Volkswagen New Beetle. Manual - part 1087

 

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Volkswagen New Beetle. Manual - part 1087

 

 

PART I 

1. 25 N.m  

2. Tensioning device for ribbed belt 

z

Turn with open-end spanner to loosen ribbed belt. See RIBBED BELT TENSIONER, 
REMOVING AND INSTALLING
  

3. Toothed belt guard - upper part  

4. Toothed belt guard - center section  

5. 27 N.m  

6. Idler wheel  

7. Tensioning roller  

8. Toothed belt 

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Mark direction of travel before removing  

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Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING
  

9. Coolant pump 

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Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING  

10. O-Ring 

z

Always replace if damaged  

Fig. 24: Disassembling And Assembling Engine 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

II. See PART II  

NOTE:

The following list refers to items in Fig. 25 .

 

2003 Volkswagen New Beetle GLS 

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

  

11. 15 N.m  

12. Tensioner for toothed belt  

13. Crankshaft toothed belt sprocket  

14. 15 N.m  

15. 20 N.m  

16. 90 N.m + 1/4 turn (90°) further 

z

Always replace  

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Counter-hold with 3099 to loosen and tighten  

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When bolting on, place two washers between toothed belt pulley and counter-hold  

17. Toothed belt guard - lower part  

18. 10 N.m 

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Insert with locking fluid D 000 600 A2  

19. Pulley 

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For power assisted steering pump  

20. 25 N.m  

21. Ribbed belt 

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Mark direction of rotation before removing  

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Removing and installing. See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING
  

22. 25 N.m  

23. Belt pulley/vibration damper 

z

Can only be installed in one position (holes are offset)  

z

Note position when installing toothed belt TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING
  

Fig. 25: Exploded View Of Engine (Front Engine Components - Part I 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

PART II 

Fig. 26: Exploded View Of Engine (Cylinder Block Components) - Part II 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Knock sensor 1 -G61- 

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Checking: 

See DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE, CHECKING AND 
ERASING
 

2. 20 N.m 

z

Tightening torque influences function of knock sensor  

3. Knock sensor 2 -G66- 

z

Checking: 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) 

4. Dipstick 

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Oil level must not be above the max. mark!  

5. Guide 

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For dipstick  

6. O-Ring 

z

Always replace  

7. Coolant pipe  

8. 20 N.m  

9. Oil filter bracket 

NOTE:

The following list refers to items in Fig. 26 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Disassembling and assembling. See PART II  

10. 15 N.m + 1/4 turn (90°) further 

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Always replace  

11. Oil cooler 

z

Coat contact area to flange, outside the seal, with AMV188 100 02  

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Ensure clearance to adjacent components  

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Note. See ENGINE, DISASSEMBLING AND ASSEMBLING  

12. 25 N.m  

13. Oil filter 

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Loosen with strap wrench  

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Tighten by hand  

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Note instructions on filter when installing  

14. Gasket 

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Always replace  

15. 10 N.m  

16. Engine speed sender 

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Checking: 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) 

17. Connection  

18. 15 N.m  

19. O-Ring 

z

Always replace  

20. Coolant thermostat 

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Checking: heat-up thermostat in water  

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Opening commences approx. 86°C  

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Opening lift min. 7 mm  

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Removing and installing. See THERMOSTAT, REMOVING AND INSTALLING  

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Observe installation position. See THERMOSTAT, REMOVING AND INSTALLING  

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Checking: heat-up thermostat in water  

21. 45 N.m  

22. Compact bracket 

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For ribbed belt tensioning roller, alternator, power steering pump and air conditioning compressor  

23. Right engine bracket  

Ribbed belt tensioner, removing and installing 

Special Tools And Equipment 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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