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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 VW Beetle / Beetle

Original Volkswagen repair manual


28,78 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

39.888 KB

378 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, Exhaust turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual VW Beetle / Beetle 4-cylinder common rail engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety regulations for 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 the 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
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Separating engine and gearbox
    18
  • 1.3 Securing engine on engine and gearbox support
    19
  • 1.4 Installing engine
    21
  • 2 Assembly mountings
    25
  • 2.1 Assembly overview - assembly mountings
    25
  • 2.2 Removing and installing engine mounting
    27
  • 2.3 Removing and installing gearbox mounting
    28
  • 2.4 Removing and installing pendulum support
    29
  • 2.5 Supporting engine in installation position
    30
  • 2.6 Adjusting assembly mountings
    35
  • 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
    36
  • 3 Engine cover panel
    37
  • 3.1 Removing and installing engine cover
    37
  • Crankshaft group
    38
  • 1 Cylinder block (pulley end)
    38
  • 1.1 Assembly overview - cylinder block (pulley end)
    38
  • 1.2 Assembly overview - sealing flange, belt pulley end
    40
  • 1.3 Removing and installing poly-V belt
    40
  • 1.4 Removing and installing tensioner for poly V-belt
    42
  • 1.5 Removing and installing vibration damper
    42
  • 1.6 Removing and installing bracket for ancillaries
    43
  • 1.7 Removing and installing engine support
    44
  • 1.8 Removing and installing sealing flange on pulley end
    45
  • 2 Cylinder block, gearbox end
    48
  • 2.1 Assembly overview - cylinder block, gearbox end
    48
  • 2.2 Removing and installing flywheel
    49
  • 2.3 Removing and installing sealing flange on gearbox side
    50
  • 3 Crankshaft
    59
  • 3.1 Assembly overview - crankshaft
    59
  • 3.2 Crankshaft dimensions
    60
  • 3.3 Renewing needle bearing in crankshaft
    60
  • 3.4 Measuring axial clearance of crankshaft
    62
  • 4 Pistons and conrods
    64
  • 4.1 Assembly overview - pistons and conrods
    64
  • 4.2 Removing and installing pistons
    66
  • 4.3 Measuring piston projection at TDC
    67
  • 4.4 Checking pistons and cylinder bores
    69
  • 4.5 Separating new conrod
    71
  • 4.6 Checking radial clearance of conrods
    71
  • 4.7 Removing and installing oil spray jets
    71
  • Cylinder head, valve gear
    73
  • 1 Cylinder head
    73
  • 1.1 Assembly overview - cylinder head
    73
  • 1.2 Assembly overview - cylinder head cover
    75
  • 1.3 Removing and installing cylinder head
    77
  • 1.4 Removing and installing cylinder head cover
    87
  • 1.5 Removing and installing injector seals
    89
  • 1.6 Removing and installing camshaft housing
    91
  • 1.7 Checking compression
    95
  • 2 Toothed belt drive
    97
  • 2.1 Assembly overview - toothed belt cover
    97
  • 2.2 Assembly overview - toothed belt
    98
  • 2.3 Removing and installing toothed belt guard
    99
  • 2.4 Removing and installing toothed belt
    102
  • 2.5 Removing toothed belt from camshaft
    113
  • 3 Valve gear
    118
  • 3.1 Assembly overview - valve gear
    118
  • 3.2 Measuring axial play of camshaft
    121
  • 3.3 Removing and installing camshaft oil seal
    122
  • 3.4 Removing and installing camshaft adjuster
    123
  • 3.5 Removing and installing camshaft control valve 1 N205
    126
  • 3.6 Removing control valve from and installing on inlet camshaft control valve 1 N205
    127
  • 3.7 Checking hydraulic compensation elements
    129
  • 3.8 Removing and installing valve stem seals
    130
  • 4 Inlet and exhaust valves
    137
  • 4.1 Checking valve guides
    137
  • 4.2 Checking valves
    138
  • 4.3 Valve dimensions
    138
  • Lubrication
    139
  • 1 Sump, oil pump
