Service
Repair Manual
Beetle 2012 ➤
The Beetle 2017 ➤
The Beetle Cabriolet 2012 ➤
The Beetle Cabriolet 2017 ➤
5-Cylinder Fuel Injection Engine (2.5L Engine, 4Valve)
Engine ID
CBTACBUACCC
A
Edition 12.2016
Service Department. Technical Information
List of Workshop Manual Repair Groups
Re pa ir G ro up
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
24 - Multiport Fuel Injection
26 - Exhaust System, Emission Controls
28 - Ignition/Glow Plug System
Service
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.
Beetle 2012 ➤, The Beetle 2017 ➤, The Beetle Cabriolet 2012 ➤, The Beetle Cabri ...
5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number/Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Cylinder Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Safety Precautions, Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Safety Precautions, Test and Measuring Instruments during Test Drive . . . . . . . . . . . . . . 5
3.3 Cooling System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Foreign Objects in Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Wire Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Radiator and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Engine and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Engine, Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Engine Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Engine, Supporting in Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4 Subframe Mount, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5 Subframe Mount, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.3 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.4 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.5 Sub-Assembly Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.6 Engine Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.7 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Overview - Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.2 Overview - Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.3 Overview - Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5 Flywheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.6 Crankshaft Seal, Replacing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.7 Sealing Flange, Removing and Installing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . 78
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Contents i
Beetle 2012 ➤, The Beetle 2017 ➤, The Beetle Cabriolet 2012 ➤, The Beetle Cabri ...
5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
3.2 Crankshaft, Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3 Crankshaft, Locking to Check/Adjust Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.5 Crankshaft, Measuring Axial Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.6 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.7 Main Bearing Shells Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.2 Overview - Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.3 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.4 Cylinder Head Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.5 Vacuum Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.6 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2 Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.1 Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.2 Timing Chain Cover Sealing Ring, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.1 Overview - Camshaft Timing Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.2 Overview - Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.3 Overview - Timing Mechanism Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.4 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.5 Valve Timing, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.3 Valve Shaft Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5 Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.1 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.2 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1 Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Overview - Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.2 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.3 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.5 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.1 Overview - Oil Filter Housing/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.2 Oil Filter Housing, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.3 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1 Coolant System/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ii Contents
Beetle 2012 ➤, The Beetle 2017 ➤, The Beetle Cabriolet 2012 ➤, The Beetle Cabri ...
5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
1.1 Connection Diagram - Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.2 Overview - Engine Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.3 Coolant System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.4 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2 Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.1 Overview - Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.2 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.3 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3 Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.1 Overview - Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.2 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.3 Coolant Fan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.1 Component Locations - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.2 Fuel System, Filling/Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.1 Overview - Fuel Rail with Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.2 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.3 Fuel Injectors, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.1 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.2 Intake Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.3 Throttle Valve Control Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.1 Overview - Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.2 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5.1 Engine Control Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1 Exhaust Pipes/Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.2 Muffler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.3 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2 Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.1 Overview - Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.2 Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3 Secondary Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.1 Overview - Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.2 Secondary Air Injection Pump Motor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 263
3.3 Secondary Air Injection Solenoid Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.1 Overview - Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Overview - Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.2 Ignition Coils with Power Output Stages, Removing and Installing . . . . . . . . . . . . . . . . . . 271
1.3 Knock Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Contents iii
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
1.4 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
iv Contents
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
00 – General, Technical Data
1 Identification
(Edition 12.2016)
⇒ N1.1 umber/Engine Specifications”, page 1
1.1 Engine Number/Engine Specifications
Engine code -arrow A- and engine number -arrow B- (“serial
number”) are located on rear side of engine, above partition of
cylinder block/upper section of oil pan.
The engine code is also stamped in on the right side on cylinder
head and on cylinder block.
A label with the “engine code” and “serial number” is also af‐
fixed to the toothed belt guard.
The first three digits describe the mechanical structure of the
engine and are still stamped on the engine. The fourth position
describes the engine output and torque. It depends on the en‐
gine control module. Four-digit engine codes are found on the
type label and vehicle data label. It can also be read via the
engine control module.
Note
Vehicle data label locations. Refer to ⇒ Maintenance; Book‐
let 20.1; Vehicle Data Label.
Engine Data
Edition 06/2011; Version 3.0
Engine Codes CBTA CBUA
Manufactured From 07/2007 From 07/2007
Emission values in accordance with TIER 2/BIN5 (US coa‐
lition)
Displacement cm³ 2480 2480
Output kW at RPM 125/5700 125/5700
Torque Nm at RPM 240/4250 240/4250
Engine idle speed
Engine speed limitation RPM approximately 6300 approximately 6300
Hole diameter in mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 9.5 9.5
5)
RPM 680 680
SULEV. Refer to 1).
Volkswagen Technical Site: https://vwts.ru
1. Identification 1
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Engine Codes CBTA CBUA
Valves per cylinder 4 4
RON minimum
95 unleaded
2)
95 unleaded
2)
Fuel injection, ignition Motronic ME 17.5 Motronic ME 17.5
Knock control 2 sensors 2 sensors
Camshaft adjustment yes yes
Intake manifold change-over no no
Oxygen sensor regulation 2 sensors 3 sensors
Catalytic Converter yes yes
Exhaust Gas Recirculation (EGR) no no
Charging no no
Secondary Air System no yes
1) SULEV: Super Ultra Low Emission Vehicles
2) Also 91 RON, but with reduced performance.
3) according to Mexico Exhaust Gas Standard NOM-042-SEMARNAT-2003
4) according to resolution No. 15, dated 12/13/1995 from Conama
5) Applies to manual and automatic transmission. If voltage supply of Engine Control Module (ECM) drops below 12 volts, idle speed is
raised in stages up to 780 RPM. Idle speed is not adjustable.
6) Engine Control Module, Replacing. Refer to ⇒ C5.1 ontrol Module,
Removing and Installing”, page 243 .
2 Rep. Gr.00 - General, Technical Data
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
2 General Information
⇒ N2.1 umbering”, page 3
2.1 Cylinder Numbering
– Remove the air filter (engine cover). Refer to ⇒ F4.2 ilter
Housing, Removing and Installing”, page 241 .
Note
Ignore -arrow-.
Note
Cylinder 1 is located opposite the fuel supply side.
Ignition sequence 1 - 2 - 4 - 5 - 3
2. General Information 3
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
3 Safety Precautions
⇒ P3.1 recautions, Working on Fuel Supply System”, page 4
⇒ P3.2 recautions, Test and Measuring Instruments during Test
Drive”, page 5
⇒ S3.3 ystem Safety Precautions”, page 5
⇒ S3.4 ystem Safety Precautions”, page 6
3.1 Safety Precautions, Working on Fuel
Supply System
Note the Following Whenever Working on the Fuel Supply Sys‐
tem:
WARNING
The fuel system is under pressure!
♦ Always wear protective eyewear and protective clothing
to prevent injuries and contact with skin.
♦ Wrap a cloth around the wiring connections before loos‐
ening hose connections. Then release pressure by care‐
fully pulling off the line.
DANGER!
Leaking fuel is a fire hazard.
WARNING
Any type of fuel leak will result in an increased risk of fire.
Do not turn on the ignition, open the front doors, or attempt to
start the engine at any time while any part of the vehicle’s fuel
system is unassembled. Failing to heed this warning could
result in fire and personal injury
Caution
Risk of destroying electronic components when disconnect‐
ing the battery.
♦ Follow the steps for disconnecting the battery.
Disconnect the battery only when the ignition is turned off. Refer
to ⇒ Electrical Equipment; Rep. Gr. 27; Battery; Battery, Discon‐
necting and Connecting.
Even Very Small Particles of Dirt Can Cause a Fault. When
Working on the Fuel Supply and on the Fuel Injection System,
Observe the Following Guidelines for a Clean Working Environ‐
ment:
♦ Always clean the connection locations and the area around
them with engine or brake cleaner before loosening.
♦ The always dry the cleaned locations.
4 Rep. Gr.00 - General, Technical Data
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
♦ Seal any open lines and connections immediately with a
suitable caps.
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored loose (for example, in tool boxes etc.).
♦ Do not work with compressed air when the system is open.
♦ Do not move the vehicle if possible.
♦ Protect any disconnected connectors from dirt and moisture
and connect them only when they are completely dry.
3.2 Safety Precautions, Test and Measur‐
ing Instruments during Test Drive
If Testing Equipment Must be Used During a Road Test, Ob‐
serve the Following:
WARNING
Distraction and testing equipment that is not secured proper‐
ly can cause accidents.
♦ Operating testing equipment while driving is a distrac‐
tion.
♦ Testing equipment that is not secure increases the risk
of injury.
♦ Always secure testing equipment on the rear seat.
♦ Have a second person operate the testing equipment.
♦ Operate the testing equipment from the rear seat.
♦ Do not operate the testing equipment from the front pas‐
senger seat.
♦ The deployment of the front passenger airbag during an
accident can cause injury to the person.
3.3 Cooling System Safety Precautions
WARNING
Hot steam may escape when opening the reservoir.
♦ Wear protective goggles and protective clothing to pre‐
vent damage to eyes and scalding.
♦ Cover the cap with a cloth and open very carefully.
3. Safety Precautions 5
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Caution
When doing any repair work, especially in the engine com‐
partment, pay attention to the following due to the tight work‐
ing conditions:
♦ Route all lines in their original locations.
♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.
Note
♦
When the engine is warm the cooling system is under pres‐
sure. If necessary release pressure before commencing re‐
pair work.
♦
Secure all hose connections with hose clamps. Refer to the
Parts Catalog for the allocation.
♦
The Spring Clip Pliers -VAS6499- are recommended for in‐
stalling spring clamps.
♦
Replace the gaskets and seals.
♦
Route the coolant hoses free of tension.
♦
Coolant hoses must not come into contact with other compo‐
nents.
♦
Pay attention to the markings on the coolant connection and
hoses.
3.4 Ignition System Safety Precautions
WARNING
To reduce the risk of personal injury and/or damage to the
fuel injection and ignition system, always observe the follow‐
ing:
Do not touch or remove ignition wires when engine is running
or turning at starter speed.
Only disconnect and reconnect wires for injection and ignition
system, including test leads, if ignition is turned off.
Fuel pump is activated with switching on the ignition and by
door contact switch on the driver door.
For this reason before opening fuel supply system, if the bat‐
tery was not disconnected, the voltage supply is interrupted..
6 Rep. Gr.00 - General, Technical Data
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
4 Repair Information
⇒ f4.1 or Clean Working Conditions”, page 7
⇒ O4.2 bjects in Engine”, page 7
⇒ C4.3 orrosion”, page 7
⇒ R4.4 outing and Securing”, page 8
⇒ a4.5 nd Condenser Assembly”, page 8
4.1 Guidelines for Clean Working Condi‐
tions
When working on the fuel supply/injection system, pay careful
attention to the following “5 rules” of cleanliness:
♦ Thoroughly clean the connection points and the surrounding
area before loosening.
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Carefully cover or seal opened components if the repair is
not performed immediately.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been loosely stored or unpackaged (for example,
in tool boxes etc.).
♦ When the fuel system is open: avoid working with com‐
pressed air if possible. If possible do not move vehicle.
♦ Protect any disconnected connectors from dirt and moisture
and connect them only when they are completely dry.
