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  • Examplepage for repair manual 4-cyl. injection engine
  • Examplepage for repair manual 2 4-cyl. injection engine
  • Examplepage for repair manual 3 4-cyl. injection engine

4-cyl. injection engine

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


20,37 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

5.884 KB

252 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel/drive plate, Crankshaft, Cylinder head, Parts of lubrication system, Repairing accelerator mechanism, Activated charcoal filter system and Engine control unit. Show more
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Repair manual New Beetle Cabrio / New Beetle 4-cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    5
  • 1 Removing and installing engine
    5
  • 1.1 Notes on removing
    6
  • 1.2 Aligning engine and gearbox mountings
    10
  • 1.3 Notes on installation
    11
  • 1.4 Specified torques
    13
  • 1.5 Aligning engine and gearbox mountings
    14
  • 1.6 Assembly mountings
    14
  • 1.7 Additional notes and assembly work for vehicles with air conditioner
    15
  • Crankshaft group
    17
  • 1 Dismantling and assembling engine
    17
  • 1.1 Assembly overview
    17
  • 1.2 Removing and installing poly V-belt
    21
  • 2 Sealing flange and flywheel/drive plate
    23
  • 2.1 Assembly overview
    23
  • 2.2 Renewing crankshaft oil seal -belt pulley end-
    26
  • 2.3 Removing and installing sealing flange -belt pulley end-
    28
  • 2.4 Removing and installing drive plate
    31
  • 3 Crankshaft
    33
  • 3.1 Assembly overview
    33
  • 3.2 Crankshaft dimensions
    37
  • 4 Dismantling and assembling pistons and conrods
    39
  • 4.1 Assembly overview
    39
  • 4.2 Piston and cylinder dimensions
    46
  • Cylinder head, valve gear
    47
  • 1 Cylinder head
    47
  • 1.1 Assembly overview
    47
  • 1.2 Removing, installing and tensioning toothed belt
    51
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    56
  • 1.4 Removing and installing cylinder head
    56
  • 1.5 Checking compression pressure
    61
  • 2 Repairing valve gear
    64
  • 2.1 Assembly overview
    64
  • 2.2 Renewing camshaft oil seal
    67
  • 2.3 Checking hydraulic bucket tappets
    70
  • 2.4 Removing and installing camshaft
    70
  • 2.5 Renewing valve stem seals
    73
  • 2.6 Checking valve guides
    76
  • 2.7 Renewing valve guides
    77
  • 2.8 Reworking valve seats
    78
  • Lubrication
    80
  • 1 Parts of lubrication system
    80
  • 1.1 Engine oil
    80
  • 1.2 Assembly overview
    81
  • 1.3 Removing and installing oil pump
    92
  • 1.4 Oil pump with balancer shaft gear assembly
    92
  • 1.5 Removing and installing oil sump
    97
  • 1.6 Checking oil pressure and oil pressure switch
    101
  • Cooling system
    104
  • 1 Parts of cooling system
    104
  • 1.1 Assembly overview - parts of cooling system, body side
    104
  • 1.2 Assembly overview - parts of cooling system, engine side
    107
  • 1.3 Coolant hose schematic diagram
    111
  • 1.4 Draining and filling coolant
    113
  • 1.5 Removing and installing radiator
    117
  • 1.6 Removing and installing coolant pump
    118
  • 1.7 Removing and installing thermostat
    120
  • 1.8 Checking radiator fan
    122
  • Fuel supply system
    124
  • 1 Parts of fuel system
    124
  • 1.1 Safety precautions when working on fuel supply system
    124
  • 1.2 Rules for cleanliness
    125
  • 1.3 Assembly overview - fuel tank with attachments and fuel filter
    125
  • 1.4 Removing and installing fuel delivery unit
    132
  • 1.5 Removing and installing fuel gauge sender
    135
  • 1.6 Removing and installing fuel tank
    135
  • 1.7 Crash fuel shut-off
    138
  • 1.8 Checking fuel pump
    139
  • 1.9 Bleeding fuel system (engine codes BEV and BGD only)
    153
  • 2 Repairing accelerator mechanism
    156
  • 2.1 Vehicles without electronic power control (EPC)
    156
  • 2.2 Vehicles with electronic power control (EPC)
    159
  • 3 Activated charcoal filter system
    161
  • 3.1 Functional description
    161
  • 3.2 Parts of the activated charcoal filter system - Assembly overview
    162
  • 3.4 Checking fuel tank breather
    165
  • Mixture preparation, injection
    170
  • 1 Repairing injection system
    170
  • 1.1 General notes on injection
    170
  • 1.2 Safety precautions
    171
  • 1.3 Rules for cleanliness
    171
  • 1.4 Component location overview
    172
  • 1.5 Intake manifold upper part - Assembly overview
    184
  • 1.6 Removing and installing upper section of intake manifold
    190
  • 1.7 Intake manifold lower part, fuel rail, injectors - Assembly overview
    195
  • 1.8 Dismantling and assembling fuel rail with injectors
    203
  • 1.9 Assembly overview - air filter
    204
  • 1.10 Technical data
    205
  • 2 Checking components
    206
  • 2.1 Checking injectors for leaks and quantity injected
    206
  • 2.2 Checking fuel pressure regulator and holding pressure
    211
  • 2.3 Checking intake manifold change-over, only for vehicles with intake manifold change-over
    218
  • 3 Engine control unit
    220
  • 3.1 Replacing engine control unit
    220
  • 3.2 Adapting functions and components
    221
  • 3.3 Reading and erasing engine control unit fault memory
    223
  • Exhaust system
    225
  • 1 Parts of exhaust system
    225
  • 1.2 Assembly overview - silencers with mountings
    230
  • 1.3 Removing and installing exhaust manifold
    232
  • 2 Secondary air system
    233
  • 2.1 Functional description
    233
  • 2.2 Parts of the secondary air system - Assembly overview
    233
  • 2.3 Checking combination valve
    238
  • 2.4 Removing and installing combi-valve
    240
  • Ignition system
    242
  • 1 Servicing ignition system
    242
  • 1.1 General notes on ignition system
    242
  • 1.2 Safety precautions
    242
  • 1.3 Parts of the ignition system - Assembly overview
    243
  • 1.4 Spark plug test data
    246
Manufacturer's designation 4-cyl. injection engine
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)
Suitable car types 1Y, 9C
Engine code AEG, APK, AQY, AVH, AZG, AZJ, BDC, BEV, BGD, BEJ, BER, BHP
Category Reparaturanleitung

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