    139
  • 1.1 Assembly overview - sump/oil pump
    139
  • 1.2 Engine oil:
    144
  • 1.3 Removing and installing sump
    144
  • 1.4 Removing and installing lower part of sump
    147
  • 1.5 Removing and installing upper part of sump
    151
  • 1.6 Removing and installing oil pump
    155
  • 1.7 Removing and installing oil level and oil temperature sender G266
    156
  • 2 Engine oil cooler
    158
  • 2.1 Removing and installing engine oil cooler
    158
  • 3 Oil filter, oil pressure switch
    159
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    159
  • 3.2 Removing and installing oil pressure switch F1
    160
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    161
  • 3.4 Checking oil pressure
    162
  • 3.5 Removing and installing oil filter housing
    162
  • 3.6 Removing and installing oil pressure regulating valve N428
    164
  • Cooling
    166
  • 1 Cooling system/coolant
    166
  • 1.1 Connection diagram - coolant hoses
    166
  • 1.2 Assembly overview - engine preheater
    168
  • 1.3 Checking cooling system for leaks
    168
  • 1.4 Draining and adding coolant
    170
  • 2 Coolant pump, regulation of cooling system
    176
  • 2.1 Assembly overview - coolant pump, thermostat
    176
  • 2.2 Assembly overview - electric coolant pump
    178
  • 2.3 Assembly overview - coolant temperature sender
    183
  • 2.4 Removing and installing electric coolant pump
    184
  • 2.5 Removing and installing coolant pump
    196
  • 2.6 Removing and installing thermostat
    197
  • 2.7 Checking thermostat
    197
  • 2.8 Removing and installing coolant valve for cylinder head N489
    198
  • 2.9 Removing and installing coolant temperature sender G62
    198
  • 2.10 Removing and installing radiator outlet coolant temperature sender G83
    199
  • 3 Coolant pipes
    201
  • 3.1 Assembly overview - coolant pipes
    201
  • 3.2 Removing and installing coolant pipes
    202
  • 4 Radiator, radiator fan
    212
  • 4.1 Assembly overview - radiator/radiator fan
    212
  • 4.2 Removing and installing radiator
    214
  • 4.3 Removing and installing water radiator for charge air cooling circuit
    215
  • 4.4 Removing and installing radiator cowl with radiator fan
    218
  • 4.5 Removing and installing radiator fan
    219
  • Turbocharging/supercharging
    220
  • 1 Exhaust turbocharger
    220
  • 1.1 Assembly overview - turbocharger
    220
  • 1.2 Removing and installing turbocharger
    222
  • 1.3 Renewing vacuum unit for turbocharger
    226
  • 1.4 Removing and installing connection for turbocharger
    231
  • 2 Charge air system
    233
  • 2.1 Assembly overview - charge air system
    233
  • 2.2 Removing and installing charge pressure sender G31
    235
  • 2.3 Checking charge air system for leaks
    235
  • Mixture preparation - injection
    238
  • 1 Injection system
    238
  • 1.1 Schematic overview - fuel system
    238
  • 1.2 Overview of fitting locations - injection system
    239
  • 1.3 Filling/bleeding fuel system
    245
  • 1.4 Checking fuel system for leaks
    245
  • 2 Vacuum system
    246
  • 2.1 Connection diagram - vacuum system
    246
  • 2.2 Checking vacuum system
    246
  • 3 Injectors/high-pressure accumulator (rail)
    248
  • 3.1 Assembly overview - injectors
    248
  • 3.2 Assembly overview - fuel rail
    250
  • 3.3 Adapting correction values for injectors
    251
  • 3.4 Testing injectors
    251
  • 3.5 Checking return flow rate of injectors with engine running
    251
  • 3.6 Checking return flow rate of injectors at starter speed
    254
  • 3.7 Testing jammed-open injectors
    255
  • 3.8 Removing and installing injectors
    256
  • 3.9 Removing and installing high-pressure lines
    259
  • 3.10 Removing and installing fuel rail
    261
  • 4 Air filter
    263
  • 4.1 Assembly overview - air filter housing
    263
  • 4.2 Removing and installing air filter housing
    264
  • 5 Intake manifold
    267
  • 5.1 Assembly overview - intake manifold
    267
  • 5.2 Removing and installing intake manifold
    269
