Service Workshop Manual Beetle 2012 > The Beetle 2017 > The Beetle Cabriolet 2012 > The Beetle Cabriolet 2017 > 4 -cylinder i inle ion engine ee 2'direct injection Edition 07.2048 Service Department. Technical InformationService List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 21 - Turbocharging/supercharging 24 - Mixture preparation - injection 26 - Exhaust system 28 - Ignition system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2018 Volkswagen AG, Wolfsburg D3EGO3FFF744-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. Contents 00 - Technical data 1 Identification 4.1 Engine number/engine data 2 General information 1 1 1 3 2.4 Numbering of cylinders 3 3 Safety information 4 3.1 Safety precautions when working on fuel system 4 3.2 Safety precautions when using testers and measuring instruments during aroadtest .... 4 3.3. Safety precautions when working on the cooling system wees ces 5 3.4 Safety precautions when working on ignition system cetttttttteseeeees 6 3.5 _ Releasing high pressure in fuel system cee . 6 4 Repair instructions 8 4.4 Rules for cleanliness . 8 42 Foreign objects in engine 8 9 9 9 10 - Removing and installing erigine ............ . 4 Removing and installing engine wee e 4.4 Removing engine : oS 1.2 Separating engide and geerbox. ; 18 4.3 Securing engigl an engine and gearbx euppart en) 14 Instaling engine 2 2 Assembly mBuntings re 21 Assembly overview - assembly mountings ar) 22 Removing and installing engine mounting 26 23 Supporting éngine in installation position S32 24 Adjusting assembly mountings 38 25 Checking adjustment of assembly mountings (engine and gearbox mountings) 40 43- Crankshaft Group... 0. see e cece ee ees ecto eeeveeeeee 44 1 Cylinder block (pulley end) 4 4.1 Assembly overview - cylinder block (pulley end) 41 12 Assembly overview - poly V-belt drive 45 1.3 Removing and installing poly-V belt 49 414 Removing and instailing tensioner for poly V-belt 50 1.5 Removing and installing vibration damper mw. & vie 82 4.6 Removing and installing bracket for ancillaries ..................9 0. eee 58 1.7 Renewing crankshaft oil seal “‘belt pulley end 58 2 Cylinder block, gearboxend .... Ong + yal ee ee serene OF 2.1 Assembly overview - cylinder block, gearbox end . . . wee . 61 2.2 Removing and installing sealing flange on gearbox side . . eee 63 3 Crankshaft .... . a seeeeeeeee seeee sees sees 71 3.1 Crankshaft dimensions . . . eee eee ae 71 3.2 Renewing needle bearing in crankshaft . . . . . . 71 4 Pistons and conrods .. - eee . eee . 73 4.1 Assembly overview - pistons and. conrods . .. 73 42 Checking pistons and cylinder bores 5 43 Separating new conrod 76 15 - Cylinder head, valve gears... se .ee eee eees 78 1 Cylinder head 78 4.41 Assembly overview - cylinder head 78 1.2 Removing and installing cylinder head a1 contanis i4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 : 1.3. Removing andi tiéialing cylinder head cover”, 89 1.4 Checking Compression ney 97 2 Goyer for timing chain 100 2.1. Removing and installing valve timing housing (timing case) 100 3 Chain drive wees 106 3.1.6 Removing and installing camshaft timing chain : 106 32° Removing and installing timing chain and chain drive for oll pump .....--s-sse0...2 142 33. Checking valve timing .....0.... ese : ee ceceee ee 13 Adjusting vaive timing hee » 116 Valve gear 123 Assembly overview - valve gear 123 Measuring axial play of camshaft ........ ...- a cee 127 Removing and installing camshaft. Leeper ge 128 “44 Removing and installing valve stem seals 130 17 -Bubrication 6.6... ieee ee ete eee eet eee eee 133 4 Sump, oil pump ia A 133 1.4, Assembly overview-sumploll pump... cs cscessecesesed veseee 133 1.2%, Engine oil 3 136 1.3“, Removing and installing oll sump 137 1.4 “Removing and installing oll pump 139 2 Engine oll cooler 141 2.1 Removing and installing engine oil cooler 141 3 Oilfiter, off regeure switch 142 3.1 Checking oil pressure and oil pressyre:switch 142 19-Cooling ......... ceteee ee eee es . cece eee 14d 1 Cooling systenvecctant 144 1.1. Connection diagram - coolent hoses 144 1.2 Checking cooling system for leaks 144 1.3. Draining and adding coolant 148 2 Coolant pump, regulation of cooling system. cee eeceeeeeeeeeeee 2. 