Volkswagen New Beetle. Manual - part 1185

 

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Volkswagen New Beetle. Manual - part 1185

 

 

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Drain engine oil. 

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Use jointed wrench 3185 when loosening and tightening sump bolts. Only loosen and tighten bolts on 
flywheel end using socket T10058  

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Remove sump cover and remove sump. It may be necessary to release sump by applying light blows with 
a rubber headed hammer.  

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Remove sealant residue from cylinder block with a flat scraper.  

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Remove sealant residue from oil sump with a rotating brush, e.g. a hand drill with a plastic brush 
attachment (wear eye protection). 

Fig. 156: Removing Sealant Residue From Oil Sump With A Rotating Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

Installing 

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Cut off tube nozzle at front marking (nozzle approx. 3 mm diameter). 

NOTE:

Observe waste disposal regulations!

NOTE:

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Note the use-by date of the sealant.  

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The sump must be installed within 5 minutes of applying silicone sealing 
compound.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 157: Applying Silicone Sealing Compound To Sump Sealing Surface 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Apply silicone sealing compound, as shown, to clean sump sealing surface. Sealing compound bead must 
be: 

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2...3 mm thick (for engine code BEV: 1...2 mm thick)  

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and run on inside of bolt holes (arrows).  

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Carefully apply sealing compound bead in areas marked by arrows. (illustration shows position of sealant 
bead on cylinder block). 

NOTE:

The sealing compound bead must not be thicker, otherwise excess sealing 
compound will enter the sump and may block the oil suction pipe strainer.

NOTE:

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When installing the sump on an engine which is removed from the 
vehicle, ensure that the sump is flush with the cylinder block on the 
flywheel end.  

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The sealant must be allowed to cure for approx. 30 minutes after 
installing the sump. After this time the engine may be filled with 
engine oil.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 158: Locating Areas For Applying Sealing Compound Bead 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install sump immediately and tighten bolts as follows:  

1. Tighten all sump/cylinder block bolts lightly using diagonal sequence.  

2. Tighten three sump/transmission bolts lightly.  

3. Tighten all sump/cylinder block bolts lightly using diagonal sequence again.  

4. Tighten sump/transmission bolts to 45 N.m.  

5. Tighten all sump/cylinder block bolts to 15 N.m using diagonal sequence.  

Engine code BEV (Oil sump lower part protection) 

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Apply silicone sealing compound D 176 501 A1, as shown, to clean sump sealing surface. 

NOTE:

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Note the use-by date of the sealant.  

z

The sump must be installed within 5 minutes of applying silicone sealing 
compound.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 159: Locating Areas For Applying Silicone Sealing Compound (Engine Code BEV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Sealing compound bead must be A = 1...2 mm. thick.  

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and run on inside of bolt holes (arrows). 

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Install spreader rivets -3- in oil sump protection -4-. See Fig. 138

NOTE:

z

The sealing compound bead must not be thicker, otherwise 
excess sealing compound will enter the sump and may block 
the oil suction pipe strainer.  

z

When installing the sump on an engine which is removed from 
the vehicle, ensure that the sump is flush with cylinder block on 
the flywheel end.  

z

The sealant must be allowed to cure for approx. 30 minutes after 
installing the sump. After this time the engine may be filled with 
engine oil.  

NOTE:

Models with oil sump protection 

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Check condition of the rubber grommets located in the cylinder block for 
spreader rivets, before installing the oil sump protection.  

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Before tightening bolts, clean the threads and apply D 000 600 A2.  

 

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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