Volkswagen New Beetle. Manual - part 1203

Fig. 78: Exploded View Of Cylinder Head Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Cylinder Head For Distortion 

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

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Straight edge  

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Feeler gauges  

Max. permissible distortion: 0.1 mm 

Fig. 79: Checking Cylinder Head For Distortion 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cylinder head, removing and installing 

Special tools and equipment 

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VAG 1306 Drip tray  

 

2003 Volkswagen New Beetle GLS 

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

  

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VAG 1332 Torque wrench (40-200 N.m)  

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VAG 1921 Hose clip pliers  

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3070 Installation tool with guide pins  

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VAS 5024 Assembly tool for spring-type clamps  

Fig. 80: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engines with Polydrive cylinder head bolts: 

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3452 Tool  

Requirements 

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The engine must be no more than warm to touch  

Work sequence 

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Note safety precautions before starting work. See SAFETY PRECAUTIONS WHEN WORKING ON 
FUEL SUPPLY .  

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Observe rules for cleanliness. See RULES OF CLEANLINESS .  

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Check whether a coded radio is installed. If so, obtain anti-theft coding.  

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With ignition switched off, disconnect battery Ground strap.  

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Remove engine cover.  

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Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

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Remove secondary air pump motor and bracket. 

WARNING:

Fuel supply lines are under pressure! Before removing from hose 
connection wrap a cloth around the connection. Then release 
pressure by carefully pulling hose off connection.

 

2003 Volkswagen New Beetle GLS 

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

  

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Separate fuel supply as well as fuel return pipes at connection on fuel rail. Fuel system is under pressure, 
therefore place a cloth over connection before hoses are pulled off.  

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Seal lines so that fuel system is not contaminated by dirt etc.  

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Remove coolant hose connections on cylinder head.  

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Remove inter-connecting, coolant, vacuum and intake hoses on engine.  

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Pull connector(s) off ignition coils.  

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Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.  

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Remove intake air hose from connection of exhaust turbocharger as follows:  

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Pull off hose at pressure regulator valve of crankshaft ventilation.  

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Disconnect harness connector at Wastegate Bypass Regulator Valve -N75-.  

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Pull off hose at Wastegate Bypass Regulator Valve -N75-.  

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Disconnect hose from solenoid valve to turbocharger at bulkhead.  

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Disconnect hose between EVAP canister and exhaust turbocharger at bulkhead.  

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Pull out securing buckle at connector of exhaust turbocharger and remove air intake hose.  

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Remove heat protection pad 1 from air guiding hose 2 (observe installation position). 

Fig. 81: Removing Heat Protection Pad 1 From Air Guiding Hose 2 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove air guiding hose 2.  

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Loosen 2 bolts from bracket of upper air guiding hose. See ONLY FOR ENGINE CODE APH , Item 8 

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Remove heat protection pad from air guiding hose (observe installation position) and loosen clamp 3. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 82: Removing Heat Protection Pad From Air Guiding Hose And Loosening Clamp 3 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove screws 1 and 4 for heat shield from behind cylinder head.  

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Loosen screws 2 and 5.  

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Remove air guiding hose, hose to turbocharger and heatshield.  

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Remove three exhaust gas turbocharger/exhaust manifold securing bolts -arrows-. 

Fig. 83: Removing Three Exhaust Gas Turbocharger/Exhaust Manifold Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

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Remove tensioning element for ribbed belt.  

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Remove toothed belt guard (upper part).  

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Set camshaft sprocket to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft sprocket must 
align with arrow on toothed belt guard. 

 

2003 Volkswagen New Beetle GLS 

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