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  • Examplepage for repair manual 4-cyl. injection engine (5 valve)
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  • Examplepage for repair manual 4-cyl. injection engine (5 valve)
  • Examplepage for repair manual 2 4-cyl. injection engine (5 valve)
  • Examplepage for repair manual 3 4-cyl. injection engine (5 valve)

4-cyl. injection engine (5 valve)

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


18,22 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

5.292 KB

222 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel/drive plate, Crankshaft, Pistons and conrods, Cylinder head, Parts of fuel system, Charge air system with turbocharger and Checking components. 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
    4
  • 1 Removing and installing engine
    4
  • 1.1 Notes on removing
    5
  • 1.2 Securing the engine to the assembly stand
    10
  • 1.3 Notes on installation
    11
  • 1.4 Specified torques
    13
  • 1.5 Aligning engine and gearbox mountings
    14
  • 1.6 Assembly mountings
    15
  • 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
    20
  • 2 Sealing flange and flywheel/drive plate
    22
  • 2.1 Assembly overview
    22
  • 2.2 Renewing crankshaft oil seal -belt pulley end-
    24
  • 2.3 Removing and installing sealing flange -belt pulley end-
    26
  • 2.4 Removing and installing drive plate
    28
  • 3 Crankshaft
    31
  • 3.1 Assembly overview
    31
  • 3.2 Crankshaft dimensions
    33
  • 4 Pistons and conrods
    34
  • 4.1 Assembly overview
    34
  • 4.2 Piston and cylinder dimensions
    41
  • Cylinder head, valve gear
    42
  • 1 Cylinder head
    42
  • 1.1 Assembly overview
    42
  • 1.2 Removing, installing and tensioning toothed belt
    46
  • 1.3 Removing and installing cylinder head
    50
  • 1.4 Checking compression pressure
    56
  • 2 Repairing valve gear
    60
  • 2.1 Assembly overview
    60
  • 2.2 Renewing camshaft oil seals
    64
  • 2.3 Checking hydraulic bucket tappets
    69
  • 2.4 Removing and installing camshafts
    70
  • 2.5 Renewing valve stem seals
    75
  • 2.6 Checking valve guides
    78
  • 2.7 Reworking valve seats
    78
  • Lubrication
    81
  • 1 Parts of lubrication system
    81
  • 1.1 Engine oil
    81
  • 1.2 Assembly overview
    82
  • 1.3 Removing and installing oil sump
    89
  • 1.4 Checking oil pressure and oil pressure switch
    92
  • Cooling system
    95
  • 1 Parts of cooling system
    95
  • 1.1 Assembly overview - parts of cooling system, body side
    95
  • 1.2 Assembly overview - parts of cooling system, engine side
    97
  • 1.3 Coolant hose schematic diagram
    101
  • 1.4 Draining and filling coolant
    104
  • 1.5 Removing and installing radiator
    108
  • 1.6 Removing and installing coolant pump
    110
  • 1.7 Removing and installing thermostat
    111
  • 1.8 Checking continued coolant circulation pump
    113
  • 1.9 Checking radiator fan
    114
  • Fuel supply system
    116
  • 1 Parts of fuel system
    116
  • 1.1 Safety precautions when working on fuel supply system
    116
  • 1.2 Rules for cleanliness
    117
  • 1.3 Assembly overview - fuel tank with attachments and fuel filter
    117
  • 1.4 Removing and installing fuel delivery unit
    124
  • 1.5 Removing and installing fuel gauge sender
    126
  • 1.6 Removing and installing fuel tank
    127
  • 1.7 Crash fuel shut-off
    129
  • 1.8 Checking fuel pump
    129
  • 2 Electronic power control (EPC)
    138
  • 2.1 Function of EPC system
    138
  • 2.2 Assembly overview
    138
  • 3 Activated charcoal filter system
    140
  • 3.1 Functional description
    140
  • 3.2 Parts of the activated charcoal filter system - Assembly overview
    141
  • 3.4 Checking fuel tank breather
    144
  • Charging
    148
  • 1 Charge air system with turbocharger
    148
  • 1.1 Safety precautions
    148
  • 1.2 Rules for cleanliness
    148
  • 1.3 General repair instructions
    149
  • 1.4 Hose connections with connector couplings
    150
  • 1.5 Assembly overview - turbocharger with attachments
    151
  • 1.6 Removing and installing turbocharger
    156
  • 1.7 Assembly overview - parts of charge air cooling
    164
  • 1.8 Overview of charge pressure control and vacuum control
    165
  • 2 Checking parts of charge air system
    169
  • 2.1 Checking charge pressure control
    169
  • 2.2 Checking charge pressure control valve pressure unit
    170
  • 2.3 Checking fuel cut-off valve
    171
  • Mixture preparation, injection
    173
  • 1 Repairing injection system
    173
  • 1.1 General notes on injection
    173
  • 1.2 Safety precautions
    174
  • 1.3 Rules for cleanliness
    174
  • 1.4 Component location overview
    175
  • 1.5 Parts of exhaust gas recirculation - Assembly overview
    178
  • 1.6 Assembly overview - air filter
    186
  • 1.7 Assembly overview - fuel rail with injectors
    187
  • 1.8 Technical data
    187
  • 2 Checking components
    189
  • 2.1 Checking injectors for leaks and quantity injected
    189
  • 2.2 Checking fuel pressure regulator and holding pressure
    191
  • 3 Engine control unit
    195
  • 3.1 Replacing engine control unit
    195
  • 3.2 Adapting functions and components
    196
  • 3.3 Reading and erasing engine control unit fault memory
    198
  • Exhaust system
    200
  • 1 Parts of exhaust system
    200
  • 1.2 Assembly overview - silencers with mountings
    203
  • 2 Secondary air system
    205
  • 2.1 Functional description
    205
  • 2.2 Parts of the secondary air system - Assembly overview
    205
  • 2.3 Overview of the secondary air system
    207
  • 2.4 Checking combination valve
    208
  • 2.5 Removing and installing combi-valve
    209
  • Ignition system
    211
  • 1 Servicing ignition system
    211
  • 1.1 General notes on ignition system
    211
  • 1.2 Safety precautions
    211
  • 1.3 Parts of the ignition system - Assembly overview
    212
  • 1.4 Removing and installing ignition coils with final output stage
    214
  • 1.5 Spark plug test data
    216
Manufacturer's designation 4-cyl. injection engine (5 valve)
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 AVC, AWP, AWU, AWV, BKF, BNU
Category Reparaturanleitung

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