Volkswagen New Beetle. Manual - part 1086

 

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Volkswagen New Beetle. Manual - part 1086

 

 

Fig. 18: Aligning Engine Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Transmission mount 

Edges -a- and -b- must be parallel with one another. 

Fig. 19: Aligning Transmission Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine/transmission mounts 

Tightening torques 

Engine mount 

1. Mount to body: 40 N.m + 90° (1/4 turn) 

NOTE:

Replace bolts

 

2003 Volkswagen New Beetle GLS 

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

  

2. Mount/bracket to body: 25 N.m  

3. Mount to engine bracket 100 N.m 

Fig. 20: Engine Mount Tightening Torques 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Transmission assembly mount 

1. Mount to body: 40 N.m + 90° (1/4 turn) 

2. Mount to body: 25 N.m  

3. Mount to transmission console 100 N.m 

Fig. 21: Transmission Assembly Mount Tightening Torques 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Replace bolts

 

2003 Volkswagen New Beetle GLS 

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

  

Pendulum support 

1. Pendulum support to transmission: 40 N.m + 90° (1/4 turn) 

2. Pendulum support to transmission: 40 N.m + 90° (1/4 turn) 

3. Pendulum support to subframe: 20 N.m + 90° (1/4 turn) 

Fig. 22: Pendulum Support Tightening Torques 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Additional information and removal instructions for vehicles with air conditioner 

To facilitate removing and installing the engine without opening the refrigerant circuit: 

z

Remove retaining clamp(s) from refrigerant pipes. 

NOTE:

Replace bolts

NOTE:

Replace bolts

NOTE:

Replace bolts

WARNING:

The air conditioner refrigerant circuit must not be opened.

NOTE:

z

The refrigerant circuit can only be opened in workshops having specially 
trained personnel and the necessary tools and workshop equipment.  

z

To prevent damage to condenser and also to the refrigerant lines/hoses, 
ensure that the lines and hoses are not stretched, kinked or bent.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

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

z

Remove air conditioner compressor, leaving refrigerant hoses connnected. 

See COMPRESSOR . 

z

Secure air conditioner compressor to towing eye so that refrigerant hoses/lines are not under tension. 

Fig. 23: Securing Air Conditioner Compressor To Towing Eye 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ENGINE - CRANKSHAFT, CYLINDER BLOCK 

ENGINE, DISASSEMBLING AND ASSEMBLING 

NOTE:

To prevent damage to bumper protect with adhesive tape.

NOTE:

z

When stripping and assembling the engine it should be secured to the engine fram
with engine and transmission bracket VW540 and supplementary set VW 540/1B. 

z

If large amounts of material (as metallic particles and abrasive fragments) remove
by a cutting or grinding tool or wear are discovered during engine repair work, thi
can be from damage to the crankshaft or connecting rod bearings due to partial 
seizure or oil loss. To prevent any further damage from occurring, carry out the 
following once the repair procedure is complete: 

{

Thoroughly clean oil channels  

{

Replace oil spray jets  

{

Replace oil cooler  

{

Replace oil filter 

I. See PART I 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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