Volkswagen New Beetle. Manual - part 1188

 

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Volkswagen New Beetle. Manual - part 1188

 

 

Fig. 4: Pulling Off Supply Line/Hose And Return Line/Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Seal pipes so that fuel system is not contaminated by dirt etc.  

z

Pull hose off solenoid valve. 

z

Loosen and remove intake hose (between charge air cooler and Throttle Valve Control Module -J338-) at 
Throttle Valve Control Module -J338-.  

z

Disconnect harness connector for Intake Air Temperature (IAT) sensor -G42-, -1- and -4- for Throttle 
Valve Control Module -J338- below Throttle Valve Control Module -J338-. 

Fig. 5: Disconnecting Harness Connector For Intake Air Temperature Sensor G42 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pull connector off Camshaft Position (CMP) sensor -G40- -arrow-. 

NOTE:

Press buttons on hose couplings to do this.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 6: Pulling Connector Off Camshaft Position Sensor G40 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Unbolt vacuum canister from cylinder head cover and pull from bracket.  

z

Disconnect fuel injectors harness connector and unclip bracket rail from fuel distributor.  

z

Unscrew Ground wire between ignition coil -1- and -2-.  

z

Disconnect connectors from ignition coils.  

z

Disconnect connector for speedometer Vehicle Speed Sensor -G22- at rear of transmission.  

z

Remove center, left and right insulation tray: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING . 

z

Remove air duct to charge air cooler at lower right of long member. 

Fig. 7: Removing Air Duct To Charge Air Cooler At Lower Right Of Long Member 
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)

  

Vehicles with manual transmission 02J 

z

Disconnect selector mechanism from transmission. 

See SELECTOR MECHANISM ON TRANSMISSION SIDE, UP TO 05.99, DISASSEMBLING 
AND ASSEMBLING
 or SELECTOR MECHANISM ON TRANSMISSION SIDE, AS OF 06.99, 
DISASSEMBLING AND ASSEMBLING
 . 

z

Remove hydraulic clutch slave cylinder. 

See CLUTCH SLAVE CYLINDER . 

Vehicles with manual transmission 02M 

z

Disconnect selector mechanism from transmission. 

See SELECTOR LEVER LOCK SOLENOID . 

z

Remove hydraulic clutch slave cylinder. 

See CLUTCH RELEASE BEARING/SLAVE CYLINDER . 

Vehicles with automatic transmission 

z

Remove selector lever cable from transmission: 

See SELECTOR LEVER CABLE . 

Continued for all vehicles 

z

Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING . 

z

Pull radiator coolant hoses off engine. 

z

Remove coolant hoses at heater core.  

z

Remove coolant hose to coolant pipe at Throttle Valve Control Module -J338-.  

NOTE:

Clutch pedal must not be depressed.

WARNING:

Observe proper disposal regulations!

NOTE:

The VAS 5024 assembly tool or VAG 1921 pliers are recommended for 
removing and installing the spring-type clamps.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove additional fan at right side of vehicle if present.  

z

Disconnect both harness connectors for cooling fan at notch at left bottom.  

z

Remove inter-connecting, coolant, vacuum and intake hoses on engine.  

z

Remove connecting hoses -arrows- between secondary air pump/combi-valve and secondary air pump/air 
cleaner. 

Fig. 8: Removing Connecting Hoses Between Secondary Air Pump/Combi-Valve And Secondary 
Air Pump/Air Cleaner
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pull connector -1- off secondary air pump.  

z

Remove secondary air pump motor and bracket.  

z

Disconnect all electric wires from transmission, alternator and starter and move clear.  

z

Remove securing clamps for power steering pressure pipe.  

z

Remove ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

z

Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected. 

See POWER STEERING PUMP, RESERVOIR, HYDRAULIC LINES . 

Vehicles with air conditioner 

z

Remove air conditioner compressor.  

z

Observe additional notes and assembly work. See INSTALLATION NOTES .  

z

Remove generator. 

NOTE:

Press buttons on hose couplings to do this.

WARNING:

The air conditioner refrigerant circuit must not be opened.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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