153 2.1 Assembly overview- thermostat .......... veces cone 153 2.2 Removing and installing coolant pump 154 2.3 Removing and installing coolant pump pulley 158 24 — Removing and instaling electric coolant pump 157 3 Radiator, radiator fan 159 3.1. Assembly overview - radiatorlradiator fan 159 3.2 Removing and installing radiator 161 3.3 Removing and installing radiator cowl . wees veces 162 34 — Removing and installing radiator fan... ee eevee veeeees 163 214 - Turbocharging/supercharging - 165 1 Exhaust turbocharger .... weet tenet eeee teen ect eenn ees 165 11 Assembly overview - turbocharger | 165 1.2. Removing and installing turbocharger 168 4.3. Removing and installing charge pressure positioner V465 172 2 Charge air system 174 2.1, Assembly overview - charge air system 174 2.2 Removing and installing charge air cooler 175 24 - Mixture preparation -injection ........ 6.06. 6c cece eee eee wee 178 1 Injection system... . s+ ceeeeees feet ceeee eens 178 2 Injectors 179 Ti contents4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. 2.1 Removing and installing injectors 179 2.2 — Renewing seals on injectors 182 23 Cleaning injectors... ee. eeeecvveeeeeeecseeeee vee vee 185 3 Airfiter 186 3.4 Assembly overview - air fiter housing ee feces cece eee 186 3.2. Removing and installing ar fiter housing feet vb vtteeeeee teens -. 187 4 Intake manifold ........ veces eee ees tteeeeeer cee eee 188 4.1 Assembly overview intake manifold vette teeter tseeeeeenes 188 4.2 Removing and installing intake manifold... eeeeeee es ceceees 193 4.3 Removing and installing throttle valve module J338 : : vo 198 44 Cleaning throttle valve module : veces vee eeeeeees 197 5 Senders and sensors... feet t eect eteesctteeesreeees 199 5.1 Checking fuel pressure sender G247 vee a 199 6 Engine (motor) control unit 202 6.1 Removing and installing engine (motor) control unit J623 202 7 High-pressure pump 204 7.4. Assembly overview - high-pressure pump bee vote ceeeeee 208 7.2 Removing and installing high-pressure pump ....... : coven 205 26 - Exhaust system 6.0... ieee eee eee eee eee ee erence eee eee nee es 208 1 Exhaust pipes and silencers 208 1.1. Assembly overview - silencers 208 1.2 Separating exhaust pipes from silencers, 208 1.3 Installation position of clamp 210 2 Exhaust gas cleaning 212 2.1 Assembly overview - emission control 212 28 - Ignition system 214 1 Ignition system. bee settee cteeeeeee sevens 24 4.1 Assembly everview- ignition system... bev teeeeteee vee 2I8 1.2 Removing and instaling engine speed sender, G28 : 216 13° Test data, spark plugs... cid eee SOR . cones 216 consents HiiBeetle 2012 > , The Beetle 2017 > . The'Béetle Cabriolet 2012'\/The Be 4-cylinder injection engine (1.2 | dirétt injection engine, EA114, turbocharger) - Edition 07.2018 IV contants4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. wy} Technical data 1 Identification (VRLO12009; Edition 07,2078) 21.1 Engine numbiétfengine data’, page 1 1A Efigine number/engine data 224 i ‘The engine number (‘code letters” and “serial number’) can be found at the joint between the engine and gearbox. ‘The engine code is also on the vehicle data sticker and on the crankcase above the gearbox. ‘There is also a sticker on the intake manifold showing the “engine code” and ‘serial number” The engine code is also included on the vehicle data sticker. Vehicles with four digit engine codes Foursplace engine codes are being introduced, starting with letter °C”. The first 3 places show the mechanical design of engine and are stamped on the engine as previously. The fourth digit shows the engine output and torque and varies according to engine con- trol unit The four-digit engine code can be found on the type plate, the vehi¢le data label and on the engine control unit (B) ne Fitting locations of Vehicle data sticker > Maintenance ; Booklet’: Vehicle data sticker Engine data Issued 08.2011; Version 3.0 Engine code (BZB Manufactured 11.09." Exhaust emission standard EUS Displacement om’ 1197 Power KW at rpm] 7715000 Torque Nm at rpm 175/1850-4100 Idling speed” rpm| 600 ... 