 Removing and installing radiator fan V7
    245
  • Turbocharging/supercharging
    247
  • 1 Exhaust turbocharger
    247
  • 1.1 Assembly overview - turbocharger
    247
  • 1.2 Removing and installing turbocharger
    248
  • 1.3 Removing and installing charge pressure positioner V465
    255
  • 2 Charge air system
    256
  • 2.1 Assembly overview - charge air system
    256
  • 2.2 Assembly overview - charge-air hose connections
    257
  • 2.3 Removing and installing charge pressure sender GX26
    258
  • 2.4 Removing and installing charge air cooler
    258
  • 2.5 Checking charge air system for leaks
    259
  • Mixture preparation - injection
    261
  • 1 Injection system
    261
  • 1.1 Overview of fitting locations - injection system
    261
  • 1.2 Releasing high pressure in fuel system
    266
  • 2 Injectors
    268
  • 2.1 Assembly overview - fuel rail with injectors
    268
  • 2.2 Removing and installing fuel rail
    269
  • 2.3 Removing and installing injectors
    269
  • 2.4 Cleaning injectors
    275
  • 3 Air filter
    276
  • 3.1 Assembly overview - air filter housing
    276
  • 3.2 Removing and installing air filter housing
    277
  • 4 Intake manifold
    278
  • 4.1 Assembly overview - intake manifold
    278
  • 4.2 Removing and installing intake manifold
    279
  • 4.3 Removing and installing throttle valve module GX3
    282
  • 4.4 Cleaning throttle valve module GX3
    284
  • 5 Senders and sensors
    286
  • 5.1 Removing and installing intake manifold sender GX9
    286
  • 5.2 Removing and installing fuel pressure sender G247
    286
  • 5.3 Checking fuel pressure sender G247
    287
  • 6 Engine (motor) control unit
    290
  • 6.1 Removing and installing engine (motor) control unit J623
    290
  • 7 High-pressure pump
    294
  • 7.1 Assembly overview - high-pressure pump
    294
  • 7.2 Removing and installing high-pressure pump
    295
  • 7.3 Removing and installing high-pressure pipe
    296
  • 8 Lambda probe
    298
  • 8.1 Assembly overview - Lambda probe
    298
  • Exhaust system
    301
  • 1 Exhaust pipes, silencers
    301
  • 1.1 Assembly overview - silencers
    301
  • 1.2 Removing and installing silencer
    301
  • 1.3 Aligning exhaust system free of stress
    302
  • 1.4 Check exhaust system for leaks
    302
  • 2 Exhaust gas cleaning
    303
  • 2.1 Assembly overview - emission control
    303
  • 2.2 Removing and installing catalytic converter
    304
  • Ignition system
    308
  • 1 Ignition system
    308
  • 1.1 Assembly overview - ignition system
    308
  • 1.2 Test data, spark plugs
    309
  • 1.3 Removing and installing ignition coils with output stage
    309
  • 1.4 Removing and installing knock sensor 1 G61
    311
  • 1.5 Removing and installing Hall sender G40
    312
  • 1.6 Removing and installing engine speed sender G28
    314
  • Electric drive systems
    316
  • 1 Warning stickers
    316
  • 1.1 Checking warning stickers
    316
  • 2 High-voltage components
    321
  • 2.1 Overview of fitting locations - high-voltage components
    321
  • 2.2 Testing high-voltage components and high-voltage cables
    322
  • 3 High-voltage battery unit
    323
  • 3.1 Assembly overview - high-voltage battery
    323
  • 3.2 Visual inspection of high-voltage battery 1 AX2
    324
  • 3.3 Removing and installing high-voltage battery 1 AX2
    324
  • 3.4 Raising high-voltage battery 1 AX2
    330
  • 3.5 Removing and installing battery regulation control unit J840
    331
  • 4 Power and control electronics for electric drive
    333
  • 4.1 Assembly overview - power and control electronics for electric drive
    333
  • 4.3 Removing and installing power and control electronics for electric drive
    336
  • 4.4 Removing and installing bracket for power and control electronics for electric drive JX1
    340
  • 4.5 Removing and installing high-voltage system fuse 3 S353
    341
  • 5 Charging unit for high-voltage battery
    344
  • 5.1 Assembly overview - charging unit for high-voltage battery
    344
  • 5.2 Removing and installing charging unit 1 for high-voltage battery AX4
    345
  • 6 Electric drive motor
    349
  • 6.1 Removing and installing three-phase current drive VX54
    349
  • 6.2 Removing and installing drive motor temperature sender G712
    349
  • 6.3 Removing and installing drive motor rotor position sender 1 G713
    349
  • 7 High-voltage cables
    350
  • 7.1 Overview of fitting locations - high-voltage cables
    350
  • 7.2 Removing and installing high-voltage wiring harness for high-voltage battery
    353
  • 7.3 Removing and installing high-voltage wiring harness for drive motor
    357
  • 7.5 Removing and installing high-voltage cable for high-voltage heater (PTC)
    361
  • 8 Charging socket
    364
  • 8.1 Assembly overview - charging socket
    364
  • 8.2 Removing and installing high-voltage battery charging socket 1 UX4
    365
  • 8.3 Emergency release charging connector
    366
  • 8.4 Removing and installing button and display module
    368
  • 9 De-energising high-voltage system
    369
  • 10 Re-energising high-voltage system
    371
  • 11 Potential equalisation lines
    372
  • 11.1 General notes - potential equalisation lines
    372
  • 11.2 Overview of fitting locations - potential equalisation lines
    372
  • 11.3 Removing and installing potential equalisation line for high-voltage battery 1 AX2
    375
Manufacturer's designation 4-cylinder injection engine (hybrid vehicles)
Manufacturer Volkswagen
Suitable for Golf VII (2013)
Suitable car types 5G1
Engine code CUKB
Category Reparaturanleitung

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