Volkswagen New Beetle. Manual - part 1194

 

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Volkswagen New Beetle. Manual - part 1194

 

 

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T40011 Locking pin  

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VAG1331 Torque wrench (5 to 50 N.m)  

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V.A.G 1332 Torque wrench (40 to 200 N.m)  

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D 000 600A2 Locking fluid 

Fig. 32: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Note safety precautions before starting work. See SAFETY PRECAUTIONS WHEN WORKING ON 
FUEL SUPPLY
  

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Observe rules for cleanliness. See RULES OF CLEANLINESS .  

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Remove engine cover.  

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Remove right-hand insulation tray. 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

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

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 33: Removing Air Duct To Charge Air Cooler At Bottom Right Of Long Member 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

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Remove tensioning element for ribbed belt. 

Engine installed: 

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Turn crankshaft to TDC No.1 cylinder (vehicles with manual transmission). 

Fig. 34: Turning Crankshaft To TDC No.1 Cylinder (Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft to TDC No.1 cylinder (vehicles with automatic transmission). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 35: Turning Crankshaft To TDC No.1 Cylinder (Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

With engine removed: 

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Turn vibration damper to TDC No. 1 cylinder -arrows-. 

Fig. 36: Turning Vibration Damper To TDC No. 1 Cylinder 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove coolant expansion tank and place to side.  

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Pull off vacuum pipes at EVAP canister and at throttle valve housing.  

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Remove toothed belt guard (upper part).  

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Install engine support bracket 10-222A with legs 10-222A/1. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 37: Installing Engine Support Bracket 10-222A With Legs 10-222A/1 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Locate bracket 3180 in lifting eye on cylinder head and take-up weight of engine.  

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Remove securing bolts from assembly mount/engine mount, assembly mount/body and assembly 
mount/body mount -arrows- and remove assembly mount complete. 

Fig. 38: Assembly Mount/Body Mount Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove vibration damper/belt pulley.  

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Remove lower and center toothed belt guard. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1192  1193  1194  1195   ..