VW New Beetle RSi (01-10) 6-cyl. Injection engine Mechanics Repair manual

Inhaltsverzeichnis

00 - Technical data

1 - Engine technical data

1.1 - Engine technical data

1.2 - Engine number

1.3 - Engine data

10 - Removing and installing engine

1 - Removing and installing engine

1.1 - Removing and installing engine

1.2 - Notes on removing

1.3 - Securing engine to assembly stand

1.4 - Notes on installing

1.5 - Tightening torques

1.6 - Aligning engine and gearbox mountings

1.7 - Assembly mountings

1.8 - Additional information and removal instructions for vehicles with air conditioner

13 - Crankshaft group

1 - Dismantling and assembling engine

1.1 - Dismantling and assembling engine
1.2 - Characteristics of the New Beetle RSi
1.3 - Dismantling and assembling engine
1.4 - Removing and installing ribbed belt

2 - Removing and installing sealing flanges and two-part flywheel

2.1 - Removing and installing sealing flanges and two-part flywheel

2.2 - Removing and installing drive plate

2.3 - Renewing crankshaft oil seal -vibration damper end‑

3 - Removing and installing crankshaft

3.1 - Removing and installing crankshaft

4 - Dismantling and assembling piston and conrod

4.1 - Dismantling and assembling piston and conrod

4.2 - Characteristics of the New Beetle RSi

4.3 - Dismantling and assembling pistons and conrods

4.4 - Piston and cylinder dimensions

15 - Cylinder head, Valve gear

1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head

1.2 - Characteristics of the New Beetle RSi

1.3 - Removing and installing cylinder head for engine codes AQP and AUE

1.4 - Removing and installing cylinder head

1.5 - Checking valve timing

1.6 - Adjusting valve timing

1.7 - Removing and installing cylinder head cover

1.8 - Checking compression pressures

2 - Servicing valve gear

2.1 - Servicing valve gear

2.2 - Characteristics of the New Beetle RSi

2.3 - Servicing valve gear for engine codes AQP and AUE

2.4 - Removing and installing camshafts

2.5 - Checking camshaft adjustment

2.6 - Renewing valve stem seals

2.7 - Checking valve guides

2.8 - Reworking valve seats

17 - Lubrication

1 - Removing and installing parts of the lubrication system

1.1 - Removing and installing parts of the lubrication system

1.2 - Characteristics of the New Beetle RSi

1.3 - Dismantling and assembling oil filter housing

1.4 - Checking oil pressure sender (G10)

1.5 - Dismantling and assembling oil pump

1.6 - Removing and installing oil sump

1.7 - Checking oil pressure and oil pressure switch

19 - Cooling system

1 - Removing and installing parts of cooling system

1.1 - Removing and installing parts of cooling system

1.2 - Characteristics of the New Beetle RSi

1.3 - Parts of coolant system, body side

1.4 - Parts of coolant system, engine side

1.5 - Supplementary radiator

1.6 - Removing and installing supplementary radiator

1.7 - Coolant hose connection diagram

1.8 - Checking continued coolant circulation pump

1.9 - Checking radiator fan

1.10 - Removing and installing coolant pump

1.11 - Dismantling and assembling coolant thermostat housing

1.12 - Draining and filling cooling system

1.13 - Removing and installing radiator

20 - Fuel supply system

1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system

1.2 - Removing and installing fuel tank with its attachments and fuel filter

1.3 - Removing and installing fuel tank with its attachments and fuel filter

1.4 - Safety precautions when working on the fuel supply system

1.5 - Rules for cleanliness

1.6 - Removing and installing suction jet pump

1.7 - Removing and installing fuel delivery unit

1.8 - Removing and installing fuel gauge sender

1.9 - Removing and installing fuel tank

1.10 - Crash fuel shut-off

1.11 - Checking fuel pump