800 Governed speed rpm| from 6200 Bore 2 mm| 710 Stroke mm| 756 ‘Compression ratio 10 Valves per cylinder 2 RON min, 95 unleaded Injection, ignition SIMOS 10 Firing order 1342 Type of mixture formation Homogeneous Charging Exhaust turbocharger 1) Notadustable \donfcation 1Beetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be 4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 2 Rep. 07: 00- Technical dataBeetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be... 4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. General information 3 + Numbering of eylinders Numbering of cylinders (B) sme Cylinder 1 is opposite the power delivery side. ni VOKSNACEN AG, oreo 2. Goneraintormation 34-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 3 Safety,information ='3.1 Safety pré@autions when working on fuel syste’ page 4 2132 utions when using testers and measuring if ‘struments during a road test’, page pabe 5 $3.4 Safety precautions when working on ignition system’, ‘23.5 Releasing high pressure in fuel system”, page 6 3.4 Safety precautions when working on fuel system a A WARNING The fuel system is pressurised! . Wear aye protection and protective clothing to avoid pos- sible injury and skin contact. ¢ Gefore loosening line connections, wrap a cloth around {he connection. Then release pressure by carerulypuling 8. For reasonsiof safety, the power supply to the fuel pump must be intaraptod betes the il sysorhopense, The toa pun would otherwise bé activated when the driver's door is opened or the ignition is switched on. Use the following options to in- terrupt the power supply: # Disconnect battery or ¢ Remove fuse for fuel pump - G6- or ¢ Pull connector off fuel delivery unit fange L\ caution (Observe the following points during all installation work, in par- ticular in the engine compartment, due to the space limitations: Route all the various lines (e.g. for fuel, hydraulics, acti- vated charcoal fiter system, coolant and refrigerant, brake uid and vacuum) and electrical wing nth original po- sitions. ¢ To avoid damaging nes, make sure there i suicient clearance to all moving or hot components. 3.2 Safety precautions when using testers and measuring instruments during a road test Note the following if testers and measuring instruments have to be used during a road test 4 Rp. 07:00- Technical data4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. @ Testers and measuring instruments must always be sediired to rear seat and operated by @ second person from this loca- tion! If test and measuring instruments are opétated from front pas- senger seat and the Vehicle is involved in an accident, there is @ possibilty thet the person sitting in this seat may receive serious injuries when the airbag is triggered. 33 Safety precautions when working on the cooling system A WARNING Hot steam may escape when expansion tank Is opened. ¢ Wear protective gogglés and clothing to avoid eye injuries and scaiding. Cover cap with a cloth and carefully open. A Caution Observe the following points duringzall installation work, in par- {cular in the engine compartment, die fo the space limrtations: Route al the various lines (e.g. for fuel, hydraulics, act- vated charcoal iter system, coolant andrefigerant brake fuid and vacuum) and electrical wiring in thet orginal po- sions. '¢ To avoid damaging lines, make sure there is sufficient clearance to all moving or hot components. Note ¢ Cooling system is pressurized when engine is warm. Ifnec- essary, release pressure before carrying out repairs. ¢ Secure all hose connections with hose clips, allocation = electronic parts catalogue ‘ETKA" © Spring-type clip pliers are recommended for installation of spring-type clips. @ Renew gaskets and seals. ¢ The arrows on the coolant pipes and on the ends of the hoses must be aligned with each other. 