Volkswagen New Beetle. Manual - part 1216

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

6. Dipstick 

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Oil level must not be above max. mark!  

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Markings. See Markings On Oil Dipstick .  

7. Guide 

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For dipstick  

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Pull off to extract oil  

8. Guide tube  

9. Oil spray jet 

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For piston cooling  

10. Pressure relieve valve, 27 N.m 

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Opening pressure: 1.3 to 1.6 bar  

11. 15 N.m  

12. Suction pipe 

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Clean strainer if soiled  

13. O-ring 

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Replace  

14. Baffle plate  

15. 15 N.m 

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Loosen and tighten with T-bar and socket, 10 mm 3185  

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Remove with hexagon key extension, 5 mm 3249  

16. Oil pan 

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Clean sealing surface before installing  

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Install with silicone sealant D 176 404 A2. See OIL PAN, REMOVING AND INSTALLING .  

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Removing and installing. See OIL PAN, REMOVING AND INSTALLING .  

17. Oil drain plug, 30 N.m 

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Replace if leaking. See Parts Catalog for correct application. In some cases, seal and drain plug are 
combined; do not interchange with separate seal and drain plug.  

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If sealing ring is leaking nip open and replace.  

18. Seal 

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Replace  

19. Oil return pipe 

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From turbocharger  

20. 10 N.m  

21. Oil pump 

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With positive pressure relief valve 12 bar  

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

 

2003 Volkswagen New Beetle GLS 

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

  

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Replace if running surfaces and gears are scored  

22. Chain sprocket 

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For oil pump  

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Check for wear  

23. 25 N.m  

24. Roller chain 

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Mark direction of rotation before removing  

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Check for wear  

25. Dowel sleeves 

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Check for tight fit  

Fig. 143: Exploded View Of Lubrication System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Markings On Oil Dipstick 

1. max. mark  

2. min. mark 

a. Area above hatched field up to max. mark: Do not top off with engine oil!  

b. Oil level within hatched field: can be topped off with engine oil  

c. Area from min. mark up to hatched field: fill with max. 0.5L. of engine oil!  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 144: Identifying Markings On Oil Dipstick 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part II 

1. Sealing plug, 40 N.m  

2. Seal 

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If sealing ring is leaking nip open and replace.  

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  

5. Gasket 

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Replace  

6. Non-return valve, 8 N.m  

7. O-ring 

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Replace  

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Fit onto shoulder of connecting pipe 8 -  

8. Connecting pipe 

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For cylinder block breather  

9. Retaining clip 

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Check for tight fit  

10. Sealing plug, 15 N.m  

11. Seal 

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If sealing ring is leaking nip open and replace 

NOTE:

The following list refers to items in Fig. 145 .

 

2003 Volkswagen New Beetle GLS 

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

  

12. 20 N.m  

13. Oil supply pipe 

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To turbocharger  

14. Banjo bolt, 30 N.m  

15. Gasket 

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Replace  

16. 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 .  

17. Seal 

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If sealing ring is leaking nip open and replace  

18. 15 N.m + 1/4 turn (90°) further 

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Replace  

19. Gasket 

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Replace  

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Install into groove on oil cooler  

20. Oil filter 

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Loosen with strap wrench  

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Tighten by hand  

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Observe installation instructions on oil filter  

21. 25 N.m  

22. Oil cooler 

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Ensure clearance to adjacent components  

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

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Coat contact area to flange, outside seal, with AMV 188 100 02  

23. Oil filter bracket 

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With pressure relief valve approx. 4 bar 

 

2003 Volkswagen New Beetle GLS 

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