Volkswagen New Beetle. Manual - part 1069

 

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Volkswagen New Beetle. Manual - part 1069

 

 

Wear limit: max. 0.15 mm 

Installed position of camshaft bearing caps 

Fig. 104: Identifying Installed Position Of Camshaft Bearing Caps 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Note offset. Before installing camshaft fit bearing caps and determine installed position. 

Valve dimensions 

Fig. 105: Identifying Valve Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine code AEG 

VALVE DIMENSIONS SPECIFICATIONS (ENGINE CODE AEG) 

NOTE:

Valves must not be reworked. Only lapping is permitted.

 

2003 Volkswagen New Beetle GLS 

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

  

Engine codes AVH, AZG, BDC, BEV, BGD 

VALVE DIMENSIONS SPECIFICATIONS (ENGINE CODES AVH, AZG, BDC, BEV, BGD) 

Valve seats, reworking 

Special tools, testers, measuring instruments and auxiliary items required 

z

Depth gauge  

z

Valve seat refacing tool 

Calculating maximum permissible reworking dimension 

z

Insert valve and press firmly against seat. 

z

Measure distance -a- between end of valve stem and upper edge of cylinder head. 

Dimension

Intake valve

Exhaust valve

Dia. a -

39.5 +/- 0.15

32.9 +/- 0.15

Dia. b - mm

6.92 + 0.02

6.92 + 0.02

Length c - mm

91.85

91.15

Angle a - degrees

45

45

Dimension

Intake valve

Exhaust valve

Dia. a - mm

39.5 +/- 0.15

32.9 +/- 0.15

Dia. b - mm

6.98 +/- 0.007

6.96 +/- 0.007

Length c - mm 
 

91.85

91.15

Angle a - degrees

45

45

NOTE:

z

When repairing engines with leaking valves, it is not sufficient to 
rework or replace valve seats and valves. It is also necessary to 
check the valve guides for wear. This particularly important on high 
mileage engines.  

z

The valve seats should only be reworked just enough to produce a 
perfect seating pattern. The maximum permissible reworking 
dimension must be calculated before reworking commences. If the 
reworking dimension is exceeded, the function of the hydraulic lifters 
can no longer be guaranteed and the cylinder head should be 
replaced.  

NOTE:

If the valve is to be replaced as part of a repair, use a new valve for the 
measuring.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 106: Measuring Distance Between End Of Valve Stem And Upper Edge Of Cylinder Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Calculate maximum permissible reworking dimension from measured distance -a- and minimum 
dimension. 

Minimum dimensions: 

Intake valve 33.8 mm 

Exhaust valve 34.1 mm 

Measured distance -a- minus minimum dimension = maximum permissible reworking dimension. 

Example: 

CALCULATING MAXIMUM PERMISSIBLE REWORKING DIMENSION (EXAMPLE) 

Reworking intake valve seat 

INTAKE VALVE SEAT DIMENSION SPECIFICATIONS 

Measured distance -a-

35.1 mm

Minimum dimension - 34.1 
 

mm

= max. perm. Rework dimension 

(1)

1.0 mm

(1)

The maximum permissible reworking dimension is shown as dimension "b" in illustrations for 
reworking of valve seats.

Dimension

Intake valve seat

Dia. a - mm

39.2

b - mm

max. permissible reworking dimension

c - mm

1.8...2.2

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 107: Reworking Intake Valve Seat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Reworking exhaust valve seat 

EXHAUST VALVE SEAT DIMENSION SPECIFICATIONS 

Z

Cylinder head lower edge

45°

Valve seat angle

30°

Upper correction angle

Dimension

Exhaust valve seat

Dia. a - mm

32.4

Dia. b - mm

max. permissible reworking dimension

c - mm

2.2...2.6

Z

Cylinder head lower edge

45°

Valve seat angle

30°

Upper correction angle

 

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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