8. Safety information 54-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 34 Safety precautions when working on ig- nition system A WARNING The fuel system is pressurised! ¢ Wear protective goggles and protective clothing to avold injury and contact with the skin. Before loosening line connections, wrap a cloth around ‘he connection. Then release pressure by careful paling line. To prevent injuries to persons.afidior damage to the injection and. ignition system, the following must be observed: # Do not touch or discénnect ignition cables when the engine is running or being turned at starter speed. ‘Switch off ignitign before connecting or disconnecting injection {and ignition system wiring as well as fest instrument cables, Fuel pump is activated by switching on ignition and via driver door contact switch. For reasons of safety, detach connector arrow from fuel pump delivery unit or remove fuse for fuel pump control unit - J538- before opening fuel system if battery is not disconnected. L\ casiion serve the folowing points during a ntalation work, par fear the engine Compartment Gua the space itatons j # Route all ibe various lines (e.g. for fuel, hydraulics, acti- vated charcoal fiter system, coolant and refrigerant, brake § fluid and vacuum) and electrical wiring in their original po- $ sitions. To avoid damaging lines, make sure there is sufficient clearance to all maving or hot components. s 35 Releasing high préssure in fuel system: A WARNING The injection system consists of a high-pressure section (max- imum approx. 120 bar) and a low-pressure section (approx. 6 bar). Prior to opening the high-pressure area, the fuel pressure in the high-pressure area musi be reduced to a residual pressure ‘of approx. 6 bar. The appropriate procedure is described as follows. = Connect > Vehicle diagnostic tester and perform Guided Function “Releasing fuel high-pressure = Switch off ignition. 6 op. o:00- Technical data4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. LX waanine The fuel lines are pressurized! Wear protective goggles and protective clothing to avoid injury and contact with the skin, Before opening the high-pressure section, wrap a cloth around the connection. - Wrap a clean cloth around the connection. Open the connec- tion carefully to allow the residual pressure of about 6 bar to escape. Caich the escaping fuel = After completing work, read event memory of engine control Unit and clear all event entries that may have been created as a result of pulling off the connector. [F) Note If the event memory was cleared, the readiness code must be generated = Vehicle diagnostic tester “Guided Functions” 8. Safety information 74-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 4 Repair instructions = "4.1 Rules for cleanliness”, page 8 = "4.2 Foreign objects in engine”, page 8 41 Rules for cleanliness When working on the fuel supply/injection system, carefully follow the “5 rules” below: 4 Thoroughly clean all joints and surrounding areas before dis- mantling. # Place removed parts on a clean surface and cover them over. Use lint-free cloths only. Carefully cover opened components or seal them if repairs cannot be carried out immediately. Install only clean parts; do not remove new parts from pack- aging until immediately before installing. Do not use parts that have been kept unpackaged (for example in toolboxes), + . 4 If system is open: do not use compressed air if possible. Try not to move the vehicle. 