Volkswagen New Beetle. Manual - part 1016

 

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Volkswagen New Beetle. Manual - part 1016

 

 

Fig. 36: Installing Drift Through Hole In Rear Of Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install toothed belts (note engine direction of rotation) on crankshaft toothed belt sprocket, intermediate 
wheel, injection pump sprocket and tensioning roller.  

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Install camshaft sprocket together with toothed belt and position using mounting bolt. 

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Camshaft sprocket should still turn  

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Tension toothed belt; using pin wrench on eccentric, turn clockwise until notch and raised mark align 
(arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 37: Tightening Lock Nut On Tensioning Roller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten lock nut on tensioning roller. 

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Tightening torque: 20 N.m (15 ft lb)  

NOTE:

Observe correct installation of tension roller in rear toothed belt guard 
(arrow).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 38: Identifying Correct Installation Of Tension Roller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check TDC mark on flywheel again.  

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Tighten camshaft sprocket mounting bolt. 

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45 N.m (33 ft lb)  

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Tighten the new mounting bolts of injection pump sprocket 

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Tightening torque: 20 N.m (15 ft lb)  

NOTE:

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After dynamically checking the "start of injection", the mounting 
bolts must be retightened 90° (1/4 turn). 

See DIESEL INJECTION PUMP, REMOVING AND INSTALLIN 

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove 2065A setting bar from camshaft.  

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Remove pin.  

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Turn crankshaft two rotations in engine direction of rotation and set again to cylinder 1 TDC.  

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Attach bracket to engine block.  

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Install engine mount (replace mounting bolts). 

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

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Securely install mount for engine to engine bracket (replace mounting bolts) 

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Tightening torque: 60 N.m (44 ft lb) plus additional 90° (1/4 turn)  

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Install bracket for subassembly/body 

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Tightening torque: 25 N.m (18 ft lb)  

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Install vacuum pump.  

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Install toothed belt guard, vibration damper, belt pulley, and valve cover.  

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

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Install sound dampening tray and engine cover  

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

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Install fuel filter with bracket  

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Disconnect fuel supply and return lines at fuel filter.  

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

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Check Diesel injection pump "start of delivery" 

See START OF INJECTION, DYNAMICALLY CHECKING AND ADJUSTING 

Semi-automatic toothed belt tensioning roller, checking 

Test sequence 

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Tighten toothed belt with firm thumb pressure. 

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The mounting bolts should only be used one time, since by design 
they have a reduced shank  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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