Volkswagen New Beetle. Manual - part 1192

 

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Volkswagen New Beetle. Manual - part 1192

 

 

z

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

z

Remove air conditioner compressor, leaving refrigerant hoses connnected. 

See COMPRESSOR . 

z

Secure air conditioner compressor to towing eye so that refrigerant hoses/lines are not under tension. 

Fig. 23: Securing Air Conditioner Compressor To Towing Eye 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ENGINE - CRANKSHAFT, CYLINDER BLOCK 

ENGINE, DISASSEMBLING AND ASSEMBLING 

NOTE:

To prevent damage to bumper protect with adhesive tape.

NOTE:

z

When stripping and assembling the engine it should be secured to the engine fram
with engine and transmission bracket VW540 and supplementary set VW 540/1B. 

z

If large amounts of material (as metallic particles and abrasive fragments) remove
by a cutting or grinding tool or wear are discovered during engine repair work, thi
can be from damage to the crankshaft or connecting rod bearings due to partial 
seizure or oil loss. To prevent any further damage from occurring, carry out the 
following once the repair procedure is complete: 

{

Thoroughly clean oil channels  

{

Replace oil spray jets  

{

Replace oil cooler  

{

Replace oil filter 

I. See PART I 

 

2003 Volkswagen New Beetle GLS 

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

  

PART I 

1. 25 N.m  

2. Tensioning device for ribbed belt 

z

Turn with open-end spanner to loosen ribbed belt. See RIBBED BELT TENSIONER, 
REMOVING AND INSTALLING
  

3. Toothed belt guard - upper part  

4. Toothed belt guard - center section  

5. 27 N.m  

6. Idler wheel  

7. Tensioning roller  

8. Toothed belt 

z

Mark direction of travel before removing  

z

Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING
  

9. Coolant pump 

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING  

10. O-Ring 

z

Always replace if damaged  

Fig. 24: Disassembling And Assembling Engine 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

II. See PART II  

NOTE:

The following list refers to items in Fig. 25 .

 

2003 Volkswagen New Beetle GLS 

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

  

11. 15 N.m  

12. Tensioner for toothed belt  

13. Crankshaft toothed belt sprocket  

14. 15 N.m  

15. 20 N.m  

16. 90 N.m + 1/4 turn (90°) further 

z

Always replace  

z

Counter-hold with 3099 to loosen and tighten  

z

When bolting on, place two washers between toothed belt pulley and counter-hold  

17. Toothed belt guard - lower part  

18. 10 N.m 

z

Insert with locking fluid D 000 600 A2  

19. Pulley 

z

For power assisted steering pump  

20. 25 N.m  

21. Ribbed belt 

z

Mark direction of rotation before removing  

z

Removing and installing. See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING
  

22. 25 N.m  

23. Belt pulley/vibration damper 

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Can only be installed in one position (holes are offset)  

z

Note position when installing toothed belt TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING
  

Fig. 25: Exploded View Of Engine (Front Engine Components - Part I 
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)

  

PART II 

Fig. 26: Exploded View Of Engine (Cylinder Block Components) - Part II 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Knock sensor 1 -G61- 

z

Checking: 

See DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE, CHECKING AND 
ERASING
 

2. 20 N.m 

z

Tightening torque influences function of knock sensor  

3. Knock sensor 2 -G66- 

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Checking: 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) 

4. Dipstick 

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Oil level must not be above the max. mark!  

5. Guide 

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For dipstick  

6. O-Ring 

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Always replace  

7. Coolant pipe  

8. 20 N.m  

9. Oil filter bracket 

NOTE:

The following list refers to items in Fig. 26 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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