Volkswagen New Beetle. Manual - part 1045

 

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Volkswagen New Beetle. Manual - part 1045

 

 

Only engine codes BDC, BGD 

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The balancer shaft gear assembly must be adjusted. See OIL PUMP WITH BALANCER SHAFT 
GEAR ASSEMBLY, REMOVING AND INSTALLING 

crankshaft or conrod bearings. Perform the following work sequences to 
prevent consequential damage once repairs are complete: 

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Thoroughly clean oil passages  

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Replace oil spray jets  

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Replace oil cooler  

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Replace oil filter  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 21: Disassembling And Assembling Engine (Parts I & II) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

I. See PART I  

II. See PART II  

Part I 

1. 45 N.m  

2. Engine bracket  

3. 25 N.m  

4. Retainer 

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According to engine versions  

5. Retainer 

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According to engine versions  

6. Clamp  

7. 10 N.m 

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For engine cover  

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According to engine versions  

8. 20 N.m 

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According to engine versions  

9. Toothed belt guard-upper part  

10. Toothed belt guard, center section  

11. 20 N.m  

12. Washer  

13. Tensioner 

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Checking semiautomatic toothed belt tensioning roller. See SEMI-AUTOMATIC TOOTHED 
BELT TENSIONING ROLLER, CHECKING
 .  

14. Toothed belt 

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Mark direction of rotation before removing  

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Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELTS, REMOVING, INSTALLING 
AND TENSIONING
  

15. Rear toothed belt guard  

16. Washer  

17. O-ring 

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Replace  

18. Coolant pump 

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Check for ease of movement  

NOTE:

The following list refers to items in Fig. 22 .

 

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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If damaged or leaking renew complete  

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Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING .  

19. 15 N.m  

20. Crankshaft toothed belt sprocket  

21. 90 N.m + 1/4 turn (90°) further 

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Replace  

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Threads and shoulder must be free of oil and grease  

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Use counter support tool 3415 to loosen and tighten  

22. Toothed belt guard, lower part  

23. 10 N.m 

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Replace  

24. Clutch 

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For air conditioning compressor  

25. Belt pulley 

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For power steering pump  

26. Ribbed belt 

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Mark direction of rotation before removing  

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Check for wear  

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Do not kink  

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Removing and installing. See RIBBED BELT, REMOVING AND INSTALLING .  

27. Belt pulley/vibration damper 

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Can only be installed in one position. Holes are offset  

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Note position when installing toothed (timing) belt. See TOOTHED BELTS, REMOVING, 
INSTALLING AND TENSIONING
 .  

28. 25 N.m  

29. Tensioning element for ribbed belt 

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Turn with open end wrench to loosen ribbed belt. See RIBBED BELT, REMOVING AND 
INSTALLING
 .  

 

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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