Volkswagen New Beetle. Manual - part 1162

Fig. 54: Installing Drive Plate With Shim 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten bolts to 60 N.m and 90° (1/4turn) further (turning further can be done in several stages).  

CRANKSHAFT, REMOVING AND INSTALLING 

Engine codes AEG, AVH, AZG, BEV 

NOTE:

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Before removing the crankshaft, prepare a suitable place to set it to 
ensure that the sensor wheel (item -8-) is free and does not get damaged.  

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When stripping and assembling the engine it should be secured to the 
engine frame with engine and transmission bracket VW 540 and 
supplementary set VW 540/1B.  

 

2003 Volkswagen New Beetle GLS 

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

  

1. Oil pump 

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With pressure relief valve of 12 bar  

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Before installing, check that both dowel sleeves for centralizing oil pump/cylinder block are 
installed  

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Removing and installing. See LUBRICATION SYSTEM COMPONENTS, REMOVING AND 
INSTALLING  

2. 15 N.m  

3. Chain sprocket 

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For oil pump drive  

4. Bearing shells 1,2, 3, 4 and 5 

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Classification for ordering spare parts. See Fig. 57  

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For bearing cap without oil groove  

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For cylinder block with oil groove  

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Do not interchange used bearing shells (mark)  

5. 65 N.m + 90° (1/4 turn) further 

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Replace  

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Threaded along complete length (screw)  

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Tighten to 65 N.m when measuring crankshaft radial clearance  

6. Bearing cap 

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Bearing cap 1: Poly V-belt pulley end  

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Bearing cap 3 with recesses for thrust washers  

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Bearing shell retaining lugs (cylinder block/bearing cap) must be on same side  

7. Bearing shell 3 

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See item - 4 -  

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Do not interchange used bearing shells (mark)  

8. Sensor wheel 

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Replace  

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For Engine speed (RPM) sensor -G28-  

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Can only be installed in one position. Holes are offset  

9. 10 N.m + 1/4 turn (90°) further 

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Replace  

10. Thrust washer 

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For bearing 3 bearing cap  

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Production version (1-part), upper thrust washers discontinued, item -12-  

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Observe method of securing  

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Lettering faces mounting bracket 

NOTE:

The following list refers to items in Fig. 55 .

 

2003 Volkswagen New Beetle GLS 

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

  

11. Crankshaft 

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Axial clearance, new: 0.07 ... 0.23 mm; Wear limit: 0.30 mm  

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Check radial clearance with Plastigage, new: 0.01 ... 0.04 mm; Wear limit: 0.15 mm  

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Do not rotate crankshaft when checking radial clearance  

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Crankshaft dimensions. See CRANKSHAFT DIMENSIONS  

12. Thrust washer 

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For cylinder block, bearing 3  

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Spare part version (2-part), lower thrust washers are only semicircular  

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Lettering faces mounting bracket  

Fig. 55: Exploded View Of Crankshaft Assembly (Engine Codes AEG, AVH, AZG, BEV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Engine codes BDC, BGD 

1. Chain sprocket  

2. Bearing shells 1,2, 3, 4 and 5 

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Classification for ordering spare parts. See Fig. 57  

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For bearing cap without oil groove  

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For cylinder block with oil groove  

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Do not interchange used bearing shells (mark)  

3. 65 N.m + 90° (1/4 turn) further 

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Replace  

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Threaded along complete length (screw)  

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Tighten to 65 N.m when measuring crankshaft radial clearance  

4. Bearing cap 

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Bearing cap 1: Ribbed belt pulley end  

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Bearing cap 3 with recesses for thrust washers  

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Bearing shell retaining lugs (cylinder block/bearing cap) must be on same side  

5. Bearing shell 3 

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See Step 2  

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Do not interchange used bearing shells (mark)  

6. Sensor wheel 

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Replace  

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For Engine speed (RPM) sensor -G28-  

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Can only be installed in one position. Holes are offset  

7. 10 N.m + 1/4 turn (90°) further 

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Replace  

8. Thrust washer 

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For bearing 3 bearing cap  

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Observe adjustment  

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Lettering faces mounting bracket  

9. Crankshaft 

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Axial clearance, new: 0.07...0.23 mm; Wear limit: 0.30 mm  

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Check radial clearance with Plastigage, new: 0.01...0.04 mm, Wear limit: 0.07 mm  

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Do not rotate crankshaft when checking radial clearance 

NOTE:

The balancer shaft gear assembly must be adjusted. See OIL PUMP WITH 
BALANCER SHAFT GEAR ASSEMBLY, REMOVING AND INSTALLING .

NOTE:

The following list refers to items in Fig. 56 .

 

2003 Volkswagen New Beetle GLS 

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