Volkswagen New Beetle. Manual - part 986

 

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Volkswagen New Beetle. Manual - part 986

 

 

Fig. 40: Cut Off Tube Nozzle At Front 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Apply silicone sealant bead as shown in Fig. 41 to clean sealing surface of sealing flange. 

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Thickness of sealant bead (arrow): 2 to 3 mm 

Fig. 41: Applying Silicone Sealant Bead To Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install sealing flange immediately and lightly tighten all bolts. 

NOTE:

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The sealing compound bead must not be too thick, otherwise 
excessive sealing compound will enter the oil pan and may block the 
suction pipe strainer. It can also drop onto the sealing surface of the 
crankshaft sealing ring.  

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Cover the sealing flange sealing surface with a clean cloth before 
applying the sealant bead.  

NOTE:

Use guide sleeve T10053/1 to install sealing flange with the oil seal already 
installed.

 

2003 Volkswagen New Beetle GLS 

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

  

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Tighten sealing flange securing bolts using alternate sequence. 

Tightening torque: 15 N.m 

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

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

CRANKSHAFT, REMOVING AND INSTALLING 

1. Bearing shells 1, 2, 4 and 5 

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For bearing cap without oil groove  

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For cylinder block with oil groove  

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Do not interchange used bearing shells (mark)  

2. Thrust washers 

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For bearing cap 3  

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Note fixing arrangement.  

3. 65 N.m plus an additional 1/4 turn (90°) 

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Always replace  

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To measure radial clearance, tighten to 65 N.m, but no further  

4. Bearing cap 

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Bearing cap 1: Belt pulley end  

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Bearing cap 3 with recesses for thrust washers  

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Bearing shell retaining lugs in cylinder block and bearing caps must align  

5. Bearing shell 3 

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For bearing cap without oil groove  

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For cylinder block with oil groove  

6. Needle bearing 

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Driving in and out. See NEEDLE BEARING IN CRANKSHAFT, REMOVING AND 
INSTALLING
  

7. Sensor wheel 

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For Engine Speed (RPM) sensor -G28-  

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Replace if damaged  

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Every time screws are loosened replace sensor wheel  

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Removing and installing. See Fig. 44

NOTE:

The sealant must be allowed to cure for approx. 30 minutes after installing 
the oil pan. Only then fill the engine with oil.

NOTE:

The following list refers to items in Fig. 42 .

 

2003 Volkswagen New Beetle GLS 

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

  

8. 10 N.m plus an additional 1/4 turn (90°) 

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Always replace  

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Every time screws are loosened replace sensor wheel  

9. Fitted pin 

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Checking projection from crankshaft. See Fig. 43  

10. Crankshaft 

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Axial clearance, New: 0.07 to 0.17 mm; Wear limit: 0.37 mm  

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Check radial clearance with Plastigage, New: 0.03 to 0.08 mm; Wear limit: 0.17 mm  

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Do not rotate crankshaft when checking radial clearance  

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Crankshaft dimensions. See CRANKSHAFT DIMENSIONS  

11. Thrust washers 

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For cylinder block, bearing 3  

Fig. 42: Explode View Of Crankshaft & Main Bearing Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Crankshaft Dowel Pin Projection, checking 

Special tools and equipment 

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Depth gauge  

Work sequence 

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Checking dowel pin projection -a- with a depth gauge when wheel sensor -1- is removed. 

1 - Sender wheel 

2 - Securing bolt 

 

2003 Volkswagen New Beetle GLS 

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

  

3 - Dowel pin projection -3- out of crankshaft a = 2.5...3.0 mm

Fig. 43: Crankshaft Dowel Pin Projection, Checking 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Sensor wheel, removing and installing 

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Replace sensor wheel -2- every time screws -1- are loosened. 

Tightening torque: 10 N.m plus an additional 90° (1/4 turn) 

Fig. 44: Proper Installed Height Of Sensor Wheel Screws 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Needle bearing in crankshaft, removing and installing 

NOTE:

After securing a second time, the securing points of the countersunk screws in 
the sensor wheel are deformed in such a way that the bolt heads touch the 
crankshaft -3- (arrows) and the wheel sensor is located loosely below the 
screws.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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