VW 4-Cylinder Direct Injection Engine (2.0 L, 4 V, EA 888 Gen III BZ, Turbocharger, Chain Drive) OEM Workshop Manual

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Description

VW 4-Cylinder Direct Injection Engine (2.0 L, 4 V, EA 888 Gen III BZ, Turbocharger, Chain Drive) OEM Workshop Manual with high-quality graphics and illustrations.

Format: PDF

Pages: 416

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

Covered VW Vehicles

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

Covered Engine IDs: CZPA | CZPB | CZPC | DKZA | DKZC

Repair Group:

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

Contents:

  • Technical data
    • Safety information
    • Safety regulations for working on fuel supply
    • Safety measures when working on vehicles with a start/stop system
    • Safety precautions when using testers and measuring instruments during a road test
    • Safety precautions when working on ignition system
    • Safety precautions when working on the cooling system
    • Safety precautions when working on exhaust system
    • Identification
    • Engine number/engine data
    • Repair instructions
    • Rules for cleanliness
    • Foreign objects in engine
    • Contact corrosion
    • Routing and attachment of lines
    • Fitting radiator and condensers
    • Checking vacuum system
  • 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
    • Checking adjustment of assembly mountings (engine and gearbox mountings)
    • Adjusting assembly mountings
    • Engine cover panel
    • Removing and installing engine cover
  • Crankshaft group
    • Cylinder block (pulley end)
    • Assembly overview – cylinder block (pulley end)
    • Removing and installing poly-V belt
    • Removing and installing tensioner for poly V-belt
    • Removing and installing vibration damper
    • Renewing seal for vibration damper
    • Removing and installing bracket for ancillaries
    • Removing and installing engine support
    • 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
    • Allocation of main bearing shells
    • Renewing needle bearing in crankshaft
    • Measuring axial clearance of crankshaft
    • Measuring radial clearance of crankshaft
    • Removing and installing sender wheel
    • Balancer shaft
    • Assembly overview – balance shaft
    • Removing and installing balance shaft
    • Renewing oil seal for balance shaft (inlet side)
    • Pistons and conrods
    • Assembly overview – pistons and conrods
    • Removing and installing pistons
    • Checking pistons and cylinder bores
    • Separating new conrod
    • Checking radial clearance of conrods
    • Removing and installing oil spray jets
  • Cylinder head, valve gear
    • Cylinder head
    • Assembly overview – cylinder head
    • Removing and installing cylinder head
    • Assembly overview – vacuum pump
    • Removing and installing vacuum pump
    • Checking compression
    • Cover for timing chain
    • Assembly overview – cover for timing chain
    • Removing and installing upper timing chain cover
    • Removing and installing timing chain cover (bottom)
    • Chain drive
    • Assembly overview – camshaft timing chains
    • Assembly overview – drive chain for balance shaft
    • Removing and installing camshaft timing chain
    • Removing and installing drive chain for balance shaft
    • Checking valve timing
    • Checking timing chain
    • Valve gear
    • Assembly overview – valve gear
    • Removing and installing camshaft
    • Installing ball for sliding piece
    • Removing and installing actuators for camshaft adjustment
    • Removing and installing camshaft control valve 1 N205
    • Removing and installing exhaust camshaft control valve 1 N318
    • Removing and installing valve stem seals
    • 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 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
    • Assembly overview – engine oil cooler
    • Removing and installing engine oil cooler
    • Removing and installing mechanical switching valve
    • Crankcase ventilation
    • Assembly overview – crankcase breather system
    • Removing and installing oil separator
    • Oil filter, oil pressure switch
    • Assembly overview – oil filter
    • Assembly overview – oil pressure switches/oil pressure control
    • Removing and installing piston cooling jet control valve N522
    • Removing and installing oil pressure switch F1
    • Removing and installing oil pressure switch for reduced oil pressure F378
    • Removing and installing stage 3 oil pressure switch F447
    • Checking oil pressure
    • Removing and installing oil pressure regulating valve N428
  • Cooling
    • Cooling system/coolant
    • Connection diagram – coolant hoses
    • Checking cooling system for leaks
    • Draining and adding coolant
    • 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 auxiliary pump for heating V488
    • Removing and installing coolant pump
    • Removing and installing toothed belt for coolant pump
    • Removing and installing coolant shut-off valve N82
    • Removing and installing coolant valve for gearbox N488
    • Removing and installing actuator for engine temperature regulation N493
    • 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 front coolant pipe
    • Removing and installing upper coolant pipes
    • Radiator, radiator fan
    • Assembly overview – radiator
    • Assembly overview – radiator cowl and radiator fan
    • Removing and installing radiator
    • Removing and installing radiator cowl
    • Removing and installing radiator fan
  • Turbocharging/supercharging
    • Exhaust turbocharger
    • Assembly overview – turbocharger
    • Removing and installing turbocharger
    • Charge air system
    • Assembly overview – charge air system
    • Assembly overview – charge-air hose connections
    • Removing and installing charge air cooler
    • Removing and installing charge pressure sender G31
    • Checking charge air system for leaks
    • Removing and installing air intake pipe between turbocharger and charge air cooler
  • Mixture preparation – injection
    • Injection system
    • Overview of fitting locations – injection system
    • Injectors
    • Assembly overview – fuel rail with injectors
    • Removing and installing fuel rail
    • Removing and installing injectors
    • Renewing seals on injectors
    • Cleaning injectors
    • Air filter
    • Assembly overview – air filter housing
    • Removing and installing air filter housing
    • Removing air duct on lock carrier
    • Intake manifold
    • Assembly overview – intake manifold
    • Removing and installing intake manifold
    • Removing and installing throttle valve module GX3
    • Cleaning throttle valve module
    • Checking intake manifold change-over
    • Senders and sensors
    • Removing and installing fuel pressure sender G247
    • Checking fuel pressure sender G247
    • Removing and installing fuel pressure sender for low-pressure G410
    • Removing and installing intake manifold sender GX9
    • Removing and installing air mass meter G70
    • Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Polo
    • Removing and installing pressure differential sender for particulate filter G1037
    • Engine (motor) control unit
    • Removing and installing engine (motor) control unit J623
    • Removing and installing engine (motor) control unit J623 with protective housing
    • High-pressure pump
    • Assembly overview – high-pressure pump
    • Removing and installing high-pressure pump
    • Removing and installing high-pressure pipe
    • Lambda probe
    • Assembly overview – Lambda probe
    • Removing and installing Lambda probe 1 before catalytic converter GX10
    • Removing and installing Lambda probe 1 after catalytic converter GX7
  • Exhaust system
    • Exhaust pipes and silencers
    • Assembly overview – silencers
    • Removing and installing silencer
    • Separating exhaust pipes from silencers
    • Aligning exhaust system free of stress
    • Checking exhaust system for leaks
    • Exhaust gas cleaning
    • Assembly overview – emission control
    • Assembly overview – bracket and pipes for pressure differential sender for particulate filter G1037
    • Removing and installing bracket for catalytic converter, Tiguan
    • Removing and installing catalytic converter
    • Removing and installing holder of pressure differential sender for particulate filter G1037
    • Exhaust gas temperature regulation
    • Assembly overview – exhaust gas temperature regulation
    • Removing and installing parts of exhaust gas temperature regulation
  • Ignition system
    • Ignition system
    • Assembly overview – ignition system
    • Removing and installing ignition coils with output stage
    • Removing and installing knock sensor I G61
    • Removing and installing Hall sender
    • Removing and installing engine speed sender G28

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