Volkswagen New Beetle. Manual - part 1117

 

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Volkswagen New Beetle. Manual - part 1117

 

 

To ease engine removal and installation without opening the A/C refrigerant circuit: 

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Remove retaining clamp(s) from refrigerant lines.  

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Remove A/C compressor:  

See A/C REFRIGERANT SYSTEM, SERVICING , item 13. 

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Attach A/C compressor to vehicle body to provide stress relief for refrigerant lines/hoses. 

Fig. 18: Attaching A/C Compressor To Vehicle Body 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ENGINE - CRANKSHAFT, CYLINDER BLOCK 

ENGINE, DISASSEMBLING AND ASSEMBLING 

WARNING:

Do NOT open the A/C refrigerant circuit.

NOTE:

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

NOTE:

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If during repairs, metal shavings or quantities of small metal particles are 
found in the engine oil - caused, for example, by partial seizure of the 
crankshaft and conrod bearings - then, besides thoroughly cleaning out 
the oil passages, also replace the oil cooler.  

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Faulty injectors can cause violent knocking noises in the engine which 
sound like faulty bearings. When this occurs, run engine at idle and 
slacken off the injector line unions one after the other. If the knocking 
stops when a specific union is loosened, this is an indication that the 

 

2003 Volkswagen New Beetle GLS 

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

  

Fuel injectors, servicing 

See FUEL INJECTORS, SERVICING . 

I. See PART I  

II. See PART II  

Part I 

1. Ribbed belt 

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Mark direction of engine rotation before removing  

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

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Vehicles with A/C with additional idler pulley, removing and installing: See Pulley, removing and 
installing
  

2. 10 N.m (7ft lb) plus additional 1/4 turn (90°)  

3. Belt pulley/vibration damper 

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Can only be installed in one position; holes are offset  

4. 25 N.m (18 ft lb)  

5. Tensioning element 

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For V-belt  

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

respective injector is faulty. 

Fig. 19: Locating External Engine Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

The following list refers to items in Fig. 20 .

 

2003 Volkswagen New Beetle GLS 

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

  

6. Generator  

7. Assembly bracket 

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for injection pump, Generator and power steering pump  

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for vehicles with A/C  

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Assembly bracket for vehicles with A/C, removing and installing:  

See 1.9L4-CYLINDER TDI ENGINE 

8. 45 N.m (33 ft lb)  

9. Banjo bolt 

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30 N.m (22 ft lb)  

10. Seal 

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Always replace  

11. Pressure accumulator  

12. Flange 

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For power steering  

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Removing and installing:  

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

13. Pulley 

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For Engine Coolant pump  

Fig. 20: Identifying Engine Components - Accessory Drive (Part 1) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pulley, removing and installing 

Only for vehicles with A/C 

 

2003 Volkswagen New Beetle GLS 

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

  

Removing 

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Remove sound dampener tray 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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

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Pry off cover -1- using screwdriver.  

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Remove mounting bolts -2- and remove pulley -3-.  

Fig. 21: Removing Ribbed Belt Pulley (Vehicles with A/C) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Position pulley -3- and tighten mounting bolt 

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Tightening torque 25 N.m (18 ft lb)  

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

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Install sound dampener tray. 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

Part II 

1. 120 N.m (88 ft lb) plus additional 1/4 turn (90°) 

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Always replace  

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To loosen and tighten, counter-hold with 3099  

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Threads and shoulder must be free of oil and grease  

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The additional quarter turn can be obtained in several stages. 

NOTE:

The following list refers to items in Fig. 22 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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