Volkswagen New Beetle. Manual - part 1170

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1168  1169  1170  1171   ..

 

 

Volkswagen New Beetle. Manual - part 1170

 

 

z

Turn crankshaft two turns in engine direction of rotation until engine is again at TDC No. 1 cylinder. Last 
45° (1/8 turn) must be completed without stopping.  

z

Check toothed belt tension again. 

Specification: Indicator and notch align 

Continuation, install complete toothed belt 

z

Install toothed belt guard center and lower parts.  

z

Install vibration damper/belt pulley. 

Tightening torque: 25 N.m 

z

Install engine mounting to cylinder block. 

Tightening torque: 45 N.m 

z

Install engine assembly mountings complete. 

z

Align assembly mountings for engine and transmission. See ENGINE AND TRANSMISSION 
MOUNTINGS, ALIGNING
 . 

Tightening torques. See ASSEMBLY MOUNTING . 

z

Remove engine support bracket 10-222 A.  

z

Install toothed belt guard, upper part.  

z

Install ribbed belt tensioning element. 

Tightening torque: 25 N.m 

z

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

z

Install coolant expansion tank.  

z

Install right side sound insulation tray: 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

z

Install engine cover.  

Semi-automatic toothed belt tensioning roller, checking 

Special tools, testers, measuring instruments and auxiliary items required

NOTE:

Insert bolts into engine bracket before installing engine bracket.

 

2003 Volkswagen New Beetle GLS 

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

  

z

T10020 Two hole pin wrench 

Fig. 81: Identifying T10020 Two Hole Pin Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installed position 

z

Angled retainer (arrow) must locate in cutout on cylinder head. 

Fig. 82: Locating Semi-Automatic Toothed Belt Tensioning Roller Angled Retainer 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

Engine must only be hand touch warm.  

Work sequence 

z

Set engine to TDC No. 1 cylinder.  

z

Press hard with thumb on toothed belt. Indicator -2- must move. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 83: Tensioning Toothed Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Release thumb pressure on toothed belt and turn crankshaft two turns in engine direction of rotation until 
engine is again at TDC No. 1 cylinder. Last 45° (1/8 turn) must be performed without stopping. 

Tensioning roller must return to its original position (notch -1- and indicator -2- are again aligned). 

Cylinder head, removing and installing 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

V.A.G 1306 Drip tray  

z

V.A.G 1332 Torque wrench (40...200 N.m)  

z

VAS 5024 Assembly tool for spring-type clips  

z

3450/2A Guide pins  

z

3450/3 Removal tool  

z

3452 Key 

Fig. 84: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Use a mirror when checking.

 

2003 Volkswagen New Beetle GLS 

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

  

z

T10112 Installation tool  

Fig. 85: Identifying T10112 Installation Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

Engine must only be hand touch warm.  

Work sequence 

z

With ignition switched off disconnect battery Ground strap.  

z

Remove engine cover.  

z

Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

z

Observe rules for cleanliness. See RULES FOR CLEANLINESS . 

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

z

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

NOTE:

During the further course of work the battery Ground strap must be 
disconnected. Therefore, please check whether a coded radio is installed. 
Obtain the radio code first if necessary.

WARNING:

z

Fire Hazard! Do NOT have anything in the area that can ignite 
fuel!  

z

Fuel system is under pressure! Before opening the system 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1168  1169  1170  1171   ..