Volkswagen New Beetle. Manual - part 1186

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1184  1185  1186  1187   ..

 

 

Volkswagen New Beetle. Manual - part 1186

 

 

Fig. 160: Installing Oil Sump Protection 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Tighten bolts -2- to 37 N.m.  

Continuation for all models 

The rest of the assembly is basically in reverse order to the disassembly sequence. 

Oil pressure and oil pressure switch, checking 

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

z

V.A.G 1342 Oil pressure tester  

z

V.A.G 1527 B Diode test lamp  

z

V.A.G 1594 A Adapter set 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 161: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Function of dynamic oil pressure warning system 

The oil pressure switch is open at no pressure and closes when the switch pressure is reached. 

The oil pressure is activated approx. 10 seconds after switching the ignition on ("terminal 15 on"). 

Switch-on delay for oil pressure warning: approx. 3 seconds 

Switch-off delay for oil pressure warning: approx. 5 seconds 

Checking warning lamp 

After switching on the ignition when the engine is not running, the oil pressure warning lamp in the instrument 
cluster must light up for approx. 3 seconds and go out again. The check is terminated if the engine is running. 

Criteria for warning 

The optical oil pressure warning switches on (the oil pressure warning lamp flashes) and the buzzer sounds 
three times for audible warning under one of the following conditions. 

z

"Ignition on", engine at rest, oil pressure switch closed  

z

Engine speed higher than 1500 RPM, oil pressure switch open  

At an engine speed greater than 5000 RPM the oil pressure warning is not erased; even when the oil pressure 
switch is closed. Oil pressure warning goes out below 5000 RPM. 

If the oil pressure switch is open (engine revs greater than 1500) for 0.5... 3 seconds, this is stored in the 
processor of the instrument cluster. If this condition happens three times while the engine is running, the oil 
pressure warning is immediately triggered and remains on, even below 1500 RPM. The oil pressure warning 
goes out when the oil pressure switch is closed for longer than 5 seconds when engine revolutions are greater 
than 1500 RPM or the ignition is switched off. 

Requirements 

z

Engine oil level OK, checking. See Dipstick Marks (Engine codes AEG, AVH, AZG, BEV)  

z

Oil pressure warning light -K3- must light up for approx. 3 seconds when ignition is switched on  

z

Engine oil temperature at least 80 °C (coolant fan must have run once) 

Work sequence 

NOTE:

Functional check and servicing the optical and acoustic oil pressure 
warning: 
See Electrical Wiring Diagrams, Troubleshooting & Component Locations

 

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 pressure switch -F1- and screw into tester. 

Fig. 162: Checking Oil Pressure And Oil Pressure Switch 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Screw tester into oil filter bracket in place of oil pressure switch.  

z

Connect brown wire of tester to Ground (-).  

z

Connect diode test lamp V.A.G 1527 B using auxiliary cables from V.A.G 1594 A to battery positive (+) 
and oil pressure switch. 

LED must not light up 

If the LED lights up: 

z

Replace 1.4 bar Oil pressure switch -F1-.  

If the LED does not light up: 

z

Start engine and increase revolutions slowly. 

At 1.2...1.6 bar LED must light up 

If the LED does not light up: 

z

Replace oil pressure switch.  

z

Increase engine speed further. 

At 2000 RPM and an oil temperature of 80 °C oil pressure should be between 2.7... 4.5 bar 

At higher engine speeds the oil pressure must not exceed 7.0 bar 

If the specifications are not attained: 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Correct mechanical damage, e.g. bearing damage.  

z

Check O-ring of sealing plug for damage. See PRE-TENSIONING CHAIN TENSIONER , item - 13 -. 

z

Replace oil filter bracket with pressure relief valve. See Fig. 139 , item -14 - or (for engine code BDC, 
BGD) oil pump with balancer shaft gear assembly.  

If no failure was found: 

z

Replace engine pump  

If the specification is exceeded: 

z

Check oil galleries.  

z

If necessary, replace oil filter bracket with pressure relief valve. See Fig. 139 , item -14-. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1184  1185  1186  1187   ..