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  • Examplepage for repair manual 5-cylinder injection engine (2.5 l engine, 4-valve)
  • Examplepage for repair manual 2 5-cylinder injection engine (2.5 l engine, 4-valve)
  • Examplepage for repair manual 3 5-cylinder injection engine (2.5 l engine, 4-valve)

5-cylinder injection engine (2.5 l engine, 4-valve)

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


20,30 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.817 KB

251 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel or drive plate, Crankshaft, Pistons and conrods, Cylinder head, Parts of fuel supply system - engine code BPS (plastic fuel tank), Activated charcoal filter system and Checking components. Show more
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Repair manual New Beetle Cabrio / New Beetle 5-cylinder injection 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
    2
  • 1 Removing and installing engine
    2
  • 1.1 Removing engine
    3
  • 1.2 Securing engine to assembly stand
    8
  • 1.3 Installing engine
    11
  • 1.4 Assembly mountings
    13
  • Crankshaft group
    14
  • 1 Dismantling and assembling engine
    14
  • 1.1 Assembly overview - add-on parts
    14
  • 1.2 Assembly overview - chain drive
    20
  • 1.3 Removing and installing poly V-belt
    24
  • 1.4 Removing and installing exhauster pump for brake servo
    25
  • 2 Sealing flange and flywheel or drive plate
    28
  • 2.1 Assembly overview - sealing flange
    28
  • 2.2 Renewing crankshaft sealing flange - belt pulley end
    29
  • 2.3 Removing and installing valve timing housing
    32
  • 2.4 Removing and installing seal on gearbox side
    35
  • 2.5 Removing and installing drive plate
    36
  • 3 Crankshaft
    38
  • 3.1 Assembly overview - crankshaft
    38
  • 3.2 Crankshaft dimensions
    39
  • 3.3 Locking crankshaft
    40
  • 4 Pistons and conrods
    43
  • 4.1 Assembly overview - pistons and conrods
    43
  • 4.2 Separating new conrod
    44
  • 4.3 Checking pistons, piston rings and cylinder bores
    45
  • 4.4 Piston and cylinder dimensions
    46
  • Cylinder head, valve gear
    47
  • 1 Cylinder head
    47
  • 1.1 Assembly overview - cylinder head
    47
  • 1.2 Removing and installing cylinder head cover
    49
  • 1.3 Removing and installing chain guard cover
    50
  • 1.4 Renewing chain guard cover seal
    54
  • 1.5 Checking valve timing
    56
  • 1.6 Adjusting valve timing
    57
  • 1.7 Removing and installing cylinder head
    61
  • 1.8 Checking compression
    67
  • 2 Valve gear
    69
  • 2.1 Assembly overview - valve gear
    69
  • 2.2 Valve dimensions
    71
  • 2.3 Checking valve guides
    71
  • 2.4 Renewing valve stem seals
    72
  • 2.5 Removing and installing camshafts
    75
  • Lubrication
    80
  • 1 Parts of lubrication system
    80
  • 1.1 Engine oil
    80
  • 1.2 Assembly overview - parts of lubrication system
    80
  • 1.3 Assembly overview - oil filter bracket
    82
  • 1.4 Draining oil filter housing
    83
  • 1.5 Removing and installing lower part of sump
    84
  • 1.6 Removing and installing upper part of sump
    85
  • 1.7 Removing and installing oil pump, vehicles to model year 2007
    88
  • 1.8 Removing and installing oil pump, vehicles from model year 2008
    92
  • 1.9 Checking oil pressure and oil pressure switch
    96
  • Cooling
    99
  • 1 Parts of cooling system
    99
  • 1.1 Assembly overview - parts of cooling system, engine side
    99
  • 1.2 Assembly overview - parts of cooling system, body side
    103
  • 1.3 Coolant hose schematic diagram
    104
  • 1.4 Draining and filling with coolant
    105
  • 1.5 Removing and installing coolant pump
    108
  • 1.6 Removing and installing thermostat
    115
  • 1.7 Removing and installing fan shroud with radiator fans V7
    117
  • 1.8 Removing and installing radiator
    118
  • 1.9 Checking cooling system for leaks
    120
  • 1.10 Checking radiator fan
    123
  • Fuel supply system
    125
