Volkswagen New Beetle. Manual - part 1118

 

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Volkswagen New Beetle. Manual - part 1118

 

 

2. 40 N.m (30 ft lb) plus additional 1/4 turn (90°) 

z

Always replace  

3. 15 N.m (11 ft lb)  

4. 22 N.m (16 ft lb)  

5. Toothed belt guard, lower section  

6. 10 N.m (7 ft lb)  

7. Toothed belt guard  

8. 45 N.m (33 ft lb)  

9. Right engine bracket  

10. Toothed belt guard, upper section  

11. Toothed belt 

z

Mark engine direction of rotation before removing  

z

Check for wear  

z

Do not kink  

z

Removing, installing and tensioning. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
 .  

12. Idler wheel  

13. 20 N.m (15 ft lb) plus additional 1/4 turn (90°) 

z

Always replace  

14. 20 N.m (15 ft lb)  

15. 20 N.m (15 ft lb)  

16. 45 N.m (33 ft lb)  

17. Camshaft sprocket 

z

Drive camshaft off of taper using hammer and drift through toothed belt guard openings  

z

to loosen and tighten bolt (item 16), counterhold using 3036  

18. Tensioning roller 

z

Semi-automatic toothed belt tensioning roller, checking. See SEMI-AUTOMATIC TOOTHED 
BELT TENSIONING ROLLER, CHECKING
 .  

19. Idler wheel  

20. Injection pump sprocket 

z

Two piece construction  

21. 30 N.m (22 ft lb)  

22. Toothed belt guard, rear  

23. Coolant pump 

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING .  

24. Idler wheel 

z

First remove, to remove coolant pump  

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING

 

2003 Volkswagen New Beetle GLS 

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

  

25. Crankshaft toothed belt sprocket  

26. Bushing  

27. Diesel injection pump 

z

Removing and installing  

See DIESEL INJECTION PUMP, SERVICING . 

28. Assembly bracket 

z

for Diesel injection pump, Generator and power steering pump.  

z

for vehicles with A/C  

z

Removing and installing  

See 1.9L4-CYLINDER TDI ENGINE . 

29. 45 N.m (33 ft lb)  

Fig. 22: Identifying Front Engine Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Ribbed belt tensioner, removing and installing 

Work sequence 

z

Remove right-hand insulation tray: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

z

Remove pipe between charge air cooler and turbocharger. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
 .  

z

Mark engine direction of rotation on ribbed belt.  

z

Swing tensioning roller in direction of arrow using 15 mm open end wrench on tensioning lever. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 23: Removing Or Installing Ribbed Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove or install ribbed belt. 

Ribbed belt, routing 

Belt drive without A/C compressor 

1. Vibration damper/pulley  

2. Tensioner  

3. Pulley - Generator  

4. Ribbed belt  

5. Pulley - Power steering pump  

NOTE:

z

Vehicles without A/C: first remove V-belt from Generator and position 
it last when installing.  

z

Vehicles with A/C: first remove V-belt from pulley and position it last 
when installing.  

z

When installing V-belt; make sure belt sits correctly in pulley.  

NOTE:

The following list refers to items in Fig. 24 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 24: View Of Belt And Pulleys 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Belt drive with A/C compressor 

1. Vibration damper/pulley  

2. Tensioner  

3. Pulley - Generator  

4. Pulley - Power steering pump  

5. Tensioner  

6. Ribbed belt  

7. Pulley - A/C  

Fig. 25: Identifying Belt Drive With A/C Compressor 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

The following list refers to items in Fig. 25 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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