42 Foreign objects in engine @ To prevent the ingress of foreign objects when carrying out installation work on the engine, open duets of the take and exhaust gas systems must be sealed with suitable plligs;for example from the engine bung Set - VAS 6122- VAS 6122 8 Rep. 0: 00- Technical dataBeetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 ~ 4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. moving and installing e1 1 Removing and installing engine -2"1.4 Removing engine’, page 9 = "1.2 Separating engine and gearbox’. page 18 +2"1.3 Securing engine on engine and geerbox support age 19 > "1.4 Installing engine’, page 21 1A Removing engine (B) nee The engine is removed downwards together with the gearbox. Special tools and workshop equipment required NAGS V.A.G 1383 A VAS 6208 © Engine support -T10416- with adapters /1, /2, (3 @ Torque wrench - V.AG 1331- The Be 1. Removing and insaling angina 9)Beetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be 4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 4 Engine and gearbox jack - V.A.G 1383 A- '# Engine and gearbox support - VAS 6095- Drip tray for workshop hoist - VAS 6208- V.A.G 1332 4 Hose clamp pliers - VAS 6340- eg 4 Stepladder - VAS 5085- Won # Torque wrench (40 ... 200 Nm) - V.AG 1332- # Guide pins - T10093- 10 ep. o.10-Removing and insaling engine4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. © Adapter - 710467- Tro4e7 ¢ Alfcable ties which are opened or cut through when engine is ‘removed must be replaced n the same positon wnen engine 3 ‘isinstalled. ¢ S8a/ disconnected fuel lines, breather lines and vacuum lines 2 ‘sasthat the system is not contaminated with dirt © LeSive ignition Key in ignition lack to prevent stesring lock from engaging. — Obsetve rules for cleanliness = page 8 = Reduce'pressure in high-pressure section of fuel system é = page 62 ; — Remove air filer > page 187. — Remove battery and battery tray =. Electrical system; Rep. of: 27 ; Battery; Removing and installing battery tray. ~ Drain eolanttrom engine eéting system and chargé ar cool ing system = page 146 LX _ warwine The fuel system is pressurised! Wear protective goggles and protective clothing to avoid injury and contact wih the skin ¢ Before loosening line connections, wrap a cloth around the connection. Then relence preveure by caretuly uling offline. — Disconnect fuel supply line -1-> Rep. gr. 20; Plug-in con- nectors; Separating plug-in connectors = Seal lines so that fuel system is not contaminated by dirt 1. Removing and instaling engine 11Beetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be... 4-cylinder injection engine (1.2 | direct injection engine, EAt1 1, turbocharger) - Ecition 07.2018 ~ Remove hose tom activated ceil iter solenoid valve 1 - N80- to activated charcoal filter. = Remove securing bolts -2.nd pull activated charcoal fter upwards, ° — Open spring-type clips and pull coolant hoses -1- and -2- off, Press locking giement-3- under the coolant hoses and pull the hoses upwards. = Place coolant Hoses towards the rear. = Release coolant hoses at heat ethanger -arrows- and pull them off. P20) open — Release coolant hoses -arrows- at gearbox end and pull them off heat exchanger. 12 Rep. o.10-Removing and insaling engine4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. Remove Lambda probe - GX10- -1- Undo and remove upper bolt of alternator -2- and press alter- nator downwards a ite. Pull connector -2- off alternator. Undo bolts -arrows- and remove heat shield from turbocharg- er. Unscrew securing nuts on turbocharger -arrows-. Remove noise insulation = General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly overview - noise in- sulation Remove left and right wheel housing liner > General body repairs, exterior; Rep. gr. 68; Removing and installing front ‘wheel housing liner Pull coolant hose (quick-releasé coupling) -arrow- off lower connection of low-temperattire radiator for charge air. Seal coolant hose to prevent ingress of dirt and leakage of residual coolant. > Pull connector -2- off coolant circulation pump - V50- Pull connecterrs -3- off knock sensor 1 - G61- and off engine speed sender - G28- -6.. 