Volkswagen New Beetle. Manual - part 1206

See CHECK CAMSHAFT POSITION (CMP) SENSOR .

17. 10 N.m  

18. 65 N.m 

z

Use counter-hold 3036 to loosen and tighten  

19. Camshaft sprocket 

z

Note installation position: small web of camshaft sprocket points outward and No. 1 Cyl. TDC 
marking is visible  

z

Note position when installing toothed belt. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING .  

20. Oil seal 

z

Replacing. See CAMSHAFT OIL SEAL, REPLACING .  

21. Valve guide 

z

Checking. See VALVE GUIDES, CHECKING .  

22. Valve stem seal 

z

Replacing. See VALVE STEM SEALS, REPLACING .  

23. Valve spring 

z

Removing and installing: remove cylinder head with 3362  

z

Installing. See VALVE STEM SEALS, REPLACING .  

24. Upper valve spring plate  

25. Valve keepers  

26. Hydraulic lifter 

z

Do not interchange  

z

With hydraulic valve clearance compensation  

z

Checking. See HYDRAULIC LIFTERS, CHECKING  

z

Store with cam contact surface downward  

z

Before installing check camshaft axial clearance. See Checking Camshaft Axial Clearance .  

z

Oil contact surface  

27. Intake camshaft bearing cap 

z

Installation position and installation sequence. See CAMSHAFT, REMOVING AND 
INSTALLING .  

28. Double bearing cap 

z

Lightly coat bearing cap contact surface with sealant AMV 174 004 01  

z

Must sit on alignment bushing  

z

Seal transitions of double-bearing cap/cylinder head. See Sealing transition points between 
double bearing cap and cylinder head .  

29. Exhaust camshaft bearing cap 

z

Installation position and installation sequence. See CAMSHAFT, REMOVING AND 
INSTALLING .  

 

2003 Volkswagen New Beetle GLS 

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

  

30. Exhaust camshaft 

z

Checking axial clearance. See Checking Camshaft Axial Clearance  

z

Removing and installing. See CAMSHAFT, REMOVING AND INSTALLING . 

Checking radial clearance with plastigage: 

z

Wear limit: 0.1 mm  

z

Run-out: max.: 0.01 mm  

Fig. 92: Exploded View Of Valve Train Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Reworking Cylinder Head Sealing Surface 

Fig. 93: Measuring Point For Reworking Cylinder Head Sealing Surface 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The dimension for reworking is measured through the holes for the cylinder head bolts. 

 

2003 Volkswagen New Beetle GLS 

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

  

-a- = minimum 139.2 mm 

Checking Camshaft Axial Clearance 

Special tools and equipment 

z

Universal dial indicator bracket VW 387  

z

Dial indicator  

Check with hydraulic lifters and chain removed and No. 2 and 4 bearing caps installed. 

Wear limit: max. 0.2 mm 

Fig. 94: Checking Camshaft Axial Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve Dimensions 

NOTE:

Valves must not be reworked. Only lapping-in is permitted.

NOTE:

The following table refers to items in Fig. 95 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 95: Valve Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

VALVE DIMENSIONS 

Sealing transition points between double bearing cap and cylinder head 

Dimension

Intake valve

Exhaust valve

dia. a (mm)

26.9

29.9

dia. b (mm)

5.963

5.943

c (mm)

104.84 - 105.34

103.64 - 104.14

Angle a (angle °)

45

45

NOTE:

Care must be taken when disposing of old sodium filled valves. They must be 
cut through in the center of the stem with a hacksaw. When doing this they 
must be perfectly dry. The valves prepared in this way can then be thrown into a 
bucket of water a maximum of ten at a time. When doing this step back quickly 
because a sudden chemical reaction causes the sodium filling to burn. After 
this treatment, the valves can be put in with the normal scrap.

 

2003 Volkswagen New Beetle GLS 

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