Volkswagen New Beetle. Manual - part 1001

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  999  1000  1001  1002   ..

 

 

Volkswagen New Beetle. Manual - part 1001

 

 

Fig. 112: Identifying Special Tools And Equipment (VW 387) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VW 387 Universal dial gauge bracket  

z

Dial gauge  

Work sequence 

z

Install old valve into corresponding guide. Due to slight differences in stem dimensions, make sure that 
an intake valve is used in intake guide and an exhaust valve in exhaust guide. End of valve stem must be 
flush with guide. 

Valve rock: max. 1.3 mm 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 113: Measuring Valve Rock 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve stem seals, replacing 

Special tools and equipment 

z

2036 Adjustable rod  

z

3047A Slide hammer  

z

3129 Seal driver  

z

VW 541/1A Valve spring lever  

z

VW 541/5 Thrust piece 

NOTE:

z

If the wear limit is exceeded, repeat the calculation with new valves. If the 
wear limit is still exceeded replace the cylinder head. Valve guides cannot 
be replaced.  

z

If the valve is to be replaced as part of a repair, use a new valve for the 
calculation.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 114: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

(with cylinder head installed) 

z

Remove camshaft. See CAMSHAFT, REMOVING AND INSTALLING .  

z

Remove hydraulic lifters and set them with contact surfaces facing down. Make sure lifters are not 
interchanged during this process.  

z

Set piston of respective cylinder to top dead center (TDC).  

z

Install tool 2036 and adjust mountings to height of studs. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 115: Installing Tool 2036 And Adjust Mountings To Height Of Studs 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

z

Remove valve stem seals using 3047A. 

NOTE:

The valves are supported by the piston crown.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  999  1000  1001  1002   ..