Name: 5-Cyl. Injection Engine (4 Valve), Mechanics
Brand: Volkswagen
SKU: CDG01bb6feb49cc
Price: 18.22 EUR
Availability: InStock

Content
Details
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Repair manual New Beetle 5-Cyl. Injection Engine , Mechanics PDF download has the following content:

Chapter overview

Materials
1
1 Technical data
1
1.1 Technical data
1
1.2 Engine number
1
1.3 Engine data
1
Removing and installing engine
3
1 Removing and installing engine
3
1.1 Removing and installing engine
3
1.2 Notes on removing
4
1.3 Securing engine to assembly stand
8
1.4 Notes on installing
9
1.5 Aligning engine and gearbox mountings
11
1.6 Tightening torques
12
1.7 Additional information and removal instructions for vehicles with air conditioner
12
Crankshaft group
14
1 Dismantling and assembling engine
14
1.1 Dismantling and assembling engine
14
1.2 Removing and installing ribbed belt
29
2 Removing and installing sealing flange and dual mass flywheel/drive plate
31
2.1 Removing and installing sealing flange and dual mass flywheel/drive plate
31
2.2 Renewing crankshaft oil seal -vibration damper end-
36
2.3 Removing and installing drive plate
39
3 Removing and installing crankshaft
41
3.1 Removing and installing crankshaft
41
4 Dismantling and assembling pistons and conrods
46
4.1 Dismantling and assembling pistons and conrods
46
4.2 Piston and cylinder dimensions
52
Cylinder head, Valve gear
53
1 Removing and installing cylinder head
53
1.1 Removing and installing cylinder head
53
1.2 Removing and installing cover
61
1.3 Removing and installing cylinder head cover
65
1.4 Removing and installing cylinder head
69
1.5 Checking valve timing
76
1.6 Adjusting valve timing
78
1.7 Checking compression pressures
85
2 Servicing valve gear
87
2.1 Servicing valve gear
87
2.2 Reworking valve seats
98
2.3 Removing and installing camshafts
100
2.4 Checking camshaft adjustment
108
2.5 Checking valve guides
113
2.6 Renewing valve stem seals
114
Lubrication
117
1 Removing and installing parts of the lubrication system
117
1.1 Removing and installing parts of the lubrication system
117
1.2 Dismantling and assembling oil filter housing
123
1.3 Dismantling and assembling oil pump
126
1.4 Removing and installing oil sump
129
1.5 Checking oil pressure and oil pressure switch
132
Cooling system
135
1 Removing and installing parts of cooling system
135
1.1 Removing and installing parts of cooling system
135
1.2 Parts of cooling system body side
136
1.3 Parts of cooling system engine side
139
1.4 Coolant hose connection diagram
144
1.5 Dismantling and assembling coolant thermostat housing
146
1.6 Draining and filling cooling system
148
1.7 Removing and installing radiator and fans
151
1.8 Removing and installing coolant pump
154
1.9 Checking continued coolant circulation pump
157
Fuel supply system
160
1 Removing and installing parts of fuel supply system
160
1.1 Removing and installing parts of fuel supply system
160
1.2 Removing and installing fuel tank with its attachments and fuel filter
161
1.3 Safety precautions when working on the fuel supply system
168
1.4 Rules for cleanliness
169
1.5 Crash fuel shut-off
169
1.6 Removing and installing fuel delivery unit
169
1.7 Removing and installing fuel gauge sender
171
1.8 Removing and installing fuel tank
171
1.9 Checking fuel pump
174
2 Electronic power control (EPC)
181
2.1 Electronic power control (EPC)
181
2.2 Function of EPC system
181
2.3 Servicing parts of electronic power control (EPC)
182
2.4 Checking accelerator pedal position sender
184
3 Activated charcoal filter system
187
3.1 Activated charcoal filter system
187
3.2 Function
187
3.3 Servicing parts of the activated charcoal filter system
188
3.4 Checking activated charcoal filter canister solenoid valve 1
190
3.5 Checking fuel tank breather
192
Exhaust system
195
1 Removing and installing parts of exhaust system
195
1.1 Removing and installing parts of exhaust system
195
1.2 Exhaust manifold, front exhaust pipe and catalytic converter with attachments
196
1.3 Silencer with mountings
200
1.4 Checking catalytic converter
204
2 Secondary air system
206
2.1 Secondary air system
206
2.2 Function
206
2.3 Removing and installing parts of the secondary air system
207
2.4 Checking secondary air system
212
2.5 Checking secondary air pump motor
214
2.6 Removing and installing secondary air pump motor
216
2.7 Checking combi-valve
217

Manufacturer's designation	5-Cyl. Injection Engine (4 Valve), Mechanics
Manufacturer	Volkswagen
Suitable for	New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)
Suitable car types	1C, 9C
Engine code	AQN
Category	Reparaturanleitung

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