Volkswagen New Beetle. Manual - part 1042

 

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Volkswagen New Beetle. Manual - part 1042

 

 

Vehicles with automatic transmission 

z

Install selector cable on transmission, adjust if necessary: 

For 01M transmission, see SELECTOR LEVER CABLE . 

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Install selector cable on transmission, adjust if necessary: 

For 09G transmission, see SELECTOR LEVER CABLE . 

Vehicles with air conditioning 

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Install air conditioning compressor: 

See CONDENSER, REMOVING AND INSTALLING . 

Continuation for all models 

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When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission 
mountings and radiator.  

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When doing this guide power steering pressure line past transmission.  

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Align assembly mountings for engine and transmission. See ENGINE AND TRANSMISSION 
MOUNTINGS, ALIGNING
 . 

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Install right side axle shaft and attach left side axle shaft to transmission. 

See FRONT AXLE SHAFT . 

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Install front exhaust pipe. See EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND 
CATALYTIC CONVERTER WITH ATTACHMENTS
 , Removing and installing parts of exhaust 
system.  

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Install power steering pump: 

See POWER STEERING PUMP, RESERVOIR, HYDRAULIC LINES 

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Reconnect electrical connections and check routing.  

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

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Install secondary air injection pump.  

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Install center, left and right insulation trays: 

NOTE:

Always replace selector cable circlip

NOTE:

Torque settings. See ASSEMBLY MOUNTING .

 

2003 Volkswagen New Beetle GLS 

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

  

See NOISE INSULATION, ASSEMBLY OVERVIEW

z

Fill system with coolant. See COOLING SYSTEM, DRAINING AND FILLING  

Vehicles without EPC 

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Adjust accelerator cable. See ACCELERATOR CABLE, ADJUSTING , servicing accelerator 
mechanism.  

Vehicles with EPC 

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Adapt (match) engine control module to throttle valve control. SeeCOMPONENTS AND 
FUNCTIONS, ADAPTING
 , Adapt components and functions  

Continuation for all models 

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If fault memory has been erased or engine control module was disconnected from permanent positive, 
respective components must be adapted to engine control module. See ENGINE CONTROL MODULE 
FAULT MEMORY, INTERROGATING AND ERASING
 , and readiness code generated again.  

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Road test vehicle and interrogate all fault memories: 

Observe the valid safety precautions when performing a road test. See SAFETY PRECAUTIONS . 

z

Read readiness code.  

Vehicles with automatic transmission 

z

Adapt transmission control module: 

For 01M, see BASIC SETTING, INITIATING 

For 09G, see BASIC SETTING, INITIATING 

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Test drive vehicle and interrogate fault memory.  

Engine and transmission mountings, aligning 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

10-222 A Support assembly with legs 10-222 A/1 and Adapter 10-222 A/3 

Locating Engine Mounting 

CAUTION: The assembly must be supported with support bar 10-222A before 

loosening bolts.

 

2003 Volkswagen New Beetle GLS 

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

  

Engine mounting 

Fig. 15: Locating Engine Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

-a- = 14.0 mm 

-b- = at least 10.0 mm 

Both bolt heads 1 must be flush with edge -c- 

Transmission mounting 

Edges -a- and -b- must be parallel with one another 

Locating Transmission Mounting 

 

2003 Volkswagen New Beetle GLS 

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

  

 

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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