Volkswagen New Beetle. Manual - part 849

 

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Volkswagen New Beetle. Manual - part 849

 

 

Fig. 20: Removing Generator (1.8L) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:44 AM

Page 26 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 21: Driving Threaded Sleeves In Generator 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Removal & Installation (1.9L TDI & TDI-PD) 

1. Disconnect battery. Raise and support vehicle. Remove bolts (arrows) on sides of insulation panel. See 

Fig. 14 . Lower and remove cover.  

2.  

Remove bolts (1). See Fig. 15 . Release clips (2). Pull heat shield out of retainer (3).  

3. On vehicle equipped with 1.9L TDI engine, pry out caps (arrows), and release fasteners underneath. See 

Fig. 22 . Remove nut (1). Pull oil dipstick out. Remove engine cover. Remove charge air pipe between 
charge air cooler and exhaust turbocharger. See Fig. 23 . Turning tensioner in direction of arrow, loosen 
tensioner. See Fig. 24 .  

NOTE:

DO NOT reuse clips (2). See Fig. 15 . Always replace after releasing. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:44 AM

Page 27 

© 2004 Mitchell Repair Information Company, LLC. 

4. On vehicles equipped with 1.9L TDI-PD engine, carefully pull front of engine cover upward (arrow "A"), 

and pull forward out of retainers (Arrow "B"). See Fig. 25 . Pull oil dipstick out. Remove engine cover. 
Remove charge air pipe between charge air cooler and exhaust turbocharger. See Fig. 26 . Turning 
tensioner in direction of arrow, loosen tensioner. See Fig. 18 .  

5.  

On all vehicles, use special tool (3090) to block tensioner. Remove belt from idler. Remove belt from 
other components. Move lock carrier into service position. See LOCK CARRIER .  

6. Remove nut from terminal 30/B+ connection. Disconnect electrical connector (2). See Fig. 20 . Remove 

harness retainer (3). Remove M8 hex bolts connecting generator to bracket. Lift generator out from 
engine compartment.  

7. To install, reverse removal procedure. Where applicable, drive threaded sleeves (A) approximately 4 mm 

in direction of arrow. See Fig. 21 . Tighten all generator bolts to specification. See TORQUE 
SPECIFICATIONS 
.  

8. Ensure all assemblies are suecurely mounted and turn freely. For aid in belt routing, see Fig. 2 . Counter-

hold tensioner, and remove special tool (3090). Slowly release tensioner to engage ribbed belt.  

9. Install charge air pipe between charge air cooler and exhaust turbocharger. See Fig. 23 or Fig. 26 . 

Tighten bolt to specification. See TORQUE SPECIFICATIONS . Start engine and check belt running. 
To complete installation, reverse removal procedure. 

CAUTION: Mark direction of rotation of serpentine belt, if it is to be reused. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:44 AM

Page 28 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 22: Removing Engine Cover (1.9L TDI) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:44 AM

Page 29 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  847  848  849  850   ..