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  • Examplepage for repair manual 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
  • Examplepage for repair manual 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)

4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)

For Beetle Limousine / Beetle Cabrio / VW Beetle / Beetle

Original Volkswagen repair manual


24,51 €7% VAT incl.

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Language: English

Digital PDF file

40.871 KB

312 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Motor cover, Cylinder block (pulley end), Crankshaft, Cover for timing chain, Chain drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Coolant pump, regulation of cooling system, Radiator, radiator fan, Exhaust turbocharger, Injectors, Intake manifold, Lambda probe and Secondary air system. Show more
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Repair manual 4-cylinder injection 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
    1
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on ignition system
    2
  • 2 Identification
    3
  • 2.1 Engine number/engine data
    3
  • 3 Repair notes
    5
  • 3.1 Rules for cleanliness
    5
  • 3.2 Foreign objects in engine
    5
  • 3.3 Contact corrosion
    5
  • 3.4 Routing and attachment of lines
    6
  • 3.5 Fitting radiator and condensers
    6
  • 3.6 Checking vacuum system
    6
  • Removing and installing engine
    7
  • 1 Removing and installing engine
    7
  • 1.1 Removing engine
    7
  • 1.2 Separating engine and gearbox
    15
  • 1.3 Securing engine on engine and gearbox support
    17
  • 1.4 Installing engine
    20
  • 2 Assembly mountings
    23
  • 2.1 Assembly overview - assembly mountings
    23
  • 2.2 Removing and installing motor mounting
    25
  • 2.3 Removing and installing gearbox mounting
    26
  • 2.4 Removing and installing pendulum support
    27
  • 2.5 Supporting engine in installation position
    27
  • 2.6 Adjusting assembly mountings
    35
  • 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
    37
  • 3 Motor cover
    38
  • 3.1 Removing and installing engine cover
    38
  • Crankshaft group
    39
  • 1 Cylinder block (pulley end)
    39
  • 1.1 Assembly overview - cylinder block (pulley end)
    39
  • 1.2 Removing and installing poly-V belt
    40
  • 1.3 Removing and installing tensioner for poly V-belt
    42
  • 1.4 Removing and installing vibration damper
    42
  • 1.5 Removing and installing bracket for ancillaries
    48
  • 1.6 Removing and installing engine support
    50
  • 2 Cylinder block, gearbox end
    52
  • 2.1 Assembly overview - cylinder block, gearbox end
    52
  • 2.2 Assembly overview - drive plate
    53
  • 2.3 Removing and installing drive plate
    54
  • 2.4 Removing and installing flywheel
    55
  • 2.5 Removing and installing sealing flange on gearbox side
    56
  • 3 Crankshaft
    60
  • 3.1 Assembly overview - crankshaft
    60
  • 3.2 Crankshaft dimensions
    61
  • 3.3 Allocation of main bearing shells
    62
  • 3.4 Renewing needle bearing in crankshaft
    63
  • 3.5 Measuring axial clearance of crankshaft
    66
  • 3.6 Measuring radial clearance of crankshaft
    67
  • 3.7 Removing and installing sender wheel
    67
  • 4 Balancer shaft
    69
  • 4.1 Assembly overview - balance shaft
    69
  • 4.2 Removing and installing balance shaft
    70
  • 4.3 Renewing oil seal for balance shaft (inlet side)
    74
  • 5 Pistons and conrods
    76
  • 5.1 Assembly overview - pistons and conrods
    76
  • 5.2 Removing and installing pistons
    77
  • 5.3 Checking pistons and cylinder bores
    79
  • 5.4 Separating new conrod
    80
  • 5.5 Checking radial clearance of conrods
    81
  • Cylinder head, valve gear
    82
  • 1 Cylinder head
    82
  • 1.1 Assembly overview - cylinder head
    82
  • 1.2 Assembly overview - camshaft housing
    85
  • 1.3 Removing and installing cylinder head
    86
  • 1.4 Removing and installing vacuum pump
    90
  • 1.5 Checking compression
    91
  • 2 Cover for timing chain
    94
  • 2.1 Assembly overview - cover for timing chain
    94
  • 2.2 Removing and installing timing chain cover
    96
  • 2.3 Renewing seal for vibration damper
    102
  • 3 Chain drive
    105
  • 3.1 Assembly overview - camshaft timing chains
    105
  • 3.2 Assembly overview - drive chain for balance shaft
    106
  • 3.3 Removing and installing camshaft timing chain
    109
  • 3.4 Removing and installing drive chain for balance shaft
    123
  • 3.5 Checking chain elongation
    123
  • 3.6 Checking valve timing
    124
  • 4 Valve gear
    127
  • 4.1 Assembly overview - valve gear
    127
  • 4.2 Removing and installing camshaft
    130
  • 4.3 Removing and installing camshaft control valve 1 N205
    143
  • 4.4 Removing and installing valve stem seals
    144
  • 5 Inlet and exhaust valves
    152
  • 5.1 Checking valve guides
    152
  • 5.2 Checking valves
    153
  • 5.3 Valve dimensions
    153
  • Lubrication
    154
  • 1 Sump, oil pump
    154
  • 1.1 Assembly overview - sump/oil pump
    154
  • 1.2 Engine oil:
    157
  • 1.3 Removing and installing lower part of sump
    157
  • 1.4 Removing and installing upper part of sump
    159
  • 1.5 Removing and installing oil pump
    162
  • 1.6 Removing and installing oil level and oil temperature sender G266
    164
  • 2 Engine oil cooler
    166
  • 2.1 Assembly overview - engine oil cooler
    166
  • 2.2 Removing and installing engine oil cooler
    166
  • 2.3 Removing and installing mechanical switching valve
