Volkswagen New Beetle. Manual - part 985

 

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Volkswagen New Beetle. Manual - part 985

 

 

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To guide seal extractor, screw center bolt into crankshaft onto limit stop by hand.  

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Unscrew inner part of oil seal extractor 3203 nine turns (approx. 17 mm) out of outer part and lock with 
knurled screw.  

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Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into 
oil seal as far as possible.  

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Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out. 

Fig. 34: Loosening Knurled Screw And Turn Inner Part Against Crankshaft To Remove Oil Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Remove oil residue from crankshaft journal using clean cloth.  

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Install guide sleeve T10053/1 onto crankshaft journal. 

installing the counterhold.

NOTE:

The oil seal sealing lip must not be oiled or greased.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 35: Installing Guide Sleeve Onto Crankshaft Journal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Slide oil seal over guide sleeve onto crankshaft journal.  

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Press in oil seal using press sleeve T10053 and screw T10053/2 (M16 x 1.5 x 60) onto stop. 

Fig. 36: Installing Crankshaft Toothed Belt Pulley With NEW Center Bolt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install crankshaft toothed belt pulley with new center bolt.  

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Install toothed belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

Sealing flange - belt pulley end, removing and installing 

Special tools and equipment 

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3099 Counterhold  

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T10053 Assembly device  

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

 

2003 Volkswagen New Beetle GLS 

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

  

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

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Hand drill with plastic brush attachment  

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D 176 04 A2 Silicone sealant  

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Flat scraper 

Fig. 37: Checking Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove toothed belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

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

Fig. 38: Removing Crankshaft Toothed (Timing) Belt Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

When installing the counterhold, place two washers between toothed belt 
gear and counter bracket.

 

2003 Volkswagen New Beetle GLS 

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

  

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Drain engine oil.  

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Remove oil pan. See OIL PAN, REMOVING AND INSTALLING .  

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Unbolt sealing flange.  

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Remove sealing flange. Release using light blows with a rubber-headed hammer if necessary.  

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Remove sealant residue on cylinder block with a flat scraper.  

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Remove sealant remains on sealing flange with a rotating plastic brush (wear eye protection). 

Fig. 39: Removing Sealant Remains On Sealing Flange With Rotating Plastic Brush 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Clean sealing surfaces. They must be free of oil and grease.  

Installing 

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Remove oil residue from crankshaft journal using clean cloth.  

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Cut off tube nozzle at front marking (nozzle approx. 3 mm diameter). 

NOTE:

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Observe the use-by date of the sealing compound.  

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The sealing flange must be installed within 5 minutes after applying the 
silicone sealant.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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