Volkswagen New Beetle. Manual - part 1090

 

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Volkswagen New Beetle. Manual - part 1090

 

 

Fig. 41: Screwing Tensioning Bolt T10092 Into Toothed Belt Tensioning Element 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Align pressure piston using pointed pliers or wire before tensioning (hole in pressure piston must align 
with hole in housing).  

z

Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.  

z

Remove toothed belt.  

z

Turn crankshaft back slightly.  

Installing 

A - Toothed belt completely removed 

If toothed belt has only been removed from camshaft. See B - TOOTHED BELT ONLY TAKEN OFF 
CAMSHAFT SPROCKET
 . 

Conditions 

z

The pistons must not be positioned at TDC  

Work sequence 

z

Bring mark on camshaft in line with the mark on cylinder head cover. 

NOTE:

When turning the camshaft the crankshaft must not be at TDC (danger of 
damage valves/piston crown).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 42: Aligning Mark On Camshaft With The Mark On Cylinder Head Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Place toothed belt on crankshaft sprocket (observe direction of rotation).  

z

Install engine mount to cylinder block. 

Tightening torque: 45 N.m 

z

Install lower part of toothed belt guard. Insert securing bolts with locking fluid "D 000 600 A2". 

Tightening torque: 10 N.m 

z

Secure vibration damper/belt pulley with one bolt (note fixing arrangement).  

z

Turn crankshaft to TDC No. 1 cylinder. 

Fig. 43: Turning Crankshaft To TDC No. 1 Cylinder

NOTE:

Before installing engine mount, insert bolts into mount.

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z

Install toothed belt onto coolant pump, tensioning roller and camshaft sprocket.  

z

Tighten toothed belt. See TENSIONING TOOTHED BELT .  

B - Toothed belt only taken off camshaft sprocket 

z

Bring mark on camshaft in line with the mark on cylinder head cover. 

Fig. 44: Aligning Mark On Camshaft With The Mark On Cylinder Head Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft to TDC No. 1 cylinder.  

z

Install toothed belt onto camshaft sprocket.  

z

Tighten toothed belt. See TENSIONING TOOTHED BELT  

Tensioning toothed belt 

z

Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 45: Tensioning Toothed Belt By Pulling Out Locking Pin T40011 And Removing Tensioning 
Bolt T10092
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their 
reference points.  

z

Install vibration damper/belt pulley 

Tightening torque: 25 N.m 

z

Install center part of toothed belt guard. (Insert securing bolts with locking fluid D 000 600 A2). 

Tightening torque: 10 N.m 

z

Install upper toothed belt guard.  

z

Install aggregate mount and engine mount. Tightening torque. See ENGINE/TRANSMISSION 
MOUNTS
 .  

z

Install ribbed belt tensioner. 

Tightening torque: 25 N.m 

z

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

z

Install air duct to charge air cooler at bottom right of long member.  

z

Install right-hand insulation tray 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

SEALING FLANGES AND DRIVE PLATE, REMOVING AND INSTALLING 

NOTE:

For repairs to the clutch: 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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