Volkswagen New Beetle. Manual - part 992

 

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Volkswagen New Beetle. Manual - part 992

 

 

z

Remove engine cover. 

{

Pull front of engine cover abruptly upward (arrow -A-) and then pull forward out of rear securing 
elements (arrow -B-).  

z

Remove poly V-belt. See POLY V-BELT, REMOVING AND INSTALLING .  

z

Remove poly V-belt tensioning element.  

z

Remove coolant expansion tank (coolant hoses remain connected).  

z

Remove fuel filter retaining plate. 

Fig. 71: Removing Engine Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install engine support bracket 10-222A and take up weight of engine in its installed position. 

Fig. 72: Installing Engine Support Bracket 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

temperature.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body and 
assembly mounting/body mounting (arrows) and remove assembly mounting complete. 

Fig. 73: Removing Securing Bolts From Engine Mounts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove toothed belt guard upper part.  

z

Remove lower charge air pipe -1-. 

{

Remove bolt/screw -2- and release connector (arrow). 

Fig. 74: Removing Lower Charge Air Pipe And Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

z

Remove engine mounting when the engine is secured with the 
support bracket 10-222A.  

z

The engine mounting may only be loosened if the assembly 
mounting has been removed.  

 

2003 Volkswagen New Beetle GLS 

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

  

{

Carefully cover or close open ends.  

z

Remove center and right side sound insulation.  

z

Unbolt engine mounting on cylinder block (arrows) and remove. 

Fig. 75: Removing Engine Mounting On Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove vibration damper/belt pulley.  

z

Remove lower and middle toothed belt guards.  

z

Set crankshaft to TDC No. 1 cylinder. 

NOTE:

z

When loosening both upper engine mounting bolts the engine must 
be raised slightly with the support bracket.  

z

When loosening the front engine mounting bolt the engine must be 
raised slightly with the support bracket.  

NOTE:

z

The engine may only be turned over using the crankshaft.  

z

Turn crankshaft in direction of rotation until the marks on the crankshaft 
toothed (timing) belt sprocket are at the top and (arrow) "4Z" -2- on the 
toothed belt guard is aligned behind the tabs -1- of the wheel sensor. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Lock hub using locking pin 3359. To do this, slide locking pin through free elongated hole on left side 
and into hole in cylinder head.  

z

Lock crankshaft toothed belt gear using crankshaft stop T10050. To do this, slide crankshaft stop into 
teeth of sprocket from front of gear. 

Fig. 77: Aligning Marks On Crankshaft Toothed (Timing) Belt Gear And On Crankshaft Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Fig. 76: Aligning Crankshaft Toothed (Timing) Belt Sprocket On Toothed 
Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

In the illustration the camshaft toothed gear is shown without the toothed 
belt.  

NOTE:

Marks on crankshaft toothed belt gear -2- and on crankshaft stop -1- must 
align with one another. The pin of the crankshaft stop must engage in the 
hole in the sealing flange.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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