Volkswagen New Beetle. Manual - part 1048

 

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Volkswagen New Beetle. Manual - part 1048

 

 

z

Remove ribbed belt.  

Installing 

z

Install in reverse order. 

After completing repairs always: 

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Start engine and check belt running. 

Belt drive without air conditioning compressor

NOTE:

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Ensure, before installing ribbed belt, that all ancillaries (Generator, 
air conditioning compressor, power steering pump) are secured 
tightly.  

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When installing the ribbed belt observe belt direction of rotation and 
that the belt is seated correctly in the belt pulleys.  

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On models which do not have an air conditioning system place the 
ribbed belt over the Generator pulley last.  

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For models with an air conditioning system place the ribbed belt over 
the air conditioning compressor last.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 27: Identifying Belt Drive Without Air Conditioning Compressor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Belt drive with air conditioning compressor

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 28: Identifying Belt Drive With Air Conditioning Compressor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

SEALING FLANGES AND FLYWHEEL/DRIVE PLATE, REMOVING AND INSTALLING 

Engine codes AEG, AVH, AZG, BEV 

1. 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 counterhold tool 3415 to loosen and tighten  

2. Crankshaft toothed belt sprocket  

NOTE:

The following list refers to items in Fig. 29 .

 

2003 Volkswagen New Beetle GLS 

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

  

3. 15 N.m  

4. Seal 

PTFE sealing rings: 

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Do not additionally oil or grease oil seal sealing lip 

Coil spring seals: 

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Oil or grease lightly oil seal sealing lip 

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Replace. See CRANKSHAFT OIL SEAL - PULLEY END, REPLACING .  

5. Sealing flange 

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Remove oil sump to remove and install  

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Must be located on dowel sleeves  

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Insert with silicone sealant D 176 404 A2. See FRONT SEALING FLANGE, REMOVING 
AND INSTALLING
 .  

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Removing and installing. See FRONT SEALING FLANGE, REMOVING AND 
INSTALLING
 .  

6. Cylinder block 

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Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING .  

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Disassembling and assembling piston and connecting rod. See PISTON AND CONNECTING 
ROD, DISASSEMBLING AND ASSEMBLING
 .  

7. 60 N.m + 1/4 turn (90°) further 

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Replace  

8. Flywheel/drive plate 

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To remove and install flywheel counter-hold with 3067  

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Removing and installing drive plate. See DRIVE PLATE, REMOVING AND INSTALLING .  

9. Intermediate plate 

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Must be located on dowel sleeves. See Fig. 32 .  

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Do not damage/bend when assembling  

10. Sealing flange with oil seal 

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Only replace complete  

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Use protective sleeve supplied when installing  

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Remove oil sump to remove and install  

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Before installing, remove oil remains from crankshaft journal with a clean cloth.  

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Remove protective sleeve first after sealing flange has been slid onto crankshaft journal 

NOTE:

Differences between PTFE sealing ring and coil spring seals. See Fig. 
31 .

 

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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