Volkswagen New Beetle. Manual - part 1714

 

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Volkswagen New Beetle. Manual - part 1714

 

 

Fig. 7: Removing & Installing Starter 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

OVERHAUL 

Manufacturer recommends replacing starter as an assembly. Exploded view and overhaul procedures are not 
available from manufacturer.  

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

Application 

Ft. Lbs. (N.m) 

Power Steering Line Retaining Bolt 

15 (20) 

Starter Mounting Bolt 

48 (65) 

INCH Lbs. (N.m)

Battery Carrier Bolt 

53 (6) 

Starter Solenoid Terminal Nut 

115 (13) 

 

2003 Volkswagen New Beetle GLS 

2001-04 STARTING & CHARGING SYSTEMS Starters - New Beetle

  

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© 2004 Mitchell Repair Information Company, LLC. 

WIRING DIAGRAMS 

See appropriate STARTING SYSTEM wiring diagram in SYSTEM WIRING DIAGRAMS article. 

 

2003 Volkswagen New Beetle GLS 

2001-04 STARTING & CHARGING SYSTEMS Starters - New Beetle

  

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Wednesday, December 14, 2005 8:39:56 AM

Page 10 

© 2004 Mitchell Repair Information Company, LLC. 

VOLKSWAGEN 

1.9L 4-Cylinder - Turbo Diesel - ALH Engine 

MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE 

SCHEDULED MAINTENANCE INTERVAL 

REMOVAL & INSTALLATION 

TIMING BELT 

Removal (Golf & Jetta) 

1. Working under hood, remove fuel supply and return lines from fuel filter. Seal fuel lines to prevent 

contamination of fuel system. Remove upper and lower right headlight assembly mounting screws. 
Disconnect harness connectors and remove right headlight assembly.  

2. Remove pipe between charge air cooler (intercooler) and intake manifold. Remove upper engine cover. 

Remove right sound damper cover.  

3. If serpentine belt is to be reused, mark rotational direction of belt. Using a 16 mm box wrench, rotate 

serpentine belt tensioner clockwise to relieve belt tension, and remove serpentine belt. Remove serpentine 
belt tensioner.  

4.  

Model Year 

(1)

Interval 

1998-99 

60,000 

2000 

40,000 

2001 

(2)

40,000 

2001 

(3)

60,000 

2002 

80,000 

2003-04 

100,000 

(1)

Replace timing belt and tensioner together.

(2)

Models equipped with automatic transmissions.

(3)

Models equipped with manual transmission.

CAUTION: This application is an interference engine. Do not rotate camshaft or 

crankshaft when timing belt is removed, or engine damage may occur. 

NOTE:

Timing belt installation procedure requires using a factory scan tester (VAG 
1551/1552) to adjust injection pump timing. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:59 AM

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© 2004 Mitchell Repair Information Company, LLC. 

Helpmelearn Repair Manuals 

 

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Remove brake booster vacuum pump. Remove upper timing belt cover. Remove engine valve cover using 
care not to damage gasket.  

5. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed 

through access hole in engine-to-transmission mating flange. See Fig. 1 .  

6. Lock camshaft in place with Camshaft Setting Bar (3418) installed on rear of camshaft. See Fig. 2 . 

Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler 
gauge, measure distance between other end of setting bar and cylinder head. Divide this dimension in 
half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar 
and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of 
same dimension between other end of bar and cylinder head. 

CAUTION: The valve cover has an integrated, vulcanized gasket. If gasket is 

damaged or leaking, replace the valve cover. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:59 AM

Page 2 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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