Volkswagen New Beetle. Manual - part 1017

 

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Volkswagen New Beetle. Manual - part 1017

 

 

Fig. 39: Tightening Toothed Belt Nut 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Notch and raised portion (arrows) must move apart.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Release thumb pressure on toothed belt. 

Tensioning roller must move back to its initial position, notch and raised portion must align again. 

SEALING FLANGE AND FLYWHEEL/DRIVE PLATE, REMOVING AND INSTALLING 

1. 15 N.m (11 ft lb)  

2. Oil seal 

z

Replacing. See SEALING RING (CRANKSHAFT PULLEY SIDE), REPLACING  

3. Sealing flange, front 

z

Must be located on dowel sleeves  

z

Removing and installing. See SEALING FLANGE (FRONT), REMOVING AND 
INSTALLING
  

4. Engine block 

z

Crankshaft, removing and installing. See CRANKSHAFT, REMOVING AND INSTALLING  

z

Pistons and connecting rods, disassembling and assembling. See PISTONS AND CONNECTING 
RODS, DISASSEMBLING AND ASSEMBLING
  

5. Flywheel/drive plate 

z

to remove and install flywheel, counter-hold using 3067  

z

Drive plate, removing and installing: See DRIVE PLATE, REMOVING AND INSTALLING  

6. 60 N.m (44 ft lb) plus additional 1/4 turn (90°) further 

z

Always replace  

7. Intermediate plate 

z

Must be located on dowel sleeves  

z

Do not damage/bend when assembling  

8. Sealing flange with oil seal 

z

Only replace as an assembly  

z

Lightly oil sealing lip on oil seal 

NOTE:

For clutch repairs: See CLUTCH ASSEMBLY

NOTE:

The following list refers to items in Fig. 40 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 40: Identifying Sealing Flange And Flywheel/Drive Plate 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Sealing ring (crankshaft pulley side), replacing 

Special tools and equipment 

z

2080 A sleeve  

z

3415 Counter support  

z

3203 Seal remover  

z

3265 Sleeve installer  

 

2003 Volkswagen New Beetle GLS 

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

  

z

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

z

VAG 1332 Torque wrench: 40 to 200 N.m (30 to 148 ft lb) 

Fig. 41: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

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

z

Remove toothed belt. See TOOTHED BELTS, REMOVING, INSTALLING, TENSIONING .  

z

Remove crankshaft toothed belt sprocket by counter-holding sprocket using 3415. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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