1. Removing and instaling engine 13;4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 Disregard items -1- and -3.. Vehicles with dual clutch gearbox — Move lock carrier to service position » General body repairs, exterior Rep. gr. 50; Leck cari, Moving to and from service position Continued for all vehicles = Unscrew nuts -arrows- on exhaust pipe together with flexible ieint. — Loosen securing bolts of clamp -arrows- and remove centre pipe towards rear. 14 ep. o.10-Removing and instaling engine4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. Separate connectors -1- — Unscrew securing nuts -2-, and press exhaust pipe towards rear out of rubber bushes using assembly lever. — Then, remove front exhaust pipe forwards. Turn it while doing 50. - Unscrew securing bolts -3- and remove catalytic converter downwards. = All cable ties that are opened or cut through when the engine is removed must be renewed/replaced in the same position ‘when the engine is installed. Disconnect all electrical wiring from gearbox, alternator and starter and lay to side. = Pull off or disconnect all other electrical connections as nec- essary from engine and lay to side = Pull vacuum and breather hoses off engine. = Pull connector off radiator fan. First unscrew bolt -1- = Then remove bolts -2- and -3.. — Remove pendulum support. — Remove right drive shaft, unbolt left drive’ shaft from gearbox snditieue— Running gear axles, stegring: Rep. gt. 40 Drive shaft; Removing and installing drive shat Vehicles with manual gearbox = Unbolt selector mechanism from’gearbox > Rep. or. 34; Selector mechanism; Assembly.overview - selector mecha- nism 5 — Remove slave cylinder of hydraulic clutch > Rep. gr. 30; Clutch mechaniam; Removingjand inetaling cutch save cy inder g Bm cry natn ey Vehicles with dual clutch gearbox Ifyou touch metal objects, electrostatic discharge may occur. This, is cue to the electrostatic charge of the human body. This charge can disturb the function of electrical components of the gearbox and of the selector mechanism. & 1. Removing and instaling engine 15)4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 = Touch an earthed object -¢.9. a water pipe ora lifting platform = before working on the mechatronic unit. = Do not touch the connectors directly, — Remove selector lever cable = Rep. gr. 34: Selector mech- anism; Removing and installing selector lever cable Undo the bolts on the engine mounting and gearbox mounting by one turn) Vehicles with air conditioning system = Remove poly V-belt = page 49 A\ warns Danger of injury due to coolant. # Do not open the air conaitioner refrigerant circuit = Remove air conditioner compressor from ancillary bracket Heating, air conditioning: Rep. gr. 87 : Air conditioner com- pressor; Removing and installing air conditioner compressor from and to bracket = Secure air conditioner compressor on right longitudinal mem- ber. Danger of damage to coolant lines and hoses. ¢ DoNOT stretch, kink or bend refrigerant lines and hoses. Continued for all vehicles Engine support - T10416- with adapters -/1-, /3- and -I3- is re- quired to lower engine and gearbox. “Toate Toate —” der block as far as it will Screw adapter - T10416/1- int 90. = Position engine support - 110416: with adapters -/2- and -/3- on cylinder biock. % — Secure engine support - T10416- haind/-tight on cylinder block using a bolt -1-. ° 16 ep. o.10-Removing and instaing engine4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. = Tighten all bolts on the engine support - 110416- to 20 Nm. Adjuster nut-2. sets correct angle between pin on engine support = 110416. and engine and gearbox jack - VAG 1383 A- — Position engine and gearbox jack - V.A.G 1383 A- on engine support - T0416. RG. Volkswagen 4 Posiigg sngine support - T10416- so that there is a gap -a- be, tween adapter -1- and sump -2., to prevent damage to sump.” — SLift engine and gearbox slightly using engine and gearbox jack © = VAG 1383 A wo Note 5 To remove securing bolts use a stepladder - VAS 5085-. = Unbolt engine side of assembly mounting from above arrows. — Unbolt gearbox side of assembly mouirting from above -arrows- (8) noe © Check that ail hoses and other connections between engine/ gearbox assembly and body have been detached. ¢ A 2nd mechanic is required to lower the engine/gearbox as- ‘sembly. ¢ Engine/gearbox assembly must be guided carefully when lon ‘ering fo prevent damage. = Carefully lower engine and gearbox. 