Volkswagen New Beetle. Manual - part 1014

 

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Volkswagen New Beetle. Manual - part 1014

 

 

Toothed belts, removing 

z

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

z

Disconnect fuel supply and return lines at fuel filter.  

z

Remove fuel filter from bracket.  

z

Remove toothed belt guard - upper section.  

z

Remove valve cover. 

z

Remove brake booster vacuum pump.  

z

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

z

Remove insulation tray - right side 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

z

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

With engine installed: 

z

Turn crankshaft to cylinder 1 TDC. 

Fig. 27: Identifying New Hole On 10-222 A/21 Guide 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Dimensions given are in mm.  

z

One hole 12.5 mm diameter (arrow) drilled in the 10-222 A/21 guide  

NOTE:

The valve cover has an integrated, vulcanized gasket. If damaged or 
leaking replace the valve cover.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 28: Identifying Timing Mark (Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft to cylinder 1 TDC. 

Fig. 29: Identifying Timing Mark (Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

With engine removed: 

Vehicles with manual transmission 

z

Install adjustment device 2068 A as shown. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 30: Installing Adjustment Device On Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Set adjustment device to 96 mm (arrow -A-). Left-hand notch of vernier scale is reference point.  

z

Turn crankshaft until flywheel TDC marking aligns with point on setting device (arrow -B-).  

Vehicles with automatic transmission 

z

Install adjustment device 2068 A as shown. 

Fig. 31: Installing Adjustment Device On Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Set adjustment device to 96 mm (arrow -A-). Left-hand notch of vernier scale is reference point.  

z

Turn crankshaft until flywheel TDC marking aligns with point of setting device (arrow -B-).  

All vehicles 

z

Lock camshaft using setting bar. 

 

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

  

 

 

 

 

 

 

 

Content   ..  1012  1013  1014  1015   ..