Volkswagen New Beetle. Manual - part 993

 

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Volkswagen New Beetle. Manual - part 993

 

 

z

Mark direction of rotation of toothed belt.  

z

Loosen camshaft sprocket securing bolts (arrows), until camshaft sprocket can be moved within elongated 
holes. 

Fig. 78: Loosening Camshaft Sprocket Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Loosen tensioning roller securing nut.  

z

Turn tensioning roller counter-clockwise with two-hole pin wrench T10020 or T10004 until tensioning 
roller can be locked with pin T10115. See Fig. 79 . 

Fig. 79: Turning Tensioning Roller Counterclockwise With Two-Hole Pin Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn tensioning roller with two-hole pin wrench T10020 or T10004 clockwise onto limit stop and tighten 
nut -1- by hand. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 80: Turning Tensioning Roller With Two-Hole Pin Wrench Clockwise Onto Limit Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

First remove toothed belt from coolant pump and then from remaining gears.  

Installing 

Requirements 

z

Lock camshaft with pin 3359  

z

Lock crankshaft with crankshaft stop T10050  

z

Tensioning roller must be installed with pin T10115 and locked right-hand. 

z

Turn camshaft gear in elongated holes to centered position (arrow). 

NOTE:

Adjustment work on toothed belts must be performed on cold engines 
only. The tensioning element indicator position is dependent upon the 
engine temperature.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 81: Turning Camshaft Gear In Elongated Holes To Centered Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Place toothed belt on crankshaft pulley, tensioning roller, camshaft gear and idler roller.  

z

Place toothed belt on coolant pump toothed belt gear last. 

Fig. 82: Tensioning Roller Seated In Rear Toothed (Timing) Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Loosen tensioning roller securing nut and pull pin T10115 off.  

z

Turn tensioning roller with two-hole pin wrench T10020 or T10004 clockwise until indicator aligns over 
tab in base plate (arrow). 

NOTE:

Make sure that tensioning roller seats correctly in rear toothed belt guard 
(arrow).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 83: Turning Tensioning Roller With Two-Hole Pin Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

{

Ensure that securing nut does not turn.  

z

Hold tensioning roller in this position and tighten tensioning roller securing nut to 20 N.m plus an 
additional 45° (1/8 turn).  

z

Insert counterhold T10172 with pin T10172/4 as shown in Fig. 84 . Press counterhold T10172 in 
direction of arrow and hold camshaft gear to pretension. 

Fig. 84: Inserting Counter-Hold With Pin 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Tighten camshaft pulley securing bolts -1- in this position to 25 N.m.  

z

Remove pin 3359 and crankshaft stop T10050.  

z

Turn crankshaft two rotations in engine direction of rotation until crankshaft is set just before TDC No. 1 
cylinder.  

z

Unlock hub with pin 3359 out of engine in direction of rotation. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  991  992  993  994   ..