VW Golf 4-Cyl 2.0 L TSI Direct-Injection Engine Workshop Manual PDF (Edition 04.2018)

Get the official Volkswagen workshop guide for the EA888 Gen 3 4-cylinder 2.0 L TSI direct-injection engine fitted to Golf Mk 7 (2013–2018) and Golf Variant (up to 2018). This PDF contains:

• Complete Technical Data (engine codes CJXB, CJXC, … DLRA)

• Safety Information for high-pressure fuel, start/stop systems, ignition, and cooling work

• Repair Instructions: engine removal, assembly mountings, cleanliness rules, vacuum system checks

• Step-by-Step Procedures grouped into logical Repair Groups (00–28) with exploded views

• Special Tools & Precautions for turbocharger, mixture preparation, high-pressure pump, lambda probe, and more

• Full Diagrams & Tables for component assemblies, tolerance specs, and service limits

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Table of Contents

• Technical data
  • Identification
    • Engine number/engine 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
  • 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 engine
  • Separating engine and gearbox
  • Securing engine on engine and gearbox support
  • Installing engine
• Assembly mountings
  • Assembly overview – assembly mountings
  • Supporting engine in installation position
  • Removing and installing motor mounting
  • Removing and installing gearbox mounting
  • Removing and installing pendulum support
  • Checking adjustment of assembly mountings (engine and gearbox mountings)
  • Adjusting assembly mountings
• Motor cover
  • 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 bracket for ancillaries
    • Removing and installing vibration damper
    • Removing and installing engine support
    • Renewing crankshaft oil seal – belt 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
    • Removing and installing sender wheel
    • Renewing needle bearing in crankshaft
    • Allocation of main bearing shells
  • Crankshaft dimensions
    • Measuring axial clearance of crankshaft
    • Measuring radial clearance of crankshaft
• 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
  • Separating new conrod
  • Checking pistons and cylinder bores
  • Checking radial clearance of conrods
• Cylinder head, valve gear
  • 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 chain elongation
    • Checking valve timing
  • Cylinder head
    • Assembly overview – cylinder head
    • Removing and installing cylinder head
    • Removing and installing vacuum pump
    • Checking compression
  • Valve gear
    • Assembly overview – valve gear
    • Removing and installing camshaft
    • Installing ball for sliding piece
    • Removing and installing valve stem seals
    • Removing and installing camshaft control valve N205
    • Removing and installing exhaust camshaft control valve N318
    • Installing ball for sliding piece
    • Removing and installing actuator for camshaft adjustment N580 / N605
  • Inlet and exhaust valves
    • Checking valve guides
    • Checking valves
    • Valve dimensions
• Lubrication
  • Sump, oil pump
    • Assembly overview – sump/oil pump
    • Removing and installing oil level and oil temperature sender G266
    • Removing and installing lower part of sump
    • Removing and installing oil pump
    • Removing and installing upper part of sump
    • Engine oil
  • 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
    • Exploded view – oil pressure switches/oil pressure control
    • Removing and installing piston cooling jet control valve N522
    • Removing and installing oil pressure regulating valve N428
    • 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
• Cooling
  • Cooling system/coolant
    • Connection diagram – coolant hoses
    • Draining and adding coolant
    • Checking cooling system for leaks
    • 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 toothed belt for coolant pump
    • Removing and installing coolant pump
    • Removing and installing auxiliary pump for heating V488
    • 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 coolant pipe at front of engine
    • Removing and installing coolant pipe on top of engine
    • Removing and installing coolant pipe on radiator cowl
  • Radiator, radiator fan
    • Assembly overview – radiator/radiator fan
    • Assembly overview – radiator cowl and radiator fan
    • Assembly overview – auxiliary radiator
    • Removing and installing radiator
    • Removing and installing auxiliary radiator
    • Removing and installing radiator cowl
    • Removing and installing radiator fan
• Turbocharging/supercharging
  • Exhaust turbocharger
    • Assembly overview – turbocharger
    • Removing and installing turbocharger
    • Adjusting charge pressure positioner V465
  • 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
• Mixture preparation – injection
  • Injection system
    • Overview of fitting locations – injection system
    • Releasing high pressure in fuel system
  • Air filter
    • Assembly overview – air filter housing
    • Removing and installing air filter housing
  • Intake manifold
    • Assembly overview – intake manifold
    • Removing and installing intake manifold
    • Removing and installing throttle valve module GX3
    • Cleaning throttle valve module
  • Injectors
    • Assembly overview – fuel rail with injectors
    • Removing and installing fuel rail
    • Removing and installing injectors
    • Renewing seals on injectors
    • Cleaning injectors
  • Senders and sensors
    • Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound
    • Removing and installing fuel pressure sender G247
    • Removing and installing fuel pressure sender for low-pressure G410
    • Removing and installing intake air temperature sender G42 / intake manifold pressure sender G71
    • Removing and installing actuator for structure-borne sound R214
  • 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
  • Engine (motor) control unit
    • Removing and installing engine (motor) control unit J623
• Exhaust system
  • Exhaust pipes and silencers
    • Assembly overview – silencers
    • Removing and installing silencer
    • Separating exhaust pipes from silencers
    • Aligning exhaust system free of stress
    • Align end exhaust pipes
    • Check exhaust system for leaks
    • Installation position of clamp
  • Exhaust gas cleaning
    • Assembly overview – emission control
    • Removing and installing catalytic converter
    • Removing and installing exhaust flap control unit J883 / J945
  • Secondary air system
    • Assembly overview – secondary air system
    • Removing and installing secondary air pump motor V101
    • Removing and installing sender 1 for secondary air pressure G609
    • Removing and installing secondary air inlet valve N112
• Ignition system
  • Ignition system
    • Assembly overview – ignition system
    • Removing and installing ignition coils with output stage
    • Removing and installing knock sensor
    • Removing and installing Hall sender
    • Removing and installing engine speed sender G28