Volkswagen New Beetle. Manual - part 1027

 

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Volkswagen New Beetle. Manual - part 1027

 

 

z

Attach T 10014 bracket to cylinder block using threaded hole in water pump area (as illustrated). 

Fig. 74: Attaching T 10014 Bracket To Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lift engine slightly using second spindle -A- until spindle -B- is relieved.  

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Remove spindle -B-.  

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Position engine at TDC with camshaft sprocket loosened and toothed belt removed from camshaft 
sprocket. See TOOTHED BELTS, REMOVING, INSTALLING, TENSIONING  

z

Remove tension roller and camshaft sprocket. 

bracket must be attached to the block to support the engine.

 

2003 Volkswagen New Beetle GLS 

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

  

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Unscrew upper bolt of belt guard, rear.  

z

Loosen socket head bolts in sequence given, then remove bolts completely. 

Fig. 75: Loosening Head Bolts In Sequence

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z

Carefully lift off cylinder head.  

Installing 

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Turn crankshaft to TDC mark before installing cylinder head.  

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Turn crankshaft against engine direction of rotation until all pistons are approximately equally spaced 
below TDC.  

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To centralize: screw guide pins from 3070/9 into outer threaded holes on intake side. 

NOTE:

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Always replace cylinder head bolts.  

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Make sure that there isn't any oil or coolant in the cylinder head bolt 
hollows (in the cylinder head).  

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Only remove the new cylinder head gasket from its packing immediately 
before installing.  

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When repairing, carefully remove any gasket remains from the cylinder 
head and cylinder block. Ensure that no long grooves or scratches are 
created. When using abrasive paper do not use a grade coarser than 100 
(e.g. 80).  

z

Carefully remove any emery or abrasive remains.  

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Handle the new gasket with extreme care. Damaging will lead to leaks.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 76: Identifying Screw Guide Pins 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install new cylinder head gasket. 

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Lettering (Part No.) must be readable.  

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Install cylinder head, screw in 8 remaining head bolts and tighten by hand.  

z

Remove guide pins with removal tool from 3070 by turning removal tool counter-clockwise until pins are 
free  

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Install remaining cylinder head bolts and tighten hand-tight.  

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Tighten cylinder head in following four stage sequence:  

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Tighten initially using torque wrench: 

Stage I = 40 N.m (30 ft lb) 

Stage II = 60 N.m (44 ft lb) 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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