Volkswagen New Beetle. Manual - part 1198

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Take off sealing flange, release using light blows with a rubber headed hammer if necessary.  

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Remove sealant residue on cylinder block with a flat scraper.  

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Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles). 

Fig. 56: Removing Sealant Remains On Sealing Flange With Rotating Plastic Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Clean sealing surface, must be free of oil and grease.  

Installing 

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Cut-off tube nozzle at forward marking (nozzle approx. 3 mm diameter).  

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Apply silicone sealing compound to clean oil pan sealing surface as shown. 

NOTE:

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Note the "use by" date of the sealant.  

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The sealing flange must be installed within 5 minutes o applying the 
silicone sealant.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 57: Applying Silicone Sealing Compound To Clean Oil Pan Sealing Surface 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Thickness of sealant bead -arrows-: 2 - 3 mm 

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Apply silicone sealant bead as shown to clean sealing surface of sealing flange. 

Fig. 58: Applying Silicone Sealant Bead To Clean Sealing Surface Of Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install sealing flange immediately and lightly tighten all bolts. 

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Tighten sealing flange securing bolts using alternate sequence. 

Tightening torque: 15 N.m 

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Remove excess sealant.  

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Install oil pan. See OIL PAN, REMOVING AND INSTALLING . 

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Install crankshaft toothed belt sprocket and hold with counter-hold tool 3099. 

NOTE:

The sealing compound bead must not be thicker, otherwise excessive 
sealing compound will enter the oil pan and may block the oil suction pipe 
strainer.

NOTE:

Use guide sleeve from 2080A to install sealing flange with the oil seal 
already installed.

NOTE:

After installing, the sealant must be allowed to dry for approx. 30 minutes 
before engine oil is filled.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 59: Installing Crankshaft Toothed Belt Sprocket And Holding With Counter-Hold Tool 3099 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten new central bolt to 90 N.m + 1/4 turn (90°) further.  

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Install compact bracket including tightening element for ribbed V-belt. See ) COMPACT BRACKET . 

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Install toothed belt and adjust valve timing. See INSTALLING .  

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

Drive plate, removing and installing 

Special tools and equipment 

NOTE:

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

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Thread and shoulder must be free of oil and grease.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 60: Identifying VW 558 Retainer 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VW 558 Retainer  

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Hex bolt M8x45 and two M10 hex nuts  

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Depth gauge  

Loosening and tightening drive plate 

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Secure counter-hold tool VW 558 to the drive plate with a hex bolt M8x45. Place two M10 hex nuts -1- 
between counter-hold tool and drive plate. 

Fig. 61: Securing Counter-Hold Tool VW 558 To The Drive Plate With Hex Bolt M8x45 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Loosen drive plate bolts.  

Installing drive plate 

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Locate drive plate and packing plate with recesses -1-.  

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Install new bolts -3- and tighten to 30 N.m. 

 

2003 Volkswagen New Beetle GLS 

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