Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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- Remove engine cover (arrows). – Remove noise insulation panel (arrows). – Remove front bumper. Refer to Body and Frame/Bumper/Service and Repair – Move lock carrier to service position. Refer to Body and Frame/Radiator Support/Service and Repair – Remove ribbed belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Serpentine Belt/Service and Repair See: Drive Belt/Service and Repair CAUTION: Mark the running direction of the belt with a crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt. – Unclip toothed belt guard on both sides and remove. – Turn crankshaft by hand to TDC. Marks -A- and -B- must align Check position of camshafts. Larger holes (arrow) of securing plates on camshaft sprockets must be on inside and must align If they are not in this position: Turn crankshaft one revolution further. – Remove sealing plug from left-side of cylinder block. Top Dead Center (TDC) mark on crankshaft must be visible or can be felt – Install 3242 crankshaft holder into opening. – Remove tensioner for ribbed belt. – Remove center and left belt guards. Notes: The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. Use spring clamp from 2024A.

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Toothed belt, removing and installing Special Tools and Equipment – - – - – - 3212 spanner wrench 3387 pin wrench T40011 pin T40026 locking pin T40028 socket T40030 camshaft adjuster gauge Removing ^ Lock carrier in service position, Refer to Body and Frame, Radiator Support, Service and Repair ^ Ribbed belt removed, Refer to Drive Belt, Service and Repair ^ Unscrew bolts (arrows) and remove ribbed belt tensioner. ^ Remove ribbed belt gear of vane pump (arrows) using 3212 spanner wrench as retainer. ^ ^ Remove 8 bolts -1-. Remove harmonic balancer -2- and thrust washer -3-. Note: ^ Thrust washer -3- is only installed on toothed belt gear with part number 06C 105 063 A. ^ No thrust washer must be installed for toothed belt gear with part number 06C 105 063 B.

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Toothed belt, removing and installing Special tools and equipment: – Spring pin from 2024A – Pin wrench 3212 – Open end wrench 3312 – Wrench 3078 (22 mm) – Clamping bolt 3242 – Camshaft bar T40005 – Puller T40001 – Torque wrench VAG 1410 – Socket attachment VAS 5122 – Tensioning roller key T40009 – Pin T40011 Removing – - – - Remove engine cover-arrows-. Remove cylinder head cover-1- and -2-. Disengage spring clips at toothed belt cover. Remove toothed belt cover. – - – Remove noise insulation -arrows-. Removing and installing ribbed belt. See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair Remove ribbed belt pulley for viscous fan. Turn crankshaft to TDC by hand. Markings -A- and -B- must be aligned. Check position of camshafts: larger holes -arrow- in securing plates on camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft one revolution. Remove sealing plug -arrow- from left side of cylinder block. TDC drilling in crankshaft must be behind sealing plug hole (feel to check).

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1. Remove air cleaner with hot air intake and intake air duct. 2. Remove accessory drive belts. Release tension on ribbed (accessory) belt tensioner using Ribbed Belt Installation Tool (3299) and remove ribbed belt at generator. Remove ribbed belt tension roller and upper timing belt guard. Remove lower V-belt cover. Hold hydraulic (P/S) pump pulley using (VAG1590) or mandrel, and remove fasteners for coolant pump pulley. Remove coolant pump pulley and V-belt. Remove vibration damper/pulley. See Fig. 2 and Fig. 3 .
3. Turn drive plate (A/T) or flywheel (M/T) to align mark (arrows in illustration) and place No. 1 cylinder at TDC. See Fig. 5 . Remove lower timing belt guard. 4. Mark the running direction on the timing belt. Remove fastener for timing belt thermo tension roller.
Remove belt and roller. Remove timing belt thermo tensioner. See Fig. 8 .

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The Volkswagen New Beetle Service Manual: 1998.-.2002 1.8L turbo, 1.9L TDI diesel, 2.0L gasoline
Maintenance procedures: from routine oil changes to poly-ribbed belt replacement.
• Engine and cylinder head service, including timing belt and camshaft replacement.
• Component testing, removal and installation for engine lubrication, cooling, and exhaust systems.
• Turbocharger service, removal and installation, and intercooler components.
• Fuel supply system service, including fuel pump delivery volume test, electrical checks, EVAP system, as well as mechanical and electronic throttle control (E-gas).
• Fuel injection and ignition system component identification, electrical testing, technical data, and throttle valve control module adaptation using the factory scan tool.

• Drivetrain maintenance, troubleshooting, adjustment and repair, including hydraulic clutch, gearshift linkage, drive axles, and transmission removal and installation.
• Repair information for ABS/EDL/ASR/ESP brake and stability systems.
• Suspension system service including struts, CV joints, stabilizer bar, rear wheel bearings, wheel alignment specifications and steering system.
• Interior and exterior body equipment: airbags, bumpers, front and rear body sections, doors, hood, lids, lights, instrument panel/dashboard, sunroof, seatbelts, seats, trim panels.
• Heating and air conditioning repair, including A/C electrical component replacement, compressor, fresh air blower, sensors, and vacuum hose layout.