4.2 Foreign Objects in Engine
♦ To prevent foreign objects from entering when working on
the engine, seal open intake and exhaust channels with
suitable plugs, for example from the Engine Bung Set VAS6122-.
4.3 Contact Corrosion
Contact corrosion can occur if incorrect fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating
are installed.
In addition, rubber or plastic parts and adhesive are made of
materials that do not conduct electricity.
If there are doubts about whether parts can be used or not, then
use new parts. Refer to the Parts Catalog.
4. Repair Information 7
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
4.4 Wire Routing and Securing
♦ Mark the lines of all types before removal to avoid inter‐
changing them and to ensure the original installation posi‐
tion.
♦ If necessary, draw sketches or take pictures.
♦ Due to the limited space inside the engine compartment, be
especially careful when working near moving or hot parts to
avoid damaging the lines.
4.5 Radiator and Condenser Assembly
When assembled correctly, the radiator, condenser and turbo‐
charger may have slight impressions on their plates. This is not
damage. Do no replace the cooler, condenser or turbocharger
because of impressions like that.
8 Rep. Gr.00 - General, Technical Data
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
10 – Engine Assembly
1 Engine, Removing and Installing
⇒ R1.1 emoving”, page 9
⇒ a1.2 nd Transmission, Separating”, page 18
⇒ S1.3 ecuring on Engine and Transmission Holder”, page 22
⇒ I1.4 nstalling”, page 24
1.1 Engine, Removing
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Engine and Gearbox Jack -VAS6931-
♦ Spring Clip Pliers
♦ Step Ladder -VAS5085-
♦ Engine Holder Bracket -T03000-
♦ Cable Tie
♦ Foam Mat
♦ Tensioning Strap -T10038-
♦ Guide Pins -T10093-
♦ Adapters For Service Position -T10467-
Removing
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
Note
♦
The engine is removed downward together with the trans‐
mission.
♦
All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when instal‐
ling engine.
♦
Seal the disconnected fuel and ventilation lines to prevent
dirt from getting into the system.
♦
Leave the key in the ignition lock to prevent the steering
wheel from locking.
♦
If engine oil must be drained because of work performed on
the removed engine, it should be performed with the engine
installed. If engine hangs on the -T03001-, the engine is not
in installation position and less engine oil flows out.
– Check the DTC memories for all control modules. Refer to
Vehicle Diagnostic Tester.
– Remove the air filter (engine cover). Refer to ⇒ F4.2 ilter
Housing, Removing and Installing”, page 241 .
– Remove the intake hose -4- between the Throttle Valve Con‐
trol Module -J338- and the air filter. To do so, disconnect
1. Engine, Removing and Installing 9
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
air hose -1-, if present, and air hose -2- (compress securing
ring) and remove spring clamp -3-.
Continuation for All Vehicles
– Remove the intake air scoop from the lock carrier -arrows-.
– Remove the E-box cover inside the engine compartment
-arrows-.
Vehicles with Automatic Transmission
– Unclip the transmission control module -3- from the bracket
-7- and remove it upward.
10 Rep. Gr.10 - Engine Assembly
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– Disconnect the connector -2- from the transmission control
module.
Continuation for All Vehicles
– Remove the bolts -1 and 6-.
– Move the bracket -7- with the power steering fluid reservoir
to the side.
The hoses remain connected.
– Disconnect the line -5- and free it up.
– Disconnect the connector -4- from the engine control module
and free up the engine wiring harness. Refer to ⇒ C5.1 on‐
trol Module, Removing and Installing”, page 243 .
– Remove the battery and the battery tray. Refer to ⇒ Electri‐
cal Equipment; Rep. Gr. 27; Battery; Battery Tray, Removing
and Installing.
– Disconnect the connector -4-, open the locking mechanism
and lay the engine wiring harness -3- on the engine.
– Disconnect the ground cable -1- and the starter connections
-2 and 5-.
1. Engine, Removing and Installing 11
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Vehicles with Automatic Transmission
– Disconnect the connector -6- from the multifunction switch.
– Remove the selector lever cable from the transmission. Re‐
fer to ⇒ Rep. Gr. 34; Selector Mechanism; Selector Mecha‐
nism, Removing and Installing.
Vehicles with Manual Transmission
– Remove the selector mechanism from the transmission. Re‐
fer to ⇒ Rep. Gr. 34; Selector Mechanism; Selector Mecha‐
nism Assembly Overview.
– Remove the brace -1-.
– Remove the clutch slave cylinder -arrows- and move it to the
side. Do not open the line system.
Caution
Do not operate the clutch pedal anymore after slave cylinder
has been removed. Slave cylinder may be damaged by doing
this.
– Disconnect connector for back-up light switch from transmis‐
sion.
Continuation for All Vehicles
– Disconnect vacuum hose from brake booster.
– Disconnect the connector from the Heated Oxygen Sensor
-G39- on the bulkhead. Move the wiring harness to the side.
– Open the cap on the reservoir and then close it again to
release the pressure in the coolant system.
– Drain the coolant. Refer to ⇒ D1.4 raining and Filling”, page
187 .
Note
The vehicle has a manual hood support that is attached to the
lock carrier.
– Perform a service position. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Lock Carrier; Service Position, Performing and Re‐
setting.
– Remove the radiator fan air shroud. Refer to ⇒ F3.3 an,
Removing and Installing”, page 212 .
12 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
To facilitate removal and installation of the engine without hav‐
ing to open the refrigerant circuit:
– Remove the ribbed belt. Refer to ⇒ B1.2 elt, Removing and
Installing”, page 51 .
WARNING
Refrigerant can cause serious injury.
♦ Do not open the A/C system refrigerant circuit.
– Remove the A/C compressor from the auxiliary components
bracket. Refer to ⇒ Heating, Ventilation and Air Conditioning;
Rep. Gr. 87; A/C Compressor; A/C Compressor, Removing
and Installing on Bracket.
Caution
Danger of causing damage to the refrigerant lines and hoses.
♦ Do not bend, twist or stretch the refrigerant lines and
hoses.
– Secure the A/C compressor with the -T10038- and a backing
onto the right longitudinal member.
– Remove the clamps for the power steering pressure line on
the transmission. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 48; Hydraulic Power Steering; Overview - Hydraulic
Pipes and Reservoir.
– Remove the nuts -1- and the power steering pump line.
– If the vehicle has an engine preheater, remove the cable -2-.
1. Engine, Removing and Installing 13
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– Remove the power steering pump from the auxiliary compo‐
nents bracket and move it forward. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48; Hydraulic Power Steering;
Power Steering Pump, Removing and Installing.
• The power steering lines remain connected to the power
steering pump.
– Remove the four nuts -2- and the bolts -3-.
– Remove the front exhaust pipe -1- from the exhaust manifold
and tie it to the side. Refer to ⇒ C2.2 onverter, Removing
and Installing”, page 258 .
Caution
♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling ele‐
ment.
– Remove the right drive axle. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40; Drive Axle; Drive Axle, Re‐
moving and Installing.
– Remove the left drive axle from the transmission. Refer to
⇒ Suspension, Wheels, Steering; Rep. Gr. 40; Drive Axle;
Drive Axle, Removing and Installing.
14 Rep. Gr.10 - Engine Assembly
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– Disconnect the fuel supply line -1- and the bleeder line -2-.
Refer to ⇒ Rep. Gr. 20; Couplings, Disconnecting Couplings.
– Seal the lines so that the fuel system is not contaminated by
dirt etc.
– Remove the coolant hoses from the heat exchanger
-arrows-.
– Open the spring clamps -arrows- and remove the coolant
hoses from the radiator.
– Remove the bolt -2- and move the windshield washer filler
tube forward -1-.
1. Engine, Removing and Installing 15
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– Remove the connector -3-.
– Remove the bolts -5- and place the coolant expansion tank
-4- on top of the engine with the hoses connected.
Note
Loosen the bolts on the engine mount and transmission mount
one turn.
– Install the -T03000- as follows:
♦ Remove the -T03000/1- from the -T03000-.
♦ Attach the -T03000- to cylinder block with pin -3- and tighten
bolts -1 and 2- hand-tight.
♦ Then install in the -T03000/1- and tighten to 20 Nm.
♦ Then tighten bolts -1 and 2- to 25 Nm.
– Install the -VAS6931- on the -T03000- and slightly lift the
engine/transmission assembly.
WARNING
Use a step ladder such as -VAS5085- to remove the bolts for
the engine/transmission mount.
16 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Note
The rear bolt -2- is accessible through a hole in the wheel
housing.
– Remove engine mount from above. To do this, remove the
bolts -1 through 3-.
– Remove the transmission mount from the transmission hold‐
er -arrows-.
Note
♦
Check that all hoses and lines between engine/transmission
assembly and body have been disconnected.
♦
A second technician is needed to lower the engine/transmis‐
sion assembly.
♦
The engine/transmission assembly must be guided with care
to prevent damage while lowering.
– Carefully lower the engine/transmission assembly. When do‐
ing this, rotate or push the engine/transmission assembly.
1. Engine, Removing and Installing 17
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
1.2 Engine and Transmission, Separating
⇒ a1.2.1 nd Transmission, Separating, Vehicles with Automatic
Transmission”, page 18
⇒ a1.2.2 nd Transmission, Separating, Vehicles with Manual
Transmission”, page 21
1.2.1 Engine and Transmission, Separating,
Vehicles with Automatic Transmission
Special tools and workshop equipment required
♦ Shop Crane -VAS6100-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Engine/Gearbox Support Shackle (2 pc.) -10-222A/12-
♦ Crankshaft Adapter -T03003-
♦ Socket - Sw15 -V/175-
♦ Hose Clamps - Up To 25mm -3094- and Hose Clamps - Up
To 40mm -3093-
Procedure
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
• Engine with the transmission is removed and secured to the
-T10359A-.
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Starter; Starter, Removing and Installing.
– Remove the bracket -1- from the upper starter bolt -arrow-.
– Remove the bolt from the top of the starter.
Note
Mark the coolant hoses on the ATF cooler to prevent mixing
them up when installing them again later.
– Clamp off the coolant hoses to the ATF cooler using -3094-
and -3093-.
18 Rep. Gr.10 - Engine Assembly
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– Open the spring clamps -A- and pull the coolant hoses
-B and C- off the ATF cooler.
– Seal the coolant hoses and connections with plugs taken
from -VAS6122-.
– Remove the upper transmission/engine bolts -arrows- using
a 12-point socket -A-.
– Turn the cap -1- in direction of -arrow- and remove it.
– Remove the six -converter nuts- using the -V/175-.
1. Engine, Removing and Installing 19
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– Turn the engine in the direction of engine rotation -arrow-
60° additional turn using the -T03003-.
Note
♦
The torque converter will be pulled out when the transmis‐
sion is separated from the engine if all 6 nuts are not re‐
moved!
♦
Counterhold the belt pulley/vibration damper using the T03003- when loosening the nuts on the torque converter.
– Remove the selector lever cable bracket from the transmis‐
sion.
20 Rep. Gr.10 - Engine Assembly
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– Secure the transmission with -10-222A/12- on the -
VAS6100- but do not lift.
– Remove the last transmission/engine bolt.
– While pressing the torque converter off the drive plate, sepa‐
rate the transmission from the engine.
