Volkswagen New Beetle. Manual - part 1066

 

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Volkswagen New Beetle. Manual - part 1066

 

 

Fig. 88: Disconnecting Fuel Supply Line And Fuel Return Line (Engine Code BDC) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

Engine codes BEV, BGD 

z

Pull fuel supply line -1- off union by pressing locking ring -2- into union -3- and collect fuel that leaks 
out with a clean cloth. 

Fig. 89: Disconnecting Fuel Supply Line (Engine Codes BEV, BGD) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all models 

z

Seal lines to avoid contamination of fuel system.  

z

Remove air cleaner assembly complete with air intake tube and secondary air injection tube. See AIR 
CLEANER, DISASSEMBLING AND ASSEMBLING
  

z

Remove intake manifold upper part: See INTAKE MANIFOLD UPPER PART, 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

  

z

Release all coolant, vacuum and intake hoses from intake manifold/cylinder head as required.  

z

Pull off/disconnect all electrical wiring as necessary on cylinder head and place to side.  

z

Disconnect coolant hose at connecting unions.  

z

Remove intake and pressure lines for secondary air injection pump.  

z

Remove pressure line bracket.  

z

Unbolt and remove secondary air injection pump motor and bracket.  

z

Disconnect following connectors: 

z

-1- for Secondary Air Injection (AIR) pump motor -V101-, -2- 

Fig. 90: Disconnecting Secondary Air Injection (AIR) Pump Motor Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

For Camshaft Position (CMP) sensor -G40-  

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For Knock Sensor (KS) 1 -G61-  

z

For injectors -N30-, -N31-, -N32-, -N33- (release from cable guide).  

z

Engine Coolant Temperature (ECT) sensor -G62- (arrow).  

z

Remove harness for Knock Sensor 1 -G61- from clip on Generator bracket. 

NOTE:

Seal the intake ports in the intake manifold lower section with clean cloths.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 91: Disconnecting Engine Coolant Temperature (ECT) Sensor Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove clips securing fuel injector harness to fuel rail and place harness to side.  

z

Unclip wiring harness from left side of cylinder head.  

z

Remove ignition cables from spark plugs (use T10112).  

z

Unclip coolant recovery hose from bracket -1- on top of toothed belt tensioner.  

z

Remove bolt -2- securing oil dipstick tube to lower intake manifold. 

Fig. 92: Removing Coolant Recovery Hose Clip 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove cover from oxygen sensor connectors on vehicle underside. See IDENTIFYING PIN 
CONNECTOR OF HEATED OXYGEN SENSOR under ENGINE CODE BEV  

z

Disconnect Heated Oxygen Sensor (HO2S) -G39- connector and unclip harness from exhaust heat shield. 

z

Remove front exhaust pipe with catalytic converter.  

z

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

z

Remove tensioning element for ribbed belt. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove bracket (item - 4 -. See PART I ) on tensioning element for ribbed belt.  

z

Remove toothed belt guard, upper part.  

z

Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. 

Mark on camshaft sprocket must align with arrow on toothed belt guard 

Fig. 93: Aligning Mark On Camshaft Sprocket With Arrow On Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Release tensioning roller and take toothed belt off camshaft pulley.  

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Turn crankshaft back slightly.  

z

Remove cylinder head cover.  

z

Remove upper rear toothed belt guard bolt.  

z

Loosen socket head bolts in sequence given and then remove complete. 

Fig. 94: Loosening Sequence Of Cylinder Head Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully lift cylinder head off.  

NOTE:

Use tool 3452 for Polydrive cylinder head bolts.

 

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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