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  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 2 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, 4V, turbocharger)

4-cylinder common rail engine (2.0 l, 4V, turbocharger)

For Beetle Limousine / Beetle Cabrio

Original Volkswagen repair manual


31,73 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

44.540 KB

427 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual Beetle Limousine / Beetle Cabrio 4-cylinder common rail engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety measures when working on fuel supply
    1
  • 1.2 Safety measures when working on vehicles with a start/stop system
    2
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on SCR system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 Repair instructions
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 Adapting learnt value for SCR system
    6
  • 3.3 Foreign objects in engine
    6
  • 3.4 Contact corrosion
    7
  • 3.5 Routing and attachment of lines
    7
  • 3.6 Fitting radiator and condensers
    7
  • 4 Technical data
    9
  • 4.1 Coolant
    9
  • Removing and installing engine
    11
  • 1 Removing and installing engine
    11
  • 1.1 Removing engine
    11
  • 1.2 Separating engine and gearbox
    21
  • 1.3 Securing engine on engine and gearbox support
    22
  • 1.4 Installing engine
    24
  • 2 Assembly mountings
    28
  • 2.1 Assembly overview - assembly mountings
    28
  • 2.2 Removing and installing engine mounting
    30
  • 2.3 Removing and installing gearbox mounting
    31
  • 2.4 Removing and installing pendulum support
    32
  • 2.5 Supporting engine in installation position
    33
  • 2.6 Adjusting assembly mountings
    38
  • 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
    39
  • 3 Engine cover panel
    40
  • 3.1 Removing and installing engine cover
    40
  • Crankshaft group
    41
  • 1 Cylinder block (pulley end)
    41
  • 1.1 Assembly overview - cylinder block (pulley end)
    41
  • 1.2 Assembly overview - sealing flange, belt pulley end
    43
  • 1.3 Removing and installing poly-V belt
    43
  • 1.4 Removing and installing tensioner for poly V-belt
    45
  • 1.5 Removing and installing vibration damper
    45
  • 1.6 Removing and installing bracket for ancillaries
    46
  • 1.7 Removing and installing engine support
    47
  • 1.8 Removing and installing sealing flange on pulley end
    48
  • 2 Cylinder block, gearbox end
    51
  • 2.1 Assembly overview - cylinder block, gearbox end
    51
  • 2.2 Removing and installing flywheel
    52
  • 2.3 Removing and installing sealing flange on gearbox side
    53
  • 3 Crankshaft
    62
  • 3.1 Assembly overview - crankshaft
    62
  • 3.2 Crankshaft dimensions
    63
  • 3.3 Renewing needle bearing in crankshaft
    63
  • 3.4 Measuring axial clearance of crankshaft
    65
  • 4 Pistons and conrods
    67
  • 4.1 Assembly overview - pistons and conrods
    67
  • 4.2 Removing and installing pistons
    69
  • 4.3 Measuring piston projection at TDC
    70
  • 4.4 Checking pistons and cylinder bores
    72
  • 4.5 Separating new conrod
    74
  • 4.6 Checking radial clearance of conrods
    74
  • 4.7 Removing and installing oil spray jets
    74
  • Cylinder head, valve gear
    76
  • 1 Cylinder head
    76
  • 1.1 Assembly overview - cylinder head
    76
  • 1.2 Assembly overview - cylinder head cover
    78
  • 1.3 Removing and installing cylinder head
    80
  • 1.4 Removing and installing cylinder head cover
    90
  • 1.5 Removing and installing injector seals
    92
  • 1.6 Removing and installing camshaft housing
    94
  • 1.7 Checking compression
    98
  • 2 Toothed belt drive
    100
  • 2.1 Assembly overview - toothed belt cover
    100
  • 2.2 Assembly overview - toothed belt
    101
  • 2.3 Removing and installing toothed belt guard
    102
  • 2.4 Removing and installing toothed belt
    105
  • 2.5 Removing toothed belt from camshaft
    116
  • 3 Valve gear
    121
  • 3.1 Assembly overview - valve gear
    121
  • 3.2 Measuring axial play of camshaft
    124
  • 3.3 Removing and installing camshaft oil seal
    125
  • 3.4 Removing and installing camshaft adjuster
    126
  • 3.5 Removing and installing camshaft control valve 1 N205
    129
  • 3.6 Removing control valve from and installing on inlet camshaft control valve 1 N205
    130
