Volkswagen New Beetle. Manual - part 979

 

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Volkswagen New Beetle. Manual - part 979

 

 

Fig. 6: Identifying Center And Left And Right Side Sound Insulation 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Drain coolant. See COOLANT, DRAINING AND FILLING .  

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Remove rear coolant hose from oil cooler.  

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Remove radiator coolant hoses from engine using hose clip pliers V.A.G 1921 or VAS 5024.  

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Remove wiring harness from Generator and lay to one side.  

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Disconnect all electrical wiring from transmission and starter and move clear.  

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Tie power steering reservoir on lock carrier.  

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Remove fuel supply hose -1- and fuel return hose -2- from fuel lines on cylinder head.  

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Remove poly V-belt. See POLY V-BELT, REMOVING AND INSTALLING .  

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Remove selector lever cable. 

See SELECTOR LEVER CABLE . 

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Remove all other inter-connecting, coolant, vacuum and intake hoses on engine.  

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Remove/disconnect all electrical connections as necessary from engine and lay to one side. 

WARNING:

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The fuel and the fuel lines in the fuel system can become very hot 
(danger of scalding.)  

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The fuel system is also under pressure! Before opening the system, 
place cloths around the connections. Then carefully loosen the 
connection to release pressure.  

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Wear eye and hand protection when performing any type of repair 
work on the fuel system!  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 7: Removing Fuel Supply Hose And Fuel Return Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove right side axle shaft and disconnect left side axle shaft at transmission: 

See FRONT AXLE SHAFT . 

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Remove securing clamps for power steering pressure line.  

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Remove power steering pump from bracket place to side; hoses remain connected: 

See POWER STEERING PUMP WITH HYDRAULIC LINES/HOSE . 

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Removing subframe: 

See SUBFRAME . 

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Remove front exhaust pipe. See FRONT EXHAUST PIPE AND CATALYST WITH 
COMPONENTS
 .  

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Unbolt pendulum support in stated sequence (arrow). 

Fig. 8: Removing Pendulum Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Vehicles with air conditioning 

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Observe additional information and removal. See ADDITIONAL NOTES AND ASSEMBLY STEPS 
FOR VEHICLES WITH AIR CONDITIONING
 .  

Continued for all vehicles 

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Insert engine bracket T10012 in engine/transmission jack V.A.G 1383 A. 

Fig. 9: Inserting Engine Bracket In Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove bracket on cylinder block for lower coolant hose. Threaded hole is required to secure engine 
bracket T10012.  

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Secure engine bracket T10012 to cylinder block with securing nuts and bolt M10 X 25 / 8.8 to N.m.  

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Lift engine and transmission lightly using engine/transmission jack V.A.G 1383 A.  

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Unbolt top of engine bracket (arrows) on engine mounting. 

Fig. 10: Removing Top Of Engine Bracket On Engine Mounting

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Unbolt top of transmissions bracket (arrows -B-) on transmission mounting. 

Fig. 11: Removing Top Of Transmissions Bracket On Transmission Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Carefully lower engine and transmission.  

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While lowering, guide power steering pressure line past transmission. 

ENGINE, ATTACHING TO ASSEMBLY STAND 

Work sequence 

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Transfer engine/transmission subassembly to workbench via engine/transmission jack VAG 1383 A. 

NOTE:

To remove securing bolts, use step ladder VAS 5085.

NOTE:

The engine and transmission must be guided carefully when lowering to 
prevent damage to the body.

NOTE:

To work on the engine outside of the vehicle, attach the engine to an assembly 
stand using the VW 313 holding fixture along with the VW 540 
engine/transmission support.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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