Volkswagen gr-10 User's Manual
Contents
1. s from refrigerant pipes Remove ribbed belt Page 13 8 Remove air conditioner compressor Repair Manual Heating amp Air Conditioning Repair Group 87 Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD Il Engine Mechanical Engine removing and installing Page 10 25 N10 0156 A 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 tape2. D 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 Repair Manual Suspension Wheels Steering Repair Group 40 zi Remove pendulum support arrows Remove front exhaust pipe with catalytic converter gt page 26 2 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 A 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 using engine gearbox jack V A G 1383 A Unbolt engine side of assembly mounting from engine carrier at top arrows Notes To remove securing bolts use step ladder V A S 5085 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 pressure pipe past the gearbox Notes Engine with gearbox must be guided carefully when lowering to prevent damage to the bodywork Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD Il Engine
3. 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 sequence Move engine transmission with V A G 1383 A lift to a workbench Lower engine transmission unit so that the transmission is supported at supporting point Remove gearbox Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD Il 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 Pulley end 3rd hole in hook at position 1 Flywheel end 2nd hole in hook at position 5 WARNING The hooks and locating pins must be secured with locking pins Notes The positions marked 1 4 on the bar must be toward the pulley end The holes in the hooks are counted up from the hook Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD II Engine Mechanical Engine removing and installing Page 10 14 A 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 Ins
4. 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 V A G 1202 A r V A G 1306 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 V A G 1332 V A G 1921 W10 0021 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 e 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 rem
5. bed V belt page 13 7 item 19 Repair Manual Electrical Equipment Repair Group 27 Install A C compressor 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 Remove front exhaust pipe Page 26 1 removing and installing parts of exhaust system Push on and tighten intake hose between charge air cooler and throttle valve control unit at throttle valve control unit Installing P A S power steering pump Repair Manual Suspension Wheels Steering Repair Group 48 Electrical connections and routing Repair Manual Electrical Equipment Repair Group 97 Install ribbed belt Page 13 8 Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD II Engine Mechanical Engine removing and installing Page 10 18 A 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 drive and check DTC memory Repair Manual 1 8 Liter 4 Cyl 5V Turbo OBDII Fuel Injection amp Ignition Repair Group 01 Match engine electronics control unit to thrott
6. e 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 MN d VM J A15 0128 Ary 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 soeedometer 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 Il Engine Mechanical Engine removing and installing Page 10 7 Notes Clutch pedal must not be depressed Vehicles with automatic gearbox Remove selector leve
7. le valve control part Repair Manual 1 8 Liter 4 Cyl 5V Turbo OBDII Fuel Injection amp Ignition Repair Group 24 Read out readiness code Repair Manual 1 8 Liter 4 Cyl 5V Turbo OBDII Fuel Injection amp Ignition Repair Group 01 If DTC memory has been erased or the engine control unit separated from the permanent positive the readiness code must be generated again Repair Manual 1 8 Liter 4 Cyl 5V Turbo OBDII Fuel Injection amp Ignition Repair Group 01 Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD Il Engine Mechanical Engine removing and installing Page 10 19 Tightening torques pared joine Exceptions pn 45 Nm Engine to gearbox connecting M10 bolts Engine to gearbox connecting M12 80 Nm bolts Torque converter to drive plate Drive shaft to joint flange gear box 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 N10 0191 WNUITIT Engine mounting a 14 0 mm b atleast 10 0 mm Both bolt heads 1 must be in flush with edge c Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD II Engine Mechanical Engine removing and installing Page 10 21 N10 0190 j Gearbox mounting Edges a and b must be parallel with one anothe
8. oved 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 amp 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 amp 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 Il 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 A 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 Il Engine Mechanical Engine removing and installing Page 10 5 Loosen and remove intak
9. r 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 N10 0145 Engine mounting 1 Mounting to body 1 40 Nm 90 1 4 tum 2 Mounting bracket to body 25 Nm 3 Mounting to engine bracket 1 60 Nm 90 1 4 tum 1 Replace bolts Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD II Engine Mechanical Engine removing and installing Page 10 23 N10 0146 A Gearbox assembly mounting 1 Mounting to body 1 40 Nm 90 1 4 tum 2 Mounting to body 25 Nm 3 Mounting to gearbox console 1 60 Nm 90 1 4 tum 1 Replace bolts I N10 0147 A Pendulum support 1 Pendulum support to gearbox 1 40 Nm 90 1 4 tum 2 Pendulum support to gearbox 1 40 Nm 90 1 4 tum 3 Pendulum support to subframe 0 20 Mm 90 1 4 tum 1 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 To facilitate removing and installing the engine without opening the refrigerant circuit Remove retaining clamp
10. r 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 Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD Il 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 Remove securing clamps for power steering pressure pipe Remove ribbed belt Page 13 8 Remove power assisted steering vane pump with bracket and lay to side hoses remain connected Repair Manual Suspension Wheels Steering Repair Group 48 Vehicles with air conditioner WARNING The air conditioner refrigerant circuit must not be opened Remove air conditioner compressor Observe additional notes and assembly work Pagei0 15 Remove generator Repair Manual Electrical Equipment Repair Group 27 Remove compact bracket including tightening element for ribbed V belt gt page 13 7 item 19 Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OB
11. tallation 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 Fit intermediate plate onto sealing flange and slide onto dowel sleeves arrows Vehicles with manual gearbox Check centering of clutch drive plate if necessary Check clutch release bearing for wear renew if necessary Lightly grease clutch release bearing release bearing guide sleeve and splines on input shaft with G 000 100 Install hydraulic clutch slave cylinder Repair Manual 5 Speed Manual Transmission 02J Repair Group 30 Install selector mechanism If necessary adjust gearchange cables Repair Manual Manual Transmission 02J Repair Group 34 Vehicles with automatic gearbox Only use nuts approved in parts programme to secure torque converter to drive plate Volkswagen New Beetle 1 8 Liter 4 Cyl 5V Turbo OBD Il 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 Vehicles with air conditioner Install generator Repair Manual Electrical Equipment Repair Group 27 Install compact bracket including tightening element for rib
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