2000 Volkswagen New Beetle GL Timing Belt Installation

TIMING BELT for VOLKSWAGEN' '1.8L 4-Cylinder - New Beetle - APH, AWP & AWV Engines Removal 1. Remove engine cover. Remove noise insulation pan from under engine compartment. 2. Remove air duct pipe between turbocharger and charge air cooler. See Fig. 1 . Air duct pipe is located along bottom right of cross member. 3. Mark rotation direction of serpentine drive belt. Move serpentine drive belt tensioner as shown to release tension on belt. See Fig. 2 . Secure tensioner using a drift, about .18" (4.5 mm) x 2.2" (55 mm). See Fig. 3 . Remove serpentine drive belt. Remove serpentine drive belt tensioner. 4. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Ensure that TDC marks on flywheel and bellhousing are aligned. See Fig. 4 or Fig. 5 . 5. Remove coolant expansion tank and set aside. Label all vacuum hoses for reassembly reference, and disconnect vacuum hoses from fuel evaporative canister. Disconnect vacuum hoses at throttle body. 6. Remove upper timing belt cover. See Fig. 6 . 7. Attach Engine Support Bridge (10-222A) with Bracket (10222), and engage retainer in right lifting eye bolt located at cylinder head. Lift engine slightly to remove weight from engine mounts. Engine may also be supported from below with a floor jack. CAUTION: Engine mount assembly is secured by torque-to-yield bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt. These bolts MUST be replaced if they are loosened or removed. 8. Remove bolts from engine mount assembly at timing belt end of engine. Remove engine mount. 9. Remove 4 crankshaft pulley socket-head bolts. Remove crankshaft pulley. It is NOT necessary to remove crankshaft pulley center bolt. 10. Remove lower and middle timing belt covers. Remove engine bracket from engine block. See Fig. 7 . If reusing old timing belt, mark timing belt with arrow to indicate original direction of rotation. 11. Screw Tensioning Bolt (T10092) or M5 x 55 x 1 stud into timing belt tensioner bracket. See Fig. 8 . Install hex nut and washer onto stud. 12. SLOWLY turn hex nut on stud to compress timing belt tensioner.

Source