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  • Examplepage for repair manual 4-cylinder injection engine (2.0 l engine, chain drive)
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  • Examplepage for repair manual 3 4-cylinder injection engine (2.0 l engine, chain drive)
  • Examplepage for repair manual 4-cylinder injection engine (2.0 l engine, chain drive)
  • Examplepage for repair manual 2 4-cylinder injection engine (2.0 l engine, chain drive)
  • Examplepage for repair manual 3 4-cylinder injection engine (2.0 l engine, chain drive)

4-cylinder injection engine (2.0 l engine, chain drive)

For Beetle Limousine / Beetle Cabrio

Original Volkswagen repair manual


29,95 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

18.877 KB

397 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 and Secondary air system. Show more
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Repair manual Beetle Limousine / Beetle Cabrio 4-cylinder injection 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 regulations for working on fuel supply
    4
  • 3.3 Safety precautions when working on cooling system
    6
  • 3.4 Safety precautions when working on ignition system
    7
  • 3.5 Releasing high pressure in fuel system
    7
  • 4 Repair instructions
    11
  • 4.1 Rules for cleanliness
    11
  • 4.2 Foreign objects in engine
    11
  • 4.3 Contact corrosion
    11
  • 4.4 Routing and attachment of lines
    12
  • 4.5 Fitting radiator and condensers
    12
  • Removing and installing engine
    13
  • 1 Removing and installing engine
    13
  • 1.1 Removing engine
    13
  • 1.2 Separating engine and gearbox
    24
  • 1.3 Securing engine on engine and gearbox support
    25
  • 1.4 Installing engine
    27
  • 2 Assembly mountings
    30
  • 2.1 Assembly overview - assembly mountings
    30
  • 2.2 Removing and installing engine mounting
    32
  • 2.3 Supporting engine in installation position
    38
  • 2.4 Adjusting assembly mountings
    44
  • 2.5 Checking adjustment of assembly mountings
    46
  • 3 Engine cover panel
    47
  • 3.1 Removing and installing engine cover
    47
  • Crankshaft group
    48
  • 1 Cylinder block (pulley end)
    48
  • 1.1 Assembly overview - poly V-belt drive
    48
  • 1.2 Removing and installing poly-V belt
    51
  • 1.3 Removing and installing tensioner for poly V-belt
    53
  • 1.4 Removing and installing vibration damper
    59
  • 1.5 Removing and installing bracket for ancillaries
    66
  • 1.6 Renewing crankshaft oil seal - belt pulley end
    69
  • 2 Cylinder block, gearbox end
    72
  • 2.1 Assembly overview - cylinder block, gearbox end
    72
  • 2.2 Removing and installing flywheel
    74
  • 2.3 Removing and installing drive plate
    76
  • 2.4 Removing and installing sealing flange on gearbox side
    79
  • 3 Crankshaft
    87
  • 3.1 Assembly overview - crankshaft
    87
  • 3.2 Renewing needle bearing in crankshaft
    89
  • 3.3 Crankshaft dimensions
    91
  • 3.4 Measuring axial clearance of crankshaft
    92
  • 3.5 Measuring radial clearance of crankshaft
    93
  • 3.6 Allocation of main bearing shells
    93
  • 3.7 Removing and installing sender wheel
    95
  • 4 Balancer shaft
    97
  • 4.1 Removing and installing balance shaft
    97
  • 5 Pistons and conrods
    105
  • 5.1 Assembly overview - pistons and conrods
    105
  • 5.2 Checking pistons and cylinder bores
    107
  • 5.3 Separating new conrod
    109
  • Cylinder head, valve gear
    111
  • 1 Cylinder head
    111
  • 1.1 Assembly overview - cylinder head
    111
  • 1.2 Removing and installing cylinder head
    115
  • 1.3 Removing and installing vacuum pump
    136
  • 1.4 Checking compression
    138
  • 2 Cover for timing chain
    140
  • 2.1 Assembly overview - cover for timing chain
    140
  • 2.2 Removing and installing timing chain cover
    142
  • 3 Chain drive
    154
  • 3.1 Assembly overview - camshaft timing chains
    154
  • 3.2 Assembly overview - drive chain for balance shaft
    156
  • 3.3 Removing and installing camshaft timing chain
    159
  • 3.4 Removing and installing drive chain for balance shaft
    170
  • 3.5 Checking valve timing
    174
  • 4 Valve gear
    177
  • 4.1 Assembly overview - valve gear
    177
  • 4.2 Measuring axial play of camshaft
    179
  • 4.3 Removing and installing camshaft
    180
  • 4.4 Removing and installing valve stem oil seals
    190
  • 4.5 Removing and installing camshaft control valve 1 N205
    196
  • 5 Inlet and exhaust valves
    198
  • 5.1 Checking valve guides
    198
  • 5.2 Valve dimensions
    199
  • Lubrication
    200
  • 1 Sump, oil pump
    200
  • 1.1 Assembly overview - sump/oil pump
    200
  • 1.2 Removing and installing lower part of sump
    203
  • 1.3 Removing and installing upper part of sump
    206
