Volkswagen New Beetle. Manual - part 982

 

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Volkswagen New Beetle. Manual - part 982

 

 

Fig. 20: Identifying A/C Compressor And Refrigerant Lines/Hoses 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ENGINE CRANKSHAFT, CYLINDER BLOCK 

ENGINE, DISASSEMBLING AND ASSEMBLING 

I. See PART I  

II. See PART II  

III. See PART III 

NOTE:

If large quantities of metal particles or other deposits (caused, for example, by 
partial seizure of the crankshaft or connecting rod bearings) are found in the 
engine oil, the oil passages must be cleaned thoroughly and the oil cooler 
replaced in order to prevent further damage.

NOTE:

The following list refers to items in Fig. 21 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 21: Disassembling And Assembling View Of Engine 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part I 

1. Toothed belt guard, upper part  

2. Toothed belt 

z

Mark direction of rotation before removing  

z

Check for wear  

z

Do not kink  

z

Removing, installing and tensioning. See TOOTHED BELT, REMOVING AND INSTALLING

3. 20 N.m plus an additional 1/8turn (45°)  

4. Tensioning roller  

5. 100 N.m  

6. 25 N.m  

7. Camshaft pulley  

8. Hub 

z

With sender wheel  

z

Use counter-bracket T10051 to loosen and tighten  

z

Use puller T10052 to remove  

z

installing and removing. See CAMSHAFT, REMOVING AND INSTALLING , removing and 
installing camshaft  

9. 10 N.m 

z

Always replace  

10. Rear toothed belt guard  

11. Sealing grommet 

NOTE:

The following list refers to items in Fig. 22 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Replace if damaged.  

12. Idler roller  

13. Coolant pump 

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING .  

14. Crankshaft toothed belt gear  

15. 120 N.m plus an additional 1/4 turn (90°) 

z

Always replace  

z

Additional turn can be done in several stages  

z

Counterhold with 3099 to loosen and tighten.  

z

Do not add oil or grease to threads and shoulder  

16. 15 N.m  

17. 20 N.m  

18. Toothed belt guard, lower part  

19. Belt pulley/vibration damper 

z

Can only be installed in one position. Holes are offset  

20. 10 N.m plus an additional 1/4 turn (90°)  

21. Cover  

22. Toothed belt guard, center section  

23. 45 N.m  

24. Engine bracket  

Fig. 22: Identifying Engine Front Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part II 

NOTE:

The following list refers to items in Fig. 23 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. Poly V-belt 

z

Mark direction of rotation before removing  

z

Check for wear  

z

Do not kink  

z

Removing and installing. See POLY V-BELT, REMOVING AND INSTALLING  

2. 10 N.m plus an additional 1/4 turn (90°)  

3. Belt pulley/vibration damper 

z

Can only be installed in one position. Holes are offset  

4. 25 N.m  

5. Tensioning element for poly V-belt 

z

Turn with open end wrench to loosen ribbed belt. See POLY V-BELT, REMOVING AND 
INSTALLING
  

6. Generator  

7. Compact bracket 

z

For Generator, air conditioning compressor and power steering pump  

8. 45 N.m 

z

Note tightening sequence. See Tightening sequence for compact bracket to cylinder block .  

9. Banjo bolt, 30 N.m  

10. Seal 

z

Always replace  

11. Pressure line  

12. Power steering pump 

z

For power steering  

z

Removing and installing:  

See POWER STEERING PUMP: VEHICLES WITH POWER STEERING PUMP IN LOWER 
SECTION, REMOVING AND INSTALLING
 . 

13. Belt pulley 

z

For power steering pump  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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