Volkswagen New Beetle. Manual - part 1079

 

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Volkswagen New Beetle. Manual - part 1079

 

 

Fig. 151: Locating Marks For Setting Crankshaft To TDC No. 1 Cylinder 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Align mark on balancer shaft chain sprocket (arrow) with fixture hole. Lock chain sprocket in this 
position with pin T10060. Fit chain onto balancer shaft chain sprocket. 

Fig. 152: Aligning Mark On Balancer Shaft Chain Sprocket With Fixture Hole 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Position milled side of oil pump shaft so that it is facing forward.  

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Install oil pump chain sprocket and tighten bolt hand tight. 

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Remove locking pin T10060 and Allen key -1-. Secure oil pump chain sprocket. 

NOTE:

The oil pump chain sprocket only fits in one position. Only the oil pump 
may be turned when installing.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 153: Removing Locking Pin And Allen Key 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Tightening torque: 20 N.m. Counter support on central bolt of vibration damper. 

The rest of the assembly is basically in reverse order to the disassembly sequence. 

Oil sump, removing and installing 

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

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3185 Jointed wrench  

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T10058 Socket  

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V.A.G1331 Torque wrench (5...50 N.m)  

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Hand drill with plastic brush attachment  

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Silicone sealing compound D 176 404 A2 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 154: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove center and right insulation trays: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

Engines with oil sump protection 

1. Rubber grommet 

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located in cylinder block  

2. Bolt, 37 N.m  

3. Spreader rivet  

4. Oil sump protection 

{

To remove spreader rivet -3- push upward. See Fig. 138  

{

Have a second technician push oil sump protection -4- against oil sump. 

Fig. 155: Removing Oil Sump Protection 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

{

Loosen bolts -2-.  

{

Carefully remove oil sump protection -4-  

Continuation for all models 

NOTE:

For engine code BEV, the oil sump is composed of two parts (upper and lower). 
The oil sump can be dismounted complete from its union to the engine block. If 
it is necessary, the upper part may be separated from the lower part. See Part I 
(Engine code BEV) .

 

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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Drain engine oil. 

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Use jointed wrench 3185 when loosening and tightening sump bolts. Only loosen and tighten bolts on 
flywheel end using socket T10058  

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Remove sump cover and remove sump. It may be necessary to release sump by applying light blows with 
a rubber headed hammer.  

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Remove sealant residue from cylinder block with a flat scraper.  

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Remove sealant residue from oil sump with a rotating brush, e.g. a hand drill with a plastic brush 
attachment (wear eye protection). 

Fig. 156: Removing Sealant Residue From Oil Sump With A Rotating Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Clean sealing surfaces. Surfaces must be free of oil and grease.  

Installing 

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Cut off tube nozzle at front marking (nozzle approx. 3 mm diameter). 

NOTE:

Observe waste disposal regulations!

NOTE:

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Note the use-by date of the sealant.  

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The sump must be installed within 5 minutes of applying silicone sealing 
compound.  

 

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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