Volkswagen New Beetle. Manual - part 1004

 

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Volkswagen New Beetle. Manual - part 1004

 

 

Fig. 129: Tooth Segment (Arrow) Of The Camshaft Gear Must Point Upward 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Align camshaft pulley to center position in elongated holes.  

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Tighten camshaft pulley securing bolts -1- by hand until there is no play.  

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Lock hub with pin 3359.  

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Install toothed belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

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Install cylinder head. See CYLINDER HEAD COVER, REMOVING AND INSTALLING .  

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Install tandem pump. See TANDEM PUMP, REMOVING AND INSTALLING .  

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If rocker shafts or ball pins and adjustment screws were replaced, unit injectors must be adjusted. See 
INJECTOR UNIT, REMOVING AND INSTALLING .  

Oil seal, removing and installing 

Special tools and equipment 

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10-203 Puller  

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3240 Oil seal extractor  

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V.A.G 1331 Torque wrench (5 to 50 N.m)  

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V.A.G 1332 Torque wrench (40 to 200 N.m)  

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Screw M12 x 1.5 x 65 

NOTE:

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When new lifters have been installed the engine must not be started for 
about 30 minutes. Hydraulic compensation elements must settle 
(otherwise valves will strike pistons).  

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Turn engine at least two revolutions after valve gear repairs to assure that 
no valve will make contact when starting.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 130: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove toothed (timing) belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

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Remove camshaft gear and hub. See CAMSHAFT, REMOVING AND INSTALLING .  

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Unscrew inner part of oil seal extractor 3240 two turns (approx. 3 mm) out of outer part and lock in 
position with knurled screw.  

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Lubricate oil seal extractor threaded head, place it in position and exerting firm pressure screw it into oil 
seal as far as possible.  

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Loosen knurled screw and turn inner part against camshaft until oil seal is pulled out. 

Fig. 131: Removing Camshaft Oil Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

 

2003 Volkswagen New Beetle GLS 

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

  

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Before installing, remove oil remains from camshaft journal with a clean cloth.  

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Tape off groove in camshaft taper with commercially available sticky tape (e.g. Tesafilm).  

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Place oil seal carefully on camshaft.  

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Press in seal with pressure piece of pulling device 10-203 and turn M12 x 1.5 x 65 bolt onto limit stop.  

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Install toothed belt. See TOOTHED BELT, REMOVING AND INSTALLING . 

Fig. 132: Installing Camshaft Oil Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ENGINE - LUBRICATION 

LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Checking oil pressure. See OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING . 

Oil system capacity 

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with oil filter: 4.5 liters  

Engine oil specifications 

NOTE:

Do not oil or grease the oil seal sealing lip.

NOTE:

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If large quantities of metal particles or other deposits (caused, for 
example, by partial seizure of the crankshaft or connecting rod bearings) 
are found in the engine oil when performing repairs, clean the oil passages 
thoroughly and replace the oil cooler (mandatory) to prevent future 
damage.  

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The oil level must not be above the max. mark or there is the possibility of 
damage to the catalytic converter! Markings. See , Fig. 134  

 

2003 Volkswagen New Beetle GLS 

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

  

Only use engine oil conforming to VW standard 505 01.

Part 1 

Part 2, Disassembling oil filter bracket. See PART 2: DISASSEMBLING OIL FILTER BRACKET . 

Part 3, Removing and installing oil return line to turbocharger. See PART 3: REMOVING AND 
INSTALLING OIL RETURN LINE TO TURBOCHARGER
 . 

1. 15 N.m  

2. Sealing flange 

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With sealing ring  

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Must be located on dowel sleeves.  

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Removing and installing. See SEALING FLANGE - BELT PULLEY END, REMOVING AND 
INSTALLING
 .  

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Insert with silicone sealant D 176 404 A2. See SEALING FLANGE - BELT PULLEY END, 
REMOVING AND INSTALLING
 .  

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Do not add oil or grease to oil seal sealing lip  

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Before installing, remove oil residue from crankshaft journal using a clean cloth  

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Replacing crankshaft oil seal, poly V-belt pulley end. See CRANKSHAFT OIL SEAL - 
PULLEY END, REPLACING
  

3. Chain tensioner with tensioning rail, 15 N.m 

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When installing, pretension spring and install  

4. Dipstick 

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Oil level must not exceed max. mark!  

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Markings. See Fig. 134  

5. Guide 

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Pull off to extract oil  

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With rubber grommet for engine cover  

6. Guide tube  

7. Oil spray jet 

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For piston cooling  

8. 25 N.m 

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Insert without sealant  

9. Dowel sleeves  

10. 15 N.m  

11. Suction line 

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Clean strainer if soiled  

NOTE:

The following list refers to items in Fig. 133 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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