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  • Examplepage for repair manual 4 - Cyl. injection engine (1.6 l) EA211
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4 - Cyl. injection engine (1.6 l) EA211

For Saveiro Cab. Dupla [BR] / Saveiro Cab. Est. / Voyage [BR] / Gol [BR]

Original Volkswagen repair manual


28,72 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

31.304 KB

377 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Power-drive unit supports, Cylinder block (pulley side), Crankshaft, Pistons and connecting rods, Toothed belt drive, Oil filter/ Oil pressure switch F1, Cooling system components, Radiator, Fuel supply unit/ Fuel level sensor G, Quick-release fastener with button, Fuel filter, Engine power electronic adjustment (electronic accelerator), Injection valves, Intake manifold, READINESS code and Exhaust pipes/silencers. Show more
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Repair manual 4 - Cyl. injection engine EA211 PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 \--- Change history ---
    1
  • 2 Safety instructions
    2
  • 2.1 Safety measures regarding work on the fuel supply
    2
  • 2.2 Safety measures in test drives using testing and measurement devices
    3
  • 2.3 Safety measures when working on the ignition system
    4
  • 2.4 Safety measures when working on the exhaust system
    4
  • 2.5 Safety measures when working on the cooling system
    4
  • 3 Identification
    6
  • 3.1 Engine number/engine characteristics
    6
  • 4 Repair instructions
    8
  • 4.1 Cleaning rules
    8
  • 4.2 General Notes
    8
  • 4.3 General repair instructions
    8
  • 4.4 Foreign bodies on the engine
    9
  • 4.5 Contact corrosion
    9
  • 4.6 Connection installation and fastening
    9
  • 4.7 Radiator and capacitor installation
    9
  • Removing and installing engine
    10
  • 1 Engine - remove and install
    10
  • 1.1 Engine - removal
    10
  • 1.2 Engine - separate gearbox
    19
  • 1.3 Secure the engine to the engine and gearbox swivelling stand
    23
  • 1.4 Engine - installation
    25
  • 2 Power-drive unit supports
    29
  • 2.1 Power unit brackets - assembly overview
    29
  • 2.2 Support engine in mounting position
    30
  • 2.3 Power-drive unit supports (engine side) - remove and install
    31
  • 2.4 Power-drive unit supports (gearbox side) - remove and install
    32
  • 2.5 Pendulum support (torque restrictor) - remove and install
    36
  • 2.6 Ancillary brackets - check adjustment
    37
  • Crankshaft group
    38
  • 1 Cylinder block (pulley side)
    38
  • 1.1 Poly-V belt - assembly overview
    38
  • 1.2 Poly-V belt - remove and install
    39
  • 1.3 Poly-V belt tensioner - remove and install
    41
  • 1.4 Crankshaft pulley (vibration damper) - remove and install
    41
  • 1.5 Engine console - remove and install
    42
  • 1.6 Crankshaft seal (pulley side) - replace
    43
  • 2 Cylinder block (gearbox side)
    47
  • 2.1 Cylinder block (gearbox side) - assembly overview
    47
  • 2.2 Flywheel - remove and install
    50
  • 2.3 Clutch Disk - removal and installation
    51
  • 2.4 Crankshaft flange (flywheel side) - replace
    53
  • 3 Crankshaft
    63
  • 3.1 Crankshaft dimensions
    63
  • 3.2 Crankshaft - check axial clearance
    63
  • 4 Pistons and connecting rods
    65
  • 4.1 Pistons and conrods - assembly overview
    65
  • 4.2 Pistons - remove and install
    68
  • 4.3 Pistons, rings, and cylinders - check (conrod with bushing)
    69
