Volkswagen New Beetle. Manual - part 1032

 

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Volkswagen New Beetle. Manual - part 1032

 

 

Fig. 91: Identifying 3120 Reamer And Cutting Fluid 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Clean and check cylinder head. 

z

Press out worn valve guides using 3121 from camshaft side (valve guides with shoulder service version 
from combustion chamber side).  

Installing 

z

Press new guides in up to shoulder (moistened with oil) from camshaft side in cold cylinder head using 
3121 drift. 

z

Ream out guides with 3120 hand reamer and plenty of cutting fluid.  

z

Rework valve seats. See VALVE SEATS, REWORKING  

Valve stem seals, replacing 

Special tools and equipment 

z

2036 Adjustable rod  

z

3047A Slide hammer  

z

3129 Seal driver  

NOTE:

Do not replace the valve guides in cylinder heads where the valve seats 
can no longer be reworked, or cylinder heads which have already been 
machined to the minimum dimension.

NOTE:

When the valve guide shoulder makes contact, do NOT allow the pressure 
to exceed 2000 psi or shoulder could break off.

 

2003 Volkswagen New Beetle GLS 

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

  

z

VW 541/1A Valve spring lever  

z

VW 541/5 Thrust piece 

Fig. 92: 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 in process.  

z

Set piston of respective cylinder to Top Dead Center.  

z

Install 2036 adjustable rod and adjust mountings to height of studs. 

Fig. 93: Installing 2036 Adjustable Rod And Adjust Mountings 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

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

z

Remove valve stem seals using 3047A. 

Fig. 94: Removing Valve Stem Seals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

Place plastic sleeve supplied on appropriate valve stem. This will prevent new valve stem seal from being 
damaged.  

z

Insert new valve stem seal in 3129 installation tool.  

z

Oil valve stem seal sealing lip and press carefully onto valve guide. 

Fig. 95: Installing Plastic Sleeve On Valve Stem 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

The valves are supported by the piston crown.

 

2003 Volkswagen New Beetle GLS 

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

  

Camshaft, removing and installing 

Special tools and equipment 

z

3359 Rig pin  

z

3418 Adjustment guide  

z

V159 Nut wrench  

z

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

Fig. 96: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove connecting pipe between charge air cooler and intake hose. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
  

z

Remove toothed belt guard, upper section.  

z

Remove valve cover.  

z

Remove brake booster vacuum pump.  

Vehicles with manual transmission: 

z

Turn crankshaft to cyl. 1 TDC. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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