Volkswagen New Beetle. Manual - part 1092

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Install guide sleeve from 2080 A onto crankshaft journal. 

Fig. 51: Installing Guide Sleeve From 2080 A Onto Crankshaft Journal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Slide oil seal over guide sleeve onto crankshaft stub.  

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Press in seal with press sleeve from 3265. To do this use old central bolt for crankshaft toothed belt 
sprocket. 

Fig. 52: Pressing In Seal With Press Sleeve From 3265 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press sleeve in onto stop.  

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Install crankshaft toothed belt sprocket and hold with counter-hold tool 3099. 

be replaced with a PTFE oil seal, but not vice versa.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 53: Installing Crankshaft Toothed Belt Sprocket And Holding With Counter-Hold Tool 3099 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten new central bolt to 90 N.m + 1/4 turn (90°) further. 

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Install toothed belt and adjust valve timing. See INSTALLING .  

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

Front sealing flange, removing and installing 

Special tools and equipment 

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3099 Counter-hold tool  

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2080 A Fitting sleeve  

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VAG 1331 Torque wrench (5-50 N.m)  

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VAG 1332 Torque wrench (40-200 N.m)  

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D 176 404 A2 Silicone sealant  

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Hand drill with plastic brush wheel  

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Flat scraper  

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Protective glasses 

NOTE:

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When bolting on, place two washers between toothed belt pulley and 
counter-hold.  

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Thread and shoulder must be free of oil and grease.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 54: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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

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Remove toothed belt. See REMOVING .  

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Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3099. 

Fig. 55: Removing Crankshaft Toothed Belt Sprocket By Counter-Holding Sprocket With 3099 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove oil pan. See OIL PAN, REMOVING AND INSTALLING .  

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Unbolt front sealing flange.  

NOTE:

When bolting on, place two washers between toothed belt pulley and 
counter-hold.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

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Take off sealing flange, release using light blows with a rubber headed hammer if necessary.  

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Remove sealant residue on cylinder block with a flat scraper.  

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Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles). 

Fig. 56: Removing Sealant Remains On Sealing Flange With Rotating Plastic Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Clean sealing surface, must be free of oil and grease.  

Installing 

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

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Apply silicone sealing compound to clean oil pan sealing surface as shown. 

NOTE:

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Note the "use by" date of the sealant.  

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The sealing flange must be installed within 5 minutes o applying the 
silicone sealant.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)