Volkswagen New Beetle. Manual - part 1003

Fig. 122: Loosening Rocker Shaft Exterior Bolts And Interior Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove rocker shafts.  

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Remove tandem pump. See TANDEM PUMP, REMOVING AND INSTALLING .  

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First remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally. 

Fig. 123: Removing Camshaft Bearing Caps 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove camshaft.  

Installing 

NOTE:

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Make sure that the camshaft bearing shells are not interchanged.  

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Mark the allocation of the camshaft bearing shells on the back with a 
waterproof felt-tipped pen.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

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Oil contact surfaces of bearing shells.  

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Install bearing shell 2 and 4 and tighten new bolts alternately and diagonally to: 

8 N.m plus an additional 1/4 turn (90°). 

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Install bearing caps 5, 1 and 3 and also tighten new screws to: 

8 N.m plus an additional 1/4 turn (90°).

NOTE:

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When installing the camshaft No. 1 cylinder cam lobes must point upward. 

Fig. 124: Identifying No. 1 Cylinder Cam Lobes 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Do not interchange used bearing shells (observe marking).  

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Observe correct seat of the bearing shell tabs in the bearing caps and the 
cylinder head when installing the camshaft.  

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Before installing the bearing caps observe that the washers for the 
cylinder head bolts are installed in the cylinder head.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 125: Identifying Camshaft Bearing Caps 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install camshaft seal. See OIL SEAL, REMOVING AND INSTALLING .  

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Install rocker shaft and tighten interior new securing bolts -2- first and then exterior bolts -1- using 
alternate and diagonal sequence evenly. 

Tightening torque: 20 N.m plus an additional 1/4 turn (90°)

NOTE:

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Seal bearing caps 1 and 5 contact surfaces with AMV 174 004 01. See 
SPECIAL TOOLS AND EQUIPMENT . See Fig. 110 .  

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Bearing cap 5 -1- must fit flush with outer edge of the cylinder head -2- 
(arrows), otherwise this may lead to tandem pump leakage. 

Fig. 126: Bearing Cap 5 Must Fit Flush With Outer Edge Of The Cylinder 
Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 127: Tightening Rocker Shaft Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install hub onto camshaft.  

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Using counterhold T10051 tighten camshaft pulley securing bolt -1- to hub. 

Tightening torque: 100 N.m 

Fig. 128: Tightening Camshaft Pulley Securing Bolt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install camshaft gear on hub.  

NOTE:

The tooth segment (arrow) of the camshaft gear must point upward.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)