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Volkswagen NEW BEETLE - Assembly Manual

Other manuals for NEW BEETLE -: Brochure

Summary of NEW BEETLE -

  • Page 1

    Z engine, removing and installing z assembly mountings z engine and gearbox mountings, 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 beetle 1.8 lit...

  • 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 v.A.G 1306 drip tray.

  • 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 lad...

  • 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. The engine is removed downward together with the gearbox. - with ignit...

  • 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 ...

  • 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 (...

  • 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 - . - disconnect connectors from...

  • 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 conti...

  • 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 st...

  • 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 sha...

  • 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. - lift engine and gearbox lightly...

  • 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. - when doing this guide the power assisted steering pressur...

  • 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. Work sequen...

  • 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 br...

  • 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 t...

  • 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...

  • 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...

  • 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 19-13 - carry out a test driv...

  • 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. Engine mounting a = 14.0 mm b = at least 10...

  • 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

    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 conden...

  • 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..