Volkswagen New Beetle. Manual - part 1012

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1010  1011  1012  1013   ..

 

 

Volkswagen New Beetle. Manual - part 1012

 

 

Fuel injectors, servicing 

See FUEL INJECTORS, SERVICING . 

I. See PART I  

II. See PART II  

Part I 

1. Ribbed belt 

z

Mark direction of engine rotation before removing  

z

Removing and installing: See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING
  

z

Vehicles with A/C with additional idler pulley, removing and installing: See Pulley, removing and 
installing
  

2. 10 N.m (7ft lb) plus additional 1/4 turn (90°)  

3. Belt pulley/vibration damper 

z

Can only be installed in one position; holes are offset  

4. 25 N.m (18 ft lb)  

5. Tensioning element 

z

For V-belt  

z

Turn with open-end wrench to loosen ribbed belt. See RIBBED BELT TENSIONER, 
REMOVING AND INSTALLING

respective injector is faulty. 

Fig. 19: Locating External Engine Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

The following list refers to items in Fig. 20 .

 

2003 Volkswagen New Beetle GLS 

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

  

6. Generator  

7. Assembly bracket 

z

for injection pump, Generator and power steering pump  

z

for vehicles with A/C  

z

Assembly bracket for vehicles with A/C, removing and installing:  

See 1.9L4-CYLINDER TDI ENGINE 

8. 45 N.m (33 ft lb)  

9. Banjo bolt 

z

30 N.m (22 ft lb)  

10. Seal 

z

Always replace  

11. Pressure accumulator  

12. Flange 

z

For power steering  

z

Removing and installing:  

See POWER STEERING PUMP IN LOWER SECTION, ASSEMBLY OVERVIEW or POWER 
STEERING PUMP IN UPPER SECTION, ASSEMBLY OVERVIEW
 

13. Pulley 

z

For Engine Coolant pump  

Fig. 20: Identifying Engine Components - Accessory Drive (Part 1) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pulley, removing and installing 

Only for vehicles with A/C 

 

2003 Volkswagen New Beetle GLS 

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

  

Removing 

z

Remove sound dampener tray 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

z

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

z

Pry off cover -1- using screwdriver.  

z

Remove mounting bolts -2- and remove pulley -3-.  

Fig. 21: Removing Ribbed Belt Pulley (Vehicles with A/C) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

Position pulley -3- and tighten mounting bolt 

z

Tightening torque 25 N.m (18 ft lb)  

z

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

z

Install sound dampener tray. 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

Part II 

1. 120 N.m (88 ft lb) plus additional 1/4 turn (90°) 

z

Always replace  

z

To loosen and tighten, counter-hold with 3099  

z

Threads and shoulder must be free of oil and grease  

z

The additional quarter turn can be obtained in several stages. 

NOTE:

The following list refers to items in Fig. 22 .

 

2003 Volkswagen New Beetle GLS 

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

  

2. 40 N.m (30 ft lb) plus additional 1/4 turn (90°) 

z

Always replace  

3. 15 N.m (11 ft lb)  

4. 22 N.m (16 ft lb)  

5. Toothed belt guard, lower section  

6. 10 N.m (7 ft lb)  

7. Toothed belt guard  

8. 45 N.m (33 ft lb)  

9. Right engine bracket  

10. Toothed belt guard, upper section  

11. Toothed belt 

z

Mark engine direction of rotation before removing  

z

Check for wear  

z

Do not kink  

z

Removing, installing and tensioning. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
 .  

12. Idler wheel  

13. 20 N.m (15 ft lb) plus additional 1/4 turn (90°) 

z

Always replace  

14. 20 N.m (15 ft lb)  

15. 20 N.m (15 ft lb)  

16. 45 N.m (33 ft lb)  

17. Camshaft sprocket 

z

Drive camshaft off of taper using hammer and drift through toothed belt guard openings  

z

to loosen and tighten bolt (item 16), counterhold using 3036  

18. Tensioning roller 

z

Semi-automatic toothed belt tensioning roller, checking. See SEMI-AUTOMATIC TOOTHED 
BELT TENSIONING ROLLER, CHECKING
 .  

19. Idler wheel  

20. Injection pump sprocket 

z

Two piece construction  

21. 30 N.m (22 ft lb)  

22. Toothed belt guard, rear  

23. Coolant pump 

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING .  

24. Idler wheel 

z

First remove, to remove coolant pump  

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1010  1011  1012  1013   ..