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Volkswagen gr-10 manual

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Table of contents for the manual

  • 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 conditi oner, additional informati on and removal instructions Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical 10 E[...]

  • 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 an d 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 Engi ne/gearbox jack V.A.G 1921 Spring - type clip pliers T10012 Engine bracket V.A.S 5085 Step ladder G 000 100 grease (vehic les with manual gearb[...]

  • 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 ignition switched off, di sconnect battery Ground strap[...]

  • 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 breat her hoses off engine. WARNING! Fuel supply pipes are under pressure! Before removing fr o m hose connection wrap a cloth around the co[...]

  • 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 c ooler and throttle valve control unit) at throttle valve control unit. - Disconnect harness connector for intake air temperature (G42), - 1 - and - 4 - for throttle valve cont rol[...]

  • 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 igniti on coil - 1 - and - 2 - . - Disconnect connectors from ignition coils. - Disconnect connecto r for spee[...]

  • 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 au tomatic gearbox - Remove selector leve r cable from gearbox: Repair Manual, Automatic Transmission 01M, Repair Group 37 Continued for all vehicles - Drain coolant Page 19 - [...]

  • 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 wire s from gearbox, alternator and starter and move clear. - Remove securing clamps fo[...]

  • 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 ve locity joint from engine. - Remove right - hand drive shaft and disconnect left - ha nd drive shaft at gearbox. Repair Manual, Suspension, Wheels[...]

  • 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 bl ock with a securing nut and M10 X 25/ 8.8 bolt and tighten to approx. 40 Nm. - Lift engine and gearbox lightly using engine/g earbox jack V.A.G 1383 A. - Unbol[...]

  • 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 asse mbly mounting from gearbox ca rrier at top - arrows - . - Carefully lower en gine with gearbox. - When doing this guide th e power assisted st eering pressure pipe past the gearbox. Notes: Engine with g[...]

  • 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 engi ne, it should be se cured to the assembly stand support clamp VW 313 using the engine and gearbox bra cket VW 540. Work sequence - Move engine/transmission with V.A.G 1383 A[...]

  • 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 au tomatic gearbox - Secure torque converter agai nst "falling out" after s eparating engine from gearbox. Continued for all vehicles - Attach lifting tackle 2024A wi th bracket 3180 as follows and lift off e[...]

  • 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 sleev es for centralizing engine/ge arbox are in the cylinder block, install if necessary. - Fit i[...]

  • 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 sufficient clearance to drive shafts. Vehicles wi[...]

  • 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 gear box mountings Page 10 - 20 . Installing drive shafts: Repair Manual, Suspension, Wheels, Steering, Repair Group 40 - Remove right hand i nner constant velocity jo int protective cov[...]

  • 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 a nd 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 e and check DTC memory: Repair Manual, 1.8 L[...]

  • 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 th e assemblies must be secured with the spe cial tool 10 - 222A. Engine mounting a = 14.0 mm b = at least 10.0 mm Both bolt heads 1 must be in flush with ed[...]

  • 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 ope n ed. Notes: To prevent damage to co ndenser and also to the refrigerant pipes/hoses, en[...]

  • 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 refr igerant hoses/pipes are not under tension. Notes: To prevent damage to bumper protect with adhesive tape.[...]