Volkswagen New Beetle. Manual - part 1132

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

  

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Attach T 10014 bracket to cylinder block using threaded hole in water pump area (as illustrated). 

Fig. 74: Attaching T 10014 Bracket To Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lift engine slightly using second spindle -A- until spindle -B- is relieved.  

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Remove spindle -B-.  

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Position engine at TDC with camshaft sprocket loosened and toothed belt removed from camshaft 
sprocket. See TOOTHED BELTS, REMOVING, INSTALLING, TENSIONING  

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Remove tension roller and camshaft sprocket. 

bracket must be attached to the block to support the engine.

 

2003 Volkswagen New Beetle GLS 

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

  

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Unscrew upper bolt of belt guard, rear.  

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Loosen socket head bolts in sequence given, then remove bolts completely. 

Fig. 75: Loosening Head Bolts In Sequence

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Carefully lift off cylinder head.  

Installing 

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Turn crankshaft to TDC mark before installing cylinder head.  

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Turn crankshaft against engine direction of rotation until all pistons are approximately equally spaced 
below TDC.  

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To centralize: screw guide pins from 3070/9 into outer threaded holes on intake side. 

NOTE:

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Always replace cylinder head bolts.  

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Make sure that there isn't any oil or coolant in the cylinder head bolt 
hollows (in the cylinder head).  

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Only remove the new cylinder head gasket from its packing immediately 
before installing.  

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When repairing, carefully remove any gasket remains from the cylinder 
head and cylinder block. Ensure that no long grooves or scratches are 
created. When using abrasive paper do not use a grade coarser than 100 
(e.g. 80).  

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Carefully remove any emery or abrasive remains.  

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Handle the new gasket with extreme care. Damaging will lead to leaks.  

 

2003 Volkswagen New Beetle GLS 

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