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

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