Volkswagen New Beetle. Manual - part 1722

 

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Volkswagen New Beetle. Manual - part 1722

 

 

Fig. 8: Installing Timing Belt Tensioner Locking Pin 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Installation 

1. Ensure camshaft is still at TDC of compression stroke for No. 1 cylinder. Align timing marks on camshaft 

sprocket with mark on cylinder head cover. See Fig. 9 .  

2.  

Install timing belt around crankshaft sprocket. If installing used belt, ensure it is installed in original 
direction of rotation. Install engine mount bracket to block. Install lower timing belt guard. Use Locking 
Fluid (D 000 600 A2) on lower timing belt cover bolts. Install crankshaft pulley, and tighten bolts to 
specification. See TORQUE SPECIFICATIONS .  

3. Rotate crankshaft to TDC No. 1 cylinder. See Fig. 9 . Place timing belt on water pump, tensioner pulley 

and camshaft sprocket.  

4. Remove Locking Pin (T40011) or drill bit and unscrew Tensioning Bolt (T10092). See Fig. 8 .  

5. Turn crankshaft 2 revolutions, and check that camshaft and crankshaft marks align properly. See Fig. 9 .  

6. Install middle and upper timing belt covers. Tighten bolts to specification. See TORQUE 

SPECIFICATIONS .  

7. Install engine mount to engine bracket and body using NEW bolts. Adjust engine mount clearance. See 

Fig. 10 .  

NOTE:

Before installing engine mount, insert bolts into engine mount. 

 

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 10 

© 2004 Mitchell Repair Information Company, LLC. 

8. Remove engine support bridge or floor jack. Install serpentine drive belt tensioner. Install serpentine drive 

belt. Install the A/C compressor drive belt (if equipped). Ensure used belts are installed in original 
direction of rotation.  

9. To complete installation, reverse remaining removal procedure. Tighten all fasteners to specification. See 

TORQUE SPECIFICATIONS .  

Fig. 9: Aligning Camshaft & Crankshaft Timing Marks 
Courtesy of AUDI OF AMERICA, 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 11 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 10: Adjusting Engine Mount Clearance 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

Application 

Ft. Lbs. (N.m) 

Camshaft Sprocket Bolt 

59 (80) 

Crankshaft Pulley Bolt 

18 (25) 

Crankshaft Sprocket Center Bolt 

(1)

Step 1 

66 (90) 

Step 2 

Plus 1/4 Turn (90 Degrees 

Engine Mount Bracket-To-Engine 

33 (45) 

Engine Mount-To-Body 

(1)

 

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 12 

© 2004 Mitchell Repair Information Company, LLC. 

Step 1 

30 (40) 

Step 2 

Plus 1/4 Turn (90 Degrees 

Engine Mount-To-Engine Bracket 

(1)

Step 1 

44 (60) 

Step 2 

Plus 1/4 Turn (90 Degrees 

Serpentine Drive Belt Tensioner Bolt 

18 (25) 

Timing Belt Cover Bolt 

15 (20) 

Timing Belt Idler Pulley Bolt 

15 (20) 

Timing Belt Tensioner Mount Bolt 

11 (15) 

Timing Belt Tensioner Pulley Bolt 

18 (25) 

Water Pump Bolt 

11 (15) 

(1)

Replace bolts if loosened or removed.

 

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 13 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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