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

4-cylinder diesel engine (2.0 l engine, common rail)

For Beetle Limousine / Beetle Cabrio

Original Volkswagen repair manual


32,02 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

16.923 KB

432 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 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 Identification
    1
  • 1.1 Engine number/engine data
    1
  • 2 Safety information
    3
  • 2.1 Safety precautions when working on fuel system
    3
  • 2.2 Safety measures when working on vehicles with a start/stop system
    4
  • 2.4 Safety precautions when working on the cooling system
    5
  • 3 Repair instructions
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 Foreign objects in engine
    7
  • 3.3 Checking vacuum system
    7
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Separating engine and gearbox
    22
  • 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 Supporting engine in installation position
    43
  • 2.4 Adjusting assembly mountings
    52
  • 2.5 Checking adjustment of assembly mountings
    53
  • 3 Engine cover panel
    55
  • 3.1 Removing and installing engine cover
    55
  • Crankshaft group
    57
  • 1 Cylinder block (pulley end)
    57
  • 1.1 Assembly overview - poly V-belt drive
    57
  • 1.2 Removing and installing poly-V belt
    61
  • 1.3 Removing and installing tensioner for poly V-belt
    66
  • 1.4 Removing and installing vibration damper
    67
  • 1.5 Removing and installing bracket for ancillaries
    69
  • 1.6 Removing and installing engine bracket
    71
  • 1.7 Assembly overview - sealing flange, belt pulley end
    74
  • 1.8 Renewing crankshaft oil seal - belt pulley end
    76
  • 1.9 Removing and installing sealing flange on pulley end
    78
  • 2 Cylinder block, gearbox end
    83
  • 2.1 Assembly overview - cylinder block, gearbox end
    83
  • 2.2 Removing and installing flywheel
    84
  • 2.3 Removing and installing sealing flange on gearbox side
    86
  • 3 Crankshaft
    100
  • 3.1 Assembly overview - crankshaft
    100
  • 3.2 Crankshaft dimensions
    101
  • 3.3 Renewing needle bearing in crankshaft
    101
  • 3.4 Measuring axial clearance of crankshaft
    103
  • 3.5 Measuring radial clearance of crankshaft
    104
  • 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
    137
  • 1.6 Removing and installing vacuum pump
    138
  • 1.7 Checking compression
    140
  • 2 Toothed belt drive
    143
  • 2.1 Assembly overview - toothed belt
    143
  • 2.2 Removing and installing toothed belt
    145
  • 3 Valve gear
    157
  • 3.1 Assembly overview - valve gear
    157
  • 3.2 Measuring axial play of camshaft
    159
  • 3.3 Measuring radial play of camshaft
    160
  • 3.4 Removing and installing camshaft oil seal
    161
  • 3.5 Removing and installing camshaft
    169
  • 3.6 Checking hydraulic compensation elements
    178
  • 3.7 Removing and installing valve stem seal
    179
  • 4 Inlet and exhaust valves
    188
  • 4.1 Reworking valve seats
    188
  • 4.2 Checking valve guides
    188
  • 4.3 Checking valves
    189
  • 4.4 Valve dimensions
    189
  • Lubrication
    190
  • 1 Engine oil:
    190
  • 1.1 Oil capacities
    190
  • 1.2 Checking engine oil level
    190
  • 2 Sump, oil pump
    192
  • 2.1 Assembly overview - sump/oil pump
    192
  • 2.2 Removing and installing oil sump
    195
  • 2.3 Removing and installing oil pump
    200
  • 2.4 Removing and installing oil level and oil temperature sender G 266
    201
  • 3 Oil filter, oil pressure switch
    203
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    203
  • 3.2 Removing and installing oil pressure switch F1
    205
  • 3.3 Checking oil pressure
    206
  • 3.4 Checking oil pressure and oil pressure switch
    207
  • 3.5 Removing and installing oil filter housing
    209
  • 4 Oil circuit
    214
  • 4.1 Assembly overview - oil circuit
    214
  • 4.2 Removing and installing oil supply line to turbocharger
    214
  • 4.3 Removing and installing oil return line for turbocharger
    216
  • Cooling
    223
  • 1 Cooling system/coolant
    223
  • 1.1 Coolant hose connection diagram
    223
  • 1.2 Overview of fitting locations – cooling system
    225
  • 1.3 Engine preheater
    229
  • 1.4 Checking cooling system for leaks
    231
  • 1.5 Draining and adding coolant
    233
  • 2 Coolant pump, regulation of cooling system
    239
  • 2.1 Assembly overview - coolant pump, thermostat
    239
  • 2.2 Coolant circulation pump 2 V178
