Volkswagen New Beetle. Manual - part 1070

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1068  1069  1070  1071   ..

 

 

Volkswagen New Beetle. Manual - part 1070

 

 

Fig. 108: Reworking Exhaust Valve Seat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Camshaft oil seal, replacing 

For coil spring seals: 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

10-203 Puller  

z

2085 Oil seal extractor  

z

3415 Counterhold  

z

V.A.G1331 Torque wrench (5 ... 50 N.m)  

z

V.A.G 1332 Torque wrench (40 ... 200 N.m)  

Fig. 109: Identifying Special Tools (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

For PTFE seals: 

z

2085 Oil seal extractor  

z

3415 Counter support  

z

T10071 Puller  

z

V.A.G 1331 Torque wrench (5..50 N.m)  

z

V.A.G 1332 Torque wrench (40...200 N.m) 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 110: Identifying Special Tools (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove toothed belt guard, upper part.  

z

Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. 

Fig. 111: Aligning Mark On Camshaft Sprocket With Arrow On Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Mark on camshaft sprocket must align with arrow on toothed belt guard 

z

Release tensioning roller and take toothed belt off camshaft pulley.  

z

Turn crankshaft back slightly.  

z

Remove camshaft pulley. To loosen camshaft pulley securing bolt, hold pulley with counter support 3415 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 112: Removing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove woodruff key from camshaft.  

z

Screw camshaft pulley securing bolt fully into camshaft onto limit stop.  

z

Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of outer part and lock in 
position with knