Volkswagen New Beetle. Manual - part 1028

 

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Volkswagen New Beetle. Manual - part 1028

 

 

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Turn further with a normal wrench: 

Stage III 1/4 turn (90°) 

Stage IV 1/4 turn (90°) 

Assembly is basically a reverse of the disassembly sequence. 

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Installing toothed belt and timing adjustment. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
  

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Coolant, filling. See COOLING SYSTEM, DRAINING AND FILLING 

Fig. 77: Tightening Cylinder Head Bolts In Sequence 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Compression pressure, checking 

 

2003 Volkswagen New Beetle GLS 

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

  

Special tools and equipment 

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3220 Hinged socket  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

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VAG 1381/12 Adaptor  

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VAG 1763 Compression tester 

Fig. 78: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirement 

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Engine oil temperature must be 30°C minimum.  

Test sequence 

 

2003 Volkswagen New Beetle GLS 

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

  

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Disconnect fuel cut-off valve on Diesel injection pump.  

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Disconnect Quantity adjuster harness connector on Diesel injection pump.  

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Remove all glow plugs using 3220 flexible wrench.  

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Screw in VAG 1381/12 adaptor in place of glow plugs. 

Fig. 79: Checking Compression With Compression Tester 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check compression using VAG 1763 compression tester.  

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Operate starter until tester display shows no further increase.  

Compression pressure: 

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New: 25 to 31 bar  

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Wear limit: 19 bar  

Permissible difference between all cylinders: 

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5 bar  

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Install glow plugs using 3220 flexible wrench 

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Tightening torque: 15 N.m (11 ft lb)  

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Check Diagnostic Trouble Code (DTC) memory: 

See DTC MEMORY, CHECKING 

VALVE TRAIN, SERVICING 

NOTE:

Trouble codes will be stored because the Diesel injection pump harness 
connector has been disconnected. Check and erase DTC memory.

 

2003 Volkswagen New Beetle GLS 

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

  

1. Bearing cap 

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Installation position. See Camshaft bearing caps, installed position  

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Installation sequence. See CAMSHAFT, REMOVING AND INSTALLING  

2. 20 N.m (15 ft lb)  

3. Camshaft 

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Axial clearance, checking. See Camshaft axial clearance, checking  

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Removing and installing: See CAMSHAFT, REMOVING AND INSTALLING  

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Checking radial clearance with plastigage Wear limit: 0.11 mm  

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Run-out: max. 0.01 mm  

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Identification and valve timing. See Identification  

4. Hydraulic lifter 

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Do not interchange  

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Checking. See HYDRAULIC LIFTERS, CHECKING  

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Store with cam contact surface facing downward  

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Before installing, check camshaft axial clearance. See Camshaft axial clearance, checking  

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Oil contact surfaces  

5. Keepers  

6. Upper valve spring plate  

7. Valve spring 

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Removing and installing: With cylinder head removed Use 2037 With cylinder head installed. See 
VALVE STEM SEALS, REPLACING  

8. Valve stem seal 

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Replacing. See VALVE STEM SEALS, REPLACING  

9. Valve guide 

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Checking. See VALVE GUIDES, CHECKING  

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Replacing. See VALVE GUIDES, REPLACING  

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Service version with collar  

10. Oil seal 

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To remove and install, remove bearing cap  

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Toothed belt, removing and installing. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
  

11. Cylinder head 

NOTE:

Cylinder heads with cracks between the valve seats may be used without 
reducing engine life, provided the cracks are small and not more than 0.5 mm 
wide.

NOTE:

The following list refers to items in Fig. 80 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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