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  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)

4-cylinder diesel engine (1.6 l engine, common rail)

For Beetle Limousine / Beetle Cabrio

Original Volkswagen repair manual


33,11 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

18.979 KB

451 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing motor, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Inlet and exhaust valves, 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 Exhaust gas temperature regulation. Show more
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Repair manual Beetle Limousine / Beetle Cabrio 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Marking
    1
  • 1.1 Engine number/engine data
    1
  • 2 General information
    3
  • 2.1 Numbering of cylinders
    3
  • 3 Safety information
    4
  • 3.1 Safety precautions when working on fuel system
    4
  • 3.2 Safety measures when working on vehicles with a start/stop system
    5
  • 3.4 Safety precautions when working on the cooling system
    6
  • 4 Repair instructions
    7
  • 4.1 Rules for cleanliness
    7
  • 4.2 Foreign objects in engine
    8
  • 4.3 Checking vacuum system
    8
  • Removing and installing engine
    9
  • 1 Removing and installing motor
    9
  • 1.1 Removing motor
    9
  • 1.2 Separating engine and gearbox
    21
  • 1.3 Securing engine on engine and gearbox support
    26
  • 1.4 Installing engine
    28
  • 2 Assembly mountings
    32
  • 2.1 Assembly overview - assembly mountings
    32
  • 2.2 Removing and installing engine mounting
    34
  • 2.3 Removing and installing gearbox mounting
    42
  • 2.4 Removing and installing pendulum support
    43
  • 2.5 Supporting engine in installation position
    44
  • 2.6 Adjusting assembly mountings
    51
  • 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
    53
  • 3 Engine cover panel
    55
  • 3.1 Removing and installing engine cover
    55
  • Crankshaft group
    56
  • 1 Cylinder block (pulley end)
    56
  • 1.1 Assembly overview - poly V-belt drive
    56
  • 1.2 Assembly overview - sealing flange, belt pulley end
    60
  • 1.3 Removing and installing poly-V belt
    62
  • 1.4 Removing and installing tensioner for poly V-belt
    66
  • 1.5 Removing and installing vibration damper
    68
  • 1.6 Removing and installing bracket for ancillaries
    69
  • 1.7 Removing and installing engine bracket
    71
  • 1.8 Renewing crankshaft oil seal - belt pulley end
    74
  • 1.9 Removing and installing sealing flange on pulley end
    77
  • 2 Cylinder block, gearbox end
    82
  • 2.1 Assembly overview - cylinder block, gearbox end
    82
  • 2.2 Removing and installing flywheel
    83
  • 2.3 Removing and installing sealing flange on gearbox side
    85
  • 3 Crankshaft
    99
  • 3.1 Assembly overview - crankshaft
    99
  • 3.2 Crankshaft dimensions
    100
  • 3.3 Renewing needle bearing in crankshaft
    100
  • 3.4 Measuring axial clearance of crankshaft
    102
  • 3.5 Measuring radial clearance of crankshaft
    103
  • 4 Pistons and conrods
    105
  • 4.1 Assembly overview - pistons and conrods
    105
  • 4.2 Measuring piston projection at TDC
    107
  • 4.3 Checking pistons and cylinder bores
    109
  • 4.4 Separating new conrod
    112
  • 4.5 Checking radial clearance of conrods
    113
  • Cylinder head, valve gear
    114
  • 1 Cylinder head
    114
  • 1.1 Assembly overview - cylinder head
    114
  • 1.2 Assembly overview - cylinder head cover
    118
  • 1.3 Removing and installing cylinder head
    120
  • 1.4 Removing and installing cylinder head cover
    135
  • 1.5 Removing and installing injector seals
    138
  • 1.6 Removing and installing vacuum pump
    139
  • 1.7 Checking compression
    141
  • 2 Toothed belt drive
    144
  • 2.1 Assembly overview - toothed belt
    144
  • 2.2 Removing and installing toothed belt
    147
  • 3 Valve gear
    171
  • 3.1 Assembly overview - valve gear
    171
  • 3.2 Measuring axial play of camshaft
    173
  • 3.3 Measuring radial play of camshaft
    174
  • 3.4 Removing and installing camshaft oil seal
    175
  • 3.5 Removing and installing camshaft
    183
  • 3.6 Checking hydraulic compensation elements
    192
  • 3.7 Removing and installing valve stem seals
    193
  • 4 Inlet and exhaust valves
    202
  • 4.1 Reworking valve seats
    202
  • 4.2 Checking valve guides
    202
  • 4.3 Checking valves
    203
  • 4.4 Valve dimensions
    203
  • Lubrication
    204
  • 1 Sump, oil pump
    204
  • 1.1 Assembly overview - sump/oil pump
    204
  • 1.2 Engine oil:
    210
  • 1.3 Removing and installing oil sump
    211
  • 1.4 Removing and installing oil pump
    215
  • 1.5 Removing and installing oil level and oil temperature sender G266
    218
  • 2 Engine oil cooler
    220
  • 2.1 Assembly overview - engine oil cooler
    220
  • 2.2 Removing and installing engine oil cooler
    220
  • 3 Oil filter, oil pressure switch
    224
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    224
  • 3.2 Removing and installing oil pressure switch F1
    225
  • 3.3 Checking oil pressure
    226
  • 3.4 Checking oil pressure and oil pressure switch
    227
  • 3.5 Removing and installing oil filter housing
    228
  • 4 Oil circuit
    233
