Volkswagen New Beetle. Manual - part 1010

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While lowering, carefully guide the power steering fluid line past the transmission. 

Engine assembly stand, attaching engine 

Work sequence 

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Transfer Engine/transmission subassembly to workbench via VAG 1383 A engine/transmission jack. 

Fig. 10: Identifying Transfer Engine/Transmission Subassembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lower the engine/transmission assembly such that the transmission is supported.  

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Remove lower engine/transmission connecting bolt.  

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Push transmission off engine, while pushing the torque converter out of the drive plate.  

Vehicles with automatic transmission 

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Remove nut from torque converter.  

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Clamp off ATF cooler hoses and disconnect at transmission cooler.  

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Seal off transmission cooler using clean plugs.  

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Secure torque converter to prevent it from falling out.  

All vehicles 

NOTE:

Carefully guide the engine and transmission assembly during the lowering 
process to prevent bodywork damage.

NOTE:

To work on the engine outside of the vehicle, attach engine to assembly stand 
using the VW 313 holding fixture along with the VW 540 engine/transmission 
support.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

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Attach 2024A engine sling using 2024 A/1 extension as follows and lift from VAG 1383 
engine/transmission jack using workshop crane: 

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Pulley end: 4th hole in hook at position 1  

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Flywheel end: 4th hole in hook at position 8  

Fig. 11: Attaching 2024A Engine Sling 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Secure engine to holding fixture VW 313 using VW 540 engine/transmission support and VW 540/1 
supplementary kit.  

Installation notes 

Installation is reverse of removal, note the following during installation: 

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Check whether centering dowels for engine/transmission are installed in the cylinder block, install if 
necessary.  

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Install intermediate plate onto sealing flange and slide onto dowel sleeves (arrows). 

WARNING:

Secure ALL hooks and locating pins with lock pins!

NOTE:

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Positions marked 1 to 4 on the bar must be located toward the pulley end 
of the engine.  

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The holes in the hooks are counted up from the hook.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 12: Installing Intermediate Plate Onto Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with manual transmission 

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Check clutch release bearing for wear, replace if necessary.  

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Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft using G 000 
100.  

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Install hydraulic clutch slave cylinder:  

See CLUTCH SLAVE CYLINDER 

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Install selector mechanism:  

See SELECTOR MECHANISM . 

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If necessary adjust gear change cables:  

See SELECTOR MECHANISM . 

Vehicles with automatic transmission 

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Replace the lock washer on the selector cable anchorage.  

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Install selector cable on transmission, adjust if necessary:  

See SELECTOR LEVER CABLE . 

All vehicles 

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When installing the engine and transmission assembly, make sure sufficient clearance to drive shafts.  

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While raising, carefully guide the power steering fluid line past the transmission.  

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Engine and Transmission subassembly is aligned transversely so there is a distance between engine 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

mount -1- and engine bracket -2- of approx. 10 mm (installed condition). 

Fig. 13: Aligning Engine Mount And Engine Bracket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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When bolting the mount support arm to the engine support and transmission console, the engine and 
transmission mount must not be stressed (aligned parallel to each other).  

Tightening torques. See TIGHTENING TORQUES . 

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Remove left-hand drive shaft and disconnect right-hand drive shaft at transmission:  

See FRONT AXLE SHAFT . 

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Remove front exhaust pipe. See FRONT EXHAUST PIPE AND CATALYST WITH 
ATTACHMENTS.  

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Remove connecting pipe between charge air cooler and intake manifold with EGR Vacuum Regulator 
solenoid valve.  

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Install power steering pump:  

See POWER STEERING PUMP: VEHICLES WITH POWER STEERING IN LOWER SECTION, 
REMOVING AND INSTALLING or POWER STEERING PUMP: VEHICLES WITH POWER 
STEERING IN UPPER SECTION, REMOVING AND INSTALLING . 

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Electrical connections and routing:  

See appropriate WIRING DIAGRAM article 

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Install ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

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Install sound dampening tray: 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle