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

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