Volkswagen NEW BEETLE - Assembly Manual Download Page 1

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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

Volkswagen New Beetle
1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical

10 Engine-Assembly (Page GR-10)

Summary of Contents for NEW BEETLE -

Page 1: ...aligning z Installation notes z Removal notes z Securing engine to assembly stand z Tightening torques z Vehicles with air conditioner additional information and removal instructions Volkswagen New Be...

Page 2: ...urbo 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...

Page 3: ...ing 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 St...

Page 4: ...ry Ground strap All cable ties which are opened or cut open when removing engine must be replaced in the same position when installing engine Remove engine cover Remove air cleaner Repair Manual 1 8 L...

Page 5: ...reather hoses off engine WARNING Fuel supply pipes are under pressure Before removing from hose connection wrap a cloth around the connection Then release pressure by carefully pulling hose off connec...

Page 6: ...e 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 belo...

Page 7: ...nition coils Disconnect connector for speedometer vehicle speed sensor G22 at rear of transmission Remove center left and right insulation tray Repair Manual Body Exterior Repair Group 50 Remove air d...

Page 8: ...rbox Repair Manual Automatic Transmission 01M Repair Group 37 Continued for all vehicles Drain coolant Page 19 13 Pull radiator coolant hoses off engine using hose clip pliers V A G 1921 Remove coolan...

Page 9: ...eering pressure pipe Remove ribbed belt Page 13 8 Remove power assisted steering vane pump with bracket and lay to side hoses remain connected Repair Manual Suspension Wheels Steering Repair Group 48...

Page 10: ...or 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 Repair Manual Suspension...

Page 11: ...l 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 Lift engine and gearbox lightly using engine gearbox jack V A G 1383 A U...

Page 12: ...Page 10 11 Unbolt gearbox side of assembly mounting from gearbox carrier at top arrows Carefully lower engine with gearbox When doing this guide the power assisted steering pressure pipe past the gear...

Page 13: ...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 Work sequence Move engine transmission with V A G...

Page 14: ...ed 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 Pulley end 3rd hole in hook at position 1 Flyw...

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: ...leeves arrows Vehicles with manual gearbox Check centering of clutch drive plate if necessary Check clutch release bearing for wear renew if necessary Lightly grease clutch release bearing release bea...

Page 17: ...ransmission 01M Repair Group 37 Continued for all vehicles When installing the assembly ensure sufficient clearance to drive shafts Vehicles with air conditioner Install generator Repair Manual Electr...

Page 18: ...inner constant velocity joint protective cover from engine if fitted Remove front exhaust pipe Page 26 1 removing and installing parts of exhaust system Push on and tighten intake hose between charge...

Page 19: ...V Turbo OBDII Fuel Injection Ignition Repair Group 01 Match engine electronics control unit to throttle valve control part Repair Manual 1 8 Liter 4 Cyl 5V Turbo OBDII Fuel Injection Ignition Repair G...

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: ...l 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 Engine mounting a 14 0...

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 1 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 1 Replace bolts Pendulum support 1 Replace bolts...

Page 25: ...ant 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 To facilitate removing and...

Page 26: ...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 dam...