Volkswagen New Beetle. Manual - part 978

 

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Volkswagen New Beetle. Manual - part 978

 

 

1998-2004 ENGINE

Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW) 

TECHNICAL DATA 

ENGINE NUMBER LOCATIONS 

The engine number ("Code letters" and "Serial number") can be found on the joint between the engine and 
transmission (arrow). 

Fig. 1: Locating Engine Number 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters) 
makes up the "engine code", and the second part (6 letters/numbers), the "serial number". If more than 999,999 
engines with the same engine code are produced, the first of the six characters is replaced with a letter. 

The engine code is also included on the vehicle data plate. 

ENGINE DATA 

ENGINE DATA 

NOTE:

There is a sticker on the toothed belt guard with "Engine code" and "Serial 
number".

Engine code letter

BEW

Production

from 07.03

Emissions fulfil

LEV 1

Displacement

liters

1.9

Output

kW at rpm

74/4000

Torque

N.m at rpm

240/1800 to 2400

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

ENGINE, REMOVING AND INSTALLING 

Special tools and equipment 

z

2024 A Engine sling  

z

T10012 Engine/trans. support  

z

VW313 Holding fixture  

z

VW 540 Holding fixture  

z

V.A.G 1202 A Workshop crane  

z

V.A.G 1306 Drip tray for VAG1202A 

Fig. 2: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bore

diameter mm

79.5

Stroke

mm

95.5

Compression ratio

17.5

CN

min.

49

Ignition sequence

1-3-4-2

Catalytic converter

yes

Exhaust gas recirculation

yes

(1)

Turbocharging

yes

Charge air cooling

yes

(1)

with exhaust gas heat exchanger

NOTE:

The following list refers to items in Fig. 2 .

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Special tools and equipment 

z

V.A.G 1331 Torque wrench (5 to 50 Nm)  

z

V.A.G 1332 Torque wrench (40 to 200 Nm)  

z

V.A.G 1383 A Engine/transmission jack  

z

VAS 5024 Assembly tool for spring-type clips  

z

VAS 5085 Step ladder  

z

G 000 100 Lubrication grease (manual transmission only)  

z

Bolt M10 x 25 / 8.8  

z

Cable ties 

Fig. 3: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTES ON REMOVING 

z

The engine is removed downward together with the transmission. 

z

All cable ties which are opened or cut through when engine is removed must be replaced in the same 
position when engine is installed.  

Work sequence 

CAUTION: When performing repair work, especially due to the confined 

conditions in the engine compartment, pay attention to the following: 

z

Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP 
system, coolant, refrigerant, brake fluid and vacuum) as well as 
electrical wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

z

Check whether a coded radio is installed. If so, obtain anti-theft coding.  

z

With ignition switched off disconnect battery Ground (GND) strap.  

z

Remove engine cover. 

{

Pull front of engine cover abruptly upward (arrow -A-) and then pull forward out of rear securing 
elements (arrow -B-).  

Fig. 4: Removing Engine Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove battery.  

z

Remove air cleaner housing with intake hose.  

z

Remove battery console.  

z

Remove lower charge air pipe -1-.  

z

Remove bolt/screw -2- and release connector (arrow). 

Fig. 5: Removing Lower Charge Air Pipe 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully cover or close open ends.  

z

Install center and left and right side sound insulation (arrow). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

 

 

 

 

 

 

 

Content   ..  976  977  978  979   ..