  • 5.3 Removing and installing throttle valve module J338
    272
  • 6 Senders and sensors
    275
  • 6.1 Removing and installing fuel pressure regulating valve N276
    275
  • 6.2 Checking fuel pressure regulating valve N276
    281
  • 6.3 Removing and installing fuel pressure sender G247
    282
  • 6.4 Removing and installing air mass meter G70
    283
  • 6.5 Removing and installing pressure differential sender G505
    285
  • 6.6 Removing and installing exhaust gas pressure sensor 1 G450
    286
  • 6.7 Removing and installing NOx sender 2 G687
    287
  • 6.8 Removing and installing NOx sender G295
    289
  • 6.10 Removing and installing fuel temperature sender G81
    290
  • 7 Engine control unit
    293
  • 7.1 Removing and installing engine (motor) control unit J623
    293
  • 8 High-pressure pump
    297
  • 8.1 Assembly overview - high-pressure pump
    297
  • 8.2 Removing and installing high-pressure pump
    297
  • 9 Lambda probe
    301
  • 9.1 Assembly overview - Lambda probe
    301
  • 9.2 Removing and installing Lambda probe
    303
  • Exhaust system
    304
  • 1 Exhaust pipes and silencers
    304
  • 1.1 Assembly overview - silencers
    304
  • 1.2 Assembly overview - front exhaust pipe
    306
  • 1.3 Removing and installing front exhaust pipe
    307
  • 1.4 Separating exhaust pipes from silencers
    308
  • 1.5 Removing and installing rear silencer
    309
  • 1.6 Aligning exhaust system free of stress
    310
  • 1.7 Check exhaust system for leaks
    311
  • 1.8 Align end exhaust pipes
    311
  • 2 Exhaust gas cleaning
    312
  • 2.1 Assembly overview - emission control
    312
  • 2.2 Removing and installing emission control module
    314
  • 2.3 Removing and installing exhaust flap control unit J883
    320
  • 3 SCR system (selective catalytic reduction)
    321
  • 3.1 Assembly overview - tank for reducing agent
    321
  • 3.2 Assembly overview - reducing agent delivery line
    323
  • 3.3 Assembly overview - delivery module for reducing agent
    324
  • 3.4 Assembly overview - injector for reducing agent
    325
  • 3.5 Removing and installing reducing agent tank
    326
  • 3.6 Disconnecting reducing agent supply line
    329
  • 3.7 Removing and installing delivery module for reducing agent
    331
  • 3.8 Removing and installing injector for reduction agent N474
    333
  • 3.9 Removing and installing control unit for reducing-agent heater J891
    335
  • 3.10 Draining reducing agent tank
    336
  • 4 Exhaust gas temperature regulation
    339
  • 4.1 Assembly overview - exhaust gas temperature regulation
    339
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    342
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    343
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    346
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    348
  • 5 Exhaust gas recirculation
    351
  • 5.1 Assembly overview - exhaust gas recirculation
    351
  • 5.2 Assembly overview - exhaust gas recirculation control motor V338
    353
  • 5.3 Removing and installing exhaust gas recirculation cooler
    353
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    356
  • 5.5 Removing and installing exhaust gas recirculation control motor V338
    358
  • 5.6 Removing and installing exhaust gas recirculation control motor 2 V339
    359
  • 5.7 Removing and installing exhaust gas recirculation temperature sensor G98
    361
  • Glow plug system
    364
  • 1 Glow plug system
    364
  • 1.1 Assembly overview - glow plug system
    364
  • 1.2 Removing and installing glow plug
    366
  • 1.3 Removing and installing automatic glow period control unit J179
    368
  • 1.4 Removing and installing Hall sender G40
    369
  • 1.5 Removing and installing engine speed sender G28
    369
Manufacturer's designation 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
Manufacturer Volkswagen
Suitable for VW Beetle (2011) / Beetle (2017)
Suitable car types 5C8, 5C2
Engine code CUUB, DELA, DGMA
Category Reparaturanleitung

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