Volkswagen New Beetle. Manual - part 1217

Fig. 145: Identifying Filter Bracket Assembly Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Oil pan, removing and installing 

Special tools and equipment 

z

3185 Extension socket wrench 

Fig. 146: Identifying 3185 Extension Socket Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

3249 Socket 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 147: Identifying 3249 Socket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VAG 1331 Torque wrench (5 to 50 N.m)  

z

Silicone sealant D 176 404 A2  

z

Hand drill with plastic brush  

z

Protective glasses  

z

Flat scraper  

Removing 

z

Removing center and right insulation tray: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING . 

z

Drain engine oil.  

z

Detach turbocharger oil return pipe from oil pan.  

z

Loosen oil pan bolts using extension socket wrench 3185. Unscrew with socket 3249.  

z

Remove oil pan; it may be necessary to release oil pan by tapping lightly with a rubber head hammer.  

z

Remove sealant residue on cylinder block with a flat scraper.  

z

Remove sealant residue on oil pan with a rotating brush, e.g. a hand drill with a plastic brush (wear 
protective glasses). 

NOTE:

Observe disposal regulations!

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 148: Removing Sealant Residue On Oil Pan With Rotating Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Clean sealing surface; it must be free of oil and grease.  

Installing 

z

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

Fig. 149: Cutting Off Tube Nozzle At Forward Marking 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

Sealing compound bead must be: 

z

2-3 mm thick  

z

and run on inside of bolt holes -arrows-

NOTE:

z

Note the use by date of the sealant.  

z

Oil pan must be installed within 5 minutes of applying silicone sealing 
compound.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Apply silicone sealing bead as shown to clean sealing surface of oil pan (illustration shows position of 
sealant bead on cylinder block). 

Fig. 150: Applying Silicone Sealing Bead To Clean Sealing Surface Of Oil Pan 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install oil pan immediately and tighten bolts as follows:  

1. Tighten all bolts oil pan/cylinder block very lightly and diagonally.  

2. Lightly tighten three bolts oil pan/transmission.  

3. Lightly tighten all bolts oil pan/cylinder block diagonally.  

4. Tighten three bolts oil pan/transmission to 45 N.m.  

5. Tighten all bolts oil pan/cylinder block diagonally to 15 N.m.  

6. Tighten oil pan/oil return pipe to 10 N.m. 

The rest of the assembly is basically a reverse of the disassembly sequence. 

Oil pressure and oil pressure switch, checking 

Special tools and equipment 

NOTE:

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

NOTE:

z

When installing the oil pan on an engine which is out of vehicle, 
ensure that the oil pan is flush with cylinder block on flywheel end.  

z

The sealant must be allowed to dry for approx. 30 minutes after 
installing the oil pan before the engine can be filled with engine oil.  

 

2003 Volkswagen New Beetle GLS 

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