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Home » Manuals » 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)
  • 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 VW Beetle / Beetle

Original Volkswagen repair manual


29,83 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

46.572 KB

395 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, 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, Turbocharger, Intake manifold, Lambda probe and Secondary air system. Show more
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Repair manual VW Beetle / Beetle 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 instructions
    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
    18
  • 1.3 Securing engine on engine and gearbox support
    20
  • 1.4 Installing engine
    22
  • 2 Assembly mountings
    25
  • 2.1 Assembly overview - assembly mountings
    25
  • 2.2 Removing and installing engine mounting
    28
  • 2.3 Removing and installing gearbox mounting
    30
  • 2.4 Removing and installing pendulum support
    31
  • 2.5 Supporting engine in installation position
    32
  • 2.6 Adjusting assembly mountings
    40
  • 2.7 Checking adjustment of assembly mountings
    42
  • 3 Engine cover panel
    43
  • 3.1 Removing and installing engine cover
    43
  • Crankshaft group
    44
  • 1 Cylinder block (pulley end)
    44
  • 1.1 Assembly overview - cylinder block (pulley end)
    44
  • 1.2 Removing and installing poly-V belt
    47
  • 1.3 Removing and installing tensioner for poly V-belt
    48
  • 1.4 Removing and installing vibration damper
    49
  • 1.5 Removing and installing bracket for ancillaries
    56
  • 1.6 Removing and installing engine support
    60
  • 2 Cylinder block, gearbox end
    62
  • 2.1 Assembly overview - cylinder block, gearbox end
    62
  • 2.2 Assembly overview - drive plate
    63
  • 2.3 Removing and installing drive plate
    64
  • 2.4 Removing and installing flywheel
    66
  • 2.5 Removing and installing sealing flange on gearbox side
    68
  • 3 Crankshaft
    73
  • 3.1 Assembly overview - crankshaft
    73
  • 3.2 Crankshaft dimensions
    76
  • 3.3 Allocation of main bearing shells
    76
  • 3.4 Renewing needle bearing in crankshaft
    78
  • 3.5 Measuring axial clearance of crankshaft
    81
  • 3.6 Measuring radial clearance of crankshaft
    82
  • 3.7 Removing and installing sender wheel
    83
  • 4 Balancer shaft
    85
  • 4.1 Assembly overview - balance shaft
    85
  • 4.2 Removing and installing balance shaft
    87
  • 4.3 Renewing oil seal for balance shaft (inlet side)
    92
  • 5 Pistons and conrods
    94
  • 5.1 Assembly overview - pistons and conrods
    94
  • 5.2 Removing and installing pistons
    98
  • 5.3 Checking pistons and cylinder bores
    100
  • 5.4 Separating new conrod
    101
  • 5.5 Checking radial clearance of conrods
    102
  • 5.6 Removing and installing oil spray jets
    102
  • Cylinder head, valve gear
    105
  • 1 Cylinder head
    105
  • 1.1 Assembly overview - cylinder head
    105
  • 1.2 Removing and installing cylinder head
    108
  • 1.3 Assembly overview - vacuum pump
    114
  • 1.4 Removing and installing vacuum pump
    115
  • 1.5 Checking compression
    117
  • 2 Cover for timing chain
    120
  • 2.1 Assembly overview - cover for timing chain
    120
  • 2.3 Removing and installing timing chain cover
    122
  • 2.4 Renewing seal for vibration damper
    130
  • 3 Chain drive
    134
  • 3.1 Assembly overview - camshaft timing chains
    134
  • 3.2 Assembly overview - drive chain for balance shaft
    137
  • 3.3 Removing and installing camshaft timing chain
    140
  • 3.4 Removing and installing drive chain for balance shaft
    152
  • 3.5 Checking valve timing
    155
  • 3.6 Checking chain elongation
    158
  • 4 Valve gear
    160
  • 4.1 Assembly overview - valve gear
    160
  • 4.2 Removing and installing camshaft
    163
  • 4.3 Installing ball for sliding piece
    172
  • 4.4 Removing and installing actuators for camshaft adjustment
    173
  • 4.5 Removing and installing valve stem seals
    174
  • 5 Inlet and exhaust valves
    186
  • 5.1 Checking valve guides
    186
  • 5.2 Checking valves
    187
  • 5.3 Valve dimensions
    187
  • Lubrication
    188
  • 1 Sump, oil pump
    188
  • 1.1 Assembly overview - sump/oil pump
    188
  • 1.2 Engine oil:
    191
  • 1.3 Removing and installing lower part of sump
    191
  • 1.4 Removing and installing upper part of sump
    197
  • 1.5 Removing and installing oil pump
    202
  • 1.6 Removing and installing oil level and oil temperature sender G266
    204
  • 2 Engine oil cooler
    206
  • 2.1 Assembly overview - engine oil cooler
    206
  • 2.2 Removing and installing engine oil cooler
    206
  • 2.3 Removing and installing mechanical switching valve
    208
  • 3 Crankcase ventilation
    209
  • 3.1 Assembly overview - crankcase breather system
    209
  • 3.2 Removing and installing oil separator
    210
  • 4 Oil filter, oil pressure switch
    213
  • 4.1 Assembly overview - oil filter
    213
  • 4.2 Assembly overview - oil pressure switches/oil pressure control
    213
  • 4.3 Removing and installing piston cooling jet control valve N522
    215
  • 4.4 Removing and installing oil pressure switch F1
    216