    239
  • 2.3 Removing and installing coolant pump
    243
  • 2.4 Removing and installing 4/2-way valve with thermostat
    245
  • 2.5 Removing and installing coolant temperature sender
    251
  • 3 Coolant pipes
    256
  • 3.1 Assembly overview - coolant pipes
    256
  • 3.2 Removing and installing coolant pipes
    258
  • 4 Radiator, radiator fan
    268
  • 4.1 Assembly overview - radiator/radiator fan
    268
  • 4.2 Removing and installing radiator
    269
  • 4.3 Removing and installing radiator cowl with radiator fan
    272
  • 4.4 Removing and installing radiator fan
    273
  • Turbocharging/supercharging
    274
  • 1 Turbocharger
    274
  • 1.1 Assembly overview - turbocharger
    274
  • 1.2 Removing and installing turbocharger
    278
  • 1.3 Renewing vacuum unit for turbocharger
    282
  • 2 Charge air system
    292
  • 2.1 Assembly overview - charge air system
    292
  • 2.2 Assembly overview - charge-air hose connections
    294
  • 2.3 Removing and installing charge air cooler
    296
  • 2.5 Checking charge air system for leaks
    300
  • Mixture preparation - injection
    305
  • 1 Injection system
    305
  • 1.1 Schematic overview - fuel system
    305
  • 1.2 Filling/bleeding fuel system
    307
  • 1.3 Checking for leaks in the fuel system
    308
  • 2 Vacuum system
    309
  • 2.1 Connection diagram - vacuum system
    309
  • 2.2 Checking vacuum system
    310
  • 3 Injectors/high-pressure accumulator (rail)
    313
  • 3.1 Assembly overview - injectors
    313
  • 3.2 Removing and installing injectors
    317
  • 3.3 Installing high-pressure lines
    322
  • 4 High-pressure pump
    325
  • 4.1 Assembly overview - high-pressure pump
    325
  • 4.2 Removing and installing high-pressure pump
    327
  • 5 Senders and sensors
    332
  • 5.1 Checking fuel pressure regulating valve N276
    332
  • 5.2 Check pressure retention valve in fuel return line
    333
  • 5.3 Removing and installing fuel pressure regulating valve N276
    334
  • 5.4 Removing and installing fuel pressure sender G247
    336
  • 5.5 Removing and installing air mass meter G70
    338
  • 5.6 Removing and installing differential pressure sensor
    340
  • 6 Intake manifold
    342
  • 6.1 Assembly overview – intake manifold
    342
  • 6.2 Removing and installing intake manifold
    343
  • 6.3 Removing and installing throttle valve module
    348
  • 7 Lambda probe
    351
  • 7.1 Removing and installing Lambda probe G39
    351
  • 8 Air filter
    353
  • 8.1 Assembly overview - air filter
    353
  • 8.2 Removing and installing air filter housing
    355
  • 8.3 Removing and installing air filter element
    356
  • 8.4 Checking changeover flap for intake air preheating
    358
  • 8.5 Removing and installing changeover flap for intake air preheating
    360
  • 9 Engine control unit
    363
  • 9.1 Removing and installing engine control unit
    363
  • 9.2 Removing and installing engine control unit with protective housing
    364
  • Exhaust system
    367
  • 1 Exhaust pipes and silencers
    367
  • 1.1 Assembly overview – silencers
    367
  • 1.2 Separating exhaust pipes/silencers, saloon
    370
  • 1.3 Removing and installing rear silencer, Cabriolet
    371
  • 1.4 Aligning exhaust system free of stress
    372
  • 1.5 Installation position of clamp
    373
  • 2 Emission control
    375
  • 2.1 Assembly overview – emission control
    375
  • 2.2 Removing and installing particulate filter with NOx storage catalytic converter
    386
  • 3 Exhaust gas temperature regulation
    394
  • 3.1 Removing and installing parts of exhaust gas temperature regulation
    394
  • 4 Exhaust gas recirculation
    405
  • 4.1 Assembly overview – exhaust gas recirculation
    405
  • 4.2 Removing and installing exhaust gas recirculation filter
    407
  • 4.3 Removing and installing exhaust gas recirculation cooler
    409
  • 4.4 Checking changeover for exhaust gas recirculation cooler
    412
  • Glow plug system
    414
  • 1 Glow plug system
    414
  • 1.1 Removing and installing glow plug
    414
  • 1.2 Removing and installing connectors for glow pin plugs
    417
  • 1.3 Removing and installing automatic glow period control unit J179
    420
  • 1.4 Removing and installing Hall sender G40
    421
  • 1.5 Removing and installing engine speed sender G28
    424
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012)
Suitable car types 5C1, 5C7
Engine code CJAA
Category Reparaturanleitung

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