1. Removing and instaling engine 17Beetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be 12 Separating engine and gearbox = 1.2.4 Vehicles with menuel gearbox’, page 18 = "1.2.2 Vehicles with dual clutch gearbox", page 18 1.2.1 Vehicles with manual gearbox Condition + Engine with gearbox removed and mounted on engine support -T40075- on engine and gearbox jack - V.A.G 1383 A- Disconnecting - Remove starter = Electrical system; Rep. or. 27 ; Starter, Removing and installing starter = Remove lower engine/gearbox securing bolts. ~ Position engine and gearbox jack - V.AG 1383 Ax by a work: bench = Lower engine/gearbox unit until gearbox rests on workbench. = Remove upper engine/gearbox securing bots. — Press gearbox off from engine, guiding the'déarbox Connecting Install in reverse order of remoyal. When doing this, observe the following: Specified torques # = Rep. gr. 34; Removing and installing gearbox; Specified torques for gearbox 1.2.2 Vehicles with dual clutch gearbox ‘Special tools and workshop equipment required # Shackle - 10-222N12 10-222 ArN2 # Workshop hoist - VAS 6100- VAS 6100 4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 18 ep. o.10-Removing and insaling engine4-cylinder injection engine (1.2 | direct injection engine, EA% 11, turbocharger) - Edition 07.2018, Lifting eye bolt - 3368- , Condition + Engine with gearbox removed and méunted on engine support = T40075- on engine and gearbox jack V.A.G 1383 A Disconnecting = Remove starter = Electrical system: Rep. gr. 27 ; Starter; Removing and installing starter = Screw eye-head bolt - 3368- into gearbox énto stop. = Attach workshop hoist - VAS 6100- with shackle - 10-222 A 12- to eye bolt - 3368- = Raise gearbox slightly. = Remove all enginelgearbox connecting bolts. hog — Press gearbox off from engine, guiding the gearbox Connecting Install in reverse order of removal. When doing this, observe the following: Specified torques @ = Rep. gr. 34 ; Removing and installing gearbox: Specified torques for gearbox 13 Securing engine on engine and gearbox support 1. Removing and instaling engine 19)Beetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be 4-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 Special tools and workshop equipment required vas 6100 + Lifting tackle - 2024 A- 4 Workshop hoist - VAS 6100- # Engine and gearbox support - VAS 6095- Condition + Gearbox detached from engine > page 18 + Engine mounted on engine support - T40075- on engine and gearbox jack - V.AG 1583 A- 20 Roe. or.10- Removing and instaling engineBeetle 2012 > , The Beetle 2017 > , The Beetle Cabriolet 2012 > , The Be... 4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. Procedure — Attach lifting tackle - 2024 A. as shown and lift engine from ‘engine and gearbox jack - VAS 6100- using workshop hoist - VAG 1383 A A Caution Use securing pins -arrows- on hooks and locking pins to avoid damage to engine. — Secure engine on engine and gearbox support - VAS 6085- 14 _Inétalling engine Installatio# is carried out in the reverse order. When installing, note the following: L\ caution F Observe the following points during all installation work, in par- {icular in the engine compartment, due to the space limitations: Route all the various lines, «9. for fuel, coolant, reriger- 4, vacuum and electrica/ wing, in their eiginal post 3 tions. ¢ Toavoid damage to lines, ensure sufficient clearance to all moving or hot components. (F) re ©°,Reinstall all cable ties in the same locations when assembling. + Secure alihose connections with hose clivs = Electronic Parts * Catelogue ‘ETKA" / ¢ Rene iRepcctia ‘nuts and bolts when performing assembly + Alnays renew Bots hich are tightened vt tufhing further angle, as well as sealsand