Volkswagen New Beetle. Manual - part 1197

 

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Volkswagen New Beetle. Manual - part 1197

 

 

Fig. 49: Screwing Center Bolt Into Crankshaft Onto Stop By Hand 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Unscrew inner part of oil seal extractor 3203 nine turns (approx. 20 mm) out of outer part and lock with 
knurled screw.  

z

Lubricate threaded head of oil seal extractor 3203, place it in position and exerting firm pressure screw it 
as far as possible into oil seal. 

Fig. 50: Lubricating Threaded Head Of Oil Seal Extractor 3203 And Placing In Position And 
Exerting Firm Pressure Screw
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.  

Installing 

NOTE:

Gradual introduction of PTFE oil seal (identifying characteristics: no annular 
spring, sealing lip wider). The sealing lip of this oil ring must not be oiled or 
lubricated. A plain encased seal of older construction (with annular spring) may 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Install guide sleeve from 2080 A onto crankshaft journal. 

Fig. 51: Installing Guide Sleeve From 2080 A Onto Crankshaft Journal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Slide oil seal over guide sleeve onto crankshaft stub.  

z

Press in seal with press sleeve from 3265. To do this use old central bolt for crankshaft toothed belt 
sprocket. 

Fig. 52: Pressing In Seal With Press Sleeve From 3265 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press sleeve in onto stop.  

z

Install crankshaft toothed belt sprocket and hold with counter-hold tool 3099. 

be replaced with a PTFE oil seal, but not vice versa.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 53: Installing Crankshaft Toothed Belt Sprocket And Holding With Counter-Hold Tool 3099 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Tighten new central bolt to 90 N.m + 1/4 turn (90°) further. 

z

Install toothed belt and adjust valve timing. See INSTALLING .  

z

Install ribbed belt and tensioning element. See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING
 .  

Front sealing flange, removing and installing 

Special tools and equipment 

z

3099 Counter-hold tool  

z

2080 A Fitting sleeve  

z

VAG 1331 Torque wrench (5-50 N.m)  

z

VAG 1332 Torque wrench (40-200 N.m)  

z

D 176 404 A2 Silicone sealant  

z

Hand drill with plastic brush wheel  

z

Flat scraper  

z

Protective glasses 

NOTE:

z

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

z

Thread and shoulder must be free of oil and grease.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 54: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

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

z

Remove toothed belt. See REMOVING .  

z

Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3099. 

Fig. 55: Removing Crankshaft Toothed Belt Sprocket By Counter-Holding Sprocket With 3099 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove oil pan. See OIL PAN, REMOVING AND INSTALLING .  

z

Unbolt front sealing flange.  

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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