Volkswagen New Beetle. Manual - part 1085

 

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Volkswagen New Beetle. Manual - part 1085

 

 

Fig. 16: Installing Intermediate Plate Onto Sealing Flange And Sliding Onto Dowel Sleeves 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with manual transmission 

z

Check centering of clutch drive plate, if necessary.  

z

Check clutch release bearing for wear, replace if necessary.  

z

Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 
100.  

Vehicles with manual transmission 02J 

z

Install hydraulic clutch slave cylinder: 

See CLUTCH SLAVE CYLINDER 

z

Install selector mechanism. 

See SELECTOR MECHANISM ON TRANSMISSION SIDE, UP TO 05.99, DISASSEMBLING 
AND ASSEMBLING
 or SELECTOR MECHANISM ON TRANSMISSION SIDE, AS OF 06.99, 
DISASSEMBLING AND ASSEMBLING
 

z

If necessary, adjust shifter cables: 

See SELECTOR MECHANISM 

Vehicles with manual transmission 02M 

z

Install hydraulic clutch slave cylinder: 

See CLUTCH RELEASE BEARING/SLAVE CYLINDER

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

z

Install selector mechanism. 

See SELECTOR LEVER LOCK SOLENOID 

z

If necessary, adjust shifter cables: 

See SELECTOR MECHANISM 

Vehicles with automatic transmission 

z

Only use nuts approved in parts program to secure torque converter to drive plate.  

z

Install selector cable on transmission, adjust if necessary: 

See SELECTOR LEVER CABLE 

z

Adapt control module for automatic transmission: 

See BASIC SETTING, INITIATING 

Continued for all vehicles 

z

When installing assembly, ensure sufficient clearance to drive shafts.  

Vehicles with air conditioner 

z

Install generator. 

See GENERATOR 

z

Install compact bracket including tightening element for ribbed V-belt. See COMPACT BRACKET , 
item 22. 

PART I 

z

Install A/C compressor.  

Continued for all vehicles 

z

Align engine and transmission mounts. See ENGINE AND TRANSMISSION MOUNTS, 
ALIGNING
 .  

z

Install drive shafts: 

See FRONT AXLE SHAFT 

z

Install right hand inner constant velocity joint protective cover from engine.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

z

Install front exhaust pipe. See EXHAUST SYSTEM COMPONENTS, REMOVING AND 
INSTALLING
 .  

z

Install intake hose (between charge air cooler and Throttle Valve Control Module) onto Throttle Valve 
Control Module -J338- and secure.  

z

Install power steering pump: 

See POWER STEERING PUMP IN LOWER SECTION, ASSEMBLY OVERVIEW or POWER 
STEERING PUMP IN UPPER SECTION, ASSEMBLY OVERVIEW
 

z

Check electrical connections and routing: 

See appropriate WIRING DIAGRAM article. 

z

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

z

Install center, left and right insulation trays: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

Fig. 17: Installing Center, Left And Right Insulation Trays 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install secondary air pump.  

z

Install connecting hoses between secondary air pump to combination valve and secondary air pump to air 
cleaner.  

z

Fill with coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

z

Perform work sequence "Procedure after correcting voltage supply open circuit". 

See PROCEDURE AFTER CORRECTING VOLTAGE SUPPLY OPEN CIRCUIT . 

z

Test drive vehicle. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Observe the valid safety precautions when carrying out a road test.

See SAFETY PRECAUTIONS . 

z

Check DTC memory and read readiness code: 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC . 

z

Generate readiness code again if DTC memory has been erased or engine control module separated from 
permanent positive. 

See READINESS CODE 

Tightening torques 

TIGHTENING TORQUES 

Engine and transmission mounts, aligning 

Engine mount 

a = 14.0 mm 

b = at least 10.0 mm 

Both bolt heads 1 must be in flush with edge -c-.

Bolted joint

Tightening torque

Bolts, nuts

M6

10 N.m

M7

15 N.m

M8

25 N.m

M10

40 N.m

M12

60 N.m

Exceptions:

 

Engine to transmission connecting bolts

M10

45 N.m

Engine to transmission connecting bolts

M12

80 N.m

Torque converter to drive plate

60 N.m

Drive shaft to joint flange/transmission

40 N.m

NOTE:

Assembly mounting tightening torques. See ENGINE/TRANSMISSION 
MOUNTS .

WARNING:

Before loosening the bolts the assemblies must be secured with the 
special tool 10-222A.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

 

 

 

 

 

 

 

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