gaskets. ov" Vehicles with manual gearbox = Check clutch release bearing for wear and renew if necessary. ~ Light lubricate cute release bearing, guide sleeve for rs lease bearing and spines on nut shaft th gressefer splines Vehicles with dual clutch gearbox = Renewing needle bearing in crankshaft = page 7 1. Removing and instaling engine 214-cylinder injection engine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 Continued for all vehicles — Check whether dowel sleaye8 for centring engine/gearbox have been fitted in cylinder block, insert if necessary. ° — Hook intermediate’plate onto sealing flange and slide onto dowel sleeves -arrows-. ~ Adjust assembly mountings = page 38 . = Install drivé shafts = Running gear, axles, steering: Rep. gf 40 ; Drive shaft; Removing and installing drive shaft Vehicles with manual gearbox — Installhydraulic clutch slave oylinder = Rep. gr. 30 : Clutch contra mechaniary; Removing and inetaling cutch slave cy inders: — Install selector mechanism: > Rep. gr. 34; Selector mecha- nism} Removing and installing gear knob Vehicles with dual clutch gearbox — Install selector lever cable > Rep. gr. 34; Selector mecha- nism; Removing and installing selector lever cable Vehicles with air conditioning system = Install air conditioner compressor > Heating, air conditioning; Rep. gr. 87%Air conditioner compressor, Removing and stalling air conditioner compressor from and to bracket = Install poly V-belt page 49 . Continued for all vehicles 22 ep. or.10- Removing and installing engine4-cylinder injection engine (1.2 | direct injection engine, EA‘ 14, turbocharger) - Edition 07.2018. = Reset service position = General body repairs, exterior; Rep. ‘gr. 50; Lock carrier; Moving to and back from service position = Electrical connections and routing = Electrical system; Rep. or. o7 — Install battery and battery tray = Electrical system; Rep. or. 27 ; Battery; Removing and installing battery tray Install air filter = page 187 = Add coolant = page 146 = Connect vehicle diagnostic tester — Erase learnt values, and adapt engine control unit to throttle valve module + Vehicle diagnostic tester:iGbided Furtetions'., = Perform vehicle system test =,.éhicle diagnostic tester “Gui- ded Fault Finding’ te — Carry out road test andiBerform vehicle test again. Specified torques Bolted connection © Specified torque Nuts and bolts M6. 10Nm_ $ M7, 15Nm. z € Ma. 20 Nm 2 M10 40Nm 3 - M12 60 Nm 8 ‘@ Engine(gearbox connecting bolts > Rep. gr. 34 ; Removing and installing gearbox; Specified torques for gearbox Bolts for assembly mountings 32 Assembly mountings", page 24 1. Removing and instaling engine 23,@ Beetle 2012 > , The Betlle 2017 > , The Beetle Cabriolet 2012,» , The Be 4-cylinder injection, éhgine (1.2 | direct injection engine, EA111, turbocharger) - Edition 07.2018 2 Assembly mountings = '2.1 Assembly overview - assembly mountings”, page 24 = '2.2 Removingand instelling engine mounting’. page 26 = °2.3 Supportidg engine in installation position”, page 32 ='2.4 Adjusting assembly mountings", page 38 ='2.5 Checking adjustment of assembly mountings (engine and g ‘988rbox mountings)", page 40 24 Assembly overview - assembly mountings 1 Pendulum support Bolt pendulum support to gearbox and then to subframe. 2- Bolt Gearbox mounting'te body * Renew after removal 40m +90" 3- Bolt Gearbox mounting to gearbox support Renew after removal 2 60Nm +90" 4- Bolt Pendulum support to subframe Renew after removal 2 100 Nm +90" 5 - Bolts, Pendulum support to gearbox Renew after removal 50m +90" 6 - Bolts, Pendulum support to ‘gearbox Renew after removal O 50.Nm +90" BIOTOHET 7-Bolt Gearbox support to gearbox Specified torque: Vehicles with manual gearbox = Rep. gr. 34 ; Removing and installing gearbox; Specified torques for gearbox Vehicles with dual clutch gearbox > Rep. gr. 34; Removing and installing gearbox; Specified torques for gearbox 8 - Gearbox mounting 1D Adjusting assembly mountings > page 38 24 ep. or.10- Removing and installing engine