Volkswagen New Beetle. Manual - part 1041

 

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Volkswagen New Beetle. Manual - part 1041

 

 

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Move engine/transmission assembly to a work bench with jack V.A.G 1383 A. 

Fig. 12: Moving Engine/Transmission Assembly To Work Bench With Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lower engine/transmission assembly so that transmission is on work bench.  

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Remove engine/transmission connecting bolts.  

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Press off transmission.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Continuation for all models 

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Attach lifting tackle 2024 A as follows and lift off engine/transmission jack V.A.G 1383 A with 
workshop crane. 

Fig. 13: Attaching Lifting Tackle To Engine Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pulley end: 3rd hole of lifting rail in position 2 

Flywheel end: 3rd hole of lifting rail in position 8 

CAUTION: Hooks and locating pins must be secured with locking pins.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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Secure engine to support clamp VW 313 using engine and transmission bracket VW 540 and 
supplementary set VW 540/1B. Dowel sleeves must be removed.  

Engine installation notes 

Installation is performed in the reverse sequence, Note the following. 

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Insert new dowel sleeves in cylinder block for centralizing engine and transmission.  

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Fit intermediate plate onto sealing flange and slide onto dowel sleeves (arrows). 

NOTE:

Positions marked 1...4 on the bar must face toward belt pulley end. The 
holes in the hook rails are counted up from the hook.

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

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Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 14: Fitting Intermediate Plate Onto Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with manual transmission 

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Lightly grease input shaft splines with G 000 100 grease.  

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Check clutch and clutch operating mechanism, then install. 

See CLUTCH ASSEMBLY . 

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Install gear shift mechanism, adjust gear shift cables if necessary: 

See SELECTOR MECHANISM 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

 

 

 

 

 

 

 

Content   ..  1039  1040  1041  1042   ..