Volkswagen New Beetle. Manual - part 1121

 

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Volkswagen New Beetle. Manual - part 1121

 

 

Fig. 35: Removing Engine Mount 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove vibration damper/belt pulley.  

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Remove toothed belt guard center and lower sections.  

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Mark engine direction of rotation on the toothed belt.  

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Remove toothed belt.  

Toothed belts, installing 

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Make sure that TDC mark on flywheel and reference mark are aligned.  

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Loosen camshaft sprocket mounting bolt 1/2 turn.  

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Place a drift through hole in rear of toothed belt guard and release the camshaft sprocket from camshaft 
taper with a light and careful hammer blow. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 36: Installing Drift Through Hole In Rear Of Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install toothed belts (note engine direction of rotation) on crankshaft toothed belt sprocket, intermediate 
wheel, injection pump sprocket and tensioning roller.  

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Install camshaft sprocket together with toothed belt and position using mounting bolt. 

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Camshaft sprocket should still turn  

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Tension toothed belt; using pin wrench on eccentric, turn clockwise until notch and raised mark align 
(arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 37: Tightening Lock Nut On Tensioning Roller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten lock nut on tensioning roller. 

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Tightening torque: 20 N.m (15 ft lb)  

NOTE:

Observe correct installation of tension roller in rear toothed belt guard 
(arrow).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 38: Identifying Correct Installation Of Tension Roller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check TDC mark on flywheel again.  

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Tighten camshaft sprocket mounting bolt. 

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45 N.m (33 ft lb)  

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Tighten the new mounting bolts of injection pump sprocket 

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Tightening torque: 20 N.m (15 ft lb)  

NOTE:

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After dynamically checking the "start of injection", the mounting 
bolts must be retightened 90° (1/4 turn). 

See DIESEL INJECTION PUMP, REMOVING AND INSTALLIN 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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