Note
Secure the torque converter from falling out.
Assembling
Assembly is performed in reverse order of removal.
Tightening Specifications
♦ Transmission Removing and installing. Refer to ⇒ Rep.
Gr. 37; Transmission Removing and Installing.
1.2.2 Engine and Transmission, Separating,
Vehicles with Manual Transmission
Special tools and workshop equipment required
♦ Engine/Gearbox Support Shackle (2 pc.) -10-222A/12-
♦ Shop Crane -VAS6100-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
Procedure
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
• Engine with the transmission is removed and secured to the
-T10359A-.
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Starter; Starter, Removing and Installing.
– Disconnect all electrical connections from the transmission
to the engine and free them up.
1. Engine, Removing and Installing 21
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– Secure the transmission with -10-222A/12- on the -
VAS6100- but do not lift.
– Remove the upper engine/transmission connecting bolts.
– Support the transmission using a -VAS6100- and remove
the last bolts.
– Remove the lower engine/transmission connecting bolts.
– Separate the transmission from the engine; when doing this,
guide the transmission.
Assembling
Assembly is performed in reverse order of removal.
Tightening Specifications
♦ Transmission Removing and installing. Refer to ⇒ Rep.
Gr. 34; Transmission Removing and Installing; Tightening
Specifications for Transmission.
1.3 Engine, Securing on Engine and
Transmission Holder
Special tools and workshop equipment required
♦ Lifting Tackle -3033-
♦ Shop Crane -VAS6100-
♦ Engine and Gearbox Bracket VAS6095A -VAS6095A-
♦ Engine And Transmission Holder - Engine Lateral Bracket
-T03001-
♦ Transport Arm -T03002-
Procedure
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
• The transmission is separated from the engine. Refer to ⇒
a1.2 nd Transmission, Separating”, page 18 .
For performing work, secure engine using -T03001- to VAS6095A-.
22 Rep. Gr.10 - Engine Assembly
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– Pull off clamp -1- for the wiring harness, remove the bolts -3-
and the cover plate -2-.
– Disconnect the connectors -1 and 2- and remove the bracket
-3- -arrows-.
– Install the -T03002-, as illustrated.
Pin -1- engages in cylinder block. Tighten knurled bolt -2hand-tight.
– Install the -T03001-.
1. Engine, Removing and Installing 23
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Tighten bolts -1 and 3- to 40 Nm, bolt -2- to 25 Nm.
Note
♦
Bolts are designed so that they cannot be lost.
♦
When removing, the -T03001- must be held tense in direc‐
tion of removal, otherwise the bolt -1- cannot be removed.
– Engage the -3033- as shown and lift out of the engine using
-VAS6100- from -VAG1383A-.
– Secure the engine to the -VAS6095A-.
1.4 Engine, Installing
Procedure
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
Install in reverse order of removal. Note the following:
Note
♦
Replace the bolts that were tightened with an additional turn.
♦
Replace the self-locking nuts and bolts, sealing rings, seals
and O-rings.
♦
Secure hose connections with standard production clamps.
Refer to the Parts Catalog.
♦
When installing, bring all cable ties back to same positions.
24 Rep. Gr.10 - Engine Assembly
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Vehicles with Manual Transmission
– Lightly coat the drive axle splines with Lubricating Grease -G
000 100-.
– Install the clutch slave cylinder. Refer to ⇒ Rep. Gr. 30;
Clutch Mechanism; Clutch Slave Cylinder Removing and In‐
stalling.
Continuation for All Vehicles
– Secure the engine mounts on the engine, shake the en‐
gine/transmission assembly to align it and tighten the sub‐
frame mount. Refer to ⇒ -2.1 Subframe Mount”, page 27 .
– Pay attention to the electrical connections and wiring routing.
Refer to ⇒ Electrical Equipment; Rep. Gr. 97; Relay Panels,
Fuse Panels and E-Boxes; Relay Panels, Fuse Panels and
E-Boxes Component Location Overview and ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
– Install the front exhaust pipe. Refer to ⇒ C2.2 onverter, Re‐
moving and Installing”, page 258 .
– Install the right drive axle and attach the left drive axle to
the transmission. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40; Drive Axle, Removing and Installing.
– Install the power steering pump. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48; Hydraulic Power Steering;
Power Steering Pump, Removing and Installing.
– Install the A/C compressor. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87; A/C Compressor Bracket.
– Install the ribbed belt. Refer to ⇒ B1.2 elt, Removing and
Installing”, page 51 .
– Install the radiator fan air shroud. Refer to ⇒ F3.3 an, Re‐
moving and Installing”, page 212 .
– Reset the service position. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Lock Carrier; Service Position, Performing and Re‐
setting.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
Vehicles with Manual Transmission
– Install the gearshift mechanism and adjust it. Refer to
⇒ Rep. Gr. 34; Overview - Gearshift Mechanism.
– Install the hydraulic clutch slave cylinder. Refer to ⇒ Rep.
Gr. 30; Clutch Mechanism; Clutch Slave Cylinder, Removing
and Installing.
Vehicles with Automatic Transmission
– Install the selector lever cable and adjust it. Refer to ⇒ Rep.
Gr. 37; Selector Mechanism; Overview - Selector Lever Ca‐
ble.
Continuation for All Vehicles
– Install the battery tray. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Battery; Battery Tray, Removing and Installing.
– Install the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Battery; Battery, Removing and Installing.
– Fill the coolant. Refer to ⇒ D1.4 raining and Filling”, page
187 .
– Adapt the engine control module. Refer to Vehicle Diagnos‐
tic Tester.
1. Engine, Removing and Installing 25
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
– Perform the vehicle system test. Refer to Vehicle Diagnostic
Tester.
Follow all safety precautions when performing the road test.
Refer to ⇒ P3.2 recautions, Test and Measuring Instruments
during Test Drive”, page 5 .
– Perform a road test.
– Perform another vehicle system test and correct any faults.
Tightening Specifications
Component Tightening Specification
Bolts and
nuts
M6 9 Nm
M7 15 Nm
M8 20 Nm
M1
0
M1
2
40 Nm
65 Nm
Volkswagen Technical Site: https://vwts.ru
26 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
2 Subframe Mount
⇒ -2.1 Subframe Mount”, page 27
⇒ M2.2 ount, Removing and Installing”, page 28
⇒ S2.3 upporting in Installation Position”, page 33
⇒ M2.4 ount, Adjusting”, page 39
⇒ M2.5 ount, Checking Adjustment”, page 41
2.1 Overview - Subframe Mount
Engine Mount
1 - = 40 Nm +90°, when replacing the bolts
2 - = 20 Nm +90°, when replacing the bolts
3 - = 60 Nm +90°, when replacing the bolts
Transmission Mount
A - = 40 Nm +90°, when replacing the bolts
B - = 60 Nm +90°, when replacing the bolts
Pendulum Support
2. Subframe Mount 27
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Note
Attach the pendulum support to the transmission first and then
to the subframe.
A - Strength category 10.9 = 50 Nm +90°, when replacing the
bolts
B - = 100 Nm +90°, when replacing the bolts
Removing: remove the bolt -B- first and then the bolts -A-.
Installing: first tighten the bolt -A- and then bolt -B-.
2.2 Engine Mount, Removing and Installing
Special tools and workshop equipment required
♦ Engine Support Bridge -10-222A-
♦ Engine Support - Automatic Transmission Hook -10-222A/7-
♦ Engine Support - Bracket w/Spindle and Hook -10-222A/10-
♦ Engine Support Bridge - Engine Support 28 -10-222A/28-
♦ Engine Support Bridge - Engine Support 31 -10-222A/31-
♦ Rail with Holes -T40091/2- from the Engine Support - Basic
Set -T40091-
♦ Mount -T40093/5- from the Engine Support - Supplement Kit
-T40093A-
♦ Engine Support - Basic Set - Square Pipe -T40091/1- (quan‐
tity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support - Basic Set - Movable Joint -T40091/3-
(quantity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support Brackets - Movable Joint 4 -T40093/4-
(quantity 2) from the Engine Support - Supplement Kit T40093A-
♦ Torque Wrench 1331 5-50Nm -VAG1331-
Removing
Note
Without removing the battery and battery tray
28 Rep. Gr.10 - Engine Assembly
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Caution
♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling ele‐
ment.
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
– Remove the exhaust system bracket from the subframe
-arrows-.
– Remove the bolt -1-.
– Remove the bolts -2 and 3-.
– Remove the pendulum support.
– Remove the air filter (engine cover). Refer to ⇒ F4.2 ilter
Housing, Removing and Installing”, page 241 .
– Remove the plenum chamber cover. Refer to ⇒ Body Exteri‐
or; Rep. Gr. 50; Bulkhead; Plenum Chamber Cover, Remov‐
ing and Installing.
– Remove lock carrier trim panel. Refer to ⇒ Body Exterior;
Rep. Gr. 66; Radiator Grille/Front Trim; Front Trim, Remov‐
ing and Installing.
– Remove the bolts -arrows- from the left and right sides of the
lock carrier bracket.
2. Subframe Mount 29
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– Remove the lower mounts on the -10-222A/28- and replace
with the -10-222A/28-1-.
– Remove the bolts in direction of -arrows- for securing the
engine support bridge on the lock carrier from the -10-222A/
28-1-.
– Use the bolts from the -10-222A/28-1- for attaching the
-10-222A/28-. Do not use the bolts for the bracket.
– Bolt tightening specification -arrows-: 8 Nm
30 Rep. Gr.10 - Engine Assembly
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Caution
A second technician is needed when positioning the
-10-222A- on the vehicle to keep the -10-222A- from tipping.
– Install the -10-222A/31-2- on the inner hole from the
-10-222A- and slide two - T40091/3- from the left side.
Note
The Engine -T40091/3- bolts point in the direction of travel.
– Install the bolts on the left side of the -10-222A/31-1- but do
not tighten them.
1 - -10-222A/31-2-
2 - -T40091/3-
3 - -10-222A/31-1-
4 - -T40093/4-
5 - -T40091/1-
6 - -10-222A/28- with -10-222A/28-1-
7 - Push the -10-222A/10- two times onto the right square
pipe.
– Install the engine support bridge and attach the -10-222A/
31-1- in the correct position.
– Slide the -T40091/1- on the left and right sides through the
-10-222A/28- from the front and position the -T40093/4- for
the rail with holes on both sides.
– Slide both -10-222A/10- in front of and behind the -
T40093/4- on the right side.
– Push the - T40091/1- through the -T40091/3-.
2. Subframe Mount 31
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1 - -T40091/2-
2 - -10-222A/10-
3 - -10-222A/11-
4 - -10-222A/12-
– Push the -T40091/2- from the right through the -T40093/4-.
– Slide the -T40091/2- into the moveable joint on the other
side and secure it with a splint.
– Tighten all threaded connections on the engine support
bridge hand-tight.
– Extend the right -10-222A/10- with the right -10-222A/7-.
– Engage the -10-222A/7- on the cylinder block -image-.
– Position the spindles and support the engine.
– Remove the bolt -2- and move the windshield washer filler
tube forward -1-.
– Remove the bolts -5- and lay the coolant reservoir on the
engine, with the hoses still connected.