  • 4.5 Removing and installing oil pressure switch for reduced oil pressure F378
    217
  • 4.6 Removing and installing stage 3 oil pressure switch F447
    218
  • 4.7 Checking oil pressure
    220
  • 4.8 Removing and installing oil pressure regulating valve N428
    224
  • Cooling
    226
  • 1 Cooling system/coolant
    226
  • 1.1 Connection diagram - coolant hoses
    226
  • 1.2 Checking cooling system for leaks
    227
  • 1.3 Draining and adding coolant
    231
  • 2 Coolant pump, regulation of cooling system
    240
  • 2.1 Assembly overview - coolant pump, thermostat
    240
  • 2.2 Assembly overview - electric coolant pump
    242
  • 2.3 Assembly overview - coolant temperature sender
    243
  • 2.4 Removing and installing auxiliary pump for heating V488
    244
  • 2.5 Removing and installing coolant pump
    247
  • 2.6 Removing and installing toothed belt for coolant pump
    248
  • 2.7 Removing and installing thermostat housing
    251
  • 2.8 Removing and installing coolant valve for gearbox N488
    255
  • 2.9 Removing and installing actuator for engine temperature regulation N493
    256
  • 2.10 Removing and installing coolant temperature sender G62
    259
  • 2.11 Removing and installing radiator outlet coolant temperature sender G83
    260
  • 3 Coolant pipes
    262
  • 3.1 Assembly overview - coolant pipes
    262
  • 3.2 Removing and installing coolant pipes
    262
  • 3.3 Removing and installing upper coolant pipes
    264
  • 4 Radiator, radiator fan
    266
  • 4.1 Assembly overview - radiator/radiator fan
    266
  • 4.2 Assembly overview – radiator cowl and radiator fan
    267
  • 4.3 Removing and installing radiator
    268
  • 4.4 Removing and installing radiator cowl
    269
  • 4.5 Removing and installing radiator fan
    271
  • 4.6 Removing and installing auxiliary radiator
    271
  • Turbocharging/supercharging
    274
  • 1 Turbocharger
    274
  • 1.1 Assembly overview - turbocharger
    274
  • 1.2 Removing and installing turbocharger
    280
  • 1.3 Adjusting charge pressure positioner V465
    289
  • 2 Charge air system
    292
  • 2.1 Assembly overview - charge air system
    292
  • 2.2 Removing and installing charge air cooler
    294
  • 2.3 Removing and installing charge pressure sender G31
    295
  • 2.4 Checking charge air system for leaks
    296
  • Mixture preparation - injection
    299
  • 1 Injection system
    299
  • 1.1 Overview of fitting locations - injection system
    299
  • 1.2 Releasing high pressure in fuel system
    308
  • 2 Injectors
    309
  • 2.1 Assembly overview - fuel rail with injectors
    309
  • 2.2 Removing and installing fuel rail
    311
  • 2.3 Removing and installing injectors
    311
  • 2.4 Renewing seals on injectors
    316
  • 2.5 Cleaning injectors
    318
  • 3 Air filter
    321
  • 3.1 Assembly overview - air filter housing
    321
  • 3.2 Removing and installing air filter housing
    323
  • 4 Intake manifold
    325
  • 4.1 Assembly overview – intake manifold
    325
  • 4.2 Removing and installing intake manifold
    327
  • 4.3 Removing and installing throttle valve module GX3
    333
  • 4.4 Cleaning throttle valve module GX3
    334
  • 5 Senders and sensors
    336
  • 5.1 Removing and installing fuel pressure sender G247
    336
  • 5.2 Checking fuel pressure sender G247
    338
  • 5.3 Removing and installing intake manifold sender GX9
    341
  • 5.4 Removing and installing air mass meter G70
    342
  • 6 Engine control unit
    344
  • 6.1 Removing and installing engine control unit J623
    344
  • 7 High-pressure pump
    348
  • 7.1 Assembly overview - high-pressure pump
    348
  • 7.2 Removing and installing high-pressure pump
    350
  • 8 Lambda probe
    354
  • 8.1 Assembly overview - Lambda probe
    354
  • 8.2 Removing and installing Lambda probe GX10
    354
  • 8.3 Removing and installing Lambda probe after catalytic converter GX7
    357
  • Exhaust system
    359
  • 1 Exhaust pipes and silencers
    359
  • 1.1 Assembly overview – silencers
    359
  • 1.2 Removing and installing rear silencer
    364
  • 1.3 Aligning exhaust system free of stress
    367
  • 1.4 Checking exhaust system for leaks
    368
  • 1.5 Installation position of clamp
    368
  • 2 Emission control
    371
  • 2.1 Assembly overview – emission control
    371
  • 2.2 Removing and installing catalytic converter
    371
  • 3 Secondary air system
    376
  • 3.1 Assembly overview - secondary air system
    376
  • 3.2 Removing and installing secondary air pump motor V101
    378
  • 3.3 Removing and installing secondary air inlet valve N112
    378
  • Ignition system
    380
  • 1 Ignition system
    380
  • 1.1 Assembly overview - ignition system
    380
  • 1.2 Test data, spark plugs
    382
  • 1.3 Removing and installing ignition coils with output stage
    382
  • 1.4 Removing and installing knock sensor 1 G61
    384
  • 1.5 Removing and installing Hall sender G40
    385
  • 1.6 Removing and installing Hall sender 3 G300
    386
  • 1.7 Removing and installing engine speed sender G28
    386
Manufacturer's designation 4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)
Manufacturer Volkswagen
Suitable for VW Beetle (2011) / Beetle (2017)
Suitable car types 5C8, 5C2
Engine code DDSA
Category Reparaturanleitung

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