Volkswagen New Beetle. Manual - part 1181

Fig. 136: Identifying Dipstick Marks (Engine Codes BDC, BGD) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bolt allocation for balancer shaft gear assembly (Engine codes BDC, BGD) 

A. M7 x 40 hex bolt  

B. M7 x 55 hex bolt  

C. M7 x 90 hex bolt  

D. Sealing plug with O-ring  

Fig. 137: Identifying Bolt Allocation For Balancer Shaft Gear Assembly (Engine codes BDC, BGD) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

The following list refers to items in Fig. 138 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. Rubber grommet 

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located in cylinder block  

2. Spreader rivet  

3. Spreader rivet 

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to remove oil sump protection push upward  

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to install press in flush  

4. Socket  

5. Bolt, 37 N.m 

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secure in cylinder block  

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clean threads before installing  

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install with locking compound D 000 600 A2  

6. Oil sump protection  

Fig. 138: Exploded View Of Oil Sump Protection Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part II (Oil filter housing, disassembling and assembling) 

1. Sealing plug, 40 N.m 

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Replace  

2. Seal 

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Installed firmly on item -1-  

3. Spring 

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For pressure relief valve, approx. 4 bar  

4. Piston 

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For pressure relief valve, approx. 4 bar 

NOTE:

The following list refers to items in Fig. 139 .

 

2003 Volkswagen New Beetle GLS 

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

  

5. Seal 

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Replace  

6. Non-return valve, 8 N.m 

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Various versions: bolted or pressed  

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Press fit valves are not available as spare parts  

7. Seal 

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Slide on up to shoulder of sealing cover item - 8 -  

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Replace if damaged  

8. Cover  

9. Retaining clip  

10. Sealing plug, 15 N.m  

11. Seal 

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If sealing ring is leaking cut open and replace.  

12. 1.4 bar oil pressure switch -F1-, 25 N.m 

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Black  

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Checking. See OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING  

13. Seal 

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If sealing ring is leaking cut open and replace.  

14. Oil filter bracket 

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With pressed in non-return valve  

15. 15 N.m + 1/4 turn (90°) further 

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Replace  

16. Seal 

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Replace  

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Clip into lugs on oil cooler  

17. Oil cooler 

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Coat contact surfaces to oil filter bracket outside seal with AMV 188 100 02  

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Ensure clearance to adjacent components  

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See note. See LUBRICATION SYSTEM COMPONENTS, REMOVING AND 
INSTALLING .  

18. 25 N.m  

19. Oil filter 

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Loosen with filter strap or oil filter key 3417  

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Tighten by hand  

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Note instructions on filter when installing 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 139: Exploded View Of Oil Filter Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

Removing 

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Remove sump and baffle plate. See OIL SUMP, REMOVING AND INSTALLING .  

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Unscrew bolt -2-.  

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Pull off chain sprocket from oil pump shaft.  

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Unscrew bolts -1- and -3- and remove oil pump. 

Fig. 140: Removing And Installing Oil Pump (Engine codes AEG, AVH, AZG, BEV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Install in reverse order. Note the following: 

 

2003 Volkswagen New Beetle GLS 

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