2014 Volkswagen Golf GTI OEM Service & Repair Manual
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Repair Manual
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ ,
Golf Plus 2009 ➤ , Passat 2006 ➤ ,
Passat CC 2009 ➤ , Scirocco 2009 ➤ ,
Tiguan 2008 ➤
4-Cylinder Common Rail Engine (2.0L, EA189)
Engine ID
CJAA
Edition 04.2016
Service
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
21 - Turbocharger, Supercharger
23 - Diesel Fuel Injection
26 - Exhaust System, Emission Controls
28 - Ignition/Glow Plug System
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D3E802238ED
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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Engine Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Engine, Supporting in its Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Engine/Transmission Mount, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Engine, Securing to the Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Overview - Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Overview - Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Ribbed Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Accessory Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4 Engine Mount Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.5 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.6 Crankshaft Seal, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.7 Sealing Flange, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.8 Crankshaft Needle Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
Contents i
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1.1 Overview - Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.2 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Overview - Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.4 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.5 Valve Seat, Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Compression Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3 Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4 Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.5 Camshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.7 Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Overview - Oil Filter Adapter and Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Overview - Oil Pump/Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Engine Oil Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Oil Filter Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Turbocharger Oil Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.1 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.2 Overview - Engine Pre-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.3 Overview - Coolant Pipe, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.4 Overview - Coolant Pipe, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.5 Overview - Radiator/Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.2 Oil Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Engine Pre-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3 4/2-Way Valve with Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.4 Fan Shroud with Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
ii Contents
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Overview - Charge Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Overview - Turbocharger and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Charge Air Hose Connections, with Connector Couplings . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Charge Air Hose Connections, with Threaded Connections . . . . . . . . . . . . . . . . . . . . . . . . 145
3.3 Turbocharger Vacuum Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.4 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.1 Fuel System, Filling/Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Fuel System Schematic Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Fuel System Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.3 Overview - Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.4 Overview - Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.5 Overview - Intake Manifold and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.1 Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.2 Fuel Return Line Pressure Retention Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.3 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.4 Fuel Pressure Regulator Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.1 Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.2 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.3 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.4 High Pressure Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.5 Fuel Pressure Regulator Valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.6 Fuel Pressure Sensor G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.7 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.8 Engine Control Module J623 , without an Anti-Theft Immobilizer . . . . . . . . . . . . . . . . . . . . 182
4.9 Engine Control Module J623 , with an Anti-Theft Immobilizer . . . . . . . . . . . . . . . . . . . . . . 183
4.10 High Pressure Reservoir (Rail), Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.1 Clamping Sleeve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.2 Clamps and Exhaust Gas Temperature Sensor, Installed Position . . . . . . . . . . . . . . . . . . 193
1.3 Exhaust System Component Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.4 Overview - Particulate Filter with NOx Reduction Catalytic Converter . . . . . . . . . . . . . . . . 197
1.5 Overview - Exhaust Door Control Unit J883 with NOx Reduction Catalytic Converter . . . . 200
1.6 Overview - Exhaust Gas Recirculation (EGR) System Component . . . . . . . . . . . . . . . . . . 201
1.7 Overview - Muffler and Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.1 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.2 EGR Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
Contents iii
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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.1 Exhaust System, Separating and Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.2 Exhaust System, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.3 Particulate Filter with NOx Absorption Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . 211
3.4 EGR Temperature Sensor G98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.1 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.2 Camshaft Position Sensor G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.3 Engine Speed Sensor G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
iv Contents
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00 – General, Technical Data
1 General Information
(Edition 04.2016)
⇒ “1.1 Safety Precautions”, page 1
⇒ “1.2 Clean Working Conditions”, page 2
⇒ “1.3 Engine Contaminants”, page 3
⇒ “1.4 Vacuum System, Checking”, page 3
⇒ “1.5 Engine Number”, page 3
1.1 Safety Precautions
⇒ “1.1.1 Fuel System”, page 1
⇒ “1.1.2 Road Test with Testing Equipment”, page 2
⇒ “1.1.3 Cooling System”, page 2
1.1.1 Fuel System
WARNING
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to clearance issues:
♦ Route all wires and lines so that the original path is fol‐
lowed.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.
♦ The fuel or fuel lines in fuel system can become very hot
(danger of scalding)!
♦ In addition, the fuel system is under pressure! Place a
cloth over the connection before opening the system.
Carefully open the connection just a little and allow the
pressure come down.
♦ Wear protective goggles and protective gloves when
working on the fuel system!
