Volkswagen New Beetle. Manual - part 1119

 

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Volkswagen New Beetle. Manual - part 1119

 

 

Toothed belts, removing, installing, tensioning 

Special tools and equipment 

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2068 A Adj. gauge TDC tool  

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3359 Rig pin  

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3418 Adjustment guide  

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10-222A Engine support bridge with 10-222A/1 bracket for engine  

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V159 nut wrench  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb) 

Fig. 26: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Support tool 10-222 A/21, modifications 

NOTE:

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Use tool 10-222A to support the engine / transmission assembly.  

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Drill a new hole in the 10-222 A/21 guide to fasten 10-222 A/8 adaptor to. 

 

2003 Volkswagen New Beetle GLS 

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

  

Toothed belts, removing 

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

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Disconnect fuel supply and return lines at fuel filter.  

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Remove fuel filter from bracket.  

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Remove toothed belt guard - upper section.  

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Remove valve cover. 

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Remove brake booster vacuum pump.  

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

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Remove insulation tray - right side 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

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

With engine installed: 

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Turn crankshaft to cylinder 1 TDC. 

Fig. 27: Identifying New Hole On 10-222 A/21 Guide 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Dimensions given are in mm.  

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One hole 12.5 mm diameter (arrow) drilled in the 10-222 A/21 guide  

NOTE:

The valve cover has an integrated, vulcanized gasket. If damaged or 
leaking replace the valve cover.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 28: Identifying Timing Mark (Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft to cylinder 1 TDC. 

Fig. 29: Identifying Timing Mark (Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

With engine removed: 

Vehicles with manual transmission 

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Install adjustment device 2068 A as shown. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 30: Installing Adjustment Device On Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set adjustment device to 96 mm (arrow -A-). Left-hand notch of vernier scale is reference point.  

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Turn crankshaft until flywheel TDC marking aligns with point on setting device (arrow -B-).  

Vehicles with automatic transmission 

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Install adjustment device 2068 A as shown. 

Fig. 31: Installing Adjustment Device On Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set adjustment device to 96 mm (arrow -A-). Left-hand notch of vernier scale is reference point.  

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Turn crankshaft until flywheel TDC marking aligns with point of setting device (arrow -B-).  

All vehicles 

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Lock camshaft using setting bar. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1117  1118  1119  1120   ..