Volkswagen New Beetle. Manual - part 1180

Fig. 133: Exploded View Of Lubrication System Components (Engine Codes BDC, BGD)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

3. Cylinder block  

4. Dipstick 

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Oil level must not exceed max. mark!  

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Markings. SeeFig. 136  

5. Dipstick guide 

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Fastened to intake manifold  

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Pull off to extract oil  

6. Guide tube  

7. Oil spray jet 

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For piston cooling  

8. Pressure relief valve, 27 N.m  

9. Oil pump with balancer shaft gear assembly 

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With pressure relief valve of 12 bar  

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Removing and installing. See OIL PUMP WITH BALANCER SHAFT GEAR ASSEMBLY, 
REMOVING AND INSTALLING .  

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Disassembling and assembling. See Oil pump with balancer shaft gear assembly, disassembling 
and assembling (Engine codes BDC, BGD) .  

10. 15 N.m + 1/4 turn (90°) further 

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Observe different lengths of bolts. See , Fig. 137  

11. 15 N.m  

12. Sump 

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 404 A2. See OIL SUMP, REMOVING AND INSTALLING  

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Removing and installing. See OIL SUMP, REMOVING AND INSTALLING  

13. Seal 

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Replace  

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Cut open seals which have been rolled on  

14. Oil drain plug, 30 N.m  

15. Chain sprocket 

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Observe installed position  

16. 20 N.m  

17. Chain guard  

18. Chain  

Part I (Engine code BEV) 

 

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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For engine codes AEG, AVH, AZG. See Part I (Engine codes AEG, AVH, AZG)  

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For engine codes BDC, BGD. See Part I (Engine codes BDC, BGD) .  

1. 15 N.m  

2. Sealing flange 

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Must be located on dowel sleeves  

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Insert with silicone sealant D 176 404 A2. See FRONT SEALING FLANGE, REMOVING 
AND INSTALLING  

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Removing and installing. See FRONT SEALING FLANGE, REMOVING AND INSTALLING

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Replacing crankshaft oil seal, poly V-belt pulley end. See CRANKSHAFT OIL SEAL - 
PULLEY END, REPLACING  

3. Pressure relief valve, 27 N.m  

4. Oil spray jet 

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For piston cooling  

5. Dipstick 

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Oil level must not exceed max. mark!  

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Markings. See Fig. 135  

6. Dipstick guide 

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Fastened to intake manifold  

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Pull off to extract oil  

7. Guide tube  

8. Dowel sleeves  

9. O-ring 

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Replace  

10. 15 N.m  

11. Suction line 

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Observe part number  

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Clean strainer if soiled  

12. Baffle plate  

13. Oil sump upper part 

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 404 A2. See OIL SUMP, REMOVING AND INSTALLING  

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Removing and installing. See OIL SUMP, REMOVING AND INSTALLING  

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Sell as a set with oil sump lower part protection. For latest oil sump part number: 

See Parts catalog 

NOTE:

The following list refers to items in Fig. 134 .

 

2003 Volkswagen New Beetle GLS 

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

  

14. 15 N.m  

15. 22 N.m  

16. Oil sump lower part protection 

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 501 A1. See ENGINE CODE BEV  

17. Sealing ring 

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Replace  

18. Oil drain plug, 30 N.m 

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Replace if leaking. See Parts catalog for correct application. In some cases seal and drain plug are 
combined; do not interchange with separate seal and drain plug.  

19. 10 N.m  

20. 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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Replace if running surfaces and gears are scored  

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Removing and installing. See Oil pump, removing and installing (Engine codes AEG, AVH, 
AZG, BEV)  

21. Chain sprocket 

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Observe installing position  

22. Chain  

23. 20 N.m 

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Use counter support T10051 to loosen and tighten  

24. Chain tensioner with tensioning rail, 15 N.m 

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When installing, pretension spring and fit  

Fig. 134: Exploded View Of Lubrication System Components (Engine Code BEV) 

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Dipstick Marks (Engine codes AEG, AVH, AZG, BEV) 

1. max. mark  

2. min. mark 

a. Area above hatched field up to max. mark: Do not add engine oil!  

b. Oil level within hatched field: Engine oil may be added  

c. Area from min. mark up to hatched field: Add max. 0.5L. of engine oil!  

Fig. 135: Identifying Dipstick Marks (Engine Codes AEG, AVH, AZG, BEV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

(Dipstick Marks) Engine codes BDC, BGD 

1. max. mark  

2. Min. mark 

a. Area above hatched field up to max. mark: Do not add engine oil!  

b. Oil level within hatched field: Engine oil may be added  

c. Area from min. mark up to hatched field: Add max. 0.5L. of engine oil!  

NOTE:

The following list refers to items in Fig. 135 .

NOTE:

The following list refers to items in Fig. 136 .

 

2003 Volkswagen New Beetle GLS 

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