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The Sister Special, '03 Beetle GL

1344 Views 47 Replies 4 Participants Last post by  billymade
(copied from new member forum post i made)
the main reason i made the account is the timing belt. it looks like an absolute PAIN to replace.
this car was a carmax car at some point, it was at carmax at 104k miles.
There are also issues with the sunroof leaking, particularly the passenger side leaks. the glove box is broken but i already grabbed a junkyard replacement. the most visible issue with the coolant leak was the reservoir had a crack in it and it would leak all the coolant out... but there seems to be a secondary leak i cant find as well, perhaps water pump?
i cant even find the oil leak, probably front main or cam seal. luckily i luckily haven't found any of the famous wiring issues that these are known for, the fans kick on when they are supposed to, all the lights work, the 6 disc changer changes, and even the cassette player plays cassettes still!
I just need to do the timing job and sunroof seal so i can get this thing out of the garage to reseal my '57 fords axle and oil pump.
my sister and my mother are taking care of the headliner, door panels, and such.
also it needs plugs, a coil, and has a leak somewhere in the exhaust. its throwing some emission codes, I was told not to bother with fixing them for now.

the car has a 2.0, 4 speed automatic, and is otherwise a base model.
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If you have any trouble codes; please post them here.

For the timing belt job; best to buy a whole kit with the waterpump and all the other parts that are on the timing belt path. I have been using FCPEURO.com lately for my VW parts and they sell high quality oem parts, fast free shipping, lifetime warranty and excellent customer service. The timing belt job is not very hard; the first time, is a bit more time consuming but if you are mechanically inclined, definitely doable.

Coolant leaks are very common; some tough to find, in that case, I use a cooling system pressure tester and that makes pinpointing them easier. I use one from HF but there are others out there as well (this has adapter for all vehicles; so, useful to work on anything you have):

PITTSBURGH AUTOMOTIVE Radiator Pressure Tester Kit


When, the waterpump wears out; it will leak coolant, possibly make a whining noise and it will get worse, as time goes on. The leak, will be on the passenger side and come out from under the harmonic balancer and typically, is pretty obvious. If it is leaking, I would address the repair right away; the waterpump, is driven by the timing belt and so, if the bearing causes a catastrophic failure, the timing belt will fail and bend valves in the head.

If you end up repairing your cooling system; you might consider, replacing many of the failure prone plastic cooling flanges with aftermarket cast aluminum versions, which won't fail again.


For leaks from the roof into the car; you might first check the drains and make sure they are not clogged.


On the 2.0L oil leaks; the valve cover gasket is common and then, the oil cooler seal, is rubber which gets hard and this leaks at the front of the engine.

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If you have any trouble codes; please post them here.

For the timing belt job; best to buy a whole kit with the waterpump and all the other parts that are on the timing belt path. I have been using FCPEURO.com lately for my VW parts and they sell high quality oem parts, fast free shipping, lifetime warranty and excellent customer service. The timing belt job is not very hard; the first time, is a bit more time consuming but if you are mechanically inclined, definitely doable.

Coolant leaks are very common; some tough to find, in that case, I use a cooling system pressure tester and that makes pinpointing them easier. I use one from HF but there are others out there as well (this has adapter for all vehicles; so, useful to work on anything you have):

PITTSBURGH AUTOMOTIVE Radiator Pressure Tester Kit


When, the waterpump wears out; it will leak coolant, possibly make a whining noise and it will get worse, as time goes on. The leak, will be on the passenger side and come out from under the harmonic balancer and typically, is pretty obvious. If it is leaking, I would address the repair right away; the waterpump, is driven by the timing belt and so, if the bearing causes a catastrophic failure, the timing belt will fail and bend valves in the head.

If you end up repairing your cooling system; you might consider, replacing many of the failure prone plastic cooling flanges with aftermarket cast aluminum versions, which won't fail again.


For leaks from the roof into the car; you might first check the drains and make sure they are not clogged.


On the 2.0L oil leaks; the valve cover gasket is common and then, the oil cooler seal, is rubber which gets hard and this leaks at the front of the engine.

i already unclogged the drains, the leak remains on the passenger side tweeter area.

i have two trouble codes at the moment, p0420, and another which is pretty much the same code, just emissions.
the water pump was included in the kit, figures they chose to put it on the dumbest spot possible... is there a chance of coolant ending up in the oil when removing the water pump? this is the first OHC belt driven engine ive touched. personally i prefer push-rod engines or chain driven OHC (modular my beloved).

also, what about degreeing the cam? set it to TDC and align the dots?
spark plugs should be easy, other than the fact the intake appears to be directly in the way.
the oil leaks arent a major concern, its a volkswagen.

This is a pretty common code with a 20+ year old VW with the original cat. You might review this video; going over temp spot checks and viewing live data, for the 02 sensors.


