Volkswagen New Beetle. Manual - part 983

 

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Volkswagen New Beetle. Manual - part 983

 

 

Fig. 23: Identifying Alternator & Power Steering Pump Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part III 

1. Cylinder block 

z

Removing and installing sealing flange and flywheel. See SEALING FLANGES AND 
FLYWHEEL, REMOVING AND INSTALLING
  

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Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING  

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Disassembling and assembling pistons and connecting rods. See PISTONS AND CONNECTING 
RODS, DISASSEMBLING AND ASSEMBLING
  

2. 3.5 N.m  

3. Bracket 

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For vacuum reservoir  

4. Vacuum reservoir  

5. 40 N.m  

6. Seal 

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Always replace  

7. Oil filter bracket 

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Disassembling and assembling. See PART 2: DISASSEMBLING OIL FILTER BRACKET  

8. 15 N.m plus an additional 1/4 turn (90°) 

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Always replace  

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First install upper left and lower right bolt, then tighten four bolts diagonally  

9. 15 N.m  

10. Engine Speed (RPM) sensor -G28-  

11. Connection union 

NOTE:

The following list refers to items in Fig. 24 .

 

2003 Volkswagen New Beetle GLS 

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

  

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For thermostat  

12. O-ring 

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Always replace  

13. Thermostat 

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Removing and installing. See THERMOSTAT, REMOVING AND INSTALLING .  

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Observe installation position. See THERMOSTAT, REMOVING AND INSTALLING , 
removing and installing thermostat  

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Checking: Heat-up thermostat in water.  

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Starts to open: approx. 85 °C  

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Ends: approx. 105 °C  

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Opening stroke: min. 7 mm  

14. 45 N.m 

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

15. Compact bracket 

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For Generator, air conditioning compressor and power steering pump  

16. Oil pan 

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Clean sealing surface before installing.  

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Install with silicone sealant D 176 404 A2. See OIL PAN, REMOVING AND INSTALLING  

Fig. 24: Identifying External Engine Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Tightening sequence for compact bracket to cylinder block 

Tightening Sequence For Compact Bracket To Cylinder Block 

Work sequence 

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Install compact bracket to cylinder block (observe dowel sleeves between compact bracket and cylinder 

 

2003 Volkswagen New Beetle GLS 

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

  

block).  

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Tighten compact bracket in tightening sequence as follows:  

1. Tighten bolt -A- to 45 N.m.  

2. Tighten bolt -B- to 45 N.m.  

3. Tighten bolt -C- to 45 N.m.  

4. Tighten bolt -D- to 45 N.m  

5. Tighten bolt -E- to 45 N.m.  

6. Tighten bolt -F- to 45 N.m.  

Fig. 25: Tightening Sequence For Compact Bracket To Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Poly V-belt, removing and installing 

Special tools and equipment 

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T10060 Mandrel  

NOTE:

The following list refers to items in Fig. 25 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 26: Identifying Special Tools And Equipment (Mandrel) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove upper charge air line -1- with connecting hose -2-.  

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Remove bolt/screw -3- and release connector (arrow). 

Fig. 27: Removing Upper Charge Air Line -1- With Connecting Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Carefully cover or close open ends.  

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Mark direction of rotation of poly V-belt.  

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Turn tensioning element in direction of arrow to relieve tension on poly V-belt and lock with mandrel 
T10060. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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