  • 1.4 Removing and installing oil pump
    213
  • 1.5 Engine oil:
    215
  • 2 Engine oil cooler
    217
  • 2.1 Removing and installing engine oil cooler
    217
  • 3 Crankcase ventilation
    221
  • 3.1 Removing and installing oil separator
    221
  • 4 Oil filter, oil pressure switch
    223
  • 4.1 Checking oil pressure and oil pressure switch
    223
  • 4.2 Assembly overview - oil filter housing, oil pressure switch
    229
  • 4.3 Removing and installing oil pressure switch F22
    232
  • 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
    233
  • 4.5 Removing and installing oil pressure regulating valve N428
    234
  • Cooling
    235
  • 1 Cooling system/coolant
    235
  • 1.1 Connection diagram - coolant hoses
    235
  • 1.2 Checking cooling system for leaks
    237
  • 1.3 Draining and adding coolant
    240
  • 2 Coolant pump, regulation of cooling system
    246
  • 2.1 Assembly overview - coolant pump, thermostat
    246
  • 2.2 Assembly overview - electric coolant pump
    249
  • 2.3 Removing and installing coolant pump with thermostat housing
    250
  • 2.5 Removing and installing thermostat
    256
  • 2.6 Removing and installing toothed belt for coolant pump
    260
  • 2.7 Renewing seal for coolant pump drive
    263
  • 2.8 Removing and installing electric coolant pump
    265
  • 2.9 Removing and installing coolant temperature sender
    266
  • 3 Coolant pipes
    270
  • 3.1 Assembly overview - coolant pipes
    270
  • 3.2 Removing and installing coolant pipes
    271
  • 4 Radiator, radiator fan
    278
  • 4.1 Assembly overview - radiator/radiator fan
    278
  • 4.2 Removing and installing radiator
    279
  • 4.3 Removing and installing radiator cowl
    281
  • 4.4 Removing and installing radiator fan
    283
  • Turbocharging/supercharging
    284
  • 1 Turbocharger
    284
  • 1.1 Assembly overview - turbocharger
    284
  • 1.2 Removing and installing turbocharger
    291
  • 1.3 Checking vacuum unit for turbocharger
    299
  • 1.4 Renewing vacuum unit for turbocharger
    301
  • 2 Charge air system
    302
  • 2.1 Schematic overview - charge air system
    302
  • 2.2 Assembly overview - charge air system
    303
  • 2.3 Checking charge air system for leaks
    304
  • 2.4 Assembly overview - charge-air hose connections
    306
  • Mixture preparation - injection
    308
  • 1 Injection system
    308
  • 1.1 Overview of fitting locations - injection system
    308
  • 2 Injectors
    315
  • 2.1 Assembly overview - fuel rail with injectors
    315
  • 2.2 Removing and installing injectors
    317
  • 2.3 Renewing seals on injectors
    321
  • 2.4 Cleaning injectors
    324
  • 3 High-pressure pump
    326
  • 3.1 Assembly overview - high-pressure pump
    326
  • 3.2 Removing and installing high-pressure pump
    328
  • 4 Senders and sensors
    331
  • 4.2 Removing and installing air mass meter
    333
  • 4.3 Removing and installing fuel pressure sender G247
    335
  • 4.4 Checking fuel pressure sender G247
    337
  • 5 Intake manifold
    341
  • 5.1 Assembly overview – intake manifold
    341
  • 5.2 Removing and installing intake manifold with fuel rail
    344
  • 5.3 Removing and installing throttle valve module
    352
  • 5.4 Cleaning throttle valve module
    354
  • 5.5 Checking intake manifold change-over
    355
  • 6 Air filter
    358
  • 6.1 Assembly overview - air filter housing
    358
  • 6.2 Removing and installing air filter housing
    360
  • 7 Engine control unit
    362
  • 7.1 Removing and installing engine control unit J623
    362
  • Exhaust system
    365
  • 1 Exhaust pipes and silencers
    365
  • 1.1 Assembly overview – silencers
    365
  • 1.2 Removing and installing front exhaust pipe
    371
  • 1.3 Separating exhaust pipes from silencers
    374
  • 1.4 Aligning exhaust system free of stress
    376
  • 1.5 Checking exhaust system for leaks
    378
  • 2 Secondary air system
    380
  • 2.1 Assembly overview - secondary air system
    380
  • 2.2 Removing and installing secondary air pump motor V101
    380
  • 2.3 Removing and installing secondary air inlet valve N112
    381
  • 3 Exhaust manifold
    384
  • Ignition system
    385
  • 1 Ignition system
    385
  • 1.1 Assembly overview - ignition system
    385
  • 1.2 Removing and installing ignition coils with output stage
    387
  • 1.3 Removing and installing knock sensor
    389
  • 1.4 Removing and installing engine speed sender G28
    390
  • 1.5 Test data, spark plugs
    391
Manufacturer's designation 4-cylinder injection engine (2.0 l engine, chain drive)
Manufacturer Volkswagen
Suitable for Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012)
Suitable car types 5C1, 5C7
Engine code CCTA, CCZA
Category Reparaturanleitung

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