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