Volkswagen New Beetle. Manual - part 1038

ENGINE, REMOVING AND INSTALLING

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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2024 A Lifting tackle  

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T10012 Engine bracket  

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VW 313 Support clamp  

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VW 540 Engine and transmission support  

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V.A.G 1202 A Workshop crane  

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V.A.G 1306 Drip tray 

Fig. 3: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1331 Torque wrench (5...50 N.m)  

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V.A.G 1332 Torque wrench (40...200 N.m)  

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V.A.G 1383 A 

Engine/transmission jack 

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VAS 5024 

Assembly tool for spring-type clips 

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VW 540/1 B 

Supplementary set 

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VAS 5085 Step ladder  

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G 000 100 Grease (vehicles with manual transmission)  

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Bolt M1 0x 25/ 8.8  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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Cable tie 

Fig. 4: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine removal notes 

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

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Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

NOTE:

During the further course of work the battery Ground strap must be 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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Interrogate fault memories of all control modules before removing engine.  

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The engine is removed downward together with the transmission.  

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All cable ties which are opened or cut open when removing engine, must be replaced in the same position 
when installing the engine. 

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With ignition switched off disconnect battery Ground strap.  

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Remove engine cover.  

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Remove power steering fluid reservoir from battery support but do not disconnect/open hoses.  

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Tie reservoir to lock support.  

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Remove battery and battery retainer.  

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Observe rules for cleanliness. See RULES FOR CLEANLINESS .  

Engine codes AEG, AVH, AZG 

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Pull fuel supply line -1- as well as fuel return line -2- off fuel rail and collect fuel that leaks out with a 
clean cloth.  

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Pull hose off Evaporative Emissions (EVAP) canister purge regulator valve -N80-. 

disconnected. Therefore, please check whether a coded radio is installed. 
Obtain the radio code first, if necessary.

NOTE:

Some components in this vehicle cannot be removed or are very difficult to 
remove when the engine is installed in the engine compartment. For this reason 
determine which components are faulty before starting to remove components 
and replace the faulty components once they have been removed.

WARNING:

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

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Fuel system is under pressure! Before opening the system place a 
cloth around the connection. Then release pressure by carefully 
loosening the connection.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 5: Evaporative Emissions (EVAP) Canister Purge Regulator Valve Hoses - Engine Codes AEG, 
AVH, AZG 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine code BDC 

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Pull fuel supply line -1- as well as fuel return line -2- off fuel rail and collect fuel that leaks out with a 
clean cloth.  

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Pull hose off Evaporative Emissions (EVAP) canister purge regulator valve -N80-.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD