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

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

For Beetle Limousine / Beetle Cabrio

Original Volkswagen repair manual


32,88 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

18.666 KB

447 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 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
    7
  • 4.3 Checking vacuum system
    8
  • Removing and installing engine
    9
  • 1 Removing and installing engine
    9
  • 1.1 Removing engine
    9
  • 1.2 Separating engine and gearbox
    23
  • 1.3 Securing engine on engine and gearbox support
    28
  • 1.4 Installing engine
    30
  • 2 Assembly mountings
    34
  • 2.1 Assembly overview - assembly mountings
    34
  • 2.2 Removing and installing engine mounting
    36
  • 2.3 Supporting engine in installation position
    45
  • 2.4 Adjusting assembly mountings
    54
  • 2.5 Checking adjustment of assembly mountings
    56
  • 3 Engine cover panel
    58
  • 3.1 Removing and installing engine cover
    58
  • Crankshaft group
    60
  • 1 Cylinder block (pulley end)
    60
  • 1.1 Assembly overview - poly V-belt drive
    60
  • 1.2 Removing and installing poly-V belt
    64
  • 1.3 Removing and installing tensioner for poly V-belt
    69
  • 1.4 Removing and installing vibration damper
    71
  • 1.5 Removing and installing bracket for ancillaries
    72
  • 1.6 Removing and installing engine bracket
    74
  • 1.7 Assembly overview - sealing flange, belt pulley end
    77
  • 1.8 Renewing crankshaft oil seal - belt pulley end
    79
  • 1.9 Removing and installing sealing flange on pulley end
    81
  • 2 Cylinder block, gearbox end
    86
  • 2.1 Assembly overview - cylinder block, gearbox end
    86
  • 2.2 Removing and installing flywheel
    87
  • 2.3 Removing and installing sealing flange on gearbox side
    89
  • 3 Crankshaft
    103
  • 3.1 Assembly overview - crankshaft
    103
  • 3.2 Crankshaft dimensions
    104
  • 3.3 Renewing needle bearing in crankshaft
    104
  • 3.4 Measuring axial clearance of crankshaft
    106
  • 3.5 Measuring radial clearance of crankshaft
    107
  • 4 Pistons and conrods
    108
  • 4.1 Assembly overview - pistons and conrods
    108
  • 4.2 Measuring piston projection at TDC
    110
  • 4.3 Checking pistons and cylinder bores
    112
  • 4.4 Separating new conrod
    115
  • 4.5 Checking radial clearance of conrods
    116
  • Cylinder head, valve gear
    117
  • 1 Cylinder head
    117
  • 1.1 Assembly overview - cylinder head
    117
  • 1.2 Assembly overview - cylinder head cover
    121
  • 1.3 Removing and installing cylinder head
    123
  • 1.4 Removing and installing cylinder head cover
    139
  • 1.5 Removing and installing vacuum pump
    142
  • 1.6 Checking compression
    144
  • 2 Toothed belt drive
    147
  • 2.1 Assembly overview - toothed belt
    147
  • 2.2 Removing and installing toothed belt
    149
  • 3 Valve gear
    173
  • 3.1 Assembly overview - valve gear
    173
  • 3.2 Measuring axial play of camshaft
    175
  • 3.3 Measuring radial play of camshaft
    176
  • 3.4 Removing and installing camshaft oil seal
    177
  • 3.5 Removing and installing camshaft
    185
  • 3.6 Checking hydraulic compensation elements
    194
  • 3.7 Removing and installing valve stem seal
    195
  • 4 Inlet and exhaust valves
    204
  • 4.1 Reworking valve seats
    204
  • 4.2 Checking valve guides
    204
  • 4.3 Checking valves
    205
  • 4.4 Valve dimensions
    205
  • Lubrication
    206
  • 1 Sump, oil pump
    206
  • 1.1 Assembly overview - sump/oil pump
    206
  • 1.2 Removing and installing oil sump
    212
  • 1.3 Removing and installing oil pump
    217
  • 1.4 Removing and installing oil level and oil temperature sender G 266
    219
  • 2 Engine oil cooler
    221
  • 2.1 Assembly overview - engine oil cooler
    221
  • 2.2 Removing and installing engine oil cooler
    221
  • 3 Oil filter, oil pressure switch
    225
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    225
  • 3.2 Removing and installing oil pressure switch F1
    226
  • 3.3 Checking oil pressure
    227
  • 3.4 Checking oil pressure and oil pressure switch
    228
  • 3.5 Removing and installing oil filter housing
    229
  • 4 Oil circuit
    235
  • 4.1 Assembly overview - oil circuit
    235
  • 4.2 Removing and installing oil return line for turbocharger
    235
  • 5 Balancer shaft module
    241
  • 5.1 Removing and installing balance shaft module
