Volkswagen New Beetle. Manual - part 1187

 

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Volkswagen New Beetle. Manual - part 1187

 

 

1998-2004 ENGINE

Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP) 

GENERAL, TECHNICAL DATA 

TECHNICAL DATA 

Engine number 

The engine number ("Code letters" and "Serial number") can be found on the front at the connection between 
the engine and transmission. 

Fig. 1: Identifying Engine Number Location 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Additionally there is a sticker on the cylinder head cover with "Engine code" and "Serial number." 

The engine code is also included on the vehicle data plate. 

Engine data 

ENGINE DATA 

Engine code

APH

AWV

AWP

Manufactured starting

02.99 and up

07.00 and up

09.01 and up

Exhaust gas limits according to

OBD II

OBD II

OBD II

Displacement l

1.8

1.8

1.8

Output kW @ RPM

110/5800

110/5700

132/5500

Torque N.m @ RPM

220 @ 2000 to 4200 220 @ 1750 to 4600 235 @ 1950 to 5000

Bore diameter mm

81.0

81.0

81.0

Stroke mm

86.4

86.4

86.4

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

ENGINE - ASSEMBLY 

ENGINE, REMOVING AND INSTALLING 

Special tools and equipment 

z

VW 313 Support clamp  

z

VW 540 Engine and transmission support  

z

2024 A Lifting tackle  

z

3180 Retainer (for turbocharged engines)  

z

VAG1202 A Workshop crane  

z

VAG1306 Drip tray 

Compression ratio

9.5:1

9.5:1

9.5:1

RON min.

95 unleaded

95 unleaded

98 unleaded

System identification

Motronic ME7.5

Motronic ME7.5

Motronic ME7.5

Emissions limits according to

TLEV

(1)

LEV

(2)

LEV

(2)

Knock sensor control

2 knock sensors

2 knock sensors

2 knock sensors

On Board Diagnostic (OBD)

OBD II

OBD II

OBD II

Oxygen sensor control

2 sensors

2 sensors

2 sensors

Three Way Catalytic Converter (TWC)

yes

yes

yes

Exhaust Gas Recirculation (EGR)

no

no

no

Variable intake manifold

no

no

no

Camshaft adjustment

no

yes

yes

Turbocharging system

yes

yes

yes

Boost pressure regulation

yes

yes

yes

Secondary air system

yes

yes

yes

(1)

TLEV = Transitional Low Emission Vehicles (emission values max. 0.125 g/mi HC)

(2)

LEV = Low Emission Vehicles (emission values max. 0.075 g/mi HC)

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 2: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VAG1331 Torque wrench (5-50 N.m)  

z

VAG1332 Torque wrench (40-200 N.m)  

z

VAG1383 A Engine/transmission jack  

z

T10012 Engine bracket  

z

VAS 5024 Assembly tool for spring-type clamps  

z

V.A.S 5085 Step ladder (not shown)  

z

G 000 100 grease (vehicles with manual transmission) (not shown)  

z

Bolt M1 0X 25 / 8.8 (not shown)  

z

Cable tie (not shown) 

Fig. 3: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Removal notes 

z

First check whether a coded radio is installed. If so, obtain anti-theft coding.  

The engine is removed downward together with the transmission. 

z

With ignition switched off, disconnect battery Ground strap.  

z

All cable ties which are opened or cut open when removing engine must be replaced in same position 
when installing engine.  

z

Remove engine cover.  

z

Remove air cleaner: 

See AIR FILTER, DISASSEMBLING AND ASSEMBLING . 

z

Remove intake hose between Mass Air Flow (MAF) sensor -G70- and turbocharger. 

See FUEL INJECTION, SERVICING . 

z

Remove power steering fluid reservoir from battery holder without disconnecting hoses.  

z

Fasten reservoir to lock carrier.  

z

Remove battery and battery retainer.  

z

Pull vacuum and breather hoses off engine. 

z

Pull off supply line/hose -1- (with white marking) and return line/hose -2- (with blue marking) and collect 
fuel that leaks out with a cloth. 

WARNING:

z

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

z

Fuel supply lines are under pressure! Before removing from 
hose connection wrap a cloth around the connection. Then 
release pressure by carefully pulling hose off connection.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

 

 

 

 

 

 

 

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