Volkswagen New Beetle. Manual - part 1115

 

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Volkswagen New Beetle. Manual - part 1115

 

 

Fig. 7: Threading On T 10012 Engine Bracket
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Attach to engine block with 25 Nm (18 ft lb)  

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Slightly lift engine/transmission assembly using VAG 1383 A jack.  

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Loosely unscrew engine mount (engine side) from top of engine bracket (arrows). 

Fig. 8: Removing Engine Mount Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Loosely unscrew engine mount/transmission mount from transmission bracket (arrows) from top. 

Fig. 9: Removing Engine Mount/Transmission Mount Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Carefully lower engine/transmission assembly. 

NOTE:

Use VAS 5085 tool to remove the mounting bolts.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

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While lowering, carefully guide the power steering fluid line past the transmission. 

Engine assembly stand, attaching engine 

Work sequence 

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Transfer Engine/transmission subassembly to workbench via VAG 1383 A engine/transmission jack. 

Fig. 10: Identifying Transfer Engine/Transmission Subassembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lower the engine/transmission assembly such that the transmission is supported.  

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Remove lower engine/transmission connecting bolt.  

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Push transmission off engine, while pushing the torque converter out of the drive plate.  

Vehicles with automatic transmission 

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Remove nut from torque converter.  

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Clamp off ATF cooler hoses and disconnect at transmission cooler.  

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Seal off transmission cooler using clean plugs.  

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Secure torque converter to prevent it from falling out.  

All vehicles 

NOTE:

Carefully guide the engine and transmission assembly during the lowering 
process to prevent bodywork damage.

NOTE:

To work on the engine outside of the vehicle, attach engine to assembly stand 
using the VW 313 holding fixture along with the VW 540 engine/transmission 
support.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

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Attach 2024A engine sling using 2024 A/1 extension as follows and lift from VAG 1383 
engine/transmission jack using workshop crane: 

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Pulley end: 4th hole in hook at position 1  

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Flywheel end: 4th hole in hook at position 8  

Fig. 11: Attaching 2024A Engine Sling 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Secure engine to holding fixture VW 313 using VW 540 engine/transmission support and VW 540/1 
supplementary kit.  

Installation notes 

Installation is reverse of removal, note the following during installation: 

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Check whether centering dowels for engine/transmission are installed in the cylinder block, install if 
necessary.  

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Install intermediate plate onto sealing flange and slide onto dowel sleeves (arrows). 

WARNING:

Secure ALL hooks and locating pins with lock pins!

NOTE:

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Positions marked 1 to 4 on the bar must be located toward the pulley end 
of the engine.  

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The holes in the hooks are counted up from the hook.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 12: Installing Intermediate Plate Onto Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with manual transmission 

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Check clutch release bearing for wear, replace if necessary.  

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

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Install hydraulic clutch slave cylinder:  

See CLUTCH SLAVE CYLINDER 

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Install selector mechanism:  

See SELECTOR MECHANISM . 

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If necessary adjust gear change cables:  

See SELECTOR MECHANISM . 

Vehicles with automatic transmission 

z

Replace the lock washer on the selector cable anchorage.  

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Install selector cable on transmission, adjust if necessary:  

See SELECTOR LEVER CABLE . 

All vehicles 

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When installing the engine and transmission assembly, make sure sufficient clearance to drive shafts.  

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While raising, carefully guide the power steering fluid line past the transmission.  

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Engine and Transmission subassembly is aligned transversely so there is a distance between engine 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

 

 

 

 

 

 

 

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