Volkswagen New Beetle. Manual - part 1065

 

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Volkswagen New Beetle. Manual - part 1065

 

 

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T10020 Two hole pin wrench 

Fig. 81: Identifying T10020 Two Hole Pin Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installed position 

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Angled retainer (arrow) must locate in cutout on cylinder head. 

Fig. 82: Locating Semi-Automatic Toothed Belt Tensioning Roller Angled Retainer 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Engine must only be hand touch warm.  

Work sequence 

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Set engine to TDC No. 1 cylinder.  

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Press hard with thumb on toothed belt. Indicator -2- must move. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 83: Tensioning Toothed Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Release thumb pressure on toothed belt and 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 performed without stopping. 

Tensioning roller must return to its original position (notch -1- and indicator -2- are again aligned). 

Cylinder head, removing and installing 

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

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V.A.G 1306 Drip tray  

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V.A.G 1332 Torque wrench (40...200 N.m)  

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VAS 5024 Assembly tool for spring-type clips  

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3450/2A Guide pins  

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3450/3 Removal tool  

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3452 Key 

Fig. 84: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Use a mirror when checking.

 

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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T10112 Installation tool  

Fig. 85: Identifying T10112 Installation Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Engine must only be hand touch warm.  

Work sequence 

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With ignition switched off disconnect battery Ground strap.  

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Remove engine cover.  

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Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

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Observe rules for cleanliness. See RULES FOR CLEANLINESS . 

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

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Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

NOTE:

During the further course of work the battery Ground strap must be 
disconnected. Therefore, please check whether a coded radio is installed. 
Obtain the radio code first if necessary.

WARNING:

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Fire Hazard! Do NOT have anything in the area that can ignite 
fuel!  

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Fuel system is under pressure! Before opening the system 

 

2003 Volkswagen New Beetle GLS 

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

  

Engine codes AEG, AVH, AZG 

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Pull fuel supply line -3-, fuel return line -2- and vacuum line -1- off at connecting point. 

Fig. 86: Removing Fuel Supply Line, Fuel Return Line And Vacuum Line (Engine codes AEG, 
AVH, AZG)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Disconnect hose from EVAP canister purge regulator valve -N80-.  

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Disconnect fuel supply line -1- and fuel return line -2- from fuel rail and collect fuel that leaks out with a 
clean cloth. 

Fig. 87: Disconnecting Fuel Supply Line And Fuel Return Line From Fuel Rail (Engine Codes 
AEG, AVH, AZG)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine code BDC 

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Disconnect fuel supply line -1- and fuel return line -2- at connection point on fuel rail. 

place a cloth around the connection. Then release pressure by 
carefully loosening the connection.  

 

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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