Volkswagen New Beetle. Manual - part 1195

Fig. 39: Removing Vibration Damper/Belt Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove engine bracket from cylinder block. 

Fig. 40: Removing Engine Bracket From Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Mark direction of rotation of toothed belt.  

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Screw tensioning bolt T10092 into toothed belt tensioning element. 

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 41: Screwing Tensioning Bolt T10092 Into Toothed Belt Tensioning Element 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Align pressure piston using pointed pliers or wire before tensioning (hole in pressure piston must align 
with hole in housing).  

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Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.  

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Remove toothed belt.  

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Turn crankshaft back slightly.  

Installing 

A - Toothed belt completely removed 

If toothed belt has only been removed from camshaft. See B - TOOTHED BELT ONLY TAKEN OFF 
CAMSHAFT SPROCKET . 

Conditions 

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The pistons must not be positioned at TDC  

Work sequence 

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Bring mark on camshaft in line with the mark on cylinder head cover. 

NOTE:

When turning the camshaft the crankshaft must not be at TDC (danger of 
damage valves/piston crown).

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 42: Aligning Mark On Camshaft With The Mark On Cylinder Head Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place toothed belt on crankshaft sprocket (observe direction of rotation).  

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Install engine mount to cylinder block. 

Tightening torque: 45 N.m 

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Install lower part of toothed belt guard. Insert securing bolts with locking fluid "D 000 600 A2". 

Tightening torque: 10 N.m 

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Secure vibration damper/belt pulley with one bolt (note fixing arrangement).  

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Turn crankshaft to TDC No. 1 cylinder. 

Fig. 43: Turning Crankshaft To TDC No. 1 Cylinder

NOTE:

Before installing engine mount, insert bolts into mount.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Install toothed belt onto coolant pump, tensioning roller and camshaft sprocket.  

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Tighten toothed belt. See TENSIONING TOOTHED BELT .  

B - Toothed belt only taken off camshaft sprocket 

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Bring mark on camshaft in line with the mark on cylinder head cover. 

Fig. 44: Aligning Mark On Camshaft With The Mark On Cylinder Head Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft to TDC No. 1 cylinder.  

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Install toothed belt onto camshaft sprocket.  

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Tighten toothed belt. See TENSIONING TOOTHED BELT  

Tensioning toothed belt 

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Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)