Volkswagen New Beetle. Manual - part 1024

 

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Volkswagen New Beetle. Manual - part 1024

 

 

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Part No. = arrow -1-  

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Production control code = arrow -2- (can be disregarded)  

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Holes = arrow -3- 

NOTE:

If different values are obtained from the piston projection measurements, 
use the largest measurement to select the proper gasket.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 66: Identifying Cylinder Head Gasket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston and cylinder dimensions in mm 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

PISTON AND CYLINDER DIMENSIONS

ENGINE - CYLINDER HEAD, VALVETRAIN 

CYLINDER HEAD, REMOVING AND INSTALLING 

Compression checking COMPRESSION PRESSURE, CHECKING 

1. Toothed belt guard, upper section  

2. Toothed belt 

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Mark direction of engine rotation before removing  

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Check for wear  

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Do not kink  

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Removing and installing. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
  

3. 20 N.m (15 ft lb)  

4. 20 N.m (15 ft lb)  

5. 45 N.m (33 ft lb)  

6. Camshaft sprocket 

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Drive off of camshaft taper using hammer and drift through toothed belt guard openings  

7. Tensioning roller (semiautomatic, toothed belt) 

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Checking: See SEMI-AUTOMATIC TOOTHED BELT TENSIONING ROLLER, 
CHECKING
  

8. Idler roller  

9. Toothed belt guard, rear  

10. 10 N.m (7 ft lb)  

Honing dimension

Piston diameter

Cylinder bore diameter

Basic dimen., mm

79.47

79.51

1st oversize, mm

79.72

79.76

2nd oversize, mm

79.97

80.01

NOTE:

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When installing an exchange cylinder head (complete with installed 
camshafts): Oil the contact surfaces between the lifters and the cam lobes 
before installing the valve cover.  

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Do NOT remove the plastic packing pieces which protect the open valves 
until immediately before installing the cylinder head.  

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If the cylinder head is replaced: 

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Replace the entire engine coolant.  

NOTE:

The following list refers to items in Fig. 67 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

11. Lifting eye  

12. Cylinder head bolt 

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Replace  

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

13. Oil deflector  

14. Valve cover 

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With vulcanized seal  

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Replace complete if damaged or leaking  

15. Seal 

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Replace if damaged  

16. Cap 

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Replace seal if damaged  

17. Breather pipe  

18. Retaining clip  

19. Pressure regulating valve 

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For Positive Crankcase Ventilation valve  

20. Gasket 

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Replace if damaged  

21. 5 N.m (44 in. lb)  

22. Fuel injector lines 

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25 N.m (18 ft lb)  

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Remove using 3035 offset tubing wrench  

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Always remove fuel line cluster as an assembly  

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Do not bend, kink or alter shape  

23. Exhauster 

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For brake booster  

24. Gasket 

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Always replace  

25. Fuel injector 

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Removing and installing:  

See FUEL INJECTORS, REMOVING AND INSTALLING

CAUTION: The valve cover seal is an integral part of the valve cover. Replace 

the valve cover only if it is damaged or leaking.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

 

 

 

 

 

 

 

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