  • 4.4 Pistons, rings, and cylinders - check (conrod without bushing)
    71
  • 4.5 Connecting rod (radial clearance) - check
    73
  • 4.6 Oil injectors - remove and install
    73
  • Cylinder head, valve gear
    75
  • 1 Engine cylinder head
    75
  • 1.1 Engine cylinder head - assembly overview
    75
  • 1.2 Cylinder head cover with camshafts - assembly overview
    77
  • 1.3 Engine cylinder head - remove and install
    78
  • 1.4 Cylinder head cover with camshafts - remove and install
    84
  • 1.5 Compression - check
    86
  • 2 Toothed belt drive
    90
  • 2.2 Toothed belt - assembly overview
    91
  • 2.3 Mechanical distribution cover - removal and installation
    92
  • 2.4 Valve timing - check
    93
  • 2.5 Remove the toothed belt from the camshafts
    98
  • 2.6 Toothed belt - remove and install
    107
  • 3 Camshaft mechanism - repair
    114
  • 3.1 Camshaft mechanism - assembly overview
    114
  • 3.2 Crankshaft - check axial clearance
    116
  • 3.3 Inlet camshaft regulator - remove and install
    117
  • 3.4 Exhaust camshaft sprocket - remove and install
    121
  • 3.5 Camshaft seal - replace
    125
  • 3.6 Camshaft adjustment valve 1 N205 - remove and install
    130
  • 3.7 Valve stem sealant - replace
    130
  • 4 Inlet and exhaust valves
    140
  • 4.1 Valve guides - check
    140
  • 4.2 Valves - check
    141
  • 4.3 Valves - dimensions
    141
  • Lubrication
    142
  • 1 Crankcase/oil pump
    142
  • 1.1 Crankcase/oil pump - assembly overview
    142
  • 1.2 Lower sump - remove and install
    144
  • 1.3 Upper crankcase - remove and install
    147
  • 1.4 Oil pump - remove and install
    150
  • 1.5 Engine oil
    152
  • 2 Engine oil cooler
    154
  • 2.1 Engine oil cooler - assembly overview
    154
  • 2.2 Engine oil cooler - remove and install
    154
  • 3 Engine crankcase ventilation
    156
  • 3.1 Engine crankcase ventilation - assembly overview
    156
  • 3.2 Crankcase ventilation device - remove and install
    157
  • 4 Oil filter/ Oil pressure switch F1
    159
  • 4.1 Oil filter/ Oil pressure switch F1 - assembly overview
    159
  • 4.2 Oil pressure switch 0.3...0.6 bar F1 - remove and install
    159
  • 4.3 Oil filter - remove and install
    161
  • 4.4 Oil pressure and Oil pressure switch F1 - check
    161
  • Cooling
    164
  • 1 Cooling system components
    164
  • 1.1 Hose connection diagram for cooling system
    164
  • 1.2 Cooling system - drainage and replenishment
    166
  • 1.3 Cooling system - check air-tightness
    173
  • 1.4 Coolant tank flap - check safety valve
    174
  • 2 Coolant/cooling system water pump
    176
  • 2.1 Water pump - assembly overview
    176
  • 2.2 Water pump - remove and install
    178
  • 2.3 Water pump sprocket - remove and install
    183
  • 2.4 Thermostat valve - removal and installation
    184
  • 2.5 Water pump toothed belt - remove and install
    192
  • 2.6 Coolant temperature sensor G62 - remove and install
    194
  • 3 Radiator
    197
  • 3.1 Radiator/ Radiator fan V7 - assembly overview
    197
  • 3.2 Radiator - remove and install
    199
  • 3.3 Cowling with Radiator fan V7 - remove and install
    201
  • 3.4 Radiator fan V7 - remove and install
    202
  • Fuel supply system
    203
  • 1 Fuel supply system components
    203
  • 1.1 Fuel tank - assembly overview
    203
  • 1.2 Fuel reservoir - remove and install
    205
  • 1.3 Fuel tank - drain
    208
  • 1.4 Cold start system components - remove and install
    215
  • 1.5 Fuel shutoff in case of crash
    216
