Volkswagen New Beetle. Manual - part 1199

Fig. 62: Locating Drive Plate And Packing Plate With Recesses 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check dimension -a- at three points and calculate average. 

Specification: 19.5 to 21.1 mm 

Fig. 63: Measuring Dimension Through Hole In Drive Plate To Milled Surface Of Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If the specification is not attained: 

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Remove drive plate again and fit shim -2-. Tighten bolts again to 30 N.m. 

NOTE:

Measured through hole in drive plate to milled surface of cylinder block.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 64: Removing Drive Plate And Shim 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten bolts to 60 N.m and turn 90° (1/4 turn) further (turning further can be done in several stages).  

CRANKSHAFT, REMOVING AND INSTALLING 

1. Oil pump 

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With pressure relieve valve of 12 bar  

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Before installing, check that both dowel sleeves for centering oil pump/cylinder head are installed  

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Removing and installing. See LUBRICATION SYSTEM COMPONENTS, REMOVING AND 
INSTALLING  

2. 15 N.m  

3. Chain sprocket 

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For oil pump drive  

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Check for wear  

4. Bearing caps 1, 2, 4 and 5 

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For bearing cap without oil groove  

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For cylinder block with oil groove  

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Do not interchange used bearing shells (mark) 

NOTE:

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Before removing the crankshaft, prepare a suitable surface so that the 
sensor wheel (item 8 ) is not making contact with anything and is not 
damaged.  

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When stripping and assembling the engine it should be secured to the 
engine frame with engine and transmission bracket VW 540 and 
supplementary set VW 540/1B.  

NOTE:

The following list refers to items in Fig. 65 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Classification for ordering replacement parts. See Upper Crankshaft Bearing Identification  

5. 65 N.m + 90° (1/4 turn) further 

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Replacing  

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Threaded along complete length (screw)  

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Tighten to 65 N.m when measuring radial clearance  

6. Bearing cap 

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Bearing cap 1: pulley end  

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Bearing cap 3 with recesses for thrust washers  

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Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side  

7. Bearing shell 3 

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For bearing cap without oil groove  

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For cylinder block with oil groove  

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Do not interchange used bearing shells (mark)  

8. Sensor wheel 

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Always replace  

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For engine speed (RPM) sensor -G28-  

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Can only be installed in one position (holes are offset)  

9. 10 N.m + 1/4 turn (90°) further 

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Always replace  

10. Thrust washer 

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For bearing 3 bearing cap  

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Note fixing arrangement  

11. Crankshaft 

Axial clearance: 

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New: 0.07-0.23 mm  

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Wear limit: 0.30 mm 

Checking radial clearance with Plastigage: 

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New: 0.01-0.04 mm  

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Wear limit: 0.15 mm  

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Do not rotate the crankshaft when checking the radial clearance  

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Crankshaft dimensions. See CRANKSHAFT DIMENSIONS

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 65: Exploded View Of Crankshaft Assembly & Oil Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Upper Crankshaft Bearing Identification 

Vehicles from approx. 05.00 

The upper crankshaft bearings are installed with the proper thickness bearing shells from the factory. Color 
points are used to identify the bearing shell thickness. 

Fig. 66: Identifying Upper Crankshaft Bearing Identification Markings On Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Letters in the lower sealing surface of the cylinder block identify which bearing thickness must be installed at 
which position. 

Color markings 

NOTE:

The arrow shows drive direction.

 

2003 Volkswagen New Beetle GLS 

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