Volkswagen New Beetle. Manual - part 1064

 

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Volkswagen New Beetle. Manual - part 1064

 

 

z

Remove toothed belt guard center and lower parts.  

z

Mark direction of rotation of toothed belt.  

z

Release tensioner and take off toothed belt.  

z

Turn crankshaft back slightly.  

Installing 

Requirements 

z

Pistons must not be positioned at TDC.  

Work sequence 

z

Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation). 

Adjusting valve timing 

z

Bring mark on camshaft into line with mark on toothed belt guard. 

Engine installed: 

Fig. 76: Aligning Mark On Camshaft With Mark On Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft to TDC No. 1 cylinder (vehicles with manual transmission). 

NOTE:

When loosening the front engine mounting bolt the engine must be raised 
slightly with the support bracket.

NOTE:

z

Engine removed:  

Begin by installing lower section of toothed belt guard as well as belt 
pulley/vibration damper. 

NOTE:

When the camshaft is turned, the crankshaft must not be at TDC. Danger of 
damage to valves or piston crowns.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 77: Locating Mark For Positioning TDC No. 1 Cylinder (Vehicles With Manual Transmission)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

z

Turn crankshaft to TDC No. 1 cylinder (vehicles with automatic transmission). 

Fig. 78: Locating Mark For Positioning TDC No. 1 Cylinder (Vehicles With Automatic 
Transmission)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine removed: 

z

Position vibration damper at TDC No. 1 cylinder (arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 79: Positioning Vibration Damper At TDC No. 1 Cylinder 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Place toothed belt on tensioning roller and camshaft pulley.  

Tensioning toothed belt 

Requirements 

z

Engine must only be hand touch warm.  

z

Camshaft sprocket is at TDC No. 1 cylinder.  

z

Before tensioning toothed belt, turn tensioning roller on eccentric with pin wrench T10020 five times 
fully onto limit stops in both directions.  

Work sequence 

z

Tension toothed belt by turning eccentric to left (direction of arrow) with 2-hole pin wrench T10020 onto 
limit stop. 

Fig. 80: Tensioning Toothed (Timing) Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).  

z

Tighten securing nut to 20 N.m.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Turn crankshaft two turns in engine direction of rotation until engine is again at TDC No. 1 cylinder. Last 
45° (1/8 turn) must be completed without stopping.  

z

Check toothed belt tension again. 

Specification: Indicator and notch align 

Continuation, install complete toothed belt 

z

Install toothed belt guard center and lower parts.  

z

Install vibration damper/belt pulley. 

Tightening torque: 25 N.m 

z

Install engine mounting to cylinder block. 

Tightening torque: 45 N.m 

z

Install engine assembly mountings complete. 

z

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

Tightening torques. See ASSEMBLY MOUNTING . 

z

Remove engine support bracket 10-222 A.  

z

Install toothed belt guard, upper part.  

z

Install ribbed belt tensioning element. 

Tightening torque: 25 N.m 

z

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

z

Install coolant expansion tank.  

z

Install right side sound insulation tray: 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

z

Install engine cover.  

Semi-automatic toothed belt tensioning roller, checking 

Special tools, testers, measuring instruments and auxiliary items required

NOTE:

Insert bolts into engine bracket before installing engine bracket.

 

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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