Volkswagen New Beetle. Manual - part 1179

 

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Volkswagen New Beetle. Manual - part 1179

 

 

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Fit new valve stem seal into installation tool 3129.  

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Oil valve stem seal sealing lip and press carefully onto valve guide.  

ENGINE - LUBRICATION 

LUBRICATION SYSTEM 

Lubrication system components, removing and installing 

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

Engine codes BDC, BGD 

Disassembling and assembling oil pump with balancer shaft gear assembly. See Oil pump with balancer shaft 
gear assembly, disassembling and assembling (Engine codes BDC, BGD)
 . 

Removing and installing oil pump with balancer shaft gear assembly. See OIL PUMP WITH BALANCER 
SHAFT GEAR ASSEMBLY, REMOVING AND INSTALLING
 . 

Continuation for all models 

Checking oil pressure and oil pressure switch. See OIL PRESSURE AND OIL PRESSURE SWITCH, 
CHECKING
 . 

Engine oil specifications 

Use engine oils which conform with VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-
grade and single grade oils conforming with API-SF and SG or ACE A A2/A3. 

NOTE:

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Metal shavings or large amounts of small metal particles found in the 
engine oil during repairs may be caused by a partial seizure of the 
crankshaft or connecting rod bearings. Perform the following work 
sequences in this situation to prevent consequential damage once repairs 
are complete: 

{

Thoroughly clean oil passages  

{

Replace oil spray jets  

{

Replace oil cooler  

{

Replace oil filter  

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The oil level must not be above the max. mark or there is a danger of 
damage to catalytic converter. For markings, see Fig. 136 .  

NOTE:

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In the factory the engine is filled with engine oil conforming with VW 
standard 503 00. This engine oil is designed for long service intervals 

 

2003 Volkswagen New Beetle GLS 

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

  

Oil system capacity 

See ENGINE OIL LEVEL, CHECKING . 

Part I (Engine codes AEG, AVH, AZG) 

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

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For engine codes BDC, BGD, see Part I (Engine codes BDC, BGD) .  

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For engine code BEV, see Part I (Engine code BEV) .  

1. 15 N.m  

2. Sealing flange 

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Must be located on dowel sleeves  

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

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

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Replacing crankshaft oil seal, poly V-belt pulley end. See CRANKSHAFT OIL SEAL - 
PULLEY END, REPLACING
  

3. Pressure relief valve, 27 N.m  

4. Oil spray jet 

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For piston cooling  

5. Dipstick 

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Oil level must not exceed max. mark!  

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Markings. See Fig. 135  

6. Dipstick guide 

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Fastened to intake manifold  

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Pull off to extract oil  

7. Guide tube  

8. Dowel sleeves  

9. O-ring 

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Replace  

10. 15 N.m  

(ESI).  

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Engine oils conforming to VW standard 500 00, 501 01 or 502 00 may also 
be used.  

NOTE:

The following list refers to items in Fig. 132 .

 

2003 Volkswagen New Beetle GLS 

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

  

11. Suction line 

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Observe part number  

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Clean strainer if soiled  

12. Baffle plate  

13. 15 N.m  

14. Oil sump protection 

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Not for all engines. See Parts catalog.  

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Assembly overview. See Fig. 138  

15. Oil drain plug, 30 N.m 

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Replace if leaking. See Parts catalog for correct application. In some cases seal and drain plug are 
combined; do not interchange with separate seal and drain plug.  

16. Oil sump 

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 404 A2. See OIL SUMP, REMOVING AND INSTALLING .  

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Removing and installing. See OIL SUMP, REMOVING AND INSTALLING .  

17. Oil pump 

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With pressure relief valve of 12 bar  

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Before installing, check that both dowel sleeves for centralizing oil pump/cylinder block are 
installed  

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Replace if running surfaces and gears are scored  

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Removing and installing. See Oil pump, removing and installing (Engine codes AEG, AVH, 
AZG, BEV)
 .  

18. Chain sprocket 

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Observe installing position  

19. 20 N.m 

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Use counter support T10051 to loosen and tighten  

20. Chain  

21. Chain tensioner with tensioning rail, 15 N.m 

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When installing, pretension spring and fit 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 132: Exploded View Of Lubrication System Components (Engine Codes AEG, AVH, AZG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part I (Engine codes BDC, BGD) 

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For engine codes AEG, AVH, AZG. See Part I (Engine codes AEG, AVH, AZG) .  

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For engine code BEV. See Part I (Engine code BEV) .  

1. 15 N.m  

2. Sealing flange 

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Must be seated on dowel sleeves  

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

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

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Replacing crankshaft oil seal, ribbed belt pulley end. See CRANKSHAFT OIL SEAL - PULLEY 
END, REPLACING
 . 

 

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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