Volkswagen New Beetle. Manual - part 1716

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1714  1715  1716  1717   ..

 

 

Volkswagen New Beetle. Manual - part 1716

 

 

1. Ensure cylinder No. 1 is at TDC. Check reference mark on flywheel and bellhousing. See Fig. 1 .  

2.  

Using Spanner Wrench (3036) counter-hold camshaft and loosen camshaft sprocket bolt 1/2 turn. See 
Fig. 4 . On New Beetle, place drift punch through rear timing belt cover and LIGHTLY tap camshaft 
sprocket loose from tapered end of camshaft. On Golf and Jetta, use a Two Arm Puller (T40001) to 
remove sprocket. Remove camshaft sprocket.  

3. Install timing belt onto crankshaft sprocket, idler pulley, water pump, injection pump sprocket, and 

tensioner pulley. Adjust injection pump sprocket on mount so mounting slots are centered. If installing 
old belt, note direction of rotation mark.  

4. Install camshaft sprocket together with timing belt. Install camshaft sprocket bolt finger tight. Camshaft 

sprocket should still be free to turn.  

5. On Golf and Jetta with automatic transaxle, use an Allen wrench to turn timing belt tensioner clockwise 

until notch and pointer align. See Fig. 5 . If tensioner is turned too far and correct tension is exceeded, 
tension must be fully released, and then readjusted. Tighten center lock nut on tensioner pulley to 
specification. See TORQUE SPECIFICATIONS .  

6. On Golf and Jetta with manual transaxle and New Beetle, install Tension Pin Wrench (MATRA V159) on 

timing belt tensioner pulley. See Fig. 6 . Turn wrench clockwise until notch and raised mark are aligned. 
Tighten tensioner pulley center nut to specification. See TORQUE SPECIFICATIONS .  

7. On all models, ensure tensioner is correctly installed in rear timing belt cover. See Fig. 7 . Ensure TDC 

marks on flywheel are still aligned. Using Spanner Wrench (3036) counter-hold camshaft and tighten 
camshaft sprocket center bolt to specification. See TORQUE SPECIFICATIONS .  

8. Install NEW torque-to-yield mounting bolts in diesel injection pump sprocket. Tighten injection pump 

bolts to 15 ft. lbs. (20 N.m). Before final tightening of injection pump mounting bolts, perform start of 
injection procedure (dynamic timing) using factory scan tester (VAG 1551/1552). After performing start 
of injection procedure, tighten injection pump sprocket mounting bolts an additional 90 degrees (1/4 
turn).  

9. Remove camshaft setting bar from rear of camshaft. Remove lock pin from injection pump.  

10. Rotate crankshaft 2 complete revolutions. Place crankshaft at TDC and ensure belt timing is correct. 

Ensure timing belt tensioner pulley marks are still aligned.  

11. To complete installation, reverse removal procedure. When installing engine mount, install mounting 

bolts in holes on bracket before attempting to fit bracket to engine block. Tighten nuts and bolts to 
specification. See TORQUE SPECIFICATIONS . Check fuel lines for leaks. Adjust drive belts to 
proper tension.  

12. Using scan tester (VAG 1551/1552), check Diesel injection pump start of delivery.  

NOTE:

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

CAUTION: Use Spanner Wrench (3036) to hold camshaft sprocket while 

loosening and tightening camshaft sprocket bolt. DO NOT use 
Camshaft Setting Bar (3418) to hold camshaft sprocket. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:00 AM

Page 7 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 4: Securing Camshaft Sprocket 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:00 AM

Page 8 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta With Automatic Transaxle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:00 AM

Page 9 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 6: Adjusting Timing Belt Tension (Golf & Jetta With Manual Transaxle, & New Beetle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 7: Installing Timing Belt Tensioner 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:41:00 AM

Page 10 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  1714  1715  1716  1717   ..