Volkswagen New Beetle
1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical
10 Engine-Assembly (Page GR-10)
zEngine, removing and installing
zAssembly mountings
zEngine and gearbox mountings, aligning
zInstallation notes
zRemoval notes
zSecuring engine to assembly stand
zTightening torques
zVehicles with air conditioner, additional information and removal instructions
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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
V.A.G 1306 Drip tray
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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
G 000 100 grease (vehicles with manual gearbox)
Bolt M10 X 25 / 8.8
Cable tie
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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.
The engine is removed downward together with the gearbox. - With ignition switched off, disconnect battery 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 Liter 4 - Cyl. 5V Turbo OBDII Fuel Injection & Ignition, Repair Group 24
-Remove intake hose between air mass meter (G70) and throttle valve control part (J338).
Repair Manual, 1.8 Liter 4 - Cyl. 5V Turbo OBDII Fuel Injection & Ignition, Repair Group 24
-Remove power steering fluid reservoir from battery holder without disconnecting hoses.
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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. Then release pressure by carefully pulling hose off connection.
-Pull off fuel supply line - 1 - and fuel return line - 2 - at disconnecting location by applying pressure to the disengaged buttons.
-Seal the pipes so that the fuel system is not contaminated by dirt etc.
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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.
-Pull connector off Hall sender (G40) - arrow - .
-Unbolt vacuum canister from cylinder head cover and pull from bracket.
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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 - .
-Disconnect connectors from ignition 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 duct to charge air cooler at lower right of long member.
Vehicles with manual gearbox
-Disconnect selector mechanism from gearbox.
Repair Manual, Manual Transmission 02J, Repair Group 34
- Remove hydraulic clutch slave cylinder.
Repair Manual, 5 - Speed Manual Transmission 02J, Repair Group 30
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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
Continued for all vehicles
-Drain coolant 
Page 19-13
-Pull radiator coolant hoses off engine using hose clip pliers V.A.G 1921.
-Remove coolant hoses at heater core.
-Remove coolant hose to coolant pipe at throttle valve control unit.
-Remove additional fan at right side of vehicle if present.
-Disconnect both harness connectors for cooling fan at notch at left bottom.
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