Volkswagen New Beetle. Manual - part 1151

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1149  1150  1151  1152   ..

 

 

Volkswagen New Beetle. Manual - part 1151

 

 

z

If damaged or leaking renew complete  

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING .  

19. 15 N.m  

20. Crankshaft toothed belt sprocket  

21. 90 N.m + 1/4 turn (90°) further 

z

Replace  

z

Threads and shoulder must be free of oil and grease  

z

Use counter support tool 3415 to loosen and tighten  

22. Toothed belt guard, lower part  

23. 10 N.m 

z

Replace  

24. Clutch 

z

For air conditioning compressor  

25. Belt pulley 

z

For power steering pump  

26. Ribbed belt 

z

Mark direction of rotation before removing  

z

Check for wear  

z

Do not kink  

z

Removing and installing. See RIBBED BELT, REMOVING AND INSTALLING .  

27. Belt pulley/vibration damper 

z

Can only be installed in one position. Holes are offset  

z

Note position when installing toothed (timing) belt. See TOOTHED BELTS, REMOVING, 
INSTALLING AND TENSIONING
 .  

28. 25 N.m  

29. Tensioning element for ribbed belt 

z

Turn with open end wrench to loosen ribbed belt. See RIBBED BELT, REMOVING AND 
INSTALLING
 .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 22: Exploded View - Front Of Engine Components (Part I) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Part II 

1. Knock Sensor (KS) 1 -G61- 

z

Gold plated contacts  

2. Connector 

z

For KS 1 -G61-  

z

Gold plated contacts  

z

Do not interchange 

See appropriate System Wiring Diagram article 

3. 20 N.m 

z

Torque setting influences function of knock sensor  

4. Connector 

z

For KS 2 -G66-  

z

Gold plated contacts  

z

Do not interchange 

See appropriate System Wiring Diagram article 

5. Knock Sensor (KS) 2 -G66- 

z

Gold plated contacts  

6. Dipstick guide  

7. Dipstick 

z

The oil level must not exceed the max. mark!  

z

Markings. See Fig. 136  

8. Coolant pipe 

z

According to engine versions  

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM .  

9. 25 N.m  

10. Retainer 

z

For ignition coil  

11. Retainer 

z

According to engine versions  

12. 10 N.m  

13. Retainer 

z

According to engine versions  

NOTE:

The following list refers to items in Fig. 23 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

14. Retainer 

z

According to engine versions  

15. Retainer 

z

According to engine versions  

16. Oil filter bracket 

z

Disassembling and assembling. See Part II (Oil filter housing, disassembling and assembling) .  

17. 15 N.m + 1/4 turn (90°) further 

z

Replace  

18. Seal 

z

Replace  

19. Oil filter 

z

Loosen with strap wrench  

z

Tighten by hand  

z

Note instructions on filter when installing  

20. 25 N.m  

21. Oil cooler 

z

Coat contact surfaces to oil filter bracket outside the seal with AMV 188 100 02  

z

Ensure clearance to adjacent components. See note at beginning of ENGINE, DISASSEMBLING 
AND ASSEMBLING
 .  

22. Seal 

z

Replace  

23. Engine speed sensor  

24. Seal 

z

Replace if damaged  

25. 40 N.m  

26. Connecting unions  

27. 15 N.m  

28. Coolant thermostat 

z

Checking: Heat up thermostat in water  

z

Starts to open at approx. 86° C  

z

Opening stroke: min. 7 mm  

z

Removing and installing. See THERMOSTAT, REMOVING AND INSTALLING .  

29. Hex socket head bolt 

z

Torque setting: 

See CONDENSER, REMOVING AND INSTALLING . 

30. Compact bracket 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

 

 

 

 

 

 

 

Content   ..  1149  1150  1151  1152   ..