VW 4-Cylinder Common Rail (1.6 l And 2.0 l, 4 V, Turbocharger, EA 288) OEM Workshop Manual

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Description

VW 4-Cylinder Common Rail (1.6 l And 2.0 l, 4 V, Turbocharger, EA 288) OEM Workshop Manual with high-quality graphics and illustrations.

Format: PDF

Pages: 601

Delivery: The download link will be sent to your email instantly after checkout.

Covered VW Vehicles

  • Polo 2018 ➤, T-Cross 2019 ➤,
  • T-Roc 2018 ➤, Tiguan 2016 ➤,
  • Tiguan RUS 2017 ➤

Covered Engine IDs: DCYA | DDMA | DFGA | DFGB | CRFC | CYKB | DFHA | DCYB | DGDB | DBGA | CRGA | DFGC | CYKC | DBGC | CRGB | CRFZ | CRFD | DGTE | DFFA | DGTC | DGTD

Repair Group:

  • Technical data
  • Removing and installing engine
  • Crankshaft group
  • Cylinder head, valve gear
  • Lubrication
  • Cooling
  • Turbocharging/supercharging
  • Mixture preparation – injection
  • Exhaust system
  • Glow plug system

Contents:

  • Technical data
  • Safety information
  • Safety measures when working on fuel supply
  • Safety measures when working on vehicles with start/stop system
  • Safety precautions when using testers and measuring instruments during a road test
  • Safety precautions when working on the cooling system
  • Safety precautions when working on the SCR system
  • Safety precautions when working on exhaust system
  • Identification
  • Engine number/engine data
  • Repair notes
  • Rules for cleanliness
  • Foreign objects in engine
  • Contact corrosion
  • Routing and attachment of lines
  • Fitting radiator and condensers
  • Technical data
  • Coolant
  • Removing and installing engine
  • Removing and installing engine
  • Removing engine
  • Separating engine and gearbox
  • Securing engine on engine and gearbox support
  • Installing engine
  • Assembly mountings
  • Assembly overview – assembly mountings
  • Removing and installing engine mounting
  • Removing and installing gearbox mounting
  • Removing and installing pendulum support
  • Supporting engine in installation position
  • Adjusting assembly mountings
  • Checking adjustment of assembly mountings (engine and gearbox mountings)
  • Engine cover panel
  • Removing and installing engine cover
  • Crankshaft group
  • Cylinder block (pulley end)
  • Assembly overview – cylinder block (pulley end)
  • Assembly overview – sealing flange, belt pulley end
  • Removing and installing poly-V belt
  • Removing and installing tensioner for poly V-belt
  • Removing and installing vibration damper
  • Removing and installing bracket for ancillaries
  • Removing and installing engine support
  • Removing and installing sealing flange on pulley end
  • Cylinder block, gearbox end
  • Assembly overview – cylinder block, gearbox end
  • Removing and installing flywheel
  • Removing and installing sealing flange on gearbox side
  • Crankshaft
  • Assembly overview – crankshaft
  • Crankshaft dimensions
  • Measuring axial clearance of crankshaft
  • Renewing needle bearing in crankshaft
  • Pistons and conrods
  • Assembly overview – pistons and conrods
  • Removing and installing pistons
  • Measuring piston projection at TDC
  • Checking pistons and cylinder bores
  • Checking radial clearance of conrods
  • Cylinder head, valve gear
  • Cylinder head
  • Assembly overview – cylinder head
  • Assembly overview – cylinder head cover
  • Removing and installing cylinder head
  • Removing and installing cylinder head cover
  • Removing and installing injector seals
  • Removing and installing camshaft housing
  • Checking compression
  • Toothed belt drive
  • Assembly overview – toothed belt cover
  • Assembly overview – toothed belt
  • Removing and installing toothed belt guard
  • Removing and installing toothed belt
  • Removing toothed belt from camshaft
  • Valve gear
  • Assembly overview – valve gear
  • Measuring axial play of camshaft
  • Removing and installing camshaft oil seal
  • Removing and installing camshaft adjuster
  • Removing and installing camshaft control valve 1 N205
  • Checking hydraulic compensation elements
  • Removing and installing valve stem seals
  • Removing and installing control valve for the camshaft adjuster
  • Inlet and exhaust valves
  • Checking valve guides
  • Checking valves
  • Valve dimensions
  • Lubrication
  • Sump, oil pump
  • Assembly overview – sump/oil pump
  • Engine oil:
  • Removing and installing sump
  • Removing and installing lower part of sump
  • Removing and installing upper part of sump
  • Removing and installing oil pump
  • Removing and installing oil level and oil temperature sender G266
  • Engine oil cooler
  • Oil filter, oil pressure switch
  • Assembly overview – oil filter housing, oil pressure switch
  • Removing and installing oil pressure switch F1
  • Removing and installing oil pressure switch for reduced oil pressure F378
  • Checking oil pressure
  • Removing and installing oil filter housing
  • Removing and installing oil pressure regulating valve N428
  • Oil circuit
  • Removing and installing oil supply line
  • Removing and installing oil return line for turbocharger
  • Cooling
  • Cooling system/coolant
  • Connection diagram – coolant hoses
  • Checking cooling system for leaks
  • Draining coolant
  • Filling with coolant
  • Checking filling quality of cooling system
  • Checking electric vacuum pump VAS 6096/2
  • Flushing cooling system
  • Flushing cooling system, quick reference guide
  • Coolant pump, regulation of cooling system
  • Assembly overview – coolant pump, thermostat
  • Assembly overview – electric coolant pump
  • Assembly overview – coolant temperature sender
  • Removing and installing electric coolant pump
  • Removing and installing coolant pump
  • Removing and installing thermostat
  • Checking thermostat
  • Removing and installing coolant valve for cylinder head N489
  • Removing and installing coolant temperature sender G62
