Volkswagen New Beetle. Manual - part 1013

 

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Volkswagen New Beetle. Manual - part 1013

 

 

25. Crankshaft toothed belt sprocket  

26. Bushing  

27. Diesel injection pump 

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Removing and installing  

See DIESEL INJECTION PUMP, SERVICING . 

28. Assembly bracket 

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for Diesel injection pump, Generator and power steering pump.  

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for vehicles with A/C  

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Removing and installing  

See 1.9L4-CYLINDER TDI ENGINE . 

29. 45 N.m (33 ft lb)  

Fig. 22: Identifying Front Engine Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Ribbed belt tensioner, removing and installing 

Work sequence 

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Remove right-hand insulation tray: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

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Remove pipe between charge air cooler and turbocharger. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
 .  

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Mark engine direction of rotation on ribbed belt.  

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Swing tensioning roller in direction of arrow using 15 mm open end wrench on tensioning lever. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 23: Removing Or Installing Ribbed Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove or install ribbed belt. 

Ribbed belt, routing 

Belt drive without A/C compressor 

1. Vibration damper/pulley  

2. Tensioner  

3. Pulley - Generator  

4. Ribbed belt  

5. Pulley - Power steering pump  

NOTE:

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Vehicles without A/C: first remove V-belt from Generator and position 
it last when installing.  

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Vehicles with A/C: first remove V-belt from pulley and position it last 
when installing.  

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When installing V-belt; make sure belt sits correctly in pulley.  

NOTE:

The following list refers to items in Fig. 24 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 24: View Of Belt And Pulleys 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Belt drive with A/C compressor 

1. Vibration damper/pulley  

2. Tensioner  

3. Pulley - Generator  

4. Pulley - Power steering pump  

5. Tensioner  

6. Ribbed belt  

7. Pulley - A/C  

Fig. 25: Identifying Belt Drive With A/C Compressor 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

The following list refers to items in Fig. 25 .

 

2003 Volkswagen New Beetle GLS 

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

  

Toothed belts, removing, installing, tensioning 

Special tools and equipment 

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2068 A Adj. gauge TDC tool  

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3359 Rig pin  

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3418 Adjustment guide  

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10-222A Engine support bridge with 10-222A/1 bracket for engine  

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V159 nut wrench  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb) 

Fig. 26: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Support tool 10-222 A/21, modifications 

NOTE:

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Use tool 10-222A to support the engine / transmission assembly.  

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Drill a new hole in the 10-222 A/21 guide to fasten 10-222 A/8 adaptor to. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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