32 Rep. Gr.10 - Engine Assembly
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Note
The rear bolt -2- is accessible through a hole in the wheel
housing.
– Remove engine mount from above. To do this, remove the
bolts -1 through 3-.
Installing
Install in reverse order of removal. Note the following:
Note
Disengage the -10-222A/7- from the cylinder block -image- and
remove.
Tightening Specifications
♦ Refer to ⇒ -2.1 Subframe Mount”, page 27
2.3 Engine, Supporting in Installation Posi‐
tion
Special tools and workshop equipment required
♦ Engine Support Bridge -10-222A-
♦ Engine Support - Automatic Transmission Hook -10-222A/7-
♦ Engine Support - Bracket w/Spindle and Hook -10-222A/10-
♦ Engine Support Bridge - Engine Support 28 -10-222A/28-
♦ Engine Support Bridge - Engine Support 31 -10-222A/31-
♦ Engine Support - Basic Set - Rail with Holes -T40091/2-
2. Subframe Mount 33
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
♦ From the Engine Support - Basic Set -T40091-
♦ Mount -T40093/5- from the Engine Support - Supplement Kit
-T40093A-
♦ Engine Support - Basic Set - Square Pipe -T40091/1- (quan‐
tity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support - Basic Set - Movable Joint -T40091/3-
(quantity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support Brackets - Movable Joint 4 -T40093/4-
(quantity 2) from the Engine Support - Supplement Kit T40093A-
♦ Torque Wrench 1331 5-50Nm -VAG1331-
Procedure
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
Caution
♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling ele‐
ment.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
– Remove the exhaust system bracket from the subframe
-arrows-.
– Remove the bolt -1-.
– Remove the bolts -2 and 3-.
– Remove the pendulum support.
– Remove the air filter (engine cover). Refer to ⇒ F4.2 ilter
Housing, Removing and Installing”, page 241 .
34 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Vehicles with Automatic Transmission
– Unclip the Transmission Control Module -J217- -3- from the
bracket -7- and remove it.
– Disconnect the connector -2- from the Transmission Control
Module -J217-.
– Remove the bolts -1 and 6-.
– Move the bracket -7- with the power steering fluid reservoir
to the side. Be careful of the electric wires -4 and 5-.
The hoses remain connected to the power steering fluid res‐
ervoir.
Continuation for All Vehicles
– Remove the battery and the battery tray. Refer to ⇒ Electri‐
cal Equipment; Rep. Gr. 27; Battery; Battery Tray, Removing
and Installing.
– Remove the plenum chamber cover. Refer to ⇒ Body Exteri‐
or; Rep. Gr. 50; Bulkhead; Plenum Chamber Cover, Remov‐
ing and Installing.
– Remove the wires -1- from the transport strap -3-.
2. Subframe Mount 35
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– Remove the transport strap -3- from the engine -2- and pull it
out of the eye -arrow-.
– Insert a -10-222A/12- in »this« eye.
– Remove lock carrier trim panel. Refer to ⇒ Body Exterior;
Rep. Gr. 66; Radiator Grille/Front Trim; Front Trim, Remov‐
ing and Installing.
– Remove the bolts -arrows- from the left and right sides of the
lock carrier bracket.
– Remove the lower mounts on the -10-222A/28- and replace
with the -10-222A/28-1-.
– Remove the bolts in direction of -arrows- for securing the
engine support bridge on the lock carrier from the -10-222A/
28-1-.
36 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
– Use the bolts from the -10-222A/28-1- for attaching the
-10-222A/28-. Do not use the bolts for the bracket.
– Bolt tightening specification -arrows-: 8 Nm
Caution
A second technician is needed when positioning the
-10-222A- on the vehicle to keep the -10-222A- from tipping.
Mount the engine support bridge on the engine/transmission
sub-assembly as follows:
1 - -10-222A/31-2-
2 - -T40091/3-
3 - -10-222A/31-1-
4 - -T40093/4-
5 - -T40091/1-
6 - -10-222A/28- with -10-222A/28-1-
7 - -10-222A/10-
– First slide the Movable Joints -2- onto the Square Pipe on
the -10-222A-.
• The bolts for the -T40091/3- -2- on the -10-222A- point to‐
wards the front end.
– Mount the -10-222A- on the suspension strut domes and
have a second technician hold it to prevent it from falling
over.
– Slide the -T40091/1- -5- on the left and right sides through
the -10-222A/28- -6- from the front and position the T40093/4- -4- on each side.
2. Subframe Mount 37
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
– Additionally insert the -10-222A/10- -7- on the right -
T40091/1-.
– Slide the -T40091/2- -9- with the -T40093/5- -10- into the
-T40093/4- -4-.
1 - -10-222A/31-2-
2 - -T40091/3-
3 - -10-222A/31-1-
4 - -T40093/4-
5 - -T40091/1-
6 - -10-222A/28- with -10-222A/28-1-
7 - -10-222A/10-
8 - -10-222A/7-
9 - -T40091/2-
10 - -T40093/5-
11 - -10-222A/11-
12 - -10-222A/12-
– Insert the securing pin into the -T40091/2- -9- and secure it
with cotter pins.
– Tighten all threaded connections on the -10-222A- hand-
tight. While doing so, adjust the height of the -10-222Aparallel over the -10-222A/28-.
– Extend the right -10-222A/10- -7- with the right -10-222A/7-
-8-.
The hooks from the -10-222A/7- point downward and will be
engaged later in the cylinder block.
– Engage the left -10-222A/11- -11- in the -10-222A/12- -12-.
38 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
– Position the spindles and hold the engine and transmission.
Do not lift.
2.4 Subframe Mount, Adjusting
Special tools and workshop equipment required
♦ Engine Support Bridge -10-222A-
♦ Engine Support - Automatic Transmission Hook -10-222A/7-
♦ Engine Support - Bracket w/Spindle and Hook -10-222A/10-
♦ Engine Support Bridge - Engine Support 28 -10-222A/28-
♦ Engine Support Bridge - Engine Support 31 -10-222A/31-
♦ Engine Support - Basic Set - Rail with Holes -T40091/2-
♦ From the Engine Support - Basic Set -T40091-
♦ Mount -T40093/5- from the Engine Support - Supplement Kit
-T40093A-
♦ Engine Support - Basic Set - Square Pipe -T40091/1- (quan‐
tity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support - Basic Set - Movable Joint -T40091/3-
(quantity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support Brackets - Movable Joint 4 -T40093/4-
(quantity 2) from the Engine Support - Supplement Kit T40093A-
♦ Torque Wrench 1331 5-50Nm -VAG1331-
Note
♦
It is not necessary to remove the air filter, the battery and the
battery tray if only the subframe mount on the engine side is
being adjusted.
♦
Engine support bridge when adjusting the engine mount,
without transmission mount. Refer to ⇒ M2.2 ount, Remov‐
ing and Installing”, page 28 .
– Support the engine with the transmission but do not lift it.
Refer to ⇒ S2.3 upporting in Installation Position”, page 33 .
Engine Mount
– Remove the bolt -2- and move the windshield washer filler
tube forward -1-.
– Remove the bolts -5- and lay the coolant reservoir on the
engine, with the hoses still connected.
– Remove the bolts -1 and 3- from the engine mount.
2. Subframe Mount 39
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– Replace the bolts on the subframe mount one after the other
and tighten them hand-tight.
Transmission Mount
– Replace the assembly mount bolts -arrows- one after the
other (if not already done) and tighten them by hand.
– Loosen left and right support arm bolts approximately two
turns.
Engine Mount
• Between engine support and right longitudinal member,
there must be clearance -a- 10 mm.
• The casting edge on the engine support -2- must be parallel
to the support arm -1-; dimension -x- must be the same at
the front and at the rear.
40 Rep. Gr.10 - Engine Assembly
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Transmission Mount
– Make sure that the edges on the support arm -1- and trans‐
mission mount -2- are parallel on the transmission side.
• Dimension -x- same size on both sides of bracket.
Continuation for All Vehicles
Installation is performed in reverse order of the removal.
Tightening Specifications
♦ Refer to ⇒ -2.1 Subframe Mount”, page 27
2.5 Subframe Mount, Checking Adjustment
• There must be at least 10 to 13 mm -a- between engine
support and right longitudinal member.
• The casting edge on the engine support -2- must be parallel
to the support arm -1-; dimension -x- must be the same at
the front and at the rear.
Note
Distance -a- can also be checked with corresponding round
stock.
Only if There is Noise (the Engine or Transmission Hitting the
Longitudinal Member When Driving Around Curves) and Dimen‐
sion -a- is Not Within 10 to 13 mm:
– Adjust the subframe mount. Refer to ⇒ M2.4 ount, Adjust‐
ing”, page 39 .
2. Subframe Mount 41
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
3 Engine Cover
⇒ C3.1 over, Removing and Installing”, page 42
3.1 Engine Cover, Removing and Installing
The engine cover and air filter are a single component. Refer to
⇒ F4.2 ilter Housing, Removing and Installing”, page 241 .
42 Rep. Gr.10 - Engine Assembly
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4 Special Tools
Special tools and workshop
equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Engine and Gearbox Jack -VAS6931-
♦ Spring Clip Pliers
♦ Step Ladder -VAS5085-
♦ Engine Holder Bracket -T03000-
♦ Cable Tie
♦ Foam Mat
4. Special Tools 43
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♦ Lifting Tackle -3033-
♦ Shop Crane -VAS6100-
♦ Engine and Gearbox Bracket -VAS6095A-
♦ Engine And Transmission Holder - Engine Lateral Bracket
-T03001-
♦ Transport Arm -T03002-
44 Rep. Gr.10 - Engine Assembly
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♦ Engine Support Bridge -10-222A-
♦ Engine Support - Automatic Transmission Hook -10-222A/7-
♦ Engine Support - Bracket w/Spindle and Hook -10-222A/10-
♦ Engine Support Bridge - Engine Support 28 -10-222A/28-
♦ Engine Support Bridge - Engine Support 31 -10-222A/31-
♦ Rail with Holes -T40091/2- from the Engine Support - Basic
Set -T40091-
♦ Mount -T40093/5- from the Engine Support - Supplement Kit
-T40093A-
♦ Engine Support - Basic Set - Square Pipe -T40091/1- (quan‐
tity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support - Basic Set - Movable Joint -T40091/3-
(quantity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support Brackets - Movable Joint 4 -T40093/4-
(quantity 2) from the Engine Support - Supplement Kit T40093A-
4. Special Tools 45
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♦ Crankshaft Adapter -T03003-
♦ Tensioning Strap -T10038-
♦ Guide Pins -T10093-
♦ Adapters For Service Position -T10467-
46 Rep. Gr.10 - Engine Assembly
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♦ Socket - Sw15 -V/175-
♦ Hose Clamps - Up To 25mm -3094- and Hose Clamps - Up
To 40mm -3093-
4. Special Tools 47
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13 – Crankshaft, Cylinder Block
1 Cylinder Block, Belt Pulley Side
⇒ -1.1 Ribbed Belt Drive”, page 48
⇒ B1.2 elt, Removing and Installing”, page 51
⇒ B1.3 elt Tensioner, Removing and Installing”, page 53
⇒ D1.4 amper, Removing and Installing”, page 55
⇒ B1.5 racket, Removing and Installing”, page 57
⇒ B1.6 racket, Removing and Installing”, page 66
⇒ F1.7 lange, Removing and Installing, Belt Pulley Side”, page
67
1.1 Overview - Ribbed Belt Drive
48 Rep. Gr.13 - Crankshaft, Cylinder Block
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1 - Bolt
❑ 23 Nm
2 - Belt Pulley
❑ For power steering
pump
3 - Bolt
❑ 23 Nm
4 - Power Steering Pump
❑ For power steering
5 - Sub-Assembly Bracket
❑ Removing and instal‐
ling. Refer to ⇒
B1.5 racket, Removing
and Installing”, page
57 .