    168
  • 3 Crankcase ventilation
    169
  • 3.1 Assembly overview - crankcase breather system
    169
  • 3.2 Removing and installing oil separator
    170
  • 4 Oil filter, oil pressure switch
    171
  • 4.1 Assembly overview - oil filter
    171
  • 4.2 Assembly overview - oil pressure switches/oil pressure control
    172
  • 4.3 Removing and installing piston cooling jet control valve N522
    173
  • 4.4 Removing and installing oil pressure switch F1
    173
  • 4.5 Removing and installing oil pressure switch for reduced oil pressure F378
    174
  • 4.6 Removing and installing stage 3 oil pressure switch F447
    175
  • 4.7 Checking oil pressure
    177
  • 4.8 Removing and installing oil pressure regulating valve N428
    180
  • Cooling
    182
  • 1 Cooling system/coolant
    182
  • 1.1 Connection diagram - coolant hoses
    182
  • 1.2 Checking cooling system for leaks
    185
  • 1.3 Draining and adding coolant
    187
  • 2 Coolant pump, regulation of cooling system
    194
  • 2.1 Assembly overview - coolant pump, thermostat
    194
  • 2.2 Assembly overview - electric coolant pump
    196
  • 2.3 Assembly overview - coolant temperature sender
    199
  • 2.5 Removing and installing coolant pump
    201
  • 2.6 Removing and installing coolant shut-off valve N82
    202
  • 2.8 Removing and installing toothed belt for coolant pump
    206
  • 2.9 Removing and installing thermostat housing
    208
  • 2.10 Removing and installing coolant temperature sender G62
    211
  • 2.11 Removing and installing radiator outlet coolant temperature sender G83
    212
  • 3 Coolant pipes
    214
  • 3.1 Assembly overview - coolant pipes
    214
  • 3.2 Removing and installing coolant pipes
    214
  • 3.3 Removing and installing upper coolant pipes
    215
  • 4 Radiator, radiator fan
    218
  • 4.1 Assembly overview - radiator/radiator fan
    218
  • 4.2 Assembly overview - radiator cowl and radiator fan
    219
  • 4.3 Removing and installing radiator
    219
  • 4.4 Removing and installing radiator cowl
    220
  • 4.5 Removing and installing radiator fan
    221
  • 4.6 Removing and installing auxiliary radiator
    221
  • Turbocharging/supercharging
    224
  • 1 Exhaust turbocharger
    224
  • 1.1 Assembly overview - turbocharger
    224
  • 1.2 Removing and installing turbocharger
    229
  • 2 Charge air system
    236
  • 2.1 Assembly overview - charge air system
    236
  • 2.2 Removing and installing charge air cooler
    237
  • 2.3 Removing and installing charge pressure sender G31
    238
  • 2.4 Checking charge air system for leaks
    238
  • Mixture preparation - injection
    241
  • 1 Injection system
    241
  • 1.1 Overview of fitting locations - injection system
    241
  • 1.2 Releasing high pressure in fuel system
    243
  • 2 Injectors
    245
  • 2.1 Assembly overview - fuel rail with injectors
    245
  • 2.2 Removing and installing fuel rail
    247
  • 2.3 Removing and installing injectors
    248
  • 2.4 Renewing seals on injectors
    250
  • 2.5 Cleaning injectors
    252
  • 3 Air filter
    254
  • 3.1 Assembly overview - air filter housing
    254
  • 3.2 Removing and installing air filter housing
    255
  • 4 Intake manifold
    257
  • 4.1 Assembly overview - intake manifold
    257
  • 4.2 Removing and installing intake manifold
    258
  • 4.3 Removing and installing throttle valve module J338
    262
  • 4.4 Cleaning throttle valve module
    263
  • 5 Senders and sensors
    265
  • 5.3 Removing and installing fuel pressure sender G247
    266
  • 5.4 Checking fuel pressure sender G247
    268
  • 6 Engine (motor) control unit
    271
  • 6.1 Removing and installing engine (motor) control unit J623
    271
  • 7 High-pressure pump
    275
  • 7.1 Assembly overview - high-pressure pump
    275
  • 7.2 Removing and installing high-pressure pump
    276
  • 8 Lambda probe
    280
  • 8.1 Assembly overview - Lambda probe
    280
  • 8.2 Removing and installing Lambda probe G39
    280
  • 8.3 Removing and installing Lambda probe after catalytic converter G130
    282
  • Exhaust system
    283
  • 1 Exhaust pipes and silencers
    283
  • 1.1 Assembly overview - silencers
    283
  • 1.2 Removing and installing rear silencer
    286
  • 1.3 Aligning exhaust system free of stress
    289
  • 1.4 Check exhaust system for leaks
    290
  • 1.5 Installation position of clamp
    290
  • 2 Exhaust gas cleaning
    292
  • 2.1 Assembly overview - emission control
    292
  • 2.2 Removing and installing catalytic converter
    292
  • 3 Secondary air system
    296
  • 3.1 Assembly overview - secondary air system
    296
  • 3.2 Removing and installing secondary air pump motor V101
    297
  • 3.3 Removing and installing secondary air inlet valve N112
    297
  • Ignition system
    299
  • 1 Ignition system
    299
  • 1.1 Assembly overview - ignition system
    299
  • 1.2 Test data, spark plugs
    300
  • 1.3 Removing and installing ignition coils with output stage
    300
  • 1.4 Removing and installing knock sensor 1 G61
    302
  • 1.5 Removing and installing Hall sender
    303
  • 1.6 Removing and installing engine speed sender G28
    303
Manufacturer's designation 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
Manufacturer Volkswagen
Suitable for Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012) / VW Beetle (2011) / Beetle (2017)
Suitable car types 5C1, 5C8, 5C2
Engine code CPPA, CPKA, CPRA, CULC
Category Reparaturanleitung

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