Volkswagen New Beetle. Manual - part 1212

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Replace rubber/metal seal for camshaft adjuster or chain tensioner and lightly coat hatched area with 
sealant D 454 300 A2. 

Fig. 122: Identifying Lightly Coated Hatched Area With Sealant D 454 300 A2 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place chain onto camshaft gears as follows:  

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Slide camshaft adjuster or chain tensioner between drive chain.  

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Oil running surfaces of both camshafts.  

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Place camshafts with drive chain and camshaft adjuster or chain tensioner in cylinder head.  

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Tighten camshaft adjuster or chain tensioner to 10 N.m (take note of dowel sleeves).  

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Tighten intake and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence to 
10 N.m (take note of dowel sleeves). 

Fig. 121: Identifying Distance Between Notches -A- And -B- At Camshaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 123: Identifying Intake And Exhaust Camshaft Bearing Caps 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install both bearing caps at chain sprockets for intake and exhaust camshafts. Check camshafts are 
positioned correctly and tighten bearing cap to 10 N.m (remember dowel sleeves). 

Fig. 124: Installing Both Bearing Caps At Chain Sprockets For Intake And Exhaust Camshafts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove retainer for chain tensioner 3366.  

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Coat hatched area of double bearing cap lightly with sealant D 454 300 A2, install and tighten to 10 N.m 
(remember dowel sleeves). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 125: Identifying Coated Hatched Area Of Double Bearing Cap With Sealant D 454 300 A2 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install remaining bearing caps and tighten to 10 N.m (remember dowel sleeves).  

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Observe installation position.  

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Install camshaft sprocket. Bevelled edge of camshaft faces outward -arrows- and TDC Cyl. 1 is visible at 
front 

Fig. 126: Installing Camshaft Sprocket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten securing bolt to 65 N.m (use counter-hold tool 3036).  

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Recheck position of camshafts relative to one another -arrows-. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 127: Rechecking Position Of Camshafts Relative To One Another 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing toothed belt and adjusting timing. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING . 

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

Camshaft adjustment, checking 

Only vehicles with engine codes: AWP, AWV 

The adjustment of the camshaft occurs dependent upon load and engine RPM. The electrical valve for camshaft 
adjustment directs oil pressure to the camshaft adjuster (mechanical adjustment device), which then moves the 
camshaft. 

Special tools and equipment 

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VAG 1551 Scan Tool or VAG 1552 vehicle system tester with VAG 1551/3 cable  

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Hand multimeter VAG 1526 or multimeter VAG 1715  

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Adapter set VAG 1594  

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VAG 1788/10 Engine speed adjuster  

Checking activation 

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Check activation of solenoid valve for camshaft adjustment via Output Diagnostic Test Mode. 

For engine code APH, see OUTPUT DIAGNOSTIC TEST MODE (DTM) . For engine codes AWP 

NOTE:

After installing new lifters the engine must not be started for approx. 30 
minutes. Hydraulic compensation elements must settle (otherwise valves 
will strike pistons).

 

2003 Volkswagen New Beetle GLS 

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