Volkswagen New Beetle. Manual - part 984

 

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Volkswagen New Beetle. Manual - part 984

 

 

Fig. 28: Turning Tensioning Element In Direction Of Arrow To Relieve Tension On Poly V-Belt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove ribbed belt.  

Installing 

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Installation is performed in reverse sequence of removal.  

After completing repairs: 

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Start engine and check belt running.  

Drive belt with no air conditioner compressor

NOTE:

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Before installing poly V-belt, make sure that all ancillaries (Generator, air 
conditioner compressor, power steering pump) are secured tightly.  

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When installing poly V-belt, check direction of rotation and proper seating 
of belt in belt pulleys.  

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For vehicles which do not have an air conditioning system: place ribbed 
belt over Generator pulley last.  

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For models with an air conditioning system: place poly V-belt over A/C 
compressor last.  

z

When installing upper charge air line lift line connection piece on charge 
air cooler slightly (engages easier).  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 29: Identifying Drive Belt Routing With No Air Conditioner Compressor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Drive belt with A/C compressor (double poly V-belt) 

Fig. 30: Identifying Drive Belt Routing With A/C Compressor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

SEALING FLANGES AND FLYWHEEL, REMOVING AND INSTALLING 

1. Seal 

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Do not add oil or grease oil seal sealing lip  

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Before installing, remove oil residue from crankshaft journal using a clean cloth  

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Replacing crankshaft oil seal, poly V-belt pulley end. See CRANKSHAFT OIL SEAL - 
PULLEY END, REPLACING
  

2. Sealing-flange belt pulley end 

NOTE:

The following list refers to items in Fig. 31 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Must be located on dowel sleeves.  

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Removing and installing. See SEALING FLANGE - BELT PULLEY END, REMOVING AND 
INSTALLING
 .  

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Insert with silicone sealant D 176 404 A2. See SEALING FLANGE - BELT PULLEY END, 
REMOVING AND INSTALLING
 .  

3. Cylinder block 

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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
 .  

4. Flywheel 

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To remove and install flywheel counterhold with 3067  

5. 60 N.m plus an additional 1/4 turn (90°) 

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Always replace  

6. Intermediate plate 

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Must be located on dowel sleeves  

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Do not damage/bend when assembling  

7. 15 N.m  

8. Sealing flange with oil seal 

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Replace complete  

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Do not add oil or grease to oil seal sealing lip  

z

Before installing, remove oil residue from crankshaft journal using a clean cloth  

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Use protective sleeve supplied when installing  

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Remove protective sleeve first after sliding sealing flange onto crankshaft journal  

Fig. 31: Removing And Installing Sealing Flanges And Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Crankshaft oil seal - pulley end, replacing 

 

2003 Volkswagen New Beetle GLS 

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

  

Special tools and equipment 

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3099 Counterhold  

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3203 Oil seal extractor  

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T10053 Assembly device  

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

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

Fig. 32: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove toothed (timing) belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

z

Remove crankshaft toothed belt gear. To do this counterhold gear with 3099. 

Fig. 33: Removing Crankshaft Toothed (Timing) Belt Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

Place two washers between toothed belt gear and counter bracket when 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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