6 - Bolt
❑ 25 Nm
7 - Bolt
❑ 25 Nm
8 - Generator
❑ Removing and instal‐
ling. Refer to ⇒ Elec‐
trical Equipment; Rep.
Gr. 27; Generator;
Generator, Removing
and Installing.
❑ To make it easier
to position the genera‐
tor, drive the threaded
bushing for the genera‐
tor bolt back slightly.
9 - Bolt
❑ 25 Nm
10 - Bracket with Lower Relay Pulley
❑ For the A/C compressor ribbed belt
❑ Do not remove the idler roller.
11 - Bolt
❑ 25 Nm
12 - Bushing
❑ Quantity: 2
13 - A/C Compressor
❑ Removing and installing. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87; A/C
Compressor; A/C Compressor, Removing and Installing.
14 - Double Bolt
❑ 25 Nm
❑ For attaching the power steering line
15 - Bolt
❑ 25 Nm
16 - Ribbed Belt for Generator, Vane Pump and Coolant Pump
❑ Ribbed belt routing. Refer to ⇒ Fig. ““Ribbed Belt Routing”“, page 51
1. Cylinder Block, Belt Pulley Side 49
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❑ Before removing, mark direction of rotation using chalk or felt-tip marker
Cau‐
tion
When installing the rib‐
bed belt, make sure it is
routed in the right direc‐
tion and that it is seated
correctly on the belt pul‐
leys and the tensioner.
❑ Check for wear
❑ Do not kink
❑ Removing and installing. Refer to ⇒ B1.2 elt, Removing and Installing”, page 51 .
17 - Ribbed Belt for A/C Compressor
❑ Ribbed belt routing. Refer to ⇒ Fig. ““Ribbed Belt Routing”“, page 51
❑ Before removing, mark direction of rotation using chalk or felt-tip marker
Cau‐
tion
When installing the rib‐
bed belt, make sure it is
routed in the right direc‐
tion and that it is seated
correctly on the belt pul‐
leys and the tensioner.
❑ Check for wear
❑ Do not kink
❑ Removing and installing. Refer to ⇒ B1.2 elt, Removing and Installing”, page 51 .
18 - Belt Pulley/Vibration Damper
❑ There are different versions
❑ To remove and install, secure the crankshaft. Refer to ⇒ L3.2 ocking”, page 84
19 - Bolts
❑ 50 Nm +90°
❑ Replace after removing
❑ Quantity: 5
❑ Use strength category 10.9 only
20 - Coolant Pump
❑ In cylinder block
❑ Removing and installing. Refer to ⇒ P2.2 ump, Removing and Installing”, page 197 .
21 - Tensioning Element for A/C Compressor Ribbed Belt
❑ 35 Nm
❑ Do not remove the tensioning roller.
❑ Removing and installing. Refer to ⇒ B1.3.1 elt Tensioner, Removing and Installing, A/C Compressor
Drive”, page 53 .
22 - Tensioning Element for Ribbed Belt for Generator, Vane Pump and Coolant Pump
❑ 35 Nm
❑ Do not remove the tensioning roller.
❑ Removing and installing. Refer to ⇒ B1.3.2 elt Tensioner, Removing and Installing, Drive Generator,
Pump”, page 54 .
23 - Bolt
❑ 40 Nm +90°
❑ Replace after removing
50 Rep. Gr.13 - Crankshaft, Cylinder Block
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24 - Bolt
❑ 25 Nm
25 - Bushing
❑ Quantity: 2
26 - Engine Mount
Ribbed Belt Routing
5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
1 - Power Steering Pump
2 - Ribbed belt for generator, vane pump and coolant pump
3 - Belt pulley - generator
4 - Idler Roller
5 - Belt pulley - air conditioning compressor
6 - Ribbed belt for A/C compressor
7 - Belt pulley - crankshaft
8 - Tension roller for A/C compressor ribbed belt
9 - Tensioning roller for ribbed belt for generator, vane pump
and coolant pump
10 - Belt pulley - coolant pump
1.2 Ribbed Belt, Removing and Installing
Special tools and workshop equipment required
♦ Locking Pin -T10060A-
Removing the Ribbed Belt:
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
– Remove right front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66; Wheel Housing Liner; Front Wheel
Housing Liner, Removing and Installing.
1. Cylinder Block, Belt Pulley Side 51
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Remove the A/C Compressor Ribbed Belt:
Caution
Risk of damage due to reversed running direction on a used
ribbed belt.
♦ Before removing the ribbed belt, mark the running direc‐
tion with chalk or a felt-tip pen for reinstallation.
– Swivel tensioning element -1- as illustrated using a 15 mm
open end wrench -A- in direction of -arrow- and secure using
-T10060A-.
– Remove ribbed belt for A/C compressor.
Removing the Ribbed Belt for the Generator, Power Steering
Pump and Coolant Pump.
Caution
Risk of damage due to reversed running direction on a used
ribbed belt.
♦ Before removing the ribbed belt, mark the running direc‐
tion with chalk or a felt-tip pen for reinstallation.
– Release the tension on the tensioner -1- for the A/C com‐
pressor ribbed belt (remove the -T10060A-).
– Insert the -T10060A- into the tensioner -2-.
– Swivel the tensioner -2- in direction of -arrow- using a 15
mm wrench -A- and then lock it into place with -T10060A-.
– Remove the generator ribbed belt, power steering pump and
coolant pump.
52 Rep. Gr.13 - Crankshaft, Cylinder Block
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Installing the Ribbed Belt:
Install in reverse order of removal while noting the following:
– Route the ribbed belt for the generator, power steering pump
and coolant pump over the belt pulley, and then over the
idler roller -4-.
– Turn the compressor ribbed belt pulley before tensioning the
ribbed belt and make sure the ribbed belt is seated correctly
on the belt pulley.
– Before installing ribbed belt for A/C compressor, secure ten‐
sioning device using the -T10060A-.
Note
Make sure the belt rotation direction is correct and that the belt
sits correctly on the pulley.
– Start the engine and check the belt running.
1.3 Ribbed Belt Tensioner, Removing and
Installing
1.3.1 Ribbed Belt Tensioner, Removing and
Installing, A/C Compressor Drive
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the ribbed belt. Refer to ⇒ B1.2 elt, Removing and
Installing”, page 51 .
– Loosen the tensioner -1- bolt -2- and remove the tensioner.
1. Cylinder Block, Belt Pulley Side 53
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– Install in reverse order of removal. Note the following:
Tightening Specifications
♦ Refer to ⇒ -1.1 Ribbed Belt Drive”, page 48
1.3.2 Ribbed Belt Tensioner, Removing and
Installing, Drive Generator, Pump
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the ribbed belt. Refer to ⇒ B1.2 elt, Removing and
Installing”, page 51 .
– Loosen the tensioner -1- bolt -2- and remove the tensioner.
– Install in reverse order of removal. Note the following:
Tightening Specifications
♦ Refer to ⇒ -1.1 Ribbed Belt Drive”, page 48
54 Rep. Gr.13 - Crankshaft, Cylinder Block
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
1.4 Vibration Damper, Removing and In‐
stalling
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Crankshaft Adapter -T03003-
♦ Crankshaft Locking Pin -T40069-
Removing
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Securing the crankshaft for valve timing inspection/adjust‐
ment. Refer to ⇒ L3.3 ocking to Check/Adjust Valve Timing”,
page 87 .
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
– Remove the front section of the right front wheel housing
liner. Refer to ⇒ Body Exterior; Rep. Gr. 66; Wheel Housing
Liner; Front Wheel Housing Liner, Removing and Installing.
– Attach the -T03003- on to belt pulley bolts.
The -T03003- can only be inserted correctly in one position.
– Rotate the crankshaft in direction of engine rotation -arrow-
far enough until arrow -A- on -T03003- points downward
vertically, relative to the engine axis.
This position corresponds approximately to TDC position of
crankshaft at cylinder 5.
1. Cylinder Block, Belt Pulley Side 55
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Note
With engine removed, TDC marking can also be seen on belt
pulley and sealing flange on belt pulley side. Notches -A and Bmust align.
– Remove the sealing plug -1- on the back of the cylinder
block.
– Look through the threaded hole. Make sure the hole -2- in
the crankshaft is lined up with the threaded hole.
Use a mirror for this.
– Turn the crankshaft slightly, if necessary.
– When the holes line up, install the -T40069- all the way into
the threaded hole and tighten it to 10 Nm. Make sure the
crankshaft can be turned.
– Remove the A/C compressor ribbed belt. Refer to ⇒ B1.2 elt,
Removing and Installing”, page 51 .
– Loosen the bolts on the vibration damper and remove the
vibration damper.
Installing
• Replace the bolts
• Use strength category 10.9 only
• 50 Nm +90°
56 Rep. Gr.13 - Crankshaft, Cylinder Block
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After Assembly Work
– Remove the -T40069- and install the sealing plug -1- on
cylinder block in the rear.
The rest of the installation follows the reverse of the removal
procedures.
Tightening Specifications
Component Nm
Sealing plug to cylinder block at rear 30 Nm
1.5 Sub-Assembly Bracket, Removing and
Installing
Special tools and workshop equipment required
♦ Engine Support Bridge -10-222A-
♦ Engine Support - Automatic Transmission Hook -10-222A/7-
♦ Engine Support - Bracket w/Spindle and Hook -10-222A/10-
♦ Engine Support Bridge - Engine Support 28 -10-222A/28-
♦ Engine Support Bridge - Engine Support 31 -10-222A/31-
♦ Rail with Holes -T40091/2- from the Engine Support - Basic
Set -T40091-
♦ Mount -T40093/5- from the Engine Support - Supplement Kit
-T40093A-
♦ Engine Support - Basic Set - Square Pipe -T40091/1- (quan‐
tity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support - Basic Set - Movable Joint -T40091/3-
(quantity 2) from the Engine Support - Basic Set -T40091-
♦ Engine Support Brackets - Movable Joint 4 -T40093/4-
(quantity 2) from the Engine Support - Supplement Kit T40093A-
♦ Torque Wrench 1331 5-50Nm -VAG1331-
1. Cylinder Block, Belt Pulley Side 57
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Note
The sub-assembly bracket can be removed and installed with‐
out having to open the refrigerant circuit.
1 - Bolt
❑ 25 Nm
❑ M8 x 110
2 - Bolt
❑ 25 Nm
❑ M8x60
3 - Bolt
❑ 25 Nm
❑ M8x30
4 - Bolt
❑ 25 Nm
❑ M8x30
5 - Bolt
❑ 25 Nm
❑ M8x30
6 - Bolt
❑ 25 Nm
❑ M8x30
Removing
Note
Without removing the battery and battery tray
Caution
♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling ele‐
ment.