  • 4.1 Assembly overview - oil circuit
    233
  • 4.2 Removing and installing oil return line for turbocharger
    233
  • 5 Balancer shaft module
    239
  • 5.1 Removing and installing balance shaft module
    239
  • Cooling
    249
  • 1 Cooling system/coolant
    249
  • 1.1 Connection diagram - coolant hoses
    249
  • 1.2 Checking cooling system for leaks
    251
  • 1.3 Draining and adding coolant
    252
  • 2 Coolant pump, regulation of cooling system
    261
  • 2.1 Assembly overview - coolant pump, thermostat
    261
  • 2.2 Assembly overview - electric coolant pump
    261
  • 2.3 Removing and installing electric coolant pump
    262
  • 2.4 Removing and installing coolant pump
    265
  • 2.5 Removing and installing 4/2-way valve with thermostat
    267
  • 2.6 Removing and installing coolant temperature sender G62
    273
  • 2.7 Removing and installing radiator outlet coolant temperature sender G83
    275
  • 3 Coolant pipes
    278
  • 3.1 Assembly overview - coolant pipes
    278
  • 3.2 Removing and installing coolant pipes
    280
  • 4 Radiator, radiator fan
    293
  • 4.1 Assembly overview - radiator/radiator fan
    293
  • 4.2 Removing and installing radiator
    294
  • 4.3 Removing and installing radiator cowl with radiator fan
    295
  • 4.4 Removing and installing radiator fan
    297
  • Turbocharging/supercharging
    298
  • 1 Turbocharger
    298
  • 1.1 Assembly overview - turbocharger
    298
  • 1.2 Removing and installing turbocharger
    300
  • 1.3 Renewing vacuum unit for turbocharger
    307
  • 2 Charge air system
    315
  • 2.1 Assembly overview - charge air system
    315
  • 2.2 Assembly overview - charge-air hose connections
    317
  • 2.3 Removing and installing charge air cooler
    319
  • 2.4 Removing and installing charge pressure sender G31
    321
  • 2.5 Checking charge air system for leaks
    322
  • Mixture preparation - injection
    326
  • 1 Injection system
    326
  • 1.1 Schematic overview - fuel system
    326
  • 1.2 Filling/bleeding fuel system
    328
  • 1.3 Checking fuel system for leaks
    329
  • 2 Vacuum system
    330
  • 2.1 Assembly overview - vacuum system
    330
  • 2.2 Checking vacuum system
    331
  • 3 Injectors/high-pressure accumulator (rail)
    335
  • 3.1 Assembly overview - injectors
    335
  • 3.2 Assembly overview - fuel system
    336
  • 3.3 Adapting correction values for injectors
    339
  • 3.4 Testing jammed-open injectors
    340
  • 3.5 Removing and installing injectors
    341
  • 3.6 Removing and installing high-pressure lines
    345
  • 3.7 Removing and installing fuel rail
    349
  • 4 Air filter
    354
  • 4.1 Assembly overview - air filter housing
    354
  • 4.2 Removing and installing air filter housing
    356
  • 5 Intake manifold
    359
  • 5.1 Assembly overview - intake manifold
    359
  • 5.2 Removing and installing intake manifold
    361
  • 5.3 Removing and installing throttle valve module J338
    365
  • 6 Senders and sensors
    367
  • 6.1 Checking fuel pressure regulating valve N276
    367
  • 6.2 Removing and installing fuel pressure regulating valve N276
    368
  • 6.3 Removing and installing fuel pressure sender G247
    370
  • 6.4 Removing and installing air mass meter G70
    373
  • 6.5 Removing and installing pressure differential sender G505
    374
  • 7 Engine (motor) control unit
    378
  • 7.1 Removing and installing engine control unit J623
    378
  • 7.2 Removing and installing engine (motor) control unit J623 with protective housing
    379
  • 8 High-pressure pump
    382
  • 8.1 Assembly overview - high-pressure pump
    382
  • 8.2 Removing and installing high-pressure pump
    384
  • 9 Lambda probe
    391
  • 9.1 Removing and installing Lambda probe
    391
  • Exhaust system
    393
  • 1 Exhaust pipes and silencers
    393
  • 1.1 Assembly overview - silencers
    393
  • 1.2 Removing and installing rear silencer
    395
  • 1.3 Aligning exhaust system free of stress
    397
  • 1.4 Installation position of clamp
    398
  • 2 Emission control
    400
  • 2.1 Assembly overview - emission control
    400
  • 2.2 Removing and installing particulate filter
    403
  • 3 Exhaust gas temperature regulation
    412
  • 3.1 Removing and installing parts of exhaust gas temperature regulation
    412
  • 4 Exhaust gas recirculation
    419
  • 4.1 Assembly overview - exhaust gas recirculation
    419
  • 4.2 Removing and installing exhaust gas recirculation cooler
    421
  • 4.3 Checking changeover for exhaust gas recirculation cooler
    424
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    425
  • 4.5 Cleaning exhaust gas recirculation system
    430
  • Glow plug system
    438
  • 1 Glow plug system
    438
  • 1.1 Removing and installing glow plug
    438
  • 1.2 Removing and installing automatic glow period control unit J179
    440
  • 1.3 Removing and installing Hall sender G40
    442
  • 1.4 Removing and installing engine speed sender G28
    443
Manufacturer's designation 4-cylinder diesel engine (1.6 l engine, common rail)
Manufacturer Volkswagen
Suitable for Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012)
Suitable car types 5C1, 5C7
Engine code CAYC
Category Reparaturanleitung

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