  • 3.7 Checking hydraulic compensation elements
    132
  • 3.8 Removing and installing valve stem seals
    133
  • 4 Inlet and exhaust valves
    140
  • 4.1 Checking valve guides
    140
  • 4.2 Checking valves
    141
  • 4.3 Valve dimensions
    141
  • Lubrication
    142
  • 1 Sump, oil pump
    142
  • 1.1 Assembly overview - sump/oil pump
    142
  • 1.2 Engine oil:
    147
  • 1.3 Removing and installing sump
    147
  • 1.4 Removing and installing lower part of sump
    150
  • 1.5 Removing and installing upper part of sump
    154
  • 1.6 Removing and installing oil pump
    158
  • 1.7 Removing and installing oil level and oil temperature sender G266
    159
  • 2 Engine oil cooler
    161
  • 2.1 Removing and installing engine oil cooler
    161
  • 3 Oil filter, oil pressure switch
    162
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    162
  • 3.2 Removing and installing oil pressure switch F1
    163
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    164
  • 3.4 Checking oil pressure
    165
  • 3.5 Removing and installing oil filter housing
    165
  • 3.6 Removing and installing oil pressure regulating valve N428
    167
  • Cooling
    169
  • 1 Cooling system/coolant
    169
  • 1.1 Connection diagram - coolant hoses
    169
  • 1.2 Assembly overview - engine preheater
    171
  • 1.3 Checking cooling system for leaks
    171
  • 1.4 Draining coolant
    173
  • 1.5 Filling with coolant
    174
  • 1.6 Checking electric vacuum pump VAS 6096/2
    184
  • 1.7 Flushing cooling system
    184
  • 1.8 Flushing cooling system, quick reference guide
    205
  • 2 Coolant pump, regulation of cooling system
    207
  • 2.1 Assembly overview - coolant pump, thermostat
    207
  • 2.2 Assembly overview - electric coolant pump
    209
  • 2.3 Assembly overview - coolant temperature sender
    214
  • 2.4 Removing and installing electric coolant pump
    215
  • 2.5 Removing and installing coolant pump
    227
  • 2.6 Removing and installing thermostat
    228
  • 2.7 Checking thermostat
    228
  • 2.8 Removing and installing coolant valve for cylinder head N489
    229
  • 2.9 Removing and installing coolant temperature sender G62
    229
  • 2.10 Removing and installing radiator outlet coolant temperature sender G83
    230
  • 3 Coolant pipes
    232
  • 3.1 Assembly overview - coolant pipes
    232
  • 3.2 Removing and installing coolant pipes
    233
  • 4 Radiator, radiator fan
    244
  • 4.1 Assembly overview - radiator/radiator fan
    244
  • 4.2 Removing and installing radiator
    246
  • 4.3 Removing and installing water radiator for charge air cooling circuit
    247
  • 4.4 Removing and installing radiator cowl with radiator fan
    250
  • 4.5 Removing and installing radiator fan
    251
  • Turbocharging/supercharging
    252
  • 1 Turbocharger
    252
  • 1.1 Assembly overview - turbocharger
    252
  • 1.2 Removing and installing turbocharger
    254
  • 1.3 Renewing vacuum unit for turbocharger
    258
  • 1.4 Removing and installing connection for turbocharger
    263
  • 2 Charge air system
    265
  • 2.1 Assembly overview - charge air system
    265
  • 2.2 Removing and installing charge pressure sender G31
    267
  • 2.3 Checking charge air system for leaks
    267
  • Mixture preparation - injection
    270
  • 1 Injection system
    270
  • 1.1 Schematic overview - fuel system
    270
  • 1.2 Overview of fitting locations - injection system
    271
  • 1.3 Filling/bleeding fuel system
    277
  • 1.4 Checking fuel system for leaks
    277
  • 2 Vacuum system
    278
  • 2.1 Connection diagram - vacuum system
    278
  • 2.2 Checking vacuum system
    278
  • 3 Injectors/high-pressure accumulator (rail)
    280
  • 3.1 Assembly overview - injectors
    280
  • 3.2 Assembly overview - fuel rail
    282
  • 3.3 Adapting correction values for injectors
    283
  • 3.4 Testing injectors
    283
  • 3.5 Checking return flow rate of injectors with engine running
    283
  • 3.6 Checking return flow rate of injectors at starter speed
    286
  • 3.7 Testing jammed-open injectors
    287
  • 3.8 Removing and installing injectors
    288
  • 3.9 Removing and installing high-pressure lines
    291
  • 3.10 Removing and installing fuel rail
    293
  • 4 Air filter
    295
  • 4.1 Assembly overview - air filter housing
    295
  • 4.2 Removing and installing air filter housing
    296
  • 5 Intake manifold
