Volkswagen New Beetle. Manual - part 1009

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1007  1008  1009  1010   ..

 

 

Volkswagen New Beetle. Manual - part 1009

 

 

Fig. 4: Disconnecting Fuel Supply And Return Lines 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Seal off lines so fuel system is not contaminated by dirt etc.  

Vehicles with manual transmission 

z

Disconnect selector mechanism from transmission.  

See SELECTOR MECHANISM ON TRANSMISSION SIDE, UP TO 5.99 DISASSEMBLING AND 
ASSEMBLING
 or SELECTOR MECHANISM ON TRANSMISSION SIDE, AS OF 6.99 
DISASSEMBLING AND ASSEMBLING
 . 

z

Remove hydraulic clutch slave cylinder:  

See CLUTCH SLAVE CYLINDER 

Vehicles with automatic transmission 

z

Remove Transmission Range selector lever cable from transmission:  

See SELECTOR LEVER CABLE 

All vehicles 

z

Remove sound dampening tray: 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 5: Removing Sound Dampening Tray 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

z

Drain engine coolant. See COOLING SYSTEM, DRAINING AND FILLING  

z

Remove line between charge air cooler and turbocharger.  

z

Pull radiator hoses off engine using VAG 1921 hose clip pliers.  

z

Remove lower coolant hose from radiator.  

z

Remove auxiliary filter, if available, on right side of vehicle.  

z

Loosely unscrew pendulum support (arrows). 

Fig. 6: Removing Pendulum Support Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pull vacuum and breather hoses off engine.  

z

Disconnect all wiring from the transmission, Generator and starter and move them to one side for 
clearance.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove front exhaust pipe. See FRONT EXHAUST PIPE AND CATALYST WITH 
ATTACHMENTS
  

z

Remove ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

z

Remove power steering pump with bracket and lay to one side.  

z

Hoses remain connected:  

See POWER STEERING PUMP, RESERVOIR, HYDRAULIC LINES . 

z

Remove right hand inner Constant Velocity joint protective cover from engine if installed.  

z

Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission:  

See FRONT AXLE SHAFT . 

z

Unscrew mounting bolts for power steering pressure line.  

Vehicles with A/C: 

z

Observe additional information and removal instructions. See VEHICLES WITH A/C, ADDITIONAL 
INFORMATION AND REMOVAL INSTRUCTIONS
 .  

z

Remove starter.  

See appropriate STARTERS article. 

All vehicles: 

z

Insert engine bracket 3396 into VAG 1383 A engine / transmission jack.  

z

Remove coolant hose bracket and lower from cylinder block.  

z

Thread hole is used to fasten T 10012 engine bracket  

z

Thread on T 10012 engine bracket using M10x 25 5/ 8.8 nut and bolt. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 7: Threading On T 10012 Engine Bracket
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

z

Attach to engine block with 25 Nm (18 ft lb)  

z

Slightly lift engine/transmission assembly using VAG 1383 A jack.  

z

Loosely unscrew engine mount (engine side) from top of engine bracket (arrows). 

Fig. 8: Removing Engine Mount Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Loosely unscrew engine mount/transmission mount from transmission bracket (arrows) from top. 

Fig. 9: Removing Engine Mount/Transmission Mount Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully lower engine/transmission assembly. 

NOTE:

Use VAS 5085 tool to remove the mounting bolts.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1007  1008  1009  1010   ..