Volkswagen New Beetle. Manual - part 1105

Fig. 110: Installing Guide Sleeve T10071/5 Onto Camshaft Journal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Slide oil seal over guide sleeve.  

z

Press seal in onto limit stop using press sleeve T10071/3 and bolt M8 x 60 -1-. 

Fig. 111: Pressing Seal In Onto Limit Stop Using Press Sleeve T10071/3 And Bolt M8 X 60 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing seal with annular spring 

z

Lightly oil sealing lip of oil seal.  

z

Install guide sleeve 3241/2 onto camshaft journal. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 112: Installing Guide Sleeve 3241/2 Onto Camshaft Journal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Slide oil seal over guide sleeve.  

z

Press seal in onto stop with press sleeve 3241/1 and bolt 3241/3. 

Fig. 113: Pressing Seal In Onto Stop With Press Sleeve 3241/1 And Bolt 3241/3 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continued for all seals 

z

Insert Camshaft Position (CMP) sensor hood into notch in inlet camshaft.  

z

Install washer (taper facing outward) and tighten securing bolt to 25 N.m.  

z

Install housing for Camshaft Position (CMP) sensor and tighten to 10 N.m.  

z

Install upper toothed belt guard.  

z

Reconnect connector on Camshaft Position (CMP) sensor -arrow-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 114: Reconnecting Connector On Camshaft Position Sensor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Hydraulic lifters, checking 

Special tools and equipment 

z

Feeler gauge  

z

Wood or plastic wedge  

Test sequence 

z

Start engine and run until radiator fan has switched on once.  

z

Increase engine speed to about 2500 RPM for approx. 2 minutes.  

If the hydraulic lifters are still noisy, locate faulty lifters as follows: 

z

Remove cylinder head cover.  

z

Rotate crankshaft clockwise, until cam of tappet to be checked is pointing upward.  

z

Determine play between cam and hydraulic lifter.  

If the play is in excess of 0.2 mm, replace hydraulic lifter. If the play is less than 0.1 mm or no play, proceed 
with check as follows:  

z

Push hydraulic lifter down lightly with a wooden or plastic wedge. If when hydraulic lifter is pushed 
down a 0.2 mm thick feeler gauge can be pushed between camshaft and hydraulic lifter, hydraulic lifter is 
to be replaced. 

NOTE:

z

Replace faulty lifter complete (cannot be adjusted or repaired). 

z

Irregular valve noises when starting engine are normal.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 115: Pushing Hydraulic Lifter Down Lightly With Wooden Or Plastic Wedge 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Camshaft, removing and installing 

(with cylinder head installed) 

Special tools and equipment 

z

3036 Counter hold tool  

z

3366 Retainer  

z

VAG 1331 Torque wrench (5 to 50 N.m)  

z

VAG 1332 Torque wrench (40 to 200 N.m)  

z

AMV174 004 01 Sealant  

z

D454 300A2 Sealant 

NOTE:

After installing new lifters the engine must not be started for approx. 30 
minutes. Hydraulic compensation elements must settle (otherwise valves will 
strike pistons).

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)