  • 1 Parts of fuel supply system - engine code BPS (plastic fuel tank)
    125
  • 1.1 Safety precautions when working on fuel supply system
    125
  • 1.2 Rules for cleanliness
    126
  • 1.3 Assembly overview - fuel tank with attachments and fuel filter
    126
  • 1.4 Emptying fuel tank
    129
  • 1.5 Removing and installing fuel delivery unit
    134
  • 1.6 Removing and installing fuel gauge sender
    136
  • 1.7 Removing and installing fuel tank
    136
  • 1.8 Assembly overview - fuel filter with attachments
    139
  • 1.9 Removing and installing fuel filter
    140
  • 1.10 Checking fuel pump
    141
  • 1.11 Bleeding fuel system
    149
  • 2 Parts of fuel supply system - engine code BPR (metal fuel tank)
    153
  • 2.1 Safety precautions when working on fuel supply system
    153
  • 2.2 Rules for cleanliness
    154
  • 2.3 Assembly overview - fuel tank with attachments and fuel filter
    154
  • 2.4 Emptying fuel tank
    157
  • 2.5 Removing and installing fuel delivery unit
    160
  • 2.6 Removing and installing fuel gauge sender
    163
  • 2.7 Removing and installing fuel tank
    163
  • 2.8 Removing and installing fuel filter
    166
  • 2.9 Checking fuel pump
    167
  • 2.10 Bleeding fuel system
    175
  • 3 Electronic power control (EPC)
    179
  • 3.1 Function of EPC system
    179
  • 3.2 Assembly overview - accelerator module
    179
  • 4 Activated charcoal filter system
    181
  • 4.1 Function
    181
  • 4.2 Overview of activated charcoal filter system
    182
  • 4.3 Assembly overview - parts of activated charcoal filter system
    185
  • 4.4 Removing and installing activated charcoal filter and fuel system diagnostic pump V144
    187
  • 4.5 Checking fuel system for leaks
    188
  • Mixture preparation - injection
    196
  • 1 Injection system
    196
  • 1.1 General notes regarding injection
    196
  • 1.2 Safety precautions
    197
  • 1.3 Rules for cleanliness
    197
  • 1.4 Technical data
    198
  • 1.5 Overview of fitting locations
    198
  • 1.6 Assembly overview - intake manifold with attachments
    201
  • 1.7 Assembly overview - fuel rail with injectors
    203
  • 1.8 Assembly overview - air filter
    204
  • 1.9 Removing and installing throttle valve module J338
    205
  • 1.10 Removing and installing intake manifold
    206
  • 1.11 Removing and installing injectors
    209
  • 2 Checking components
    212
  • 2.1 Checking injectors for leaks and quantity injected
    212
  • 2.2 Checking fuel pressure regulator and holding pressure, engine code BPS
    214
  • 2.3 Checking fuel pressure regulator and holding pressure, engine code BPR
    217
  • 3 Engine control unit
    222
  • 3.1 Reading and erasing engine control unit fault memory
    222
  • 3.2 Removing and installing engine control unit
    223
  • Exhaust system
    224
  • 1 Parts of the exhaust system
    224
  • 1.1 Assembly overview - exhaust manifold with attachments
    226
  • 1.2 Removing and installing exhaust manifold
    226
  • 1.5 Assembly overview - silencers with mountings
    232
  • 1.6 Removing and installing front exhaust pipe with catalytic converter
    233
  • 1.7 Separating and joining front and rear silencers
    234
  • 1.8 Aligning exhaust system free of stress
    235
  • 2 Secondary air system
    237
  • 2.1 Function
    237
  • 2.2 Assembly overview - secondary air system
    237
  • 2.3 Removing and installing secondary air pump motor V101
    239
  • 2.4 Checking secondary air inlet valve N112
    240
  • Ignition system
    242
  • 1 Ignition system
    242
  • 1.1 General notes on ignition system
    242
  • 1.2 Safety precautions
    242
  • 1.3 Assembly overview - ignition system
    242
  • 1.4 Removing and installing ignition coils with output stage
    244
  • 1.5 Test data, spark plugs
    245
Manufacturer's designation 5-cylinder injection engine (2.5 l engine, 4-valve)
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007)
Suitable car types 1Y, 1C
Engine code BPS
Category Reparaturanleitung

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