Volkswagen New Beetle. Manual - part 980

 

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Volkswagen New Beetle. Manual - part 980

 

 

Fig. 12: Attaching Engine To Assembly Stand 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lower engine/transmission assembly so that transmission is supported by work bench.  

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Remove engine/transmission connecting bolts.  

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Push transmission off engine.  

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Attach lifting tackle 2024A as follows and lift off engine/transmission jack V.A.G 1383 A using 
workshop crane. 

Fig. 13: Attaching Lifting Tackle And Lift Off Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Belt pulley end: 2nd hole on support bar in position 1  

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Flywheel end: 4th hole on support bar in position 8  

WARNING:

Secure ALL hooks and locating pins with lock pins!

NOTE:

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Positions marked 1 to 4 on the bar must face toward the pulley end of 
the engine.  

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The holes in the hook rails are counted up from the hook.  

 

2003 Volkswagen New Beetle GLS 

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

  

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Secure engine to holding fixture VW 313 using engine and transmission support VW 540 and 
supplementary set VW 540/1B. 

NOTES ON INSTALLING 

Installation is performed in reverse order. Note following: 

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Install intermediate plate onto sealing flange slide onto dowel sleeves (arrows). 

Fig. 14: Installing Intermediate Plate Onto Sealing Flange And Slide Onto Dowel Sleeves 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lightly grease input shaft splines with G 000 grease.  

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When installing, make sure that clearance exists between surrounding components.  

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Align engine and transmission mountings. See ENGINE AND TRANSMISSION MOUNTINGS, 
ALIGNING
 . 

Tightening torques. See ASSEMBLY MOUNTINGS , assembly mountings. 

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Install axle shafts: 

NOTE:

First loosen coolant pipe on flywheel end.

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

the engine compartment, pay attention to the following. 

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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.  

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Ensure sufficient clearance to all moving hot components.  

 

2003 Volkswagen New Beetle GLS 

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

  

See FRONT AXLE SHAFT . 

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

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Install assembly. 

See SUBFRAME . 

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Install selector lever cable. 

See SELECTOR LEVER CABLE . 

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Installing power steering pump: 

See POWER STEERING PUMP WITH HYDRAULIC LINES/HOSE . 

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Check electrical connections and routing:  

Vehicles with air conditioning 

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Install Generator. 

See GENERATOR . 

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Install air conditioning compressor: 

See CONDENSER, REMOVING AND INSTALLING . 

Continued for all vehicles 

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

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Fill with coolant. See COOLANT, DRAINING AND FILLING .  

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Install center, left and right sound insulation trays: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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Perform a road test and check Diagnostic Trouble Code (DTC) memory. See ENGINE CONTROL 
MODULE (DTC) MEMORY, READING AND ERASING
 .  

TIGHTENING TORQUES 

TIGHTENING TORQUES 

Threaded connection

(1)

 Torque setting

Bolts, nuts

M6

10 N.m

M7

15 N.m

 

2003 Volkswagen New Beetle GLS 

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

  

ENGINE AND TRANSMISSION MOUNTINGS, ALIGNING 

Engine mounting clearances. See Fig. 15 . 

a = 14.0 mm 

b = At least 10.0 mm 

Both bolt heads -1- must be in flush with edge -c-. 

Fig. 15: Identifying Engine Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Transmission mounting clearances. See Fig. 16 . 

Edges -a- and -b- must be parallel with one another. 

c = 18 to 20 mm 

M8

25 N.m

M10

40 N.m

M12

60 N.m

(1)

Deviations from above: Engine to transmission connecting bolts. See TRANSMISSION .

NOTE:

Tightening torques for assembly mounting. See ASSEMBLY MOUNTINGS .

WARNING:

Before loosening the bolts, the assembly must be supported with support 
bar 10-222A.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  978  979  980  981   ..