Volkswagen New Beetle, New Beetle Convertible 1998 .

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Toothed BeltPage 1 of 18Volkswagen New Beetle, New Beetle Convertible 1998-20081.9 Liter 4 Cyl. 2V TDI PD Engine Mechanical, Fuel Injection & GlowPlug, Engine Code(s): BEW15 - Removal and Installation.Toothed BeltSpecial tools, testers and auxiliary items requiredSecuring pin 3359Pin wrench T10020 or T10004Securing pin T10115Crankshaft stop T10050Torque wrench V.A.G 1331Torque wrench V.A.G 1332Engine support bridge 10 - 222 A with adapter 10 - 222 A /8 (change the guide 10 - 222A/21 guide 10 - 222 A/21 for the engine support bridge 10 - 222 A )Pin wrench T10020 or T10004Counter-holder tool T10172Pin T10172/4Spanner wrench 3387 (for engines equipped with the hydraulic tensioning system)Marking plate T10008 (for engines equipped with the hydraulic tensioning -A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 2 of 18Note:A new toothed belt tensioning roller has been introduced. The tensioning roller has anadditional hex socket - arrow - . Use a hex wrench instead of a spanner wrenchT10020 or T10004 to tension/relieve the toothed belt. The work procedure does notchange due to this.Changing the.guide 10 - 222 A/21 for the engine support bridge 10 - 222 AThe engine support bridge is needed to support the engine/transmission subassembly.A new hole is required for securing the bracket for engine 10 - 222 A/8 to the guide 10 222 A/21 .Dimensions in mm.Drill a 12.5 mm dia. hole - arrow - into the guide 10 - 222 A /21 VW-A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 3 of 18Note:Adjustments to the toothed belt may generally only be performed when the engine iscold.Remove the engine cover and, if present, remove the upper engine noise insulationEngine, Removing .Remove ribbed drive beltRibbed Drive Belt .Remove the ribbed drive belt tensioner.Remove the coolant reservoir (the coolant hoses remain connected).Remove the fuel filter retaining bracket.Mount the engine support bridge 10 - 222 A and support the engine in installationposition.Remove the engine mount/engine mount bracket, engine mount/longitudinal memberand engine mount/longitudinal member bracket bolts - arrows - and remove the ta/VW-A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 4 of 18Note:The engine mount may only be removed if the engine is supported by the enginesupport bridge 10 - 222 A !The engine mount bracket may only be loosened only when the engine mount isremoved.Remove the upper toothed belt guard.Disconnect the lower charge air pipe - 1 - . Remove the bolt - 2 - and release theelectrical connections - arrows - . Carefully cover or seal any open ends.Remove the center and right noise insulationBody Exterior - Repair Group 50 .Unbolt - arrows - and remove the engine mount bracket at cylinder block .Note:To loosen both upper engine mount bracket bolts, the engine must be raised slightlywith the engine support bridge.To loosen the lower engine mount bracket bolt, the engine must be lowered W-A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 5 of 18with the engine support bridge.Remove vibration damper/belt pulley.Remove lower and middle toothed belt cover.Turn crankshaft to set cylinder 1 at TDC.Note:Rotate the engine only by the crankshaft.Turn the crankshaft in the direction of the engine far enough until the marking on thecrankshaft toothed belt sprocket is positioned on the top and the arrow "4Z" - 2 - onthe rear toothed belt guard is positioned across from the tabs of the sensor wheel onthe hub - 1 - .In the illustration, the camshaft-toothed belt sprocket is shown without the toothedbelt.Lock the hub with the rig pin 3359 . To do this, push the rig pin through the left-sidedempty slot in the bore of the cylinder -NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 6 of 18Also, lock the toothed belt crankshaft sprocket with the crankshaft stop T10050 . Pushthe crankshaft stop from the front side of the toothed belt sprocket into the teeth.Note:The marking on the toothed belt sprocket-crankshaft - 2 - and on the crankshaft stop 1 - must align. The pin on the crankshaft stop must engage in the hole on the sealingflange.Mark rotational direction of toothed belt.With Hydraulic Tensioning SystemIdentification:With tensioning device for toothed belt - arrow - .Insert an Allen wrench into socket-head up to stop and press the tensioning rollercounterclockwise in - direction of arrow - , until tensioning device of toothed belt canbe secured using marking plate T10008 A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 7 of 18If the Allen wrench is not inserted deep enough, the socket head could break off.The toothed belt tensioner is oil-dampened and must be compressed slowly byapplying constant pressure.Loosen the nut of the