Volkswagen New Beetle. Manual - part 1007

2 to 3 mm thick.

Run bead along inner side of bolt holes (arrows).

Fig. 141: Applying Silicone Sealing Compound To Clean Oil Pan Sealing Surface
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Apply sealing compound bead carefully to areas marked by arrows.

Fig. 142: Apply Sealing Compound Bead Carefully To Areas Marked By Arrows
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Install oil pan immediately and tighten all oil pan bolts as follows:

1. Tighten all oil pan/cylinder block bolts lightly using diagonal sequence.

NOTE:

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

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

2. Tighten three oil pan/transmission bolts lightly.

3. Tighten all oil pan/cylinder block bolts lightly using diagonal sequence again.

4. Tighten all oil pan/cylinder block bolts to 15 N.m using diagonal sequence.

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

Further assembly is reverse of the disassembling procedure.

Oil pump, removing and installing

Removing

Remove oil pan and baffle plate. See OIL PAN, REMOVING AND INSTALLING .

Remove bolt -2-.

Remove chain gear from oil pump shaft.

Remove bolts -1- and -3- and remove oil pump.

Fig. 143: Removing Bolts -1- And -3- And Oil Pump
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Installing

Installation is performed in reverse sequence of removal. Note the following:

NOTE:

When installing the oil pan with the engine out of the vehicle, make sure
that the oil pan is flush with the cylinder block at the flywheel end.

Let sealing compound dry for approx. 30 minutes after installing oil sump.
Only then fill engine with oil.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

Dowel sleeves. See Fig. 133 , position 9 above oil pump.

Installed position of oil pump shaft/chain gear: installation possible in only one position.

Install oil pan and baffle plate. See OIL PAN, REMOVING AND INSTALLING .

Tightening torques. See PART 1

Oil pressure and oil pressure switch, checking

Special tools and equipment

V.A.G 1342 Oil pressure tester

V.A.G 1527 B Diode test lamp

V.A.G 1594 A Adapter set

Fig. 144: Identifying Special Tools And Equipment
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Function of dynamic oil pressure warning system

The oil pressure switch is open at no pressure and closes when switch pressure is reached.

The oil pressure is activated approx. 10 seconds after switching ignition on ("terminal 15 on").

Switch-on delay of oil pressure warning: Approx. 3 seconds

Switch off delay for oil pressure warning: Approx. 5 seconds

Checking warning lamp

After switching on ignition when engine is not running, oil pressure warning lamp in instrument cluster must
light up for approx. 3 seconds and go out again afterward. The test will be terminated if engine is running.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

Criteria for warning

Switching on of optical oil pressure warning (oil pressure warning lamp flashes) and the buzzer sounding three
times for acoustical warning will occur under one of the following conditions:

"Ignition on", engine at rest, oil pressure switch closed

Engine speed higher than 1500 rpm, oil pressure switch open

At engine revolutions greater than 5000 rpm the oil pressure warning will not be triggered, even when the
oil pressure switch is closed.

If the oil pressure switch is open (engine revs greater than 1500 rpm) for 0.5 to 3 seconds, this is stored in
the combi-processor of instrument cluster. If this condition happens three times while the engine is
running, the oil pressure warning is immediately triggered and remains on, even below 1500 rpm. Oil
pressure warning goes out when oil pressure switch is closed for longer than 5 seconds when engine
revolutions are greater than 1500 rpm or ignition is "switched off".

Requirements

Engine oil level OK, checking. See , Fig. 134 .

Oil pressure warning light -K3- must light up for approx. 3 seconds when ignition is switched on.

Engine oil temperature at least 80°C (coolant fan must have run once).

Work sequence

Remove Oil pressure switch -F1- and install in tester.

Fig. 145: VAG 1432 Pressure Tester
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Thread tester into oil filter bracket in place of oil pressure switch.

Connect brown tester wire to Ground (GND).

Connect diode test lamp V.A.G 1527 B using aux. cables from V.A.G 1594 A to battery positive (+) and
oil pressure switch.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

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