Volkswagen New Beetle. Manual - part 1116

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

  

Fig. 14: Installing Sound Dampening Tray 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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Fill with engine coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

Tightening torques 

TIGHTENING TORQUE CHART - ENGINE REMOVAL & INSTALLATION 

Engine and transmission assembly, mountings 

Tightening torques 

Bolted joint

Metric Size

Tightening torque

Bolts, nuts

M 6

10 Nm

7 ft lb

M 8

25 Nm

18 ft lb

M10

40 Nm

30 ft lb

M 12

60 Nm

44 ft lb

Variations on the above:
Engine to transmission M12 connecting bolts

80 Nm

59 ft lb

Torque converter to drive plate

60 Nm

44 ft lb

Drive shaft to flange / transmission

40 Nm

30 ft lb

Front exhaust pipe to turbocharger

25 Nm

18 ft lb

 

2003 Volkswagen New Beetle GLS 

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

  

FRONT ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE CHART 

Fig. 15: Identifying Front Engine/Transmission Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

RIGHT REAR ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE CHART 

NOTE:

The FRONT ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE CHART 
table refers to items in Fig. 15 .

Application

Specfication

1 - Mount to body 

(1)

40 Nm (30 ft lb) + 90° (1/4 turn.)

2 - Mount/bracket to body

25 Nm (18 ft lb)

3 - Mount to engine bracket 

(1)

60 Nm (44 ft lb) + 90° (1/4 turn.)

(1)

Replace bolts

NOTE:

The RIGHT REAR ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE 
CHART table refers to items in Fig. 16 .

Application

Specification

1 - Mount to body 

(1)

40 Nm (30 ft lb) + 90° (1/4 turn.)

2 - Mount to body

25 Nm (18 ft lb)

3 - Mount to transmisison console 

(1)

60 Nm (44 ft lb) + 90° (1/4 turn.)

(1)

Replace bolts

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 16: Identifying Right Rear Engine/Transmission Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PENDULUM SUPPORT TIGHTENING TORQUE CHART 

Fig. 17: Identifying Pendulum Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with A/C, additional information and removal instructions 

NOTE:

The PENDULUM SUPPORT TIGHTENING TORQUE CHART table refers to items 
in Fig. 17 .

Application

Specification

1 - Pendulum support to transmission 

(1)

40 Nm (30 ft lb) + 90° (1/4 turn.)

2 - Pendulum support to transmission 

(1)

40 Nm (30 ft lb)+ 90° (1/4 turn.)

3 - Pendulum support to engine 

(1)

20 Nm (15 ft lb) + 90° (1/4 turn.)

(1)

Replace bolts

 

2003 Volkswagen New Beetle GLS 

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