Volkswagen New Beetle. Manual - part 1154

 

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Volkswagen New Beetle. Manual - part 1154

 

 

3. 15 N.m  

4. Seal 

PTFE sealing rings: 

z

Do not additionally oil or grease oil seal sealing lip 

Coil spring seals: 

z

Oil or grease lightly oil seal sealing lip 

z

Replace. See CRANKSHAFT OIL SEAL - PULLEY END, REPLACING .  

5. Sealing flange 

z

Remove oil sump to remove and install  

z

Must be located on dowel sleeves  

z

Insert with silicone sealant D 176 404 A2. See FRONT SEALING FLANGE, REMOVING 
AND INSTALLING
 .  

z

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

6. Cylinder block 

z

Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING .  

z

Disassembling and assembling piston and connecting rod. See PISTON AND CONNECTING 
ROD, DISASSEMBLING AND ASSEMBLING
 .  

7. 60 N.m + 1/4 turn (90°) further 

z

Replace  

8. Flywheel/drive plate 

z

To remove and install flywheel counter-hold with 3067  

z

Removing and installing drive plate. See DRIVE PLATE, REMOVING AND INSTALLING .  

9. Intermediate plate 

z

Must be located on dowel sleeves. See Fig. 32 .  

z

Do not damage/bend when assembling  

10. Sealing flange with oil seal 

z

Only replace complete  

z

Use protective sleeve supplied when installing  

z

Remove oil sump to remove and install  

z

Before installing, remove oil remains from crankshaft journal with a clean cloth.  

z

Remove protective sleeve first after sealing flange has been slid onto crankshaft journal 

NOTE:

Differences between PTFE sealing ring and coil spring seals. See Fig. 
31 .

 

2003 Volkswagen New Beetle GLS 

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

  

PTFE sealing rings: 

z

Do not additionally oil or grease oil seal sealing lip 

Coil spring seals: 

z

Oil or grease lightly the seal sealing lip  

z

Differences between PTFE sealing ring and coil spring seals. See Fig. 31 .  

Fig. 29: Sealing Flanges & Flywheel/Drive Plate (Engine Codes AEG, AVH, AZG, BEV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes BDC, BGD 

NOTE:

The following list refers to items in Fig. 30 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. 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  

2. Crankshaft toothed belt sprocket  

3. 15 N.m  

4. Seal 

PTFE sealing rings:  

z

Do not additionally oil or grease oil seal sealing lip 

Coil spring seals: 

z

Oil or grease lightly the seal sealing lip  

z

Differences between PTFE sealing ring and coil spring seals, see Fig. 31 .  

z

Replacing. See CRANKSHAFT OIL SEAL - PULLEY END, REPLACING .  

5. Sealing flange 

z

Remove oil sump to remove and install  

z

Must be seated on dowel sleeves  

z

Insert with silicone sealant D 176 404 A2. See FRONT SEALING FLANGE, REMOVING 
AND INSTALLING
 .  

z

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

6. Cylinder block 

z

Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING .  

z

Disassembling and assembling piston and connecting rod. See PISTON AND CONNECTING 
ROD, DISASSEMBLING AND ASSEMBLING
 .  

7. 60 N.m + 1/4 turn (90°) further 

z

Replace  

8. Flywheel/drive plate 

z

Counter support with 3067 when removing and installing flywheel  

z

Removing and installing drive plate. See DRIVE PLATE, REMOVING AND INSTALLING .  

9. Intermediate plate 

z

Must be located on dowel sleeves. See Fig. 32 .  

z

Do not damage/bend when assembling  

10. Sealing flange with oil seal 

z

Only replace complete  

z

Use protective sleeve supplied when installing 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove oil sump to remove and install  

z

Before installing, remove oil remains from crankshaft journal with a clean cloth.  

z

Remove protective sleeve first after sealing flange has been slid onto crankshaft journal  

z

PTFE sealing rings: Do not additionally oil or grease oil seal sealing lip  

z

Coil spring seals: Oil or grease lightly the seal sealing lip  

z

Differences between PTFE sealing ring and coil spring seals. See Fig. 31  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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