Volkswagen New Beetle. Manual - part 1169

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Remove bolts (arrows).  

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Loosen bolt (arrow -A-). 

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Remove vibration damper/belt pulley. 

Fig. 74: Removing Vibration Damper/Belt Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove engine bracket from cylinder block. 

Fig. 75: Removing Engine Bracket From Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

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Only remove engine mounting when the engine is secured with 
the support bracket 10-222A.  

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The engine bracket must be only released when the engine 
mounting is removed.  

 

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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Remove toothed belt guard center and lower parts.  

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Mark direction of rotation of toothed belt.  

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Release tensioner and take off toothed belt.  

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Turn crankshaft back slightly.  

Installing 

Requirements 

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Pistons must not be positioned at TDC.  

Work sequence 

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Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation). 

Adjusting valve timing 

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Bring mark on camshaft into line with mark on toothed belt guard. 

Engine installed: 

Fig. 76: Aligning Mark On Camshaft With Mark On Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft to TDC No. 1 cylinder (vehicles with manual transmission). 

NOTE:

When loosening the front engine mounting bolt the engine must be raised 
slightly with the support bracket.

NOTE:

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Engine removed:  

Begin by installing lower section of toothed belt guard as well as belt 
pulley/vibration damper. 

NOTE:

When the camshaft is turned, the crankshaft must not be at TDC. Danger of 
damage to valves or piston crowns.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 77: Locating Mark For Positioning TDC No. 1 Cylinder (Vehicles With Manual Transmission)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft to TDC No. 1 cylinder (vehicles with automatic transmission). 

Fig. 78: Locating Mark For Positioning TDC No. 1 Cylinder (Vehicles With Automatic 
Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine removed: 

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Position vibration damper at TDC No. 1 cylinder (arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 79: Positioning Vibration Damper At TDC No. 1 Cylinder 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place toothed belt on tensioning roller and camshaft pulley.  

Tensioning toothed belt 

Requirements 

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Engine must only be hand touch warm.  

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Camshaft sprocket is at TDC No. 1 cylinder.  

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Before tensioning toothed belt, turn tensioning roller on eccentric with pin wrench T10020 five times 
fully onto limit stops in both directions.  

Work sequence 

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Tension toothed belt by turning eccentric to left (direction of arrow) with 2-hole pin wrench T10020 onto 
limit stop. 

Fig. 80: Tensioning Toothed (Timing) Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).  

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Tighten securing nut to 20 N.m.  

 

2003 Volkswagen New Beetle GLS 

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