Volkswagen New Beetle. Manual - part 1720

 

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Volkswagen New Beetle. Manual - part 1720

 

 

Fig. 1: Identifying Air Duct 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. Mark rotation direction of serpentine drive belt. Move serpentine drive belt tensioner as shown to release 

tension on belt. See Fig. 2 . Secure tensioner using a drift, about .18" (4.5 mm) x 2.2" (55 mm). See Fig. 
3
 . Remove serpentine drive belt. Remove serpentine drive belt tensioner. 

4. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Ensure that TDC marks on 

flywheel and bellhousing are aligned. See Fig. 4 or Fig. 5 .  

5. Remove coolant expansion tank and set aside. Label all vacuum hoses for reassembly reference, and 

disconnect vacuum hoses from fuel evaporative canister. Disconnect vacuum hoses at throttle body.  

6. Remove upper timing belt cover. See Fig. 6 .  

7. Attach Engine Support Bridge (10-222A) with Bracket (10222), and engage retainer in right lifting eye 

bolt located at cylinder head. Lift engine slightly to remove weight from engine mounts. Engine may also 
be supported from below with a floor jack. 

NOTE:

On vehicles without headlight cleaning system, Connecting Rod Support 
(3090) can also be used to secure tensioner. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:23 AM

Page 2 

© 2004 Mitchell Repair Information Company, LLC. 

8.  

Remove bolts from engine mount assembly at timing belt end of engine. Remove engine mount.  

9. Remove 4 crankshaft pulley socket-head bolts. Remove crankshaft pulley. It is NOT necessary to remove 

crankshaft pulley center bolt.  

10. Remove lower and middle timing belt covers. Remove engine bracket from engine block. See Fig. 7 . If 

reusing old timing belt, mark timing belt with arrow to indicate original direction of rotation.  

11. Screw Tensioning Bolt (T10092) or M5 x 55 x 1 stud into timing belt tensioner bracket. See Fig. 8 . 

Install hex nut and washer onto stud.  

12. SLOWLY turn hex nut on stud to compress timing belt tensioner. Compress tensioner just enough so that 

Locking Pin (T40011) or drill bit can be inserted through the tensioner body, locking the tensioner in 
place.  

13.  

Remove timing belt. Turn crankshaft back just slightly to ensure that crankshaft is not at TDC for any 
cylinder in case camshaft moves.  

CAUTION: Engine mount assembly is secured by torque-to-yield bold. 

Crankshaft pulley CENTER bolt is also a torque-to-yield bolt. These 
bolts MUST be replaced if they are loosened or removed. 

CAUTION: When turning camshaft, crankshaft must not be at TDC, or there is a 

potential for valves to contact pistons. Install timing belt when 
engine is cold or lukewarm. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:23 AM

Page 3 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 2: Releasing Serpentine Drive Belt Tension (1 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:23 AM

Page 4 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 3: Releasing Serpentine Drive Belt Tension (2 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:23 AM

Page 5 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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