Volkswagen New Beetle. Manual - part 1026

Cylinder head, removing and installing 

Special tools and equipment 

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10-222A Engine support bridge  

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10-222 A/8 Adaptor  

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3035 Injector line wrench  

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3070 Guide pins & handle-1112 mm  

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T 10014 Engine support  

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VAG 1306 Drip tray for VAG 1202A 

Fig. 70: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

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VAG 1332 Torque wrench: 40 to 200 N.m(30to148ftlb)  

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VAG 1921 Hose clip pliers 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 71: Identifying Special Tools And Equipment (2 Of 2)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Engine must NOT be more than warm to the touch.  

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Pistons must NOT be positioned at TDC.  

Removing 

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With ignition switched OFF, disconnect battery Ground strap.  

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Remove engine cover.  

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Remove Air Cleaner.  

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Remove connecting pipe between Charge Air cooler and intake manifold/EGR Vacuum Regulator 
Solenoid valve.  

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Remove sound dampening tray: 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

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Drain engine coolant. See COOLING SYSTEM, DRAINING AND FILLING  

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Disconnect fuel supply and return lines at fuel filter. 

CAUTION: Obtain radio anti-theft code from customer before disconnecting battery 

ground strap.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 72: Disconnecting Fuel Supply And Return Lines 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Seal lines so fuel system is not contaminated by dirt etc.  

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

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

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Unscrew wiper arms. 

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M8 hex nuts = 20 N.m (15 ft lb)  

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Remove plenum chamber cover. 

WARNING:

Fire hazard! Do NOT have anything in the area that can ignite Diesel 
fuel!

 

2003 Volkswagen New Beetle GLS 

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

  

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

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Disconnect fuel supply and return lines at fuel filter.  

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Remove fuel filter with bracket  

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Disconnect all coolant, vacuum and breather hoses from engine.  

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Disconnect all wiring connections from transmission, Generator and starter and move to one side.  

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Loosely unscrew coolant reservoir and place to side.  

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Remove toothed belt guard upper section.  

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Remove valve cover.  

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Remove brake booster vacuum pump.  

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Unscrew turbocharger oil return line to cylinder block.  

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Unscrew oil supply line at turbocharger  

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Remove injection lines. 

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Remove return line from injector jets/injection pump.  

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Remove glowplug harness connector.  

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Install engine support bracket 10-222A with 10-222 A/1 legs. 

Fig. 73: Installing Engine Support Bracket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Loosely unscrew subassembly (engine side) from upper engine bracket (arrows).  

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Remove engine mount and engine bracket.  

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Lift engine again slightly using spindle -B-. 

NOTE:

Always remove injection lines as a set. Use 3035 offset tubing wrench to 
loosen/tighten the injection lines.

NOTE:

Both lifting eyes are located on the cylinder head, therefore an additional 

 

2003 Volkswagen New Beetle GLS 

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