Volkswagen New Beetle. Manual - part 1006

4. Banjo bolt, 25 N.m  

5. Clamp  

6. 10 N.m  

7. Bracket  

8. 25 N.m 

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Always replace  

9. 10 N.m  

10. 10 N.m  

Fig. 136: Turbocharger Oil Lines 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

Removing 

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Remove sound insulation.  

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Position drip tray V.A.G 1306 underneath.  

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Remove air filter housing.  

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Unscrew union nut -2- or banjo bolt -4- at oil filter bracket.  

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Remove bolt -6-.  

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Unfasten union nut -2- at turbocharger.  

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Remove bolt -9- from bracket -7-.  

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Remove nut -8- and remove bracket -7-. 

NOTE:

The following list refers to items in Fig. 137 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove oil return line -1-. 

Fig. 137: Turbocharger Oil Lines 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is performed in reverse sequence of removal. In the process, note the following: 

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Install bracket -7- with nut -8- loosely to exhaust manifold.  

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Install union nut -2- or banjo bolt -4- at oil filter bracket hand-tight.  

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Install union nut -2- hand-tight at turbocharger.  

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Install union nut -2- or banjo bolt -4- at oil filter bracket with correct tightening torque.  

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Install union nut -2- to turbocharger with correct tightening torque.  

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Position clamps -5- on oil return line.  

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Install bolts -6- and -9- with correct tightening torque.  

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Tighten nut -8- with correct tightening torque. 

CAUTION: Adhere strictly to the installation procedure for the oil return line.

NOTE:

The following list refers to items in Fig. 138 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 138: Turbocharger Oil Lines 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Oil pan, removing and installing 

Special tools and equipment 

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3185 Jointed wrench  

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T10058 Socket insert  

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V.A.G1331 Torque wrench (5 to 50 N.m)  

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Hand drill with plastic brush attachment  

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Silicone sealing compound D 176 404 A2 

Fig. 139: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove center and right side sound insulation: 

 

2003 Volkswagen New Beetle GLS 

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

  

See NOISE INSULATION, ASSEMBLY OVERVIEW .

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Drain engine oil. 

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Unbolt oil pan. 

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Remove oil pan. Loosen oil pan with light blows from a rubber-headed hammer, if necessary.  

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Use a flat scraper to remove sealant residue on cylinder block.  

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Remove sealant residue from oil pan with a rotating brush, e.g. a hand drill with a plastic brush 
attachment (wear protective goggles). 

Fig. 140: Removing Sealant Residue From Oil Pan With Rotating Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Clean sealing surfaces. They must be free of oil and grease.  

Installing 

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Cut off tube nozzle at front marking (nozzle approx. 3 mm diameter).  

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Apply silicone sealing compound, as shown, to clean oil pan sealing surface. Sealant bead must be: 

NOTE:

Observe disposal regulations!

NOTE:

Loosen bolts on flywheel end of oil pan with jointed wrench 3185 and 
remove with socket T10058.

NOTE:

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Observe the use-by date of the sealing compound.  

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The oil pan must be installed within 5 minutes of applying silicone sealing 
compound.  

 

2003 Volkswagen New Beetle GLS 

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