Volkswagen New Beetle. Manual - part 1011

 

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Volkswagen New Beetle. Manual - part 1011

 

 

Fig. 14: Installing Sound Dampening Tray 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

z

Fill with engine coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

Tightening torques 

TIGHTENING TORQUE CHART - ENGINE REMOVAL & INSTALLATION 

Engine and transmission assembly, mountings 

Tightening torques 

Bolted joint

Metric Size

Tightening torque

Bolts, nuts

M 6

10 Nm

7 ft lb

M 8

25 Nm

18 ft lb

M10

40 Nm

30 ft lb

M 12

60 Nm

44 ft lb

Variations on the above:
Engine to transmission M12 connecting bolts

80 Nm

59 ft lb

Torque converter to drive plate

60 Nm

44 ft lb

Drive shaft to flange / transmission

40 Nm

30 ft lb

Front exhaust pipe to turbocharger

25 Nm

18 ft lb

 

2003 Volkswagen New Beetle GLS 

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

  

FRONT ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE CHART 

Fig. 15: Identifying Front Engine/Transmission Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

RIGHT REAR ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE CHART 

NOTE:

The FRONT ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE CHART 
table refers to items in Fig. 15 .

Application

Specfication

1 - Mount to body 

(1)

40 Nm (30 ft lb) + 90° (1/4 turn.)

2 - Mount/bracket to body

25 Nm (18 ft lb)

3 - Mount to engine bracket 

(1)

60 Nm (44 ft lb) + 90° (1/4 turn.)

(1)

Replace bolts

NOTE:

The RIGHT REAR ENGINE/TRANSMISSION MOUNT TIGHTENING TORQUE 
CHART table refers to items in Fig. 16 .

Application

Specification

1 - Mount to body 

(1)

40 Nm (30 ft lb) + 90° (1/4 turn.)

2 - Mount to body

25 Nm (18 ft lb)

3 - Mount to transmisison console 

(1)

60 Nm (44 ft lb) + 90° (1/4 turn.)

(1)

Replace bolts

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 16: Identifying Right Rear Engine/Transmission Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PENDULUM SUPPORT TIGHTENING TORQUE CHART 

Fig. 17: Identifying Pendulum Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with A/C, additional information and removal instructions 

NOTE:

The PENDULUM SUPPORT TIGHTENING TORQUE CHART table refers to items 
in Fig. 17 .

Application

Specification

1 - Pendulum support to transmission 

(1)

40 Nm (30 ft lb) + 90° (1/4 turn.)

2 - Pendulum support to transmission 

(1)

40 Nm (30 ft lb)+ 90° (1/4 turn.)

3 - Pendulum support to engine 

(1)

20 Nm (15 ft lb) + 90° (1/4 turn.)

(1)

Replace bolts

 

2003 Volkswagen New Beetle GLS 

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

  

To ease engine removal and installation without opening the A/C refrigerant circuit: 

z

Remove retaining clamp(s) from refrigerant lines.  

z

Remove A/C compressor:  

See A/C REFRIGERANT SYSTEM, SERVICING , item 13. 

z

Attach A/C compressor to vehicle body to provide stress relief for refrigerant lines/hoses. 

Fig. 18: Attaching A/C Compressor To Vehicle Body 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ENGINE - CRANKSHAFT, CYLINDER BLOCK 

ENGINE, DISASSEMBLING AND ASSEMBLING 

WARNING:

Do NOT open the A/C refrigerant circuit.

NOTE:

To prevent damage to the condenser and to the refrigerant lines/hoses, make 
sure that the lines and hoses are not stretched, kinked or bent.

NOTE:

z

If during repairs, metal shavings or quantities of small metal particles are 
found in the engine oil - caused, for example, by partial seizure of the 
crankshaft and conrod bearings - then, besides thoroughly cleaning out 
the oil passages, also replace the oil cooler.  

z

Faulty injectors can cause violent knocking noises in the engine which 
sound like faulty bearings. When this occurs, run engine at idle and 
slacken off the injector line unions one after the other. If the knocking 
stops when a specific union is loosened, this is an indication that the 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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