Volkswagen New Beetle. Manual - part 1110

Fig. 140: Mounting Fitting Tool 3362 On Cylinder Head With Fitting Tool Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Position fitting tool for compressing valve springs to one of following positions: 

Outer intake valves: lower position 

Center intake valve: upper position 

Exhaust valve: lower position 

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Connect pressure hose to compressed air system supplying at least 6 bar and remove valve springs.  

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Pull off valve stem seals with 3364. 

Fig. 141: Pulling Off Valve Stem Seals With 3364 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Place plastic sleeve -A- supplied on appropriate valve stem. This will prevent new valve stem seal being 
damaged. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 142: Placing Plastic Sleeve -A- Supplied On Appropriate Valve Stem 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place new valve stem seal in fitting tool 3365.  

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Oil sealing lip of valve stem seal -B- insert in installation tool 3365 and press carefully onto valve guide. 

The rest of the assembly is basically a reverse of the disassembling sequence. 

ENGINE - LUBRICATION 

LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Checking oil pressure and oil pressure switch. See OIL PRESSURE AND OIL PRESSURE SWITCH, 
CHECKING . 

Oil system capacity: 

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Without oil filter: 4.0 liters  

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With oil filter: 4.5 liters (4.8 qt.)  

NOTE:

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If large quantities of metal particles or other deposits (caused, for 
example, by partial seizure of the crankshaft or connecting rod bearings) 
are found in the engine oil when performing repairs, clean the oil passages 
thoroughly and replace the oil cooler in order to prevent further damage 
from occurring later.  

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The oil level must not be above the max. mark, or there is danger of 
damage to the catalyst! Marking. See Markings On Oil Dipstick . 

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Thoroughly clean oil passages  

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Replace oil spray jets, oil cooler, and oil filter  

 

2003 Volkswagen New Beetle GLS 

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

  

Oil Capacities up to MY 2000 

Checking oil pressure. See OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING . 

Engine oil specifications: 

The following terms must appear on the oil container singly or in combination with other designations: 

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VW 502 00 or VW500 00 or VW501 01  

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ACEA A2 or ACEA A3  

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API-SJ or API-SL  

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Engine oils are graded according to their viscosity. The proper grade to be used in your engine depends 
on existing climatic or seasonal conditions.  

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The engine oil which was first put into your engine has a viscosity grade of SAE 5W-40. You can use this 
oil over all temperature ranges for normal driving. If engine oil viscosity grade SAE 5W-40 is not 
available, you can also use SAE 5W-30.  

Part I 

Part II, disassembly oil filter bracket. See PART II . 

1. 15 N.m  

2. Sealing flange 

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Must be located on dowel sleeves  

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 404 A2. See FRONT SEALING FLANGE, REMOVING 
AND INSTALLING .  

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Replacing crankshaft oil seal (pulley end). See CRANKSHAFT OIL SEAL (BELT PULLEY 
END), REPLACING .  

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Removing and installing. See FRONT SEALING FLANGE, REMOVING AND 
INSTALLING .  

3. Chain tensioner with tensioning rail, 15 N.m 

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Check for wear  

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When installing, pretension spring and install  

4. Chain sprocket 

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For oil pump drive  

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Check for wear  

5. Cylinder block 

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Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING . 

NOTE:

The following list refers to items in Fig. 143 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Disassembling and assembling pistons and connecting rods. See PISTONS AND CONNECTING 
RODS, DISASSEMBLING AND ASSEMBLING .  

6. Dipstick 

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Oil level must not be above max. mark!  

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Markings. See Markings On Oil Dipstick .  

7. Guide 

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For dipstick  

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Pull off to extract oil  

8. Guide tube  

9. Oil spray jet 

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For piston cooling  

10. Pressure relieve valve, 27 N.m 

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Opening pressure: 1.3 to 1.6 bar  

11. 15 N.m  

12. Suction pipe 

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Clean strainer if soiled  

13. O-ring 

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Replace  

14. Baffle plate  

15. 15 N.m 

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Loosen and tighten with T-bar and socket, 10 mm 3185  

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Remove with hexagon key extension, 5 mm 3249  

16. Oil pan 

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Clean sealing surface before installing  

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Install with silicone sealant D 176 404 A2. See OIL PAN, REMOVING AND INSTALLING .  

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Removing and installing. See OIL PAN, REMOVING AND INSTALLING .  

17. Oil drain plug, 30 N.m 

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Replace if leaking. See Parts Catalog for correct application. In some cases, seal and drain plug are 
combined; do not interchange with separate seal and drain plug.  

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If sealing ring is leaking nip open and replace.  

18. Seal 

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Replace  

19. Oil return pipe 

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From turbocharger  

20. 10 N.m  

21. Oil pump 

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With positive pressure relief valve 12 bar  

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Before installing, check that both dowel sleeves for centering oil pump/cylinder head are installed 

 

2003 Volkswagen New Beetle GLS 

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