Volkswagen New Beetle. Manual - part 1719

Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 7: Identifying Right-Hand Engine Mount 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 2.0L 4-Cylinder - AEG, AVH, AZG, BDC & BEV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:22 AM

Page 8 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 8: Releasing/Adjusting Timing Belt Tension 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Installation (AEG, AVH, AZG, BDC & BEV Engine Codes) 

1. Ensure crankshaft and camshaft timing marks are still aligned. See Fig. 5 and Fig. 6 .  

2. Install timing belt around crankshaft and water pump sprockets. Install engine support on front of engine 

block. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS .  

3. Install timing belt lower and center covers. Install crankshaft pulley and tighten bolts to specification. 

Install engine mount-to-body and engine support. Remove floor jack or engine support bar from engine.  

4. Install timing belt on camshaft sprocket and timing belt tensioner. Make sure there is no slack in timing 

belt.  

5. To tension timing belt, engine must be at most warm to the touch. Rotate tensioner pulley 

counterclockwise until tensioner arrow is aligned with cut-out on cylinder head. See Fig. 8 .  

6. Tighten tensioner pulley center nut to specification. Rotate crankshaft 2 revolutions in normal direction of 

rotation, and recheck check belt tension. Adjust tension as necessary. Recheck all timing marks again.  

7. Install upper timing belt cover. Install serpentine belt tensioner and serpentine belt. To complete 

installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE 
SPECIFICATIONS .  

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 2.0L 4-Cylinder - AEG, AVH, AZG, BDC & BEV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:22 AM

Page 9 

© 2004 Mitchell Repair Information Company, LLC. 

Application 

Ft. Lbs. (N.m) 

Camshaft Sprocket Bolt 

74 (100) 

Camshaft Sprocket Sealing Plug 

18 (25) 

Crankshaft Pulley Socket-Head Bolts 

Golf, GTI & Jetta 

30 (40) 

New Beetle 

18 (25) 

Crankshaft Sprocket Center Bolt 

(1)

 , 

(2)

66 (90) 

Engine Mounting Bolts 

Engine Support-To-Engine Block 

33 (45) 

Mounting Bracket-To-Body (Small Bolt) 

18 (25) 

Mounting Bracket-To-Body Bolts (Large Bolts) 

(1)

(2)

Mount-To-Body 

74 (100) 

Serpentine Belt Tensioner Bolt 

18 (25) 

Timing Belt Tensioner Center Nut 

15 (20) 

Water Pump Bolt 

11 (15) 

INCH Lbs. (N.m)

Timing Belt Cover Bolt 

89 (10) 

Valve Cover Retaining Nut 

89 (10) 

(1)

Replace torque-to-yield bolt on installation.

(2)

First tighten to (40 N.m), then tighten bolts an additional 90 degrees (1/4 turn).

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 2.0L 4-Cylinder - AEG, AVH, AZG, BDC & BEV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:22 AM

Page 10 

© 2004 Mitchell Repair Information Company, LLC. 

VOLKSWAGEN 

1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines 

MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE 

The manufacturer suggests the timing belt AND tensioner be replaced at 105,000 mile intervals.  

REMOVAL & INSTALLATION 

TIMING BELT 

Removal 

1. Remove engine cover. Remove noise insulation pan from under engine compartment.  

2. Remove air duct pipe between turbocharger and charge air cooler. See Fig. 1 . Air duct pipe is located 

along bottom right of cross member. 

CAUTION: This application is an interference engine. Do not rotate camshaft or 

crankshaft when timing belt is removed, or engine damage may occur. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines

  

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:23 AM

Page 1 

© 2004 Mitchell Repair Information Company, LLC. 

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:27 AM

Page 1 

© 2004 Mitchell Repair Information Company, LLC.