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  • Examplepage for repair manual 4-cylinder unit injector diesel engine
  • Examplepage for repair manual 2 4-cylinder unit injector diesel engine
  • Examplepage for repair manual 3 4-cylinder unit injector diesel engine

4-cylinder unit injector diesel engine

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


16,33 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

7.298 KB

196 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flanges and flywheel, Crankshaft, Piston and conrod, Cylinder head and Parts of the lubrication system. Show more
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Repair manual New Beetle Cabrio / New Beetle 4-cylinder unit injector diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Notes on removing
    4
  • 1.2 Fastening the engine to the assembly stand
    8
  • 1.3 Notes on installation
    9
  • 1.4 Torque settings
    12
  • 1.5 Aligning engine and gearbox mountings
    12
  • 1.6 Assembly mountings
    13
  • Crankshaft group
    16
  • 1 Dismantling and assembling engine
    16
  • 1.1 Assembly overview
    16
  • 1.2 Removing and installing poly V-belt
    21
  • 2 Sealing flanges and flywheel
    24
  • 2.1 Assembly overview
    24
  • 2.2 Renewing crankshaft oil seal - belt pulley end
    25
  • 2.3 Removing and installing sealing flange -belt pulley end-
    26
  • 3 Crankshaft
    29
  • 3.1 Assembly overview
    29
  • 3.3 Crankshaft dimensions
    32
  • 4 Piston and conrod
    33
  • 4.1 Assembly overview
    33
  • 4.2 Checking piston projection at TDC
    36
  • 4.3 Piston and cylinder dimensions
    37
  • Cylinder head, valve gear
    38
  • 1 Cylinder head
    38
  • 1.1 Assembly overview
    38
  • 1.2 Removing and installing cylinder head cover
    41
  • 1.3 Removing and installing toothed belt
    43
  • 1.4 Removing and installing cylinder head
    55
  • 1.5 Check compression pressures
    63
  • 2 Valve gear
    66
  • 2.1 Assembly overview
    66
  • 2.2 Removing and installing camshaft oil seal
    69
  • 2.3 Removing and installing camshaft
    70
  • 2.4 Renewing valve stem seals
    74
  • 2.5 Checking valve guides
    76
  • Lubrication
    78
  • 1 Parts of the lubrication system
    78
  • 1.1 Engine oil
    78
  • 1.2 Assembly overview
    79
  • 1.3 Removing and installing oil pan
    87
  • 1.4 Removing and installing oil pump
    89
  • 1.5 Checking oil pressure and oil pressure switch
    90
  • Cooling system
    93
  • 1 Parts of cooling system
    93
  • 1.1 Parts of cooling system - body side - Assembly overview
    93
  • 1.2 Parts of cooling system - engine side - Assembly overview
    95
  • 1.3 Coolant hose schematic diagram
    100
  • 1.4 Draining and filling coolant
    104
  • 1.5 Removing and installing radiator
    107
  • 1.6 Removing and installing coolant pump
    109
  • 1.7 Removing and installing thermostat
    111
  • 1.8 Checking glow pin plugs
    112
  • Fuel supply system
    114
  • 1 Parts of fuel supply system
    114
  • 1.1 Safety precautions when working on fuel supply system
    115
  • 1.2 Rules for cleanliness
    115
  • 1.3 Fuel tank with attachments - Assembly overview
    116
  • 1.4 Fuel fliter - Assembly overview
    118
  • 1.5 Fuel cooler - Assembly overview
    119
  • 1.6 Emptying fuel tank
    119
  • 1.7 Removing and installing fuel delivery unit
    122
  • 1.8 Removing and installing fuel gauge sender
    123
  • 1.9 Check fuel gauge sender
    124
  • 1.10 Removing and installing fuel tank
    125
  • 1.11 Checking fuel pump
    127
  • 1.12 Check tandem pump
    132
  • 1.13 Removing and installing tandem pump
    134
  • 2 Electronic power control (EPC)
    137
  • 2.1 Function of EPC system
    137
  • 2.2 Accelerator pedal module - Assembly overview
    137
  • Charging
    139
  • 1 Charge air system with turbocharger
    139
  • 1.1 Safety precautions
    140
  • 1.2 Rules for cleanliness
    140
  • 1.3 Turbocharger with attachments - Assembly overview
    140
  • 1.4 Parts of charge air cooling - Assembly overview
    146
  • 1.5 Vacuum hoses for connection diagram
    148
  • 1.6 Removing and installing charge air cooler
    152
  • Mixture preparation, Injection
    154
  • 1 Diesel direct injection system
    154
  • 1.1 Safety precautions
    154
  • 1.2 Rules for cleanliness
    155
  • 1.3 Fitting locations overview
    155
  • 1.4 Intake manifold flap - Assembly overview
    158
  • 1.5 Servicing unit injector - Assembly overview
    163
  • 1.6 Installing and removing unit injector
    164
  • 1.7 Removing and installing O-rings for injector unit
    168
  • 1.8 Air filter - Assembly overview
    169
  • 2 Engine control unit
    171
  • 2.1 Reading and erasing engine control unit fault memory
    171
  • 2.2 Removing and installing engine control unit
    172
  • Exhaust system
    174
  • 1 Parts of exhaust system
    174
  • 1.1 Front exhaust pipe and catalyst with attachments - Assembly overview
    174
  • 1.2 Silencer with mountings - Assembly overview
    177
  • 2 Exhaust gas recirculation system
    179
  • 2.1 Parts of exhaust gas recirculation - Assembly overview
    179
  • 2.2 Check exhaust gas recirculation valve - engine codes ATD, AXR, BSW
    183
  • Glow plug system
    187
  • 1 Glow plug system
    187
  • 1.1 Removing and installing glow plugs, checking
    187
Manufacturer's designation 4-cylinder unit injector diesel engine
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)
Suitable car types 1Y, 9C
Engine code AXR, BEW, BSW
Category Reparaturanleitung

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