58 Rep. Gr.13 - Crankshaft, Cylinder Block
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– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the exhaust system bracket from the subframe
-arrows-.
– Remove the bolt -1-.
– Remove the bolts -2 and 3-.
– Remove the pendulum support.
– Remove the air filter (engine cover). Refer to ⇒ F4.2 ilter
Housing, Removing and Installing”, page 241 .
– Remove the plenum chamber cover. Refer to ⇒ Body Exteri‐
or; Rep. Gr. 50; Bulkhead; Plenum Chamber Cover, Remov‐
ing and Installing.
– Remove lock carrier trim panel. Refer to ⇒ Body Exterior;
Rep. Gr. 66; Radiator Grille/Front Trim; Front Trim, Remov‐
ing and Installing.
– Remove the bolts -arrows- from the left and right sides of the
lock carrier bracket.
– Remove the lower mounts on the -10-222A/28- and replace
with the -10-222A/28-1-.
1. Cylinder Block, Belt Pulley Side 59
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
– Remove the bolts in direction of -arrows- for securing the
engine support bridge on the lock carrier from the -10-222A/
28-1-.
– Use the bolts from the -10-222A/28-1- for attaching the
-10-222A/28-. Do not use the bolts for the bracket.
– Bolt tightening specification -arrows-: 8 Nm
Caution
A second technician is needed when positioning the
-10-222A- on the vehicle to keep the -10-222A- from tipping.
– Install the -10-222A/31-2- on the inner hole from the
-10-222A- and slide two - T40091/3- from the left side.
Note
The Engine -T40091/3- bolts point in the direction of travel.
– Install the bolts on the left side of the -10-222A/31-1- but do
not tighten them.
60 Rep. Gr.13 - Crankshaft, Cylinder Block
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
1 - -10-222A/31-2-
2 - -T40091/3-
3 - -10-222A/31-1-
4 - -T40093/4-
5 - -T40091/1-
6 - -10-222A/28- with -10-222A/28-1-
7 - Push the -10-222A/10- two times onto the right square
pipe.
– Install the engine support bridge and attach the -10-222A/
31-1- in the correct position.
– Slide the -T40091/1- on the left and right sides through the
-10-222A/28- from the front and position the -T40093/4- for
the rail with holes on both sides.
– Slide both -10-222A/10- in front of and behind the -
T40093/4- on the right side.
– Push the - T40091/1- through the -T40091/3-.
1 - -T40091/2-
2 - -10-222A/10-
3 - -10-222A/11-
4 - -10-222A/12-
– Push the -T40091/2- from the right through the -T40093/4-.
– Slide the -T40091/2- into the moveable joint on the other
side and secure it with a splint.
– Tighten all threaded connections on the engine support
bridge hand-tight.
– Extend the right -10-222A/10- with the right -10-222A/7-.
1. Cylinder Block, Belt Pulley Side 61
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5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
– Engage the -10-222A/7- on the cylinder block -image-.
– Position the spindles and support the engine. Do not lift.
– Remove the bolt -2- and move the windshield washer filler
tube forward -1-.
– Remove the bolts -5- and lay the coolant reservoir on the
engine, with the hoses still connected.
– Remove the bolts from the engine mount -2-.
Note
The rear bolt -2- is accessible through a hole in the wheel
housing.
62 Rep. Gr.13 - Crankshaft, Cylinder Block
Beetle 2012 ➤, The Beetle 2017 ➤, The Beetle Cabriolet 2012 ➤, The Beetle Cabri ...
5-Cylinder Fuel Injection Engine (2.5L Engine, 4-Valve) - Edition 12.2016
Caution
Risk of damaging due to reversed running direction on a
used ribbed belt:
♦ Before removing the ribbed belt, mark the running direc‐
tion with chalk or a felt-tip pen for reinstallation.
– Ribbed belt, removing. Refer to ⇒ B1.2 elt, Removing and
Installing”, page 51 .
– Remove the ribbed belt tensioner (A/C compressor). Refer
to ⇒ B1.3.1 elt Tensioner, Removing and Installing, A/C
Compressor Drive”, page 53
– Remove the ribbed belt tensioning damper (generator,
power steering pump and coolant pump). Refer to ⇒
B1.3.2 elt Tensioner, Removing and Installing, Drive Gener‐
ator, Pump”, page 54
– Remove the generator. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27; Generator; Generator, Removing and Installing.
WARNING
Refrigerant can cause serious injury.
♦ Do not open the A/C system refrigerant circuit.
– Remove the A/C compressor from the auxiliary components
bracket. Refer to ⇒ Heating, Ventilation and Air Conditioning;
Rep. Gr. 87; A/C Compressor; A/C Compressor, Removing
and Installing on Bracket.
Securing A/C Compressor to Body
Caution
Danger of causing damage to the refrigerant lines and hoses.
♦ Do not bend, twist or stretch the refrigerant lines and
hoses.
– Remove the clamps for the power steering pressure line on
the transmission. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 48; Hydraulic Power Steering; Overview - Hydraulic
Pipes and Reservoir.
– Remove the nuts -1- and the power steering pump line.
1. Cylinder Block, Belt Pulley Side 63
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– Remove the power steering pump from the auxiliary compo‐
nents bracket and move it forward. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48; Hydraulic Power Steering;
Power Steering Pump, Removing and Installing.
• The power steering lines remain connected to the power
steering pump.
Note
Note the different bolt lengths.
– Remove the bolts -1 through 6- and then remove the sub-as‐
sembly bracket from the cylinder block.
Installing
Install in reverse order of removal. Note the following:
64 Rep. Gr.13 - Crankshaft, Cylinder Block
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Note
Note the different bolt lengths.
– Mount the subassembly bracket and then install the bolts
-5-.
– Tighten the new bolt in three steps in the following se‐
quence: -1 through 6-
1. Tighten bolts hand-tight.
2. Tighten the bolts to 20 Nm.
3. Tighten the bolts an additional 90°.
– Install the engine mount. Refer to ⇒ M2.2 ount, Removing
and Installing”, page 28 .
– Install the generator. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Generator; Generator, Removing and Installing.
– Install the A/C compressor to the auxiliary components
bracket. Refer to ⇒ Heating, Ventilation and Air Conditioning;
Rep. Gr. 87; A/C Compressor; A/C Compressor, Removing
and Installing on Bracket.
– Install the ribbed belt tensioning damper (generator, power
steering pump and coolant pump). Refer to ⇒ B1.3.2 elt Ten‐
sioner, Removing and Installing, Drive Generator, Pump”,
page 54
– Install the ribbed belt tensioner (A/C compressor). Refer to
⇒ B1.3.1 elt Tensioner, Removing and Installing, A/C Com‐
pressor Drive”, page 53
– Attach the power steering pump to the sub-assembly brack‐
et. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48;
Hydraulic Power Steering; Power Steering Pump, Removing
and Installing.
Caution
Risk of damaging due to reversed running direction on a
used ribbed belt:
♦ Before removing the ribbed belt, mark the running direc‐
tion with chalk or a felt-tip pen for reinstallation.
– Install ribbed belt. Refer to ⇒ B1.2 elt, Removing and Instal‐
ling”, page 51
Ribbed Belt Routing
1. Cylinder Block, Belt Pulley Side 65
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1 - Power Steering Pump
2 - Ribbed belt for generator, vane pump and coolant pump
3 - Belt pulley - generator
4 - Idler Roller
5 - Belt pulley - air conditioning compressor
6 - Ribbed belt for A/C compressor
7 - Belt pulley - crankshaft
8 - Tension roller for A/C compressor ribbed belt
9 - Tensioning roller for ribbed belt for generator, vane pump
and coolant pump
10 - Belt pulley - coolant pump
Note
Disengage the -10-222A/7- from the cylinder block -image- and
remove.
1.6 Engine Bracket, Removing and Instal‐
ling
– The engine bracket is integrated inside the engine mount.
Refer to ⇒ M2.2 ount, Removing and Installing”, page 28
66 Rep. Gr.13 - Crankshaft, Cylinder Block
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1.7 Sealing Flange, Removing and Instal‐
ling, Belt Pulley Side
Special tools and workshop equipment required
♦ Trim Removal Wedge -3409-
♦ Oil Seal Guide Sleeve -T03004-
♦ Hand drill with plastic brush attachment- adaptation
♦ Protective eyewear
♦ Silicone Sealant -D 174 003 A2-
Removing
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the A/C compressor ribbed belt. Refer to ⇒ B1.2 elt,
Removing and Installing”, page 51 .
– Secure the crankshaft. Refer to ⇒ L3.2 ocking”, page 84 .
– Remove the belt pulley from the crankshaft.
– Remove the tensioner -1-. Refer to ⇒ B1.3.1 elt Tensioner,
Removing and Installing, A/C Compressor Drive”, page 53 .
– Remove the bolts -2-.
– Beginning at the alignment sleeves -arrows-, remove the
sealing flange -1- with a screwdriver -A-.
– Use -3409- to support screwdriver in order to prevent dam‐
age to the cylinder block sealing surface.
Sealing flange is damaged while removing.
– Press off sealing flange completely.
1. Cylinder Block, Belt Pulley Side 67
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Note
Clean the -3409- after removing the sealing flange, because it
is intended for removal of interior trim components.
Installing
WARNING
To prevent injuries from shavings, wear protective goggles
and protective clothing.
– Remove remainder of sealant from cylinder block for exam‐
ple using a rotating plastic brush.
Caution
Make sure that no sealant residue enters the engine.
– Clean sealing surface of cylinder block and crankshaft jour‐
nals; they must be free of oil and grease.
Note
♦
Do not additionally oil or grease sealing lip of sealing flange!
♦
The following work steps must be followed so that the seal‐
ing lip of sealing flange does not roll itself up when installing.
– Widen sealing lip of new sealing flange as illustrated using
-T03004-.
The surface -A- is the outer side.
– After a short while, remove the -T03004- and turn it 180°
rotated in the seal.
68 Rep. Gr.13 - Crankshaft, Cylinder Block
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The -T03004- must protrude approximately 3 mm on the
inner side -B-.
The surface -A- is the outer side.
The surface -B- is the inner side (sealing surface).
– Cut the tube nozzle at the front marking (nozzle diameter:
approximately 2 mm).
Note
The sealing flange for crankshaft - belt pulley side- must be
installed within 5 minutes after application of sealant.
– Apply sealant bead -A- as illustrated into groove of sealing
flange.
♦ Sealant bead width: 2.5 to 3.0 mm
♦ Seal bead height over the sealing surface: approximately 1.0
mm
– Insert sealing flange using -T03004- on crankshaft journals
and press uniformly on the cylinder block.
1. Cylinder Block, Belt Pulley Side 69
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– Tighten the bolt -A- evenly and in a diagonal sequence.
The rest of the installation follows the reverse of the removal
procedures. Note the following:
♦ Remove the -T40069- from the back of the cylinder block
and install the bolt.
