Volkswagen New Beetle. Manual - part 1008

 

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Volkswagen New Beetle. Manual - part 1008

 

 

LED must not light up 

If LED lights up: 

z

Replace 0.7 bar Oil pressure switch -F1-.  

If LED does not light up: 

z

Start engine and increase speed slowly. At 0.55 to 0.85 bar pressure: 

LED must light up 

If LED does not light up: 

z

Replace oil pressure switch.  

z

Increase engine speed further. 

At 2000 rpm and an oil temperature of 80°C oil pressure should be at least 2.0 bar. 

At higher engine speeds oil pressure must not exceed 7.0 bar 

If specifications are not obtained: 

z

Mechanical damage possible, e.g. repair bearing damage.  

z

Replace oil filter bracket with pressure relief valve. See Fig. 135 , item 4 or oil pump.  

If the specification is exceeded: 

z

Check oil galleries.  

z

If necessary, replace oil filter bracket with pressure relief valve. See Fig. 135 , item 4  

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle 

GENERAL, TECHNICAL DATA 

TECHNICAL DATA 

Engine Code and Serial number, locations 

The Engine Code number ("Code letters" plus "Serial number") can be found between the Diesel injection 
pump and the exhaust manifold on the engine block. 

Fig. 1: Identifying Engine Code Number 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

There is also a sticker on the toothed belt guard showing the "Engine code" and "Serial number". 

The Engine Code is also included on the vehicle data plate. 

Engine data 

ENGINE DATA 

Engine Code letters

ALH

Production

from 10.97

Displacement liters

1.9

Power kW at 1/min

66/3750

Torque N.m at 1/min

210/1900

Bore diameter mm

79.5

Stroke mm

95.5

Compression

19.5

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

ENGINE - ASSEMBLY 

ENGINE, REMOVING AND INSTALLING 

Special tools and equipment 

z

2024 A Engine sling  

z

T10012 Engine/trans. support  

z

VW 313 Holding fixture  

z

VW 540 Holding fixture / transmission support  

z

VAG 1202 A Workshop crane  

z

VAG 1306 Drip tray for VAG 1202A 

Fig. 2: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VAG 1331 Torque wrench: 5 to 50 Nm (3.7 to 37 ft lb)  

z

VAG 1332 Torque wrench 40 to 200 Nm (30 to 148 ft lb)  

z

VAG 1383A Engine/transmission jack  

z

VAG 1921 Hose clip pliers  

z

VAS 5085 Step ladder  

z

G 000 100 grease (manual transmission only)  

z

M10 x 25 / 8.8 Bolt  

CZ (Cetane rating) minimum

45

Ignition sequence

1 - 3 - 4 - 2

Catalytic converter

YES

Exhaust Gas Recirculation

YES 

(1)

Turbocharging

YES

Charge Air cooling

YES

(1)

With EGR cooling

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

z

Cable tie 

Fig. 3: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Disconnect fuel supply and return lines at fuel filter. 

CAUTION: Obtain the radio anti-theft code from the customer BEFORE disconnecting 

the battery Ground strap.

NOTE:

z

After making sure that the ignition is switched OFF, disconnect the battery 
Ground strap.  

z

All cable ties which were opened or cut open to remove the 
engine/transmission assembly, must be replaced in the original position 
when installing the engine.  

z

Remove the engine/transmission assembly downward.  

z

Remove the engine cover.  

z

Remove power steering reservoir from battery support, thereby not having 
to loosen the fluid hoses.  

z

Attach coolant reservoir to upper radiator support.  

z

Remove the battery and battery hold-down.  

z

Remove Air Cleaner.  

z

Remove connecting pipe between the Charge Air cooler and intake 
manifold complete with EGR Vacuum Regulator solenoid valve -N18-.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

 

 

 

 

 

 

 

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