Volkswagen New Beetle. Manual - part 996

 

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Volkswagen New Beetle. Manual - part 996

 

 

z

Check whether a coded radio is installed. If installed obtain anti-theft coding.  

z

With ignition switched off disconnect battery Ground (GND) strap.  

z

Remove air cleaner housing with intake hose.  

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Drain coolant. See COOLANT, DRAINING AND FILLING . 

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Extract fuel from tandem pump. See TANDEM PUMP, REMOVING AND INSTALLING .  

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Remove/separate connections for glow plugs, fuel temperature sensor, unit injectors (central connector) 
and coolant temperature sensor.  

z

Remove fuel hoses and coolant hose off lines on cylinder head (arrows). 

the engine compartment, pay attention to the following: 

z

Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

WARNING:

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The fuel and the fuel lines in the fuel system can become very 
hot (danger of scalding).  

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The fuel system is also under pressure! Before opening the 
system, place cloths around the connections. Then carefully 
loosen the connection to release pressure.  

z

Wear eye and hand protection when performing any type of 
repair work on the fuel system!  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 92: Removing Coolant Hose And Connectors From Line Union 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove coolant hose -1- and connectors -2- from line union.  

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Remove hose from vacuum reservoir.  

z

Remove plenum chamber cover (outer) and plenum chamber sealing part. 

See PLENUM CHAMBER SEALING ASSEMBLY, REMOVING AND INSTALLING . 

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Separate quick-release coupling on right side at heat exchanger (from exhaust gas heat exchanger).  

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Separate hose connections -1- on non-return valve -3- and to vacuum reservoir.  

z

Pull union -2- off brake booster. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 93: Hose Connections On Non-Return Valve, Vacuum Reservoir & Brake Booster 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Separate vacuum hoses for vacuum hoses of bypass flap (AGR cooler), of intake manifold and 
turbocharger at unions.  

z

Remove front exhaust pipe. See EXHAUST SYSTEM COMPONENTS, REMOVING AND 
INSTALLING
 .  

z

Disconnect connector -1-. See Fig. 94 .  

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Remove connecting hose -7-.  

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Pull vacuum hose -5- off rear charge air pipe -6-. See Fig. 94 .  

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Separate connecting hose at rear charge air pipe -6- and remove it.  

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Disconnect oil return line -2- from union on cylinder block. See Fig. 94 .  

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Remove bolts -3- and -4- and take off bracket. See Fig. 94 . 

Fig. 94: Removing Components Of Cylinder Head Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Disconnect oil supply line at oil filter bracket (arrow) and at coolant pipe. 

Fig. 95: Disconnecting Oil Supply Line At Oil Filter Bracket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Disconnect oil supply line at exhaust gas turbocharger and exhaust manifold (arrows) and move aside. 

Fig. 96: Disconnecting Oil Supply Line At Exhaust Gas Turbocharger And Exhaust Manifold 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

NOTE:

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Both lifting eyes for the support are located on the cylinder head, an 
additional bracket for supporting the engine must be secured on the 
cylinder block.  

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Hook spindle -B- onto cylinder head.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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