Tightening Specifications
Component Nm
Belt pulley to crankshaft 50 Nm +90°
additional turn
(replacing
bolts)
Tensioning element to auxiliary component
bracket
Sealing flange to cylinder block 10
Sealing plug to cylinder block at rear 30
35
70 Rep. Gr.13 - Crankshaft, Cylinder Block
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2 Cylinder Block, Transmission Side
⇒ -2.1 Cylinder Block, Transmission Side”, page 71
⇒ -2.2 Drive Plate”, page 73
⇒ -2.3 Flywheel”, page 73
⇒ P2.4 late, Removing and Installing”, page 74
⇒ R2.5 emoving and Installing”, page 76
⇒ S2.6 eal, Replacing, Transmission Side”, page 76
⇒ F2.7 lange, Removing and Installing, Transmission Side”,
page 78
2.1 Overview - Cylinder Block, Transmission Side
2. Cylinder Block, Transmission Side 71
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1 - Belt Pulley/Vibration
Damper
❑ There are different ver‐
sions
2 - Bolts
❑ 50 Nm + 90° additional
turn
❑ Replace after removing
❑ Quantity: 5
❑ Use strength category
10.9 only
3 - Bolt
❑ 10 Nm
4 - Sealing Flange on Belt
Pulley Side
❑ With integrated sealing
ring
❑ Removing and instal‐
ling. Refer to ⇒
F1.7 lange, Removing
and Installing, Belt Pul‐
ley Side”, page 67 .
5 - Cylinder Block
6 - Bolt
❑ 60 Nm +90°
❑ Replace after removing
7 - Drive Plate/Flywheel
♦ To remove, secure crank‐
shaft using the Crankshaft
Locking Pin -T40069-.
♦ Flywheel must not be pried
out or timing housing cov‐
er will be damaged
❑ Drive Plate, Removing and installing. Refer to ⇒ P2.4 late, Removing and Installing”, page 74 .
8 - Sensor Wheel
❑ For Engine Speed Sensor -G28❑ With position holder
9 - Seal on Transmission Side
❑ Removing and installing. Refer to ⇒ S2.6 eal, Replacing, Transmission Side”, page 76 .
10 - Control Housing Cover
❑ Removing and installing. Refer to ⇒ F2.7 lange, Removing and Installing, Transmission Side”, page
78 .
11 - O-ring
❑ Replace after removing
12 - Bolt
❑ 25 Nm
13 - Alignment Sleeves
14 - Bolt
❑ 5 Nm
15 - Engine Speed Sensor -G28-
72 Rep. Gr.13 - Crankshaft, Cylinder Block
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16 - Gasket
❑ Replace after removing
2.2 Overview - Drive Plate
1 - Washer with Recesses
2 - Shim
3 - Bolts
❑ Replace after removing
❑ Tightening specifica‐
tion. Refer to ⇒
P2.4 late, Removing
and Installing”, page
74 .
– Install the drive plate only using the washer with openings
-1- without a shim -2-.
2.3 Overview - Flywheel
2. Cylinder Block, Transmission Side 73
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1 - Flywheel
2 - Bolts
❑ 60 Nm +90°
❑ Replace after removing
2.4 Drive Plate, Removing and Installing
Special tools and workshop equipment required
♦ Depth Gauge
Work Steps Specified
Value Meas‐
urement
1. Replace the
bolts
2. Tightening the
bolts
3. Measuring.
Refer to
⇒ P2.4 late, Re‐
moving and In‐
stalling”, page
74 .
4. Tightening the
bolts
18.8 to 20.4
mm
Tightening
Specification
30 Nm
60 Nm
Additional
Turn
74 Rep. Gr.13 - Crankshaft, Cylinder Block
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Work Steps Specified
Value Meas‐
Tightening
Specification
Additional
Turn
urement
5. Tightening the
bolts with addi‐
tional turn
90° addition‐
al turn (tight‐
ening can be
done in
stages).
6. Installing the
30 Nm
sealing plug
Removing
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the transmission. Refer to ⇒ Rep. Gr. 34; Transmis‐
sion, Removing and Installing and ⇒ Rep. Gr. 37; Transmis‐
sion, Removing and Installing.
– Secure the crankshaft. Refer to ⇒ L3.2 ocking”, page 84
and remove the drive plate.
Installing
– Install the drive plate only using the washer with openings
-1- without a shim -2-.
– Install the new bolts -3- and tighten to 30 Nm.
– Check dimension -a- an three points and calculate mean
value.
Specified value: 18.8 to 20.4 mm
Note
Measure through drive plate hole to surface of control housing
cover.
2. Cylinder Block, Transmission Side 75
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If the specification is not obtained:
– Remove drive plate using the shim -2-. Tighten the bolts -3-
again to 30 Nm and repeat the measurement.
If the specified value is OK:
The rest of the installation follows the reverse of the removal
procedures. Note the following:
♦ Remove the -T40069- from the cylinder block at the rear and
install the plug (30 Nm).
Tightening Specifications
♦ Refer to ⇒ -2.3 Flywheel”, page 73
2.5 Flywheel, Removing and Installing
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Crankshaft Adapter -T03003-
♦ Crankshaft Locking Pin -T40069-
Removing
– Remove the transmission. Refer to ⇒ Rep. Gr. 37; Transmis‐
sion, Removing and Installing.
– Secure the crankshaft. Refer to ⇒ L3.2 ocking”, page 84 .
– Mark flywheel to engine.
– Loosen the bolts and remove the flywheel.
Installing
Install in reverse order of removal. Note the following:
– Use new bolts.
Tightening Specifications
♦ Refer to ⇒ -2.3 Flywheel”, page 73
2.6 Crankshaft Seal, Replacing, Transmis‐
sion Side
Special tools and workshop equipment required
♦ Seal Installer - Crankshaft -T10122A-
♦ Puller - Crankshaft/Power Steering Seal -T20143-
Removing
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
76 Rep. Gr.13 - Crankshaft, Cylinder Block
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– Remove the transmission. Refer to ⇒ Rep. Gr. 34; Transmis‐
sion, Removing and Installing and ⇒ Rep. Gr. 37; Transmis‐
sion, Removing and Installing.
– Secure the crankshaft. Refer to ⇒ L3.2 ocking”, page 84 .
– Remove the flywheel and drive plate and then remove the
sensor wheel for the Engine Speed Sensor -G28- from the
crankshaft.
– Remove the gasket with the -T20143/2-.
Be careful not to damage the sealing surface on the crank‐
shaft.
Installing
Note
Do not coat the lip on the seal with oil or grease.
– Clean the sealing surfaces. They must be free of oil and
grease.
– Remove any oil residue on the crankshaft pins with a clean
cloth.
– Place the -T10122/1- on the -T10122/2- and slide the gasket
-A- onto the pull sleeve.
– Remove the -T10122/1-.
2. Cylinder Block, Transmission Side 77
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– Attach the -T10122/2- and seal -A- on the crankshaft.
– Press in sealing ring all around evenly and flush using -
T10122/3-.
The rest of the installation follows the reverse of the removal
procedures. Note the following:
♦ Remove the -T40069- from the back of the cylinder block
and install the bolt.
Tightening Specifications
♦ Refer to ⇒ L3.2 ocking”, page 84 .
♦ Refer to ⇒ -2.3 Flywheel”, page 73
2.7 Sealing Flange, Removing and Instal‐
ling, Transmission Side
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Hand drill with plastic brush attachment- adaptation
♦ Protective eyewear
♦ Silicone Sealant -D 174 003 A2-
Removing
• Engine removed, transmission disconnected from flange
– Observe the safety precautions. Refer to ⇒ P3 recautions”,
page 4 .
– Follow repair instructions. Refer to ⇒ I4 nformation”, page 7 .
– Remove the timing chain cover. Refer to ⇒ C2.1 hain Cover,
Removing and Installing”, page 122 .
– Remove the flywheel and drive plate and then remove the
sensor wheel for the Engine Speed Sensor -G28- from the
crankshaft.
– Remove the cylinder head. Refer to ⇒ H1.3 ead, Removing
and Installing”, page 110 .
– Disengage the wiring harness -arrow- and remove the En‐
gine Speed Sensor -G28- -1- and vacuum pump -2-.
78 Rep. Gr.13 - Crankshaft, Cylinder Block
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– Remove the screws -3-.
– Remove the control housing cover -1- from the cylinder
block -2- or form the oil pan lower section -3- on the upper
and lower marked locations -A- using a screwdriver.
Start near the alignment sleeves -arrows-.
Note
Be careful not to damage the sealing surfaces.
– Remove the seal from the removed control housing cover.
Installing
WARNING
To prevent injuries from shavings, wear protective goggles
and protective clothing.
2. Cylinder Block, Transmission Side 79
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– Remove the sealant residue from the cylinder block, oil pan
upper section and control housing cover using a rotating
plastic brush.
Caution
Make sure that no sealant residue gets into the engine.
– Clean sealing surfaces of cylinder block, upper section of oil
pan and control housing cover, they must be free of oil and
grease.
– Replace the seals -1 and 2-.
– Cut the tube nozzle at the front marking (nozzle diameter:
approximately 1 mm).
Note
The control housing cover must be installed within five minutes
after application of sealant.
– Apply a bead of sealant -A- on the control housing cover as
illustrated.
80 Rep. Gr.13 - Crankshaft, Cylinder Block
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♦ The sealant bead must be 1.5 to 2.0 mm thick.
♦ Pay special attention to course of sealant bead in area
-arrow-.
– Install the control housing cover so that the alignment sleeve
fit into the holes in the cylinder block.
– Install the bolts hand-tight.
– Install the bolts -3- in the cylinder block and in the oil pan
upper section and tighten to 10 Nm.
– Tighten the bolts in the cylinder block and oil pan upper
section to 25 Nm.
– Wipe off any sealant that leaks out.
– Install the alignment sleeves all the way.
– Install a new seal. Refer to ⇒ S2.6 eal, Replacing, Transmis‐
sion Side”, page 76 .
The rest of the installation follows the reverse of the removal
procedures. Note the following:
2. Cylinder Block, Transmission Side 81
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♦ Install the brake booster vacuum pump. Refer to ⇒
P1.5 ump, Removing and Installing”, page 118 .
♦ Install the cylinder head. Refer to ⇒ H1.3 ead, Removing
and Installing”, page 110 .
♦ Install the drive plate. Refer to ⇒ P2.4 late, Removing and
Installing”, page 74 .
♦ Remove the -T40069- from the back of the cylinder block
and install the bolt.
♦ Fill the coolant. Refer to ⇒ D1.4 raining and Filling”, page
187 .
Tightening Specifications
♦ Refer to ⇒ L3.2 ocking”, page 84 .
♦ Refer to ⇒ -2.3 Flywheel”, page 73
82 Rep. Gr.13 - Crankshaft, Cylinder Block
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3 Crankshaft
⇒ -3.1 Crankshaft”, page 83
⇒ L3.2 ocking”, page 84
⇒ L3.3 ocking to Check/Adjust Valve Timing”, page 87
⇒ D3.4 imensions”, page 88
⇒ M3.5 easuring Axial Play”, page 89
⇒ M3.6 easuring Radial Clearance”, page 89
⇒ B3.7 earing Shells Allocation”, page 90
3.1 Overview - Crankshaft
3. Crankshaft 83
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1 - Bolt
❑ 40 Nm +90°
❑ Tighten to 40 Nm to
measure the radial play
in the crankshaft. Do
not tighten any further.
