Volkswagen New Beetle. Manual - part 1109

Fig. 134: Determining Valve Rock 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Determine valve rock. 

Wear limit: 0.8 mm 

If rock tolerance is exceeded: 

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Replace cylinder head.  

Valve guides, replacing 

Special tools and equipment 

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Press tool VW 411  

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Drift 3360  

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Support 3361  

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Hand reamer 3363 and cutting fluid 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 135: Identifying Press Tool VW 411 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Check whether valve seat insert rings and if necessary cylinder head sealing surface can be reworked. If 
not, then valve guide should not be replaced.  

First set the support as follows: 

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Install mount pins for cylinder head bolt holes -A- into threaded hole positions 2 and 3. 

Fig. 136: Installing Mount Pins For Cylinder Head Bolt Holes -A- Into Threaded Hole Positions 2 
And 3 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install pin -B- into relevant hole for valve angle. 

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Outer intake valves: 21.5°  

 

2003 Volkswagen New Beetle GLS 

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

  

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Center intake valve: 15°  

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Exhaust valve: 20°  

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Press worn valve guides out with drift 3360 from camshaft side. 

Fig. 137: Pressing Worn Valve Guides Out With Drift 3360 From Camshaft Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Coat new valve guides with oil and press with drift 3360 into cold cylinder head from camshaft side until 
shoulder makes contact.  

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Ream guides out with hand reamer 3363 using plenty of cutting fluid.  

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Rework valve seats. See VALVE SEATS, REFACING .  

Valve stem seals, replacing 

(with cylinder head installed) 

Special tools and equipment 

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VAG1331 Torque wrench (5-50 N.m)  

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VAG1332 Torque wrench (40-200 N.m)  

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3122B Spark plug removal tool  

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3364 Puller  

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VW 653/3 Pressure hose  

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3362 Valve spring compressor and press piece 3362/1 

NOTE:

When the shoulder on guide makes contact, the pressure must not exceed 10 
kN (approx. 1.0 t) otherwise shoulder may break off.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 138: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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3365 Fitting tool 

Fig. 139: Identifying 3365 Fitting Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove camshafts. See CAMSHAFT, REMOVING AND INSTALLING .  

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Remove hydraulic lifters and place them with contact surface downward. When doing this ensure that 
lifters are not interchanged.  

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Remove spark plugs with spark plug removal tool3122B.  

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Set piston of appropriate cylinder to BDC (bottom dead center).  

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Screw pressure hose VW 653/3 into spark plug thread.  

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Mount fitting tool 3362 on cylinder head with fitting tool securing bolts. 

 

2003 Volkswagen New Beetle GLS 

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