    241
  • Cooling
    251
  • 1 Cooling system/coolant
    251
  • 1.1 Coolant hose connection diagram
    251
  • 1.2 Checking cooling system for leaks
    253
  • 1.3 Draining and adding coolant
    254
  • 2 Coolant pump, regulation of cooling system
    261
  • 2.1 Assembly overview - coolant pump, thermostat
    261
  • 2.2 Coolant circulation pump 2 V178
    261
  • 2.3 Removing and installing coolant pump
    265
  • 2.4 Removing and installing 4/2-way valve with thermostat
    267
  • 2.5 Removing and installing coolant temperature sender
    273
  • 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
    293
  • 4.3 Removing and installing radiator cowl with radiator fan
    296
  • 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
    314
  • 2.1 Assembly overview - charge air system
    314
  • 2.2 Assembly overview - charge-air hose connections
    316
  • 2.3 Removing and installing charge air cooler
    318
  • 2.5 Checking charge air system for leaks
    321
  • Mixture preparation - injection
    325
  • 1 Injection system
    325
  • 1.1 Schematic overview - fuel system
    325
  • 1.2 Filling/bleeding fuel system
    327
  • 1.3 Checking fuel system for leaks
    328
  • 2 Vacuum system
    329
  • 2.1 Connection diagram - vacuum system
    329
  • 2.2 Checking vacuum system
    330
  • 3 Injectors/high-pressure accumulator (rail)
    333
  • 3.1 Assembly overview - injectors
    333
  • 3.2 Adapting correction values for injectors
    336
  • 3.3 Testing jammed-open injectors
    337
  • 3.4 Removing and installing injectors
    339
  • 3.5 Removing and installing fuel rail
    343
  • 3.6 Removing and installing high-pressure lines
    347
  • 4 High-pressure pump
    352
  • 4.1 Assembly overview - high-pressure pump
    352
  • 4.2 Removing and installing high-pressure pump
    354
  • 5 Senders and sensors
    360
  • 5.1 Checking fuel pressure regulating valve
    360
  • 5.2 Removing and installing fuel pressure regulating valve
    361
  • 5.3 Removing and installing fuel pressure sender
    363
  • 5.4 Removing and installing air mass meter
    366
  • 5.5 Removing and installing differential pressure sensor
    367
  • 6 Intake manifold
    369
  • 6.1 Assembly overview – intake manifold
    369
  • 6.2 Removing and installing intake manifold
    370
  • 6.3 Removing and installing throttle valve module
    375
  • 7 Lambda probe
    377
  • 7.1 Removing and installing Lambda probe G39 with Lambda probe heater Z19
    377
  • 8 Air filter
    379
  • 8.1 Assembly overview - air filter housing
    379
  • 8.2 Removing and installing air filter housing
    381
  • 8.3 Checking changeover flap for intake air preheating
    383
  • 8.4 Removing and installing changeover flap for intake air preheating
    384
  • 9 Engine control unit
    387
  • 9.1 Removing and installing engine control unit
    387
  • 9.2 Removing and installing engine control unit with protective housing
    388
  • Exhaust system
    391
  • 1 Exhaust pipes and silencers
    391
  • 1.1 Assembly overview – silencers
    391
  • 1.2 Separating exhaust pipes from silencers
    392
  • 1.3 Aligning exhaust system free of stress
    394
  • 1.4 Installation position of clamp
    395
  • 2 Emission control
    397
  • 2.1 Assembly overview – emission control
    397
  • 2.2 Removing and installing particulate filter
    400
  • 3 Exhaust gas temperature regulation
    409
  • 3.1 Removing and installing parts of exhaust gas temperature regulation
    409
  • 4 Exhaust gas recirculation
    416
  • 4.1 Assembly overview – exhaust gas recirculation
    416
  • 4.2 Removing and installing exhaust gas recirculation cooler
    417
  • 4.3 Checking changeover for exhaust gas recirculation cooler
    420
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    421
  • 4.5 Cleaning exhaust gas recirculation system
    426
  • Glow plug system
    434
  • 1 Glow plug system
    434
  • 1.1 Removing and installing glow plug
    434
  • 1.2 Removing and installing automatic glow period control unit J179
    436
  • 1.3 Removing and installing Hall sender G40
    438
  • 1.4 Removing and installing engine speed sender G28
    439
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail, generation II)
Manufacturer Volkswagen
Suitable for Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012)
Suitable car types 5C1, 5C7
Engine code CFFB
Category Reparaturanleitung

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