Volkswagen New Beetle. Manual - part 1005

12. O-ring 

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Always replace  

13. Baffle plate  

14. 15 N.m  

15. 15 N.m  

16. Oil pan 

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 404 A2. See OIL PAN, REMOVING AND INSTALLING .  

17. Seal 

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Always replace  

18. Oil drain plug, 30 N.m 

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Replace plug with attached seal  

19. 19-Oil pump 

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With pressure relief valve of 12 bar  

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Before installing, check that both dowel sleeves for centering oil pump/cylinder block are installed  

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Replace if contact surfaces and gears are scored  

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Removing and installing. See OIL PUMP, REMOVING AND INSTALLING  

20. Chain gear for oil pump  

21. 25 N.m 

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Use counter-bracket T10051 to loosen and tighten  

22. Chain 

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Mark direction of rotation before removing  

Fig. 133: Identifying Lubrication System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Dipstick Marks 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

1. max. mark  

2. min. mark  

a. Area above hatched field up to max. mark: Do not top up with engine oil!  

b. Oil level within hatched field: Engine oil level can be topped up.  

c. Area from min. mark up to hatched field: Add a max. of 0.5 liter of engine oil!  

Fig. 134: Identifying Dipstick Marks 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part 2: Disassembling oil filter bracket 

1. Oil pressure switch -F1-, 20 N.m 

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0.7 bar connector, brown  

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If sealing ring is leaking, cut open and replace  

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Checking. See OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING  

2. Seal 

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Always replace  

3. 15 N.m plus an additional 1/4 turn (90°) 

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Always replace  

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First install upper left and lower right bolt, then tighten four bolts diagonally  

4. Oil filter bracket  

5. Seal 

NOTE:

The following lists refers to items in Fig. 134 .

NOTE:

The following list refers to items in Fig. 135 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

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Always replace  

6. Oil supply line 

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To exhaust turbocharger  

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Removing and installing. See PART 3: REMOVING AND INSTALLING OIL RETURN 
LINE TO TURBOCHARGER  

7. Banjo bolt, 20 N.m 

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Prescribed torque. See item 4 in PART 3: REMOVING AND INSTALLING OIL RETURN 
LINE TO TURBOCHARGER .  

8. Sealing cap, 25 N.m 

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Loosen and tighten with oil filter wrench 3417  

9. O-ring 

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Always replace  

10. Oil filter element 

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Note installed position: top  

11. Sealing plug, 25 N.m  

12. Seal 

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Always replace  

13. Oil cooler 

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Make sure clearance to adjacent components.  

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See note. See LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

14. Seal 

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Always replace  

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Install into groove on oil cooler.  

15. Sealing plug, 10 N.m 

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If sealing ring is leaking, cut open and replace  

16. Sealing plug 

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For pressure relieve valve  

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Do not loosen  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 135: Disassembling Oil Filter Bracket Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part 3: Removing and installing oil return line to turbocharger 

Assembly overview 

1. Oil supply line 

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To exhaust turbocharger  

2. Union nut, 22 N.m 

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When tightening and loosening counterhold line union  

3. Seal 

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Always replace  

NOTE:

The following list refers to items in Fig. 136 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)