Volkswagen New Beetle. Manual - part 1020

 

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Volkswagen New Beetle. Manual - part 1020

 

 

Fig. 52: Removing Crankshaft Toothed Belt Sprocket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Drain engine oil.  

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Remove oil pan. See OIL PAN, REMOVING AND INSTALLING  

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Unbolt front sealing flange.  

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Remove sealing flange and if necessary, release using light blows with a rubber hammer.  

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Remove sealant residue on engine block with a flat scraper.  

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Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles). 

Fig. 53: Removing Sealant Remains On Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Clean sealing surface. 

Installing 

NOTE:

Surface must be free of oil and grease

 

2003 Volkswagen New Beetle GLS 

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

  

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Cut off tube nozzle at forward mark (nozzle approx. 3 mm diameter)  

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Apply silicone sealing compound, as shown, to a clean oil pan sealing surface. 

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Thickness of sealant bead must be (arrows): 2 to 3 mm 

Fig. 54: Applying Silicone Sealant Bead To Clean Sealing Surface 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Apply silicone sealant bead as shown to the clean sealing surface of the sealing flange.  

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Install sealing flange immediately, then lightly tighten all bolts. 

NOTE:

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Observe the "must be used by" date on the sealant tube.  

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Oil pan must be installed within 5 minutes after applying silicone sealing 
compound.  

CAUTION: The sealing compound bead thickness specification must NOT be 

thicker, otherwise excess sealing compound will enter the oil pan 
and could block the oil suction pipe strainer.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 55: Applying Silicone Sealant Bead To Clean Sealing Surface
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Tighten sealing flange mounting bolts using a staggered tightening pattern. 

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Tightening torque: 15 N.m (11 ft lb)  

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Install oil pan. See OIL PAN, REMOVING AND INSTALLING 

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Install toothed belt and adjust timing. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
  

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

CRANKSHAFT, REMOVING AND INSTALLING 

1. Bearing shells:1, 2, 4 and 5 

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For bearing caps without oil groove  

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For engine block with oil groove  

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Do NOT interchange used bearing shells (mark)  

2. 65 N.m (48 ft lb) plus additional 1/4 turn (90°) 

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Replace  

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Threaded along complete length of screw  

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To measure radial clearance tighten to 65 N.m (48 ft lb) but no further  

3. Bearing cap 

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Bearing cap 1: Pulley end  

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Bearing cap 3 with recesses for thrust washers  

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Bearing shell retaining lugs engine block/bearing cap must be on the same side  

4. Bearing shell 3 

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Bearing cap w/o oil groove  

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For engine block with oil groove  

5. Thrust washer 

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For bearing cap 3  

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Note fixing arrangement  

6. Sensor wheel 

NOTE:

Use guide sleeve from 2080A to install the sealing flange if the oil seal is 
already installed.

NOTE:

After installing; allow the sealant to dry for approx. 30 minutes before 
adding engine oil.

NOTE:

The following list refers to items in Fig. 56 .

 

2003 Volkswagen New Beetle GLS 

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

  

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For Engine Speed sensor  

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

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Always replace  

8. Fitted pin 

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Checking projection from crankshaft. See Crankshaft dowel pin projection, checking  

9. Crankshaft 

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Axial clearance new: 0.07 to 0.17 mm Wear limit: 0.37 mm  

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Check radial clearance with Plastigage New: 0.03 to 0.08 mm Wear limit: 0.17 mm  

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Do not rotate crankshaft when checking radial clearance  

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Crankshaft dimensions. See CRANKSHAFT DIMENSIONS (MM)  

10. Thrust washer  

11. For engine block, bearing 3  

Fig. 56: Exploded View Of Crankshaft & Main Bearing Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Crankshaft dowel pin projection, checking 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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