WORKSHOP MANUAL
1.0L ENGINE (3-cylinder direct injection engine 4V, EA 211 TURBOCHARGER)
Golf 2013 ➤, Golf 2017 ➤, Golf Sportsvan 2015 ➤, Golf Sportsvan 2018 ➤, Golf Variant 2014 ➤, Golf Variant 2017 ➤, Polo 2014 ➤, Polo 2018 ➤, T-Cross 2019 ➤, T-Roc 2018 ➤, Touran 2016 ➤, Up! 2017 ➤
CONTENT
REPAIR GROUPS
– Technical data
Safety information
Safety regulations for 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 ignition system
Safety precautions when working on exhaust system
Identification
Engine number/engine data
Repair notes
Rules for cleanliness
General information
General repair instructions
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
Adjusting assembly mountings
Checking adjustment of assembly mountings (engine and gearbox mountings)
– Crankshaft group
Cylinder block (pulley end)
Assembly overview – poly V-belt drive
Removing and installing poly-V belt
Removing and installing tensioner for poly V-belt
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
Crankshaft dimensions
Renewing needle bearing in crankshaft
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
Setting piston to TDC position
– Cylinder head, valve gear
Cylinder head
Assembly overview – cylinder head
Assembly overview – camshaft housing
Removing and installing cylinder head
Removing and installing camshaft housing
Checking compression
Toothed belt drive
Assembly overview – toothed belt cover
Assembly overview – toothed belt
Removing and installing toothed belt
Preassembling and installing test tool VAS 611 007
Checking valve timing
Adjusting valve timing
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
Removing and installing exhaust camshaft control valve 1 N318
Removing and installing valve stem seals
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 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
Crankcase ventilation
Assembly overview – crankcase breather system
Removing and installing oil separator
Oil filter, oil pressure switch
Assembly overview – oil filter/oil pressure switch
Removing and installing oil pressure sender G10
Checking oil pressure and oil pressure switch
Removing and installing oil filter housing
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
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
Removing and installing toothed belt pulley for coolant pump
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
Assembly overview – radiator blind
Removing and installing radiator
Removing and installing water radiator for charge air cooling circuit
Removing and installing radiator cowl
Removing and installing radiator fan V7
Removing and installing radiator blind
Removing and installing radiator blind control motor V544
– Turbocharging/supercharging
Turbocharger
Assembly overview – turbocharger
Removing and installing turbocharger
Removing and installing charge pressure positioner V465
Removing and installing connection for turbocharger
Charge air system
Assembly overview – charge air system
Removing and installing charge air cooler
Removing and installing charge pressure sender GX26
Checking charge air system for leaks
Removing and installing air pipe
– 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
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 GX3
Senders and sensors
Assembly overview – actuator for structure-borne sound R214 and control unit for structureborne sound J869
Removing and installing fuel pressure sender G247
Checking fuel pressure sender G247
Removing and installing intake manifold sender GX9
Removing and installing exhaust gas pressure sensor 1 G450
Engine control unit
Assembly overview – engine control unit
Removing and installing engine (motor) control unit J623
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
– Exhaust system
Exhaust pipes and silencers
Assembly overview – silencers
Separating exhaust pipes from silencers
Removing and installing silencer
Aligning exhaust system free of stress
Checking exhaust system for leaks
Installation position of clamp
Emission control
Assembly overview – emission control
Removing and installing catalytic converter
Removing and installing particulate filter
– Ignition system
Ignition system
Assembly overview – ignition system
Removing and installing ignition coils with output stage
Removing and installing knock sensor 1 G61
Removing and installing Hall sender
Removing and installing engine speed sender G28
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