    299
  • 5.1 Assembly overview - intake manifold
    299
  • 5.2 Removing and installing intake manifold
    301
  • 5.3 Removing and installing throttle valve module J338
    304
  • 6 Senders and sensors
    307
  • 6.1 Removing and installing fuel pressure regulating valve N276
    307
  • 6.2 Checking fuel pressure regulating valve N276
    313
  • 6.3 Removing and installing fuel pressure sender G247
    314
  • 6.4 Removing and installing air mass meter G70
    315
  • 6.5 Removing and installing pressure differential sender G505
    317
  • 6.6 Removing and installing exhaust gas pressure sensor 1 G450
    318
  • 6.7 Removing and installing NOx sender 2 G687
    319
  • 6.8 Removing and installing control unit for NOx sender GX30
    321
  • 6.10 Removing and installing fuel temperature sender G81
    327
  • 7 Engine control unit
    330
  • 7.1 Removing and installing engine (motor) control unit J623
    330
  • 8 High-pressure pump
    334
  • 8.1 Assembly overview - high-pressure pump
    334
  • 8.2 Removing and installing high-pressure pump
    334
  • 9 Lambda probe
    338
  • 9.1 Assembly overview - Lambda probe
    338
  • 9.2 Removing and installing Lambda probe
    340
  • Exhaust system
    343
  • 1 Exhaust pipes and silencers
    343
  • 1.1 Assembly overview - silencers
    343
  • 1.2 Assembly overview - front exhaust pipe
    345
  • 1.3 Removing and installing front exhaust pipe
    346
  • 1.4 Separating exhaust pipes from silencers
    347
  • 1.5 Removing and installing rear silencer
    348
  • 1.6 Aligning exhaust system free of stress
    349
  • 1.7 Checking exhaust system for leaks
    349
  • 1.8 Installation position of clamp
    350
  • 1.9 Align end exhaust pipes
    350
  • 2 Emission control
    352
  • 2.1 Assembly overview - emission control
    352
  • 2.2 Removing and installing emission control module
    354
  • 2.3 Removing and installing exhaust flap control unit J883
    360
  • 3 SCR system (selective catalytic reduction)
    362
  • 3.1 Assembly overview - tank for reducing agent
    362
  • 3.2 Assembly overview - reducing agent delivery line
    364
  • 3.3 Assembly overview - delivery module for reducing agent
    365
  • 3.4 Assembly overview - injector for reducing agent
    366
  • 3.5 Removing and installing reducing agent tank
    367
  • 3.6 Removing and installing reducing agent supply line
    369
  • 3.7 Removing and installing reducing agent supply line
    371
  • 3.8 Disconnecting reducing agent supply line
    375
  • 3.9 Removing and installing delivery module for reducing agent
    379
  • 3.10 Removing and installing injector for reduction agent N474
    381
  • 3.11 Removing and installing control unit for reducing-agent heater J891
    382
  • 3.12 Draining reducing agent tank
    383
  • 4 Exhaust gas temperature regulation
    386
  • 4.1 Assembly overview - exhaust gas temperature regulation
    386
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    389
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    390
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    393
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    394
  • 5 Exhaust gas recirculation
    397
  • 5.1 Assembly overview - exhaust gas recirculation
    397
  • 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
    401
  • 5.3 Removing and installing exhaust gas recirculation cooler
    401
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    404
  • 5.5 Removing and installing exhaust gas recirculation valve 1 GX5
    407
  • 5.6 Removing and installing exhaust gas recirculation valve 2 GX6
    408
  • 5.7 Removing and installing exhaust gas recirculation temperature sensor G98
    411
  • Glow plug system
    413
  • 1 Glow plug system
    413
  • 1.1 Assembly overview - glow plug system
    413
  • 1.2 Removing and installing glow plug
    415
  • 1.3 Removing and installing automatic glow period control unit J179
    417
  • 1.4 Removing and installing Hall sender G40
    418
  • 1.5 Removing and installing engine speed sender G28
    418
Manufacturer's designation 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
Manufacturer Volkswagen
Suitable for Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012)
Suitable car types 5C1, 5C7
Engine code CUUB, CVCA, DELA, DEBA
Category Reparaturanleitung

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