Volkswagen New Beetle. Manual - part 1196

Fig. 45: Tensioning Toothed Belt By Pulling Out Locking Pin T40011 And Removing Tensioning 
Bolt T10092 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their 
reference points.  

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Install vibration damper/belt pulley 

Tightening torque: 25 N.m 

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Install center part of toothed belt guard. (Insert securing bolts with locking fluid D 000 600 A2). 

Tightening torque: 10 N.m 

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Install upper toothed belt guard.  

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Install aggregate mount and engine mount. Tightening torque. See ENGINE/TRANSMISSION 
MOUNTS .  

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Install ribbed belt tensioner. 

Tightening torque: 25 N.m 

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Install ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

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Install air duct to charge air cooler at bottom right of long member.  

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Install right-hand insulation tray 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

SEALING FLANGES AND DRIVE PLATE, REMOVING AND INSTALLING 

NOTE:

For repairs to the clutch: 

 

2003 Volkswagen New Beetle GLS 

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

  

1. 90 N.m + 1/4 turn (90°) further 

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Always replace  

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Counter-hold with 3099 to loosen and tighten  

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Threads and shoulder must be free of oil and grease  

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When bolting on, place two washers between toothed belt pulley and counter-hold  

2. Crankshaft toothed belt sprocket  

3. 15 N.m  

4. Oil seal 

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Replacing. See CRANKSHAFT OIL SEAL (BELT PULLEY END), REPLACING  

5. Sealing flange 

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Must be located on dowel sleeves  

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

6. Cylinder block 

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Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING  

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Disassembling and assembling pistons and connecting rods. See PISTONS AND CONNECTING 
RODS, DISASSEMBLING AND ASSEMBLING  

7. 60 N.m + 1/4 turn (90°) further 

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Always replace  

8. Flywheel/drive plate 

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To remove and install flywheel counter-hold with 3067  

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Removing and installing drive plate. See DRIVE PLATE, REMOVING AND INSTALLING  

9. Intermediate plate 

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Must be located on dowel sleeves  

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Do not damage/bend when assembling  

10. Sealing flange with oil seal 

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Only replace complete  

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Remove oil pan to be able to remove and install. See OIL PAN, REMOVING AND 
INSTALLING  

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Install new sealing flange with fitting sleeve (before installing do not pull sealing sleeve out of oil 
seal)  

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Before installing, remove oil residue from crankshaft journal using a clean cloth  

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Do not additionally oil or grease the oil seal sealing lip  

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Use protective sleeve supplied when installing 

For 02J, see CLUTCH ASSEMBLY 

For 02M, see CLUTCH ASSEMBLY

NOTE:

The following list refers to items in Fig. 46 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove protective sleeve first after sealing flange has been slid onto crankshaft journal  

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Install new sealing flange with fitting sleeve (before installing do not pull sealing sleeve out of oil 
seal)  

Fig. 46: Identifying Front And Rear Sealing Flanges And Drive Plate 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Crankshaft oil seal (belt pulley end), replacing 

Special tools and equipment 

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3099 Counter-hold tool  

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VAG 1331 Torque wrench (5-50 N.m)  

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VAG 1332 Torque wrench (40-200 N.m)  

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3203 Oil seal extractor  

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2080 A Fitting sleeve  

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3265 Fitting sleeve 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 47: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove ribbed belt and tensioning element. See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING .  

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Remove toothed belt. See REMOVING .  

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Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3099. 

Fig. 48: Removing Crankshaft Toothed Belt Sprocket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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To guide seal extractor, screw center bolt into crankshaft onto stop by hand. 

NOTE:

When bolting on counter-hold place two washers between toothed belt 
pulley and counter-hold.

 

2003 Volkswagen New Beetle GLS 

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