Volkswagen New Beetle. Manual - part 1000

 

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Volkswagen New Beetle. Manual - part 1000

 

 

1. 20 N.m plus an additional 1/4 turn (90°) 

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Always replace  

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Note sequence when loosening and tightening. See CAMSHAFT, REMOVING AND 
INSTALLING
 .  

2. Rocker shaft 

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Do not interchange  

3. Cylinder head bolt 

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Note sequence when loosening and tightening. See CYLINDER HEAD, REMOVING AND 
INSTALLING
 .  

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Before installing, install washers item 4 into cylinder head  

4. Washer 

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For cylinder head bolts  

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Install into cylinder head before installing bearing caps  

5. Hydraulic lifters 

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Do not interchange.  

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With hydraulic valve clearance compensation.  

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Store with cam contact surface downward.  

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Before installing check camshaft axial clearance. See Checking camshaft axial clearance  

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Oil contact surfaces.  

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Before removing, remove camshaft bearing shells  

6. Keepers  

7. Valve spring plate  

8. Exterior valve spring 

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Removing and installing: Cylinder head  

Removed: with 2037 

Installed: See VALVE STEM SEALS, REPLACING , Replacing valve stem seals 

9. Interior valve spring 

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Removing and installing: Cylinder head  

Removed: with 2037 

Installed: See VALVE STEM SEALS, REPLACING . 

10. Valve stem seal 

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Replacing. See VALVE STEM SEALS, REPLACING  

11. Valve guide 

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Checking. See VALVE GUIDES, CHECKING

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

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If wear limit is exceeded, replace cylinder head  

12. Unit injector 

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Removing and installing. See INJECTOR UNIT, REMOVING AND INSTALLING .  

13. Cylinder head 

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See notes under VALVE TRAIN, SERVICING  

14. Seal 

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Do not add oil or grease oil seal sealing lip  

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Remove oil residues of camshaft pin with a clean cloth before installing.  

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Seal groove on camshaft taper when installing with commercially available sticky tape (e.g. 
Tesafilm)  

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Removing and installing. See OIL SEAL, REMOVING AND INSTALLING  

15. Valves 

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Replace valve when scoring can be seen at shaft and contact surfaces  

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Do not rework. Only lapping-in is permitted  

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Valve dimensions. See Fig. 111  

16. Bearing shell 

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Do not interchange used bearing shells (mark)  

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Make sure tabs seating correctly in bearing cap and cylinder head  

17. Camshaft 

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Checking axial clearance. See Checking camshaft axial clearance  

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Removing and installing. See CAMSHAFT, REMOVING AND INSTALLING  

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Check radial clearance with plastigage 

Wear limit: 0.11 mm 

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Run-out: max. 0.04 mm  

18. Bearing cap 

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Installation sequence. See CAMSHAFT, REMOVING AND INSTALLING .  

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Install seal bearing cap contact surfaces 1 and 5 with AMV 174 004 01. See Sealing bearing cap 
contact surfaces 1 and 5 with AMV 174 004 01
  

19. 8 N.m plus an additional 1/4 turn (90°) 

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Always replace  

Checking camshaft axial clearance 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 109: Checking Camshaft Axial Clearance (End Play) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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Dial gauge  

Measure with hydraulic lifters removed and with first, third and last bearing caps installed. 

Wear limit: max. 0.15 mm 

Sealing bearing cap contact surfaces 1 and 5 with AMV 174 004 01 

Fig. 110: Sealing Bearing Cap Contact Surfaces 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Apply a thin even coat of sealant AMV 17400401 onto surfaces -1-. 

Valve dimensions 

NOTE:

Observe that no sealant comes into the grooves (arrows).

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 111: Identifying Valve Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

VALVE DIMENSIONS 

Valve guides, checking 

Special tools and equipment 

NOTE:

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

Dimensions

Intake valve

Exhaust valve

diameter a (mm)

35.95

31.45

diameter b (mm)

6.980

6.956

length c (mm)

89.95

89.95

contact face angle

45 degrees

45 degrees

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

 

 

 

 

 

 

 

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