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  • Examplepage for repair manual 5-Cyl. Injection Engine (4 Valve), Mechanics
  • Examplepage for repair manual 2 5-Cyl. Injection Engine (4 Valve), Mechanics
  • Examplepage for repair manual 3 5-Cyl. Injection Engine (4 Valve), Mechanics

5-Cyl. Injection Engine (4 Valve), Mechanics

For New Beetle

Original Volkswagen repair manual


18,22 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.249 KB

222 Sites

Detailed technical data

Immediately readable

This repair manual contains: Technical data, Removing and installing engine, Electronic power control (EPC) and Activated charcoal filter system. Show more
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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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