❑ Replace after removing
❑ Fully threaded
2 - Bearing Cap
❑ Bearing cap 1: belt pul‐
ley side
❑ Retaining tabs of bear‐
ing shells and cylin‐
der block/bearing caps
must lie above one an‐
other
3 - Bearing Shell for Bearing
Cap
❑ Without oil groove
❑ Do not interchange
used bearing shells (la‐
bel)
4 - Crankshaft
❑ Axial play new: 0.07 to
0.21 mm
Wear limit: 0.30 mm.
❑ Measure the radial
clearance with a Plas‐
tigauge®.
New 0.0023 to 0.043mm
Wear limit: 0.07 mm
❑ Do not turn the crank‐
shaft when measuring
radial clearance
❑ Crankshaft dimensions. Refer to ⇒ D3.4 imensions”, page 88 .
❑ Secure the crankshaft. Refer to ⇒ L3.2 ocking”, page 84
5 - Thrust Washers
❑ For bearing 3
❑ Side lubricating grooves face outward
6 - Cylinder Block Bearing Shell
❑ With oil groove
❑ Classification for replacement part ordering. Refer to ⇒ B3.7 earing Shells Allocation”, page 90
❑ Do not interchange used bearing shells (label)
7 - Cylinder Block
3.2 Crankshaft, Locking
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Crankshaft Adapter -T03003-
♦ Crankshaft Locking Pin -T40069-
84 Rep. Gr.13 - Crankshaft, Cylinder Block
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Securing the crankshaft for valve timing inspection/adjustment.
Refer to ⇒ L3.3 ocking to Check/Adjust Valve Timing”, page
87 .
Procedure
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
– Remove the front section of the right front wheel housing
liner. Refer to ⇒ Body Exterior; Rep. Gr. 66; Wheel Housing
Liner; Front Wheel Housing Liner, Removing and Installing.
– Attach the -T03003- on to belt pulley bolts.
The -T03003- can only be inserted correctly in one position.
– Rotate the crankshaft in direction of engine rotation -arrow-
far enough until arrow -A- on -T03003- points downward
vertically, relative to the engine axis.
This position corresponds approximately to TDC position of
crankshaft at cylinder 5.
Note
With engine removed, TDC marking can also be seen on belt
pulley and sealing flange on belt pulley side. Notches -A and B-
must align.
– Remove the sealing plug -1- on the back of the cylinder
block.
3. Crankshaft 85
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– Look through the threaded hole. Make sure the hole -2- in
the crankshaft is lined up with the threaded hole.
Use a mirror for this.
– Turn the crankshaft slightly, if necessary.
– When the holes line up, install the -T40069- all the way into
the threaded hole and tighten it to 10 Nm.
Note
With engine removed, TDC marking can also be seen on belt
pulley and sealing flange on belt pulley side. Notches -A and Bmust align.
– Make sure the crankshaft can be turned.
After Assembly Work
– Remove the -T40069- and install the sealing plug -1- on
cylinder block in the rear.
86 Rep. Gr.13 - Crankshaft, Cylinder Block
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The rest of the installation follows the reverse of the removal
procedures.
Tightening Specifications
Component Nm
Sealing plug to cylinder block at rear 30 Nm
3.3 Crankshaft, Locking to Check/Adjust
Valve Timing
– Remove the cylinder head cover. Refer to ⇒ H1.4 ead Cov‐
er, Removing and Installing”, page 116 .
– Perform the work listed in “Crankshaft, Locking”. Refer to ⇒
L3.2 ocking”, page 84 .
Note
If threaded holes in camshafts -arrows- do not stand upward,
crankshaft must be rotated one rotation (360°) in direction of
engine rotation.
In Order to Be Able to Precisely Check and Adjust Valve Tim‐
ing, Always Note the Following:
♦ Only turn crankshaft only in direction of engine rotation
-arrow-. Do not rotate crankshaft back, not even slightly!
3. Crankshaft 87
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♦ Crankshaft must not be rotated out over the TDC marking.
This means bore -2- in crankshaft must not stand above
threaded opening.
If crankshaft was rotated out over the TDC marking:
– Turn the crankshaft back 45° opposite the direction of en‐
gine rotation.
– Turn the crankshaft again in direction of engine rotation to
TDC
When the crankshaft is positioned slightly in front of the TDC
position (hole in crankshaft is 90 % visible), the -T40069can be screwed in, although slightly more difficult.
3.4 Crankshaft Dimensions
(Dimensions in mm)
Honing Dimen‐
sion
Standard di‐
mension
1st oversize 57.75 -0.022
2nd oversize 57.50 -0.022
Stage III 57.25 -0.022
Crankshaft Bearing
Pin Diameter
58.00 -0.022
-0.042
-0.042
-0.042
-0.042
Connecting Rod Bear‐
ing
Pin Diameter
47.80 -0.022
-0.042
47.55 -0.022
-0.042
47.30 -0.022
-0.042
47.05 -0.022
-0.042
88 Rep. Gr.13 - Crankshaft, Cylinder Block
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3.5 Crankshaft, Measuring Axial Play
Special tools and workshop equipment required
♦ Dial Gauge Holder -VW387-
♦ Dial Gauge - 0-10mm -VAS6079-
Test Sequence
– Attach the -VAS6079- with the -VW387- to the cylinder block
and set against the crankshaft counterweight.
– Press the crankshaft by hand against the -VAS6079- and set
the -VAS6079- to “0”.
– Press crankshaft off the gauge and read the value.
Axial play:
• New: 0.07 to 0.21 mm.
• Wear limit: 0.30 mm.
3.6 Crankshaft, Measuring Radial Clear‐
ance
Special tools and workshop equipment required
♦
Plastigauge
Conditions
• Do not turn the crankshaft when checking the radial clear‐
ance.
Test Sequence
Note
♦
Do not interchange used bearings
♦
Bearing shells that are worn down to the nickel layer must
be replaced.
– Remove main bearing cover and clean the bearing cap and
pins.
–
Place Plastigauge® over entire width of bearing journal or
into bearing shells.
•
Plastigauge® must rest in center of bearing shell.
– Install and tighten the main bearing cover. Do not turn the
crankshaft while doing this.
– Remove the main bearing cover again.
®
3. Crankshaft 89
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–
Compare the width of the Plastigauge® with measuring
scale.
Radial clearance:
• New: 0.023 to 0.043 mm
• Wear limit: 0.07 mm
3.7 Main Bearing Shells Allocation
From the factory, the upper bearing shells are allocated to the
cylinder block with the correct thickness. Colored dots serve to
identify the bearing shell thickness.
The letters marked on the lower sealing surface of the cylinder
block identify which bearing thickness must be installed in which
location.
G - Yellow
B - Blue
W - White
Crankshaft/Upper Bearing Shell Marking
Note
♦
The -arrow- points in the direction of travel.
♦
If the color markings are not legible, use the blue bearing
shell.
♦
The lower crankshaft bearing shells are always shipped as
replacement part with “yellow” color marking.
90 Rep. Gr.13 - Crankshaft, Cylinder Block
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4 Piston and Connecting Rod
⇒ -4.1 Piston and Connecting Rod”, page 91
⇒ R4.2 emoving and Installing”, page 93
⇒ a4.3 nd Cylinder Bore, Checking”, page 96
⇒ C4.4 onnecting Rod, Separating”, page 98
4.1 Overview - Piston and Connecting Rod
4. Piston and Connecting Rod 91
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1 - Connecting Rod Bolt
❑ 30 Nm +90°
❑ Tighten to 30 Nm to
measure radial play but
do not tighten further.
❑ Replace after removing
❑ Lubricate threads and
contact surface
2 - Relief Valve
❑ 27 Nm
❑ Opening pressure: 1.3
to 1.6 bar (18.85 to
23.2 psi) pressure
3 - Oil Spray Jet
❑ For piston cooling
4 - Connecting Rod Cover
❑ Note the installation po‐
sition
❑ Due to the separation
procedure (cracking) of
the connecting rod, the
cap only fits in one po‐
sition and only to the
corresponding connect‐
ing rod.
❑ Mark which cylinder to
which it belongs -B-.
❑ Installed position: mark‐
ings -A- face the pulley
side
5 - Bearing Shell
❑ Note the installation po‐
sition
❑ Do not interchange used bearing shells.
❑ New axial play: 0.10 to 0.35 mm
Wear limit: 0.4 mm
❑
Measure radial clearance with Plastigauge®:
New: 0.02 to 0.06 mm
Wear limit: 0.09 mm.
Do not turn crankshaft when measuring radial play.
6 - Connecting Rod
❑ Always replace as a set.
❑ With cracked bearing cap
❑ New connecting rod, separating. Refer to ⇒ C4.4 onnecting Rod, Separating”, page 98 .
❑ Mark which cylinder to which it belongs -B-.
❑ Installed position: markings -A- face the pulley side
7 - Circlip
8 - Piston Pin
❑ If difficult to move, heat piston to 60 °C (140 °F)
❑ Remove and install using the Pilot Drift -VW222A-
92 Rep. Gr.13 - Crankshaft, Cylinder Block
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9 - Piston
❑ Check. Refer to ⇒ Fig. ““Pistons, Checking”“, page 97 .
❑ Mark installed position and cylinder allocation
❑ Arrow on piston face points toward belt pulley side
❑ Install with piston ring compressor
❑ Checking the cylinder bore. Refer to ⇒ Fig. ““Checking the Cylinder Bore”“, page 97 .
10 - Piston Rings
❑ Offset gaps by 120°
❑ Use piston ring pliers for removing and installing
❑ Markings face toward piston crown
❑ Checking the ring gap. Refer to ⇒ Fig. ““Checking the Piston Ring Gap”“, page 96 .
❑ Checking the piston ring groove clearance. Refer to ⇒ Fig. ““Piston Ring Groove Clearance, Checking”
“, page 96 .
Bearing Shells Installed Position
Bearing shell -1- with connecting rod oil bore -arrow-.
Bearing shell -2- without connected rod cover oil bore.
– Place bearing shells centrally into connecting rod and con‐
necting rod cover.
The dimension -a- must be the same at left and right.
4.2 Piston, Removing and Installing
Special tools and workshop equipment required
♦ Drip Tray -VAG1306- or Shop Crane - Drip Tray -VAS6208-
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Spring Clip Pliers
♦ Polydrive Bit Drive Socket -T10070- or Polydrive Bit Drive
Socket - 3452-
♦ Puller - Ignition Coil -T40039-
♦ Silicone Sealant -D 174 003 A2-
Removing
– Remove the engine. Refer to ⇒ R1.1 emoving”, page 9 .
– Separate the engine and the transmission. Refer to ⇒
a1.2 nd Transmission, Separating”, page 18 .
4. Piston and Connecting Rod 93
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– Secure engine to the engine and transmission holder. Re‐
fer to ⇒ S1.3 ecuring on Engine and Transmission Holder”,
page 22 .
– Remove the cylinder head. Refer to ⇒ H1.3 ead, Removing
and Installing”, page 110 .
– Remove the oil pan upper section. Refer to ⇒ P1.3 an Upper
Section, Removing and Installing”, page 162 .
94 Rep. Gr.13 - Crankshaft, Cylinder Block