Volkswagen New Beetle. Manual - part 1178

Valve guides, replacing 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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3121 Drift 

Fig. 125: Identifying 3121 Drift 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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3120 Reamer and cutting fluid 

Fig. 126: Identifying 3120 Reamer & Cutting Fluid 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Clean and check cylinder head. Cylinder heads in which valve seats can no longer be reworked. Note 
minimum dimension. See VALVE SEATS, REWORKING . Cylinder heads which have already been 
machined to minimum dimension, should not have valve guides replaced. See Fig. 102 .  

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Press out worn valve guides with drift 3121 from camshaft side (repair version guides, with a shoulder, 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

from combustion chamber side).  

Installing 

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Press in new guides, moistened with oil, from camshaft side onto shoulder in cold cylinder head using 
drift 3121. 

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Ream valve guide using hand reamer 3120. Always use cutting fluid when doing this.  

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Reworking valve seats. See VALVE SEATS, REWORKING .  

Valve stem seals, replacing 

(with cylinder head installed) 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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2036 Assembly device  

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3047A Puller  

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3122 B Spark plug wrench  

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3129 Installation tool  

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T10112 Installation tool  

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V.A.G 1331 Torque wrench (5..50 N.m) 

Fig. 127: Identifying Special Tools (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VW 541/1A Lever  

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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VW 541/5 Press piece  

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VW 653/3 Pressure hose  

Fig. 128: Identifying Special Tools (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove camshaft. See CAMSHAFT, REMOVING AND INSTALLING .  

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Take out hydraulic lifter and place down with running surface downward. Ensure hydraulic lifters are not 
interchanged when doing this.  

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Disconnect spark plug connectors with tool T10112  

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Remove spark plugs with spark plug wrench 3122B.  

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

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Mount assembly device 2036 and adjust mountings to height of studs. 

Fig. 129: Mounting Assembly Device 2036, VW 653/3 & VW 541/1A 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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

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Connect pressure hose to compressed air supply of at least 6 bar.  

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Remove valve springs with assembly lever VW 541/1A and thrust piece VW 541/5. 

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Pull off valve stem seals with 3047A. 

Fig. 130: Removing Valve Stem Seal 
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 -B- 
being damaged. 

Fig. 131: Installing Valve Stem Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Tight keepers can be loosened by tapping lightly on the lever.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD