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Volkswagen New Beetle Assembly Manual

1.8 liter 4-cyl. 5v turbo obd ii engine mechanical
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Volkswagen New Beetle
1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical
10 Engine-Assembly (Page GR-10)
Engine, removing and installing
Assembly mountings
Engine and gearbox mountings, aligning
Installation notes
Removal notes
Securing engine to assembly stand
Tightening torques
Vehicles with air conditioner, additional information and removal instructions

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Summary of Contents for Volkswagen New Beetle

  • Page 1 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical 10 Engine-Assembly (Page GR-10) Engine, removing and installing Assembly mountings Engine and gearbox mountings, aligning Installation notes Removal notes Securing engine to assembly stand Tightening torques Vehicles with air conditioner, additional information and removal instructions...
  • Page 2 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Technical data (Page 10-1) Special tools and equipment VW 313 Support clamp VW 540 Engine and gearbox support 2024 A Lifting tackle 3180 Retainer (for engine code AGU) V.A.G 1202 A Workshop crane...
  • Page 3 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-2) V.A.G 1331 Torque wrench (5-50 Nm) V.A.G 1332 Torque wrench (40-200 Nm) V.A.G 1383 A Engine/gearbox jack V.A.G 1921 Spring - type clip pliers T10012 Engine bracket V.A.S 5085 Step ladder...
  • Page 4 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-3) Removal notes - First check whether a coded radio is fitted. If this is the case obtain the anti - theft coding.
  • Page 5 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-4) - Fasten reservoir to lock carrier. - Remove battery and battery retainer. - Pull vacuum and breather hoses off engine. WARNING! Fuel supply pipes are under pressure! Before removing from hose connection wrap a cloth around the connection.
  • Page 6 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-5) - Loosen and remove intake hose (between charge air cooler and throttle valve control unit) at throttle valve control unit. - Disconnect harness connector for intake air temperature (G42), - 1 - and - 4 - for throttle valve control unit (J338) below throttle valve control unit.
  • Page 7 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-6) - Disconnect fuel injectors harness connector and unclip bracket rail from fuel distributor. - Unscrew Ground wire between ignition coil - 1 - and - 2 - .
  • Page 8 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-7) Notes: Clutch pedal must not be depressed. Vehicles with automatic gearbox - Remove selector lever cable from gearbox: Repair Manual, Automatic Transmission 01M, Repair Group 37...
  • Page 9 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-8) - Remove inter - connecting, coolant, vacuum and intake hoses on engine. - Remove secondary air pump motor and bracket. - Disconnect all electric wires from gearbox, alternator and starter and move clear.
  • Page 10 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-9) Continued for all vehicles - Remove protective cover for right - hand inner constant velocity joint from engine. - Remove right - hand drive shaft and disconnect left - hand drive shaft at gearbox.
  • Page 11 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-10) Continued for all vehicles - Fit engine bracket T 10012 onto cylinder block with a securing nut and M10 X 25/ 8.8 bolt and tighten to approx. 40 Nm.
  • Page 12 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-11) - Unbolt gearbox side of assembly mounting from gearbox carrier at top - arrows - . - Carefully lower engine with gearbox.
  • Page 13 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-12) Securing engine to assembly stand When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the engine and gearbox bracket VW 540.
  • Page 14 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-13) Vehicles with automatic gearbox - Secure torque converter against "falling out" after separating engine from gearbox. Continued for all vehicles - Attach lifting tackle 2024A with bracket 3180 as follows and lift off engine/gearbox jack V.A.G 1383 with workshop crane V.A.G 1383 A.
  • Page 15 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-14) - Secure engine to support clamp VW 313 using engine and gearbox bracket VW 540.
  • Page 16 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-15) Installation notes Installation is carried out in the reverse sequence, when doing this note the following: - Check whether the dowel sleeves for centralizing engine/gearbox are in the cylinder block, install if necessary.
  • Page 17 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-16) - Install selector cable on gearbox, adjust if necessary: Repair Manual, Automatic Transmission 01M, Repair Group 37 Continued for all vehicles - When installing the assembly, ensure sufficient clearance to drive shafts.
  • Page 18 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-17) Continued for all vehicles - Align engine and gearbox mountings Page 10-20 Installing drive shafts: Repair Manual, Suspension, Wheels, Steering, Repair Group 40 - Remove right hand inner constant velocity joint protective cover from engine if fitted.
  • Page 19 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-18) - Install center, left and right insulation trays: Repair Manual, Body-Exterior, Repair Group 50 - Install secondary air pump. Filling with coolant...
  • Page 20 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-19) Tightening torques...
  • Page 21 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-20) Engine and gearbox mountings, aligning WARNING! Before loosening the bolts the assemblies must be secured with the special tool 10 - 222A.
  • Page 22 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-21) Gearbox mounting Edges - a - and - b - must be parallel with one another.
  • Page 23 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-22) Assembly mountings Tightening torques Engine mounting Replace bolts...
  • Page 24 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-23) Gearbox assembly mounting Replace bolts Pendulum support Replace bolts...
  • Page 25 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-24) Vehicles with air conditioner, additional information and removal instructions WARNING! The air conditioner refrigerant circuit must not be opened. Notes: To prevent damage to condenser and also to the refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
  • Page 26 Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-25) - Secure air conditioner compressor to towing eye so that the refrigerant hoses/pipes are not under tension. Notes: To prevent damage to bumper protect with adhesive tape.