  • 2 Fuel supply unit/ Fuel level sensor G
    217
  • 2.1 Fuel pump (pre-supply pump) G6 - remove and install
    217
  • 2.2 Fuel gauge sensor G - remove and install
    219
  • 3 Quick-release fastener with button
    221
  • 3.1 Quick-release fastener with button - disconnect
    221
  • 4 Fuel filter
    225
  • 4.1 Fuel filter - remove and install
    225
  • 5 Activated charcoal filter system
    226
  • 5.1 Operation
    226
  • 5.2 Activated charcoal filter system components - repair
    226
  • 5.3 Fuel tank ventilation - check
    227
  • 6 Engine power electronic adjustment (electronic accelerator)
    229
  • 6.2 Electronic accelerator system operation
    229
  • 7 Fuel pump (pre-supply pump) G6
    231
  • 7.1 Fuel pump (pre-supply pump) G6 - check
    231
  • Mixture preparation - injection
    243
  • 1 Injection system
    243
  • 1.1 Sensors, switches (intake side) - assembly overview
    243
  • 1.2 Sensor, ignition coils and lambda probe (exhaust side) - assembly overview
    244
  • 1.3 Injection system - assembly overview
    244
  • 2 Injection valves
    248
  • 2.1 Fuel rail with injection valves - assembly overview
    248
  • 2.2 Injection valves - remove and install
    251
  • 2.3 Injection valves - check
    255
  • 2.4 Injection valves - clean
    258
  • 3 Air cleaner
    260
  • 3.1 Air filter - assembly overview
    260
  • 3.2 Air filter - remove and install
    261
  • 4 Intake manifold
    262
  • 4.1 Intake manifold - assembly overview
    262
  • 4.2 Intake manifold - remove and install
    263
  • 4.3 Throttle butterfly valve control unit J338 - remove and install
    265
  • 4.4 Throttle valve control unit J338 - clean
    266
  • 4.5 Supply system pressure, fuel pressure gauge and residual pressure - check
    267
  • 5 READINESS code
    274
  • 5.1 Function
    274
  • 5.2 Creating and Interpreting the READINESS code
    274
  • 6 Transmitters and sensors
    275
  • 7 Engine control unit J623
    277
  • 7.1 Engine control unit J623 - remove and install
    277
  • 8 Lambda probe
    281
  • 8.1 Lambda probe - assembly overview
    281
  • 8.2 Lambda probe - remove and install
    282
  • Exhaust system
    285
  • 1 Exhaust pipes/silencers
    285
  • 1.1 Exhaust pipes/silencers - exploded view
    285
  • 1.2 Separate exhaust pipes/silencers
    286
  • 1.3 Silencers - remove and install
    286
  • 1.4 Exhaust system - free of stress alignment
    287
  • 1.5 Exhaust system - check air-tightness
    287
  • 1.6 Pipe clamp installation position
    288
  • 2 Exhaust gas purging
    289
  • 2.1 Front exhaust pipe with catalytic converters - assembly overview
    289
  • 2.2 Front exhaust pipe with catalytic converters - remove and install
    290
  • Ignition system
    293
  • 1 Ignition system
    293
  • 1.1 Ignition system - assembly overview
    293
  • 1.2 Ignition coils with final power stage - assembly overview
    295
  • 1.3 Test data, spark plugs
    295
  • 1.4 Ignition coil with final power stage - remove and install
    296
  • 1.5 Knock sensor 1 G61 - remove and install
    299
  • 1.6 Hall Sensor G40 - remove and install
    299
  • 1.7 Engine speed sensor G28 - remove and install
    300
Manufacturer's designation 4 - Cyl. injection engine (1.6 l) EA211
Manufacturer Volkswagen
Suitable for Saveiro Cab. Dupla [BR] (2017 >) / Saveiro Cab. Est. (2017 >) / Voyage [BR] (2019 >) / Gol [BR] (2019 >)
Suitable car types 5UD, 5UG, 5U7
Engine code CWSA
Category Reparaturanleitung

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