Volkswagen New Beetle. Manual - part 1124

Fig. 45: Installing Sealing Ring 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install crankshaft toothed belt sprocket and hold using 3099 counterhold.  

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Install toothed belt and tension. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING  

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

Drive plate, removing and installing 

Special tools and equipment 

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VW 558 Counter-hold tool  

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Hex bolt M8x45 and two M10 hex nuts  

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Depth gauge 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 46: Identifying VW 558 Counter-Hold Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Drive plate, loosening and tightening 

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Secure VW 558 counterhold to drive plate using M8 x 45 hex bolt.  

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Place two M10 hex nuts between counterhold and drive plate. 

Position of counterhold tool: 

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A - To loosen  

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B - To tighten 

Fig. 47: Holding Drive Plate 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Drive plate, installing 

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Position drive plate and backing plate with recesses -1-. 

 

2003 Volkswagen New Beetle GLS 

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

  

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Install new bolts -3- and tighten. 

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30 N.m (22 ft lb) 

Fig. 48: Installing Drive Plate And Backing Plate 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check dimension -a- at three points and calculate average. 

Specification: 19.5 to 21.1 mm 

Fig. 49: Checking Drive Plate Installed Dimension 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If specification not obtained 

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Remove drive plate and install shim -2-. 

NOTE:

Because of the hole in the drive plate it is measured on the milled surface 
of the engine block

 

2003 Volkswagen New Beetle GLS 

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

  

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Tighten bolts -3-. 

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30 N.m (22 ft lb)  

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Tighten bolts -3- to 60 N.m (44 ft lb) and turn an additional 90° (1 /4 turn) further. 

Fig. 50: Installing Drive Plate And Shim 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Sealing flange (front), removing and installing 

Special tools and equipment 

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2080 A Sleeve  

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3415 Counter support  

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

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VAG 1332 Torque wrench: 40 to 200 N.m (30 to 148 ft lb)  

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Hand drill w/ plastic brush insert  

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D 176 404 A2 Silicone sealant  

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Flat scraper 

NOTE:

The 1/4 turn additional can be achieved in more than one step.

 

2003 Volkswagen New Beetle GLS 

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