Volkswagen New Beetle. Manual - part 1140

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1138  1139  1140  1141   ..

 

 

Volkswagen New Beetle. Manual - part 1140

 

 

Part II 

1. Sealing plug 

z

25 N.m (18 ft lb)  

2. Gasket 

z

Always replace  

3. Oil cooler 

z

Make sure clearance between adjacent components  

z

See note. See LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

4. Gasket 

z

Always replace  

z

Install into oil cooler groove  

5. Seal 

z

If seal leaks, nip open and replace.  

6. Plug 

z

10 N.m (7 ft lb)  

7. Sealing plug 

z

Do NOT open  

8. Spring 

z

For pressure relief valve, approx. 5 bar  

9. Piston 

z

For pressure relief valve, approx. 5 bar  

10. 0.9 bar oil pressure switch -F1- 

z

25 N.m (18 ft lb)  

z

Gray  

z

Checking: See OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING  

11. Gasket 

z

Always replace  

12. 15 N.m (11 ft lb) plus additional1/4 turn (90°) 

z

Always replace  

z

Place bolts first top left and right, then tighten all four bolts over cross  

13. Oil filter bracket  

14. Seal 

z

Always replace  

15. Oil supply pipe 

z

To the turbocharger  

NOTE:

The following list refers to items in Fig. 103 .

 

2003 Volkswagen New Beetle GLS 

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

  

16. Banjo bolt 

z

20 N.m (15 ft lb)  

17. Sealing cap 

z

25 N.m (18 ft lb)  

z

Loosen and tighten using 3417 oil filter wrench  

18. O-ring 

z

Always replace  

19. Oil filter element  

Fig. 103: Exploded View Of Oil Filter Bracket Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Dipstick, markings 

1. MAX. mark  

2. MIN. mark  

a. Area above cross-hatched zone up to the MAX. mark: 

Do not top-up with engine oil! 

b. Oil level within cross-hatched zone: 

Can be topped-up with engine oil, as necessary 

c. Area from MIN. mark up to cross-hatched zone: 

Fill with 0.5 ltr. (.47 quarts) of engine oil maximum!

NOTE:

The following lists refers to items in Fig. 104 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 104: Identifying Oil Level Mark On Dipstick 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Oil pan, removing and installing 

Special tools and equipment 

z

Hand drill with plastic brush  

z

D 176 404 A2 Silicone sealant  

z

Scraper  

Oil pan, removing 

z

Remove center, left and right insulation trays: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

z

Drain engine oil.  

z

Unscrew oil pan.  

z

Loosen oil pan with light blows from a rubber hammer, if necessary.  

z

Remove sealant residue on cylinder block with a flat scraper.  

z

Remove sealant residue on the oil pan with a rotating brush, e.g. a hand drill with a plastic brush (wear 
protective glasses).  

z

Clean sealing surfaces, must be free of oil and grease. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 105: Removing Sealant Residue On Oil Pan 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

Cut-off tube nozzle at forward mark (approx. 3 mm diameter).  

z

Apply silicone sealing compound as shown to a clean oil pan sealing surface. 

z

Bead must be: 2 to 3 mm thick.  

z

Bead must run on the inside of bolt holes (arrows). 

NOTE:

z

Note the "use by date" on the sealant container.  

z

Oil pan must be installed within 5 minutes after applying the silicone 
sealing compound.  

NOTE:

The sealing bead must not be thicker, or excess compound will enter 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1138  1139  1140  1141   ..