Volkswagen New Beetle. Manual - part 1068

 

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Volkswagen New Beetle. Manual - part 1068

 

 

Fig. 100: Locating Fuses 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Disconnect connectors for outer injectors.  

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Disconnect spark plug connectors with tool T10012  

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Remove spark plugs with spark plug wrench 3122B.  

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Check compression pressures using compression tester V.A.G 1763 and adapter V.A.G 1763/6. 

Vehicles without EPC 

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Have a second technician fully depress accelerator pedal.  

Continuation for all models 

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Have a second technician operate starter motor.  

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Operate starter until tester shows no further pressure increase.  

Compression pressure values 

New: 10...13 bar 

Wear limit: 7.5 bar 

Permissible difference between all cylinders: 3 bar 

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Adapt (match) engine control module to throttle valve control module. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 .  

NOTE:

Removing the fuse interrupts the voltage supply to the injectors.

NOTE:

To use the compression tester. See Operating instructions.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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If fault memory has been erased or engine control module was disconnected from permanent positive, 
respective components must be adapted to engine control module and readiness code generated again. See 
COMPONENTS AND FUNCTIONS, ADAPTING .  

VALVE GEAR, SERVICING 

1. 100 N.m 

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Use counter support tool 3415 to loosen and tighten  

2. Camshaft pulley  

3. Seal 

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Replacing. See CAMSHAFT OIL SEAL, REPLACING  

4. Woodruff key 

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Check if seated securely  

5. 20 N.m  

6. Bearing cap 

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Installation position. See Fig. 104  

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Installation sequence. See CAMSHAFT, REMOVING AND INSTALLING  

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Coat contact surfaces of bearing cap 1 lightly with sealing compound AMV 174 004 01.  

7. Camshaft 

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Checking axial clearance. See Fig. 103  

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Removing and installing. See CAMSHAFT, REMOVING AND INSTALLING  

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Check radial clearance with Plastigage, Wear limit: 0.1 mm  

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Run-out: max. 0.05 mm  

8. Hydraulic lifter 

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Do not interchange  

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With hydraulic valve clearance compensation  

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Checking. See HYDRAULIC LIFTERS, CHECKING  

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Store with cam contact surface downward  

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Before installing check camshaft axial clearance. See Fig. 103

NOTE:

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Cylinder heads which have cracks between the valve seats or between 
valve seat inserts and the spark plug thread can be used further without 
reducing service life, provided the cracks do not exceed a maximum of 0.3 
mm in width, or when no more than the first four spark plug threads are 
cracked.  

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When new lifters have been installed the engine must not be started for 
about 30 minutes. (Otherwise valves will contact pistons) Then, finally, 
rotate crankshaft two complete revolutions.  

NOTE:

The following list refers to items in Fig. 101 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

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Oil contact surface  

9. Keepers  

10. Valve spring upper plate  

11. Valve spring 

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

12. Valve stem seal 

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Replacing. See VALVE STEM SEALS, REPLACING  

13. Valve guide 

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Checking. See VALVE GUIDES, CHECKING  

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Replacing. See VALVE GUIDES, REPLACING  

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Repair version with shoulder  

14. Cylinder head 

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Reworking sealing surface. See Fig. 102  

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Reworking valve seats. See VALVE SEATS, REWORKING  

15. Valves 

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Do not rework, only lapping is permitted  

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Valve dimensions. See Fig. 105  

Fig. 101: Disassembled View Of Valve Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Reworking cylinder head sealing surface 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 102: Identifying Cylinder Head Reworking Dimension (Cylinder Head Height) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cylinder head reworking dimension: -a- = min. 132.6 mm 

Checking Camshaft Axial Clearance 

Fig. 103: Checking Camshaft Axial Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, testers, measuring instruments and auxiliary items required 

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Universal dial gauge bracket VW 387  

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Dial gauge  

Check with hydraulic lifters removed and with first and last bearing caps installed. 

NOTE:

When the sealing surface has been reworked, the valves must be set deeper by 
the same amount.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

 

 

 

 

 

 

 

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