Volkswagen New Beetle User Manual

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Engine, removing and installing

z

Assembly mountings

z Engine and gearbox mountings, aligning
z Installation notes

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Removal notes

z Securing engine to assembly stand
z Tightening torques

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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)

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

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

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.

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.

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.

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

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.