tensioning roller.Remove the toothed belt tensioner bolts - arrows - and remove the tensioner.Remove toothed belt.With Friction Dampened Tensioning SystemLoosen the bolts - arrows - of the camshaft sprockets, until the camshaft sprocket canbe turned in the slots.Loosen the nut of the tensioning -A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 8 of 18Turn the tensioner roller using the spanner wrench T10020 or T10004 counterclockwiseuntil the toothed belt tensioner roller can be locked with the securing pin T10115 .Now turn the tensioner roller clockwise using the spanner wrench T10020 or T10004 allthe way until it stops and tighten the mounting bolt - 1 - hand tight.First, take the toothed belt from the coolant pump and then from the remainingsprockets.InstallingNote:Adjustments to the toothed belt may generally only be performed when the engine iscold.With Hydraulic Tensioning SystemCamshaft is secured with the rig pin 3359Crankshaft is secured with the crankshaft stop A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 9 of 18Loosen the bolts - 1 - of the camshaft sprockets, until the camshaft sprocket can beturned in the slots.Turn the camshaft sprocket in its slot clockwise in - direction of arrow - onto the stop.Now carefully turn the eccentric pulley with the spanner wrench 3387 clockwise, untilthe tab on the eccentric pulley is immediately in front of the stop - B - .Mount the toothed belt on the camshaft sprocket, tensioning roller, toothed belt sprocket- crankshaft and then on the toothed belt sprocket - coolant pump.Install the toothed belt /VW-A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 10 of 18Turn the eccentric pulley with the spanner wrench 3387 counterclockwise (the tab onthe eccentric pulley moves toward the stop - A - ), until it is possible to remove themarking plate T10008 free of stress and when dimension - a - is less than 4 mm.Then turn the tensioner clockwise to release the pressure far enough (the tab moves inthe direction of the stop - B - ), until dimension - a - is reached.Specified dimension - a - : 4 plusminus 1 mmNote:Dimension - a - will get smaller while tightening the tensioner mounting nut. Adjustwith a 4 mm dia. drill bit.If the engine is at operating temperature, dimension - a - can get smaller by 1 mm.Hold the tensioning roller in this position and tighten the nut on the tensioning roller asfollows:20 Nm and 45 degree ( 1 / 8 turn) furtherTighten camshaft sprocket bolts - 1 - to 25 B-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 11 of 18Remove the rig pin 3359 and the crankshaft stop T10050 .Turn crankshaft over twice in engine running direction and then set cyl. 1 to TDC again.Note:While doing so, the crankshaft stop tab must engage in the sealing flange.If the crankshaft was turned past TDC for cylinder 1 and if the crankshaft stop couldnot engage the sealing flange, turn the crankshaft back 1 / 4 revolution, in order to turncrankshaft in engine running direction again to TDC for cylinder 1. It is not reliable tocorrect this by turning the engine against running direction to set the crankshaft stop .After having set the crankshaft stop T10050 , make sure that- dimension - a - is attained, - the tab can be secured with the rig pin 3359 .If dimension - a - is not obtained:Tension the tensioner one more time. Hold the tensioner secure with the pin wrench3387 while loosening the mounting nut and release the tension on the tensioner farenough until dimension - a - is attained.Specified dimension - a - : 4 plusminus 1 mmTighten the mounting nut once again to 20 Nm 45 degree ( 1 / 8 turn).If the hub cannot be locked:Pull the crankshaft stop tab out of the bore in the sealing flange and turn the crankshaftuntil the hub can be locked with the rig pin 3359 .Loosen the camshaft sprocket bolts - 1 - GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 12 of 18Turn the crankshaft against the engine running direction until the crankshaft stop tab ispositioned shortly before the sealing flange bore - arrow - .Now turn the crankshaft in engine running direction until the crankshaft stop tabengages the sealing flange.Tighten camshaft sprocket bolts to 25 Nm.Remove the rig pin 3359 and the crankshaft stop T10050 .Continue turning crankshaft two rotations in direction of engine rotation until thecrankshaft is again at TDC for cylinder 1.Note:While doing so, the crankshaft stop tab must engage in the sealing flange.If the crankshaft was turned past TDC for cylinder 1 and if the crankshaft stop couldnot engage the sealing flange, turn the crankshaft back 1 / 4 revolution, in order to turncrankshaft in engine running direction again to TDC for cylinder 1. It is not reliable tocorrect this by turning the engine against running direction to set the crankshaft stop .Check