To reduce the risk of personal injury and/or damage to the fuel
injection and glow plug system, always observe the following:
♦ Only disconnect and reconnect wires for the glow plug and fuel
injection systems including test leads when the ignition is
turned off.
♦ Always turn the ignition off before disconnecting or connecting
the battery. Failing to do so could damage the diesel direct
injection system control module.
Always observe the following when removing and installing the
fuel level sensor or the fuel pump from a full or partially filled fuel
tank.
♦ Place the extractor hose from an exhaust extraction system
near the fuel tank opening and extract the fuel vapors. If no
exhaust extraction system is available, a radial fan (as long as
motor is not in air flow) with a displacement greater than 15
m
3
/h can be used.
♦ Prevent fuel from contacting skin! Wear fuel resistant gloves!
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
1. General Information 1
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1.1.2 Road Test with Testing Equipment
If special testing equipment is required during a road test, note
the following:
♦ Testing and measuring instruments must be secured on the
rear seat and operated by a second technician.
If the vehicle is involved in a collision while testing and measuring
equipment is operated from the front passenger seat, the person
sitting in that seat could be seriously injured when the airbag de‐
ploys.
1.1.3 Cooling System
WARNING
The coolant system is under pressure when the engine is
warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering coolant reservoir cap with a cloth
and carefully opening.
Caution
The vehicle could overheat if the cap is installed incorrectly.
♦ Close the cap on the coolant expansion tank until it locks
into place.
1.2 Clean Working Conditions
When working on the turbocharger, carefully observe the follow‐
ing:
Rules of Cleanliness
♦ Always clean the connection locations and the area around
them before loosening.
♦ Place removed parts on a clean surface and cover them using
lint free cloths.
♦ Carefully cover or plug unpacked components if repairs can‐
not be performed immediately.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them. Do not use
parts that have been stored loose (for example, in a tool box).
♦ Supplied transport and protective packaging and sealing cov‐
ers should only be removed immediately before installing.
♦ During repairs, clean oil from connections and hose ends.
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
2 Rep. Gr.00 - General, Technical Data
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1.3 Engine Contaminants
Note
If large quantities of metal particles or other deposits such as
those caused by partial seizure of the crankshaft or connecting
rod damage are found in the engine oil, clean the oil passages
thoroughly and replace the engine oil cooler to prevent further
damage.
1.4 Vacuum System, Checking
For all information regarding the vacuum system. Refer to
⇒ “3.3 Vacuum System, Checking”, page 166 .
1.5 Engine Number
Four digit engine codes were introduce in Model Year (MY) 2008.
The first three digits describe the mechanical structure of the en‐
gine and are still stamped on the engine, as before. The fourth
digit describes the engine output and depends on the Engine
Control Module (ECM). The four digit engine code is on the type
plate, the vehicle data label and the ECM.
The engine number (“engine code” and “serial number”) are lo‐
cated at the engine/transmission joint -arrow-.
In addition, a sticker with the “engine code” and “serial number”
is affixed to the toothed belt guard.
The engine code is also included on the vehicle data label.
The engine number consists of up to nine alphanumeric charac‐
ters. The first part (maximum 4 letters) represents the “engine
code”, the second (six digit) is the “serial number”. If more than
999,999 engines with the same engine code are produced, the
first of the six characters is replaced with a letter.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
1. General Information 3
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2 Specifications
⇒ “2.1 Engine Data”, page 4
2.1 Engine Data
Engine Code CJAA
Manufactured from 09.2009
Emission values in accordance with
ULEV2
1
Standard
Displacement liter 2.0
Output kW at RPM 103 at 4200
Torque Nm at RPM 320 at
1750 to 2500
Bore diameter, mm 81.0
Stroke mm 95.5
Valves per cylinder 4
Compression ratio 16.5
Fuel conforms to
ASTM D 975 Standard
2
Ignition sequence 1-3-4-2
Balance shaft assembly no
Catalytic Converter yes
Exhaust Gas Recirculation (EGR) yes
Turbocharger, Supercharger yes
Charge air cooler yes
Particulate filter yes
Selective Catalytic Reduction (SCR) system no
♦
1
: ULEV 2 = Ultra Low Emissions Vehicle 2
♦
2
: With a sulfur content less than 15 mg/kg of diesel fuel.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2006 ...
4-Cylinder Common Rail Engine (2.0L, EA189) - Edition 04.2016
4 Rep. Gr.00 - General, Technical Data
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