  • Removing and installing radiator outlet coolant temperature sender G83
  • Coolant pipes
  • Assembly overview – coolant pipes
  • Removing and installing coolant pipes
  • Radiator, radiator fan
  • Assembly overview – radiator/radiator fan
  • Assembly overview – radiator cowl and radiator fan
  • Removing and installing radiator
  • Removing and installing water radiator for charge air cooling circuit
  • Removing and installing radiator cowl
  • Removing and installing radiator fan
  • Turbocharging/supercharging
  • Turbocharger
  • Assembly overview – turbocharger
  • Removing and installing turbocharger
  • Renewing vacuum unit for turbocharger
  • Removing and installing connection for turbocharger
  • Charge air system
  • Assembly overview – charge air system
  • Removing and installing charge pressure sender G31
  • Checking charge air system for leaks
  • Removing and installing air pipe
  • Checking charge air cooler for leaks
  • Mixture preparation – injection
  • Injection system
  • Schematic overview – fuel system
  • Overview of fitting locations – injection system
  • Filling/bleeding fuel system
  • Checking fuel system for leaks
  • Vacuum system
  • Connection diagram – vacuum system
  • Checking vacuum system
  • Injectors/high-pressure accumulator (rail)
  • Assembly overview – injectors
  • Assembly overview – fuel rail
  • Adapting correction values for injectors
  • Testing injectors
  • Checking return flow rate of injectors with engine running
  • Checking return flow rate of injectors at starter speed
  • Testing jammed-open injectors
  • Removing and installing injectors
  • Removing and installing high-pressure lines
  • Removing and installing fuel rail
  • Air filter
  • Assembly overview – air filter housing
  • Removing and installing air filter housing
  • Removing and installing air guide on lock carrier
  • Intake manifold
  • Assembly overview – intake manifold
  • Removing and installing intake manifold
  • Removing and installing throttle valve module J338
  • Senders and sensors
  • Removing and installing fuel pressure regulating valve N276
  • Checking fuel pressure regulating valve N276
  • Removing and installing fuel pressure sender G247
  • Removing and installing air mass meter G70 / intake air temperature sender G42
  • Removing and installing pressure differential sender G505
  • Removing and installing exhaust gas pressure sensor 1 G450
  • Removing and installing NOx sender 2 G687
  • Removing and installing charge air temperature sender ahead of charge air cooler G810
  • Removing and installing charge air temperature sender after charge air cooler G811
  • Removing and installing fuel temperature sender G81
  • Removing and installing control unit for NOx sender GX30
  • Removing and installing temperature and pressure sender for low-pressure fuel system GX20
  • Engine control unit
  • Removing and installing engine (motor) control unit J623
  • Removing and installing engine control unit J623 (with protective housing)
  • High-pressure pump
  • Assembly overview – high-pressure pump
  • Removing and installing high-pressure pump
  • Lambda probe
  • Assembly overview – Lambda probe
  • Removing and installing Lambda probe
  • Exhaust system
  • Exhaust pipes and silencers
  • Assembly overview – silencers
  • Assembly overview – front exhaust pipe
  • Removing and installing front exhaust pipe
  • Separating exhaust pipes from silencers
  • Removing and installing silencer
  • Aligning exhaust system free of stress
  • Checking exhaust system for leaks
  • Installation position of clamp
  • Align end exhaust pipes
  • Removing and installing bracket for front exhaust pipe
  • Emission control
  • Assembly overview – emission control
  • Removing and installing catalytic converter
  • Removing and installing particulate filter
  • Removing and installing emission control module
  • Removing and installing exhaust flap control unit J883
  • SCR system (selective catalytic reduction)
  • Assembly overview – tank for reducing agent
  • Assembly overview – reducing agent delivery line
  • Assembly overview – delivery module for reducing agent
  • Removing and installing reducing agent tank
  • Removing and installing front section of reducing agent supply line
  • Removing and installing delivery module for reducing agent
  • Removing and installing injector for reduction agent N474
  • Removing and installing control unit for reducing-agent heater J891
  • Assembly overview – injector for reducing agent
  • Draining reducing agent tank
  • Removing and installing rear section of reducing agent supply line
  • Removing and installing filler pipe for reducing agent tank
  • Disconnecting reducing agent supply line
  • SCR – resetting learnt values
  • Exhaust gas temperature regulation
  • Assembly overview – exhaust gas temperature regulation
  • Removing and installing exhaust gas temperature sender 1 G235
  • Removing and installing exhaust gas temperature sender 2 G448
  • Removing and installing exhaust gas temperature sender 3 G495
  • Removing and installing exhaust gas temperature sender 4 G648
  • Exhaust gas recirculation
  • Assembly overview – exhaust gas recirculation
  • Assembly overview – exhaust gas recirculation valve 1 GX5
  • Removing and installing exhaust gas recirculation cooler
  • Removing and installing exhaust gas recirculation valve 1 GX5
  • Removing and installing exhaust gas recirculation valve 2 GX6
  • Removing and installing exhaust gas recirculation temperature sensor G98
  • Checking exhaust gas recirculation cooler for leaks
  • Glow plug system
  • Glow plug system
  • Assembly overview – glow plug system
  • Removing and installing glow plug
  • Removing and installing automatic glow period control unit J179
  • Removing and installing Hall sender G40
  • Removing and installing engine speed sender G28

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