Volkswagen New Beetle. Manual - part 1122

 

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Volkswagen New Beetle. Manual - part 1122

 

 

z

Remove 2065A setting bar from camshaft.  

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Remove pin.  

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Turn crankshaft two rotations in engine direction of rotation and set again to cylinder 1 TDC.  

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Attach bracket to engine block.  

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Install engine mount (replace mounting bolts). 

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

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Securely install mount for engine to engine bracket (replace mounting bolts) 

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Tightening torque: 60 N.m (44 ft lb) plus additional 90° (1/4 turn)  

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Install bracket for subassembly/body 

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Tightening torque: 25 N.m (18 ft lb)  

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Install vacuum pump.  

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Install toothed belt guard, vibration damper, belt pulley, and valve cover.  

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

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Install sound dampening tray and engine cover  

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

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Install fuel filter with bracket  

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Disconnect fuel supply and return lines at fuel filter.  

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

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Check Diesel injection pump "start of delivery" 

See START OF INJECTION, DYNAMICALLY CHECKING AND ADJUSTING 

Semi-automatic toothed belt tensioning roller, checking 

Test sequence 

z

Tighten toothed belt with firm thumb pressure. 

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The mounting bolts should only be used one time, since by design 
they have a reduced shank  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 39: Tightening Toothed Belt Nut 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Notch and raised portion (arrows) must move apart.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Release thumb pressure on toothed belt. 

Tensioning roller must move back to its initial position, notch and raised portion must align again. 

SEALING FLANGE AND FLYWHEEL/DRIVE PLATE, REMOVING AND INSTALLING 

1. 15 N.m (11 ft lb)  

2. Oil seal 

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Replacing. See SEALING RING (CRANKSHAFT PULLEY SIDE), REPLACING  

3. Sealing flange, front 

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Must be located on dowel sleeves  

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Removing and installing. See SEALING FLANGE (FRONT), REMOVING AND 
INSTALLING
  

4. Engine block 

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Crankshaft, removing and installing. See CRANKSHAFT, REMOVING AND INSTALLING  

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Pistons and connecting rods, disassembling and assembling. See PISTONS AND CONNECTING 
RODS, DISASSEMBLING AND ASSEMBLING
  

5. Flywheel/drive plate 

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to remove and install flywheel, counter-hold using 3067  

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Drive plate, removing and installing: See DRIVE PLATE, REMOVING AND INSTALLING  

6. 60 N.m (44 ft lb) plus additional 1/4 turn (90°) further 

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Always replace  

7. Intermediate plate 

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Must be located on dowel sleeves  

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Do not damage/bend when assembling  

8. Sealing flange with oil seal 

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Only replace as an assembly  

z

Lightly oil sealing lip on oil seal 

NOTE:

For clutch repairs: See CLUTCH ASSEMBLY

NOTE:

The following list refers to items in Fig. 40 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 40: Identifying Sealing Flange And Flywheel/Drive Plate 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Sealing ring (crankshaft pulley side), replacing 

Special tools and equipment 

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2080 A sleeve  

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3415 Counter support  

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3203 Seal remover  

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3265 Sleeve installer  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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