• 1999 New Beetle Parts

. 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.

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.

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. 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. 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. Fuel supply pipes are under pressure! Before removing from hose connection wrap a cloth around the connection. 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. 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 -.

1999 New Beetle Parts

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. 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. 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.

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. 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. 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. 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.

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. 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. 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.

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.

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. Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical Engine, removing and installing (Page 10-19) Tightening torques. 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. 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. 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. 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.

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. 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.