Having said that, this code popped up on me recently; seeing, the high cost of a new cat, I tried running Seafoam through my intake/throttle body and the code went away, stayed away! Not too expensive and worth a try! :)
As to the timing belt replacement; there are many videos on youtube, that you can review.


Here is the service manual online; going over the VW factory info and steps:


You might download the VW ERWIN service manual here:


Spark plugs; vw recommends a tool but needle nose pliers, can typically grab the wires out? You do not have to remove the intake manifold; with the right swivel/universal, extensions, spark plug socket and ratchet, you should be fine.


Spark plug wire end removal tool: (probably nice to have but not required):


If you are going to keep the car long term; investing, in the tool and being able to remove the wires, damage-free, might not be a bad investment?

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As to the timing belt replacement; there are many videos on youtube, that you can review.


Here is the service manual online; going over the VW factory info and steps:


You might download the VW ERWIN service manual here:


Spark plugs; vw recommends a tool but needle nose pliers, can typically grab the wires out? You do not have to remove the intake manifold; with the right swivel/universal, extensions, spark plug socket and ratchet, you should be fine.


Spark plug wire end removal tool: (probably nice to have but not required):


If you are going to keep the car long term; investing, in the tool and being able to remove the wires, damage-free, might not be a bad investment?

this is my sisters first car, i dont expect another 50k out of it
The 2.0L was probably one of the most bulletproof engines; of the VW Mark IV era they made, if maintained, you will probably be surprised, how long they last.

These “common 2.0L problems” might be interesting to watch:



Sent from my iPhone using Tapatalk
The 2.0L was probably one of the most bulletproof engines; of the VW Mark IV era they made, if maintained, you will probably be surprised, how long they last.

These “common 2.0L problems” might be interesting to watch:



Sent from my iPhone using Tapatalk
nonono, you dont get what im saying. i dont expect this car to survive. the motor will outlive the car.
nonono, you dont get what im saying. i dont expect this car to survive. the motor will outlive the car.
Just looked at a 2005 from a 17-year-old girl. Didn't think anyone could trash an interior that bad :)
Just looked at a 2005 from a 17-year-old girl. Didn't think anyone could trash an interior that bad :)
the interior on this car is tan, when we got it you could have thought it was black. previous owners boyfriend was a mechanic, she always picked him up, everything is black, both door panels are sagging and broken, the headliner is falling, etc. the seats are leather and not torn at least.
I started tearing into it, made good progress, im glad im doing the timing belt now because its nearly loose enough to slide it off the water pump.
The cat code will be easy to resolve at least, something broke the wire to the o2 sensor, and it probably just needs replaced/soldered.
also, i stripped a crank pulley hex bolt thing, why cant vw just use normal bolts like they used to?
i stripped a crank pulley hex bolt thing, why cant vw just use normal bolts like they used to?
Would that be one of the four that hold the harmonic balance pulley in place?
Would that be one of the four that hold the harmonic balance pulley in place?
yes.
Tire Wheel Automotive tire Locking hubs Tread

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heres my progress. at least the bolts come out easy. first time my metric set has been used this much in a loooong time.
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4

I got a set of these for Christmas, so far I’ve used it twice and it worked perfect.

I got a set of these for Christmas, so far I’ve used it twice and it worked perfect.
I will see about using an extractor, my normal method of using a torx didnt work.
I will see about using an extractor, my normal method of using a torx didnt work.

I believe it’s Lowe’s that has craftsman tools now.

My method for removing those bolts is a solid chunk of steel rod about a foot long. I give the head of each bolt a solid hit by placing that rod on the head of each bolt and using a two lb hammer. Bang. Then I tap the 6mm hex all the way to the bottom of the hole after cleaning it out with a pick. Then I attach the ratchet to the Allen socket and I’ve only had one fail to come out so far.

You will need to replace the damaged bolt.
Made good progress last weekend, i keep getting a security error when uploading files, but the timing belt is replaced, motor is back together, have g13 coolant in it, a new mann filter, valvoline european blend oil, etc. the glovebox has been replaced and works properly now, i have the headliner dropped and ready for recovering, the o2 sensor is broken off at the plug in the "box", a new one is on the way. hopefully this car will be back together and out of the garage by next weekend.

also, i e6000'd the sunroof drains after cleaning them out, wont leak now! sunroof is fully functional, the door panel fabric has been recovered, etc. its shaping up. something major i need to look at is the power steering leak, theres a crimp on the front of the car that leaks.
oh also, the water pump (and sunroof) had been siliconed to seal them, luckily it was easy to clean up.

the fender liner is in, last thing i need to do while the car is in the air is replace the o2 sensor.
oh also, the water pump (and sunroof) had been siliconed to seal them, luckily it was easy to clean up.

the fender liner is in, last thing i need to do while the car is in the air is replace the o2 sensor.

Silicone may not seal that water pump.
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