again.With Friction Dampened Tensioning SystemCamshaft is secured with the rig pin 3359Crankshaft is secured with the crankshaft stop T10050Tensioning roller secured with pin T10115 and seated on right stopNote:Adjustments to toothed belt may generally only be performed when the engine is cold,because the indicator position of the tensioning element changes depending -GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 13 of 18engine temperature.Turn the camshaft sprocket in its slots - arrows - to middle position.Mount the toothed belt onto the toothed belt sprocket - crankshaft, the tensioner, thecamshaft sprocket and the idler roller and finally on the coolant pump toothed beltsprocket.Note:Make sure the tensioner roller is properly positioned in the rear toothed belt guard arrow - .Loosen the nut of the tensioner roller and pull out the locking pin T10115 GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 14 of 18Turn the tensioner roller clockwise using the spanner wrench T10020 or T10004 untilthe indicator is located centrally in the gap of the base plate - arrow - . Make sure thatthe nut does not turn along with it.Hold the tensioner roller in this position and tighten the nut on the tensioner roller asfollows:20 Nm and 45 degree ( 1 / 8 turn) furtherInstall the counter-holder T10172 with pins T10172/4 as illustrated. Push the counterholder in - direction of arrow - and hold the camshaft sprocket pre-tensioned.In this position, tighten the camshaft sprocket bolts - 1 - to 25 Nm.Remove the rig pin 3359 and the crankshaft stop T10050 .Continue turning crankshaft two rotations in direction of engine rotation until thecrankshaft is shortly before TDC for cylinder -GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 15 of 18Lock the hub with the rig pin 3359 from the rotating movement in engine rotationdirection.Check if the crankshaft can be locked with the crankshaft stop T10050 .If the crankshaft cannot be locked:Loosen the bolts - arrows - of the camshaft VW-A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 16 of 18Turn the crankshaft against the engine running direction until the crankshaft stop tab ispositioned shortly before the sealing flange bore - arrow - .Now turn the crankshaft in engine running direction until the crankshaft stop tabengages the sealing flange.Install the counter-holder T10172 with pins T10172/4 as illustrated. Push the counterholder in - direction of arrow - and hold the camshaft sprocket pre-tensioned.In this position, tighten the camshaft sprocket bolts - 1 - to 25 Nm.Remove the rig pin 3359 and the crankshaft stop T10050 .Continue turning crankshaft two rotations in direction of engine rotation until thecrankshaft is shortly before TDC for cylinder 1.Check again.Continuation for AllInstall the center and lower toothed belt guards.Install the belt pulley/vibration -A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 17 of 18Tightening specification: 10 Nm 90 degree ( 1 / 4 additional turn)Set engine mount bracket in place at cylinder block and fasten bolts - arrows - .Tightening specification: 45 NmNote:Before installing engine mount bracket, insert screws in bracket.Before the engine mount can be installed, all bolts for the engine mount bracket mustbe tightened to the specified tightening specification.Install the engine mount/longitudinal member (replace the mount bolts).Tightening specification: 40 Nm 90 degree ( 1 / 4 additional turn)Align the engine mountPowertrain Mount, Aligning .Tighten the engine mount to engine mount bracket bolts, To do so, bring contactsurfaces into contact using the engine support bridge 10 - 222 A .Tightening specification: 100 NmInstall the engine mount/longitudinal member bracket bolts.Tightening specification: 25 NmInstall the upper toothed belt guard.Install the fuel filter retaining plate.Install coolant expansion -NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

Toothed BeltPage 18 of 18Install the ribbed belt tensioning element.Tightening specification: 25 NmInstall ribbed drive beltRibbed Drive Belt .Install the engine cover, and if equipped, the upper engine insulationRemoving .Install the center and right noise insulationEngine,Body Exterior - Repair Group 50 .Install the lower charge air pipe.Copyright 2008 Volkswagen of America, Inc. and Bentley Publishers. All rights reserved. Last /VW-A-NB-GE06.ebn/VW/A/NB/Repair%20M. 8/7/2009

1.9 Liter 4 Cyl. 2V TDI PD Engine Mechanical, Fuel Injection & Glow Plug, Engine Code(s): BEW 15 - Removal and Installation . Toothed Belt Special tools, testers and auxiliary items required Securing pin 3359 Pin wrench T10020 or T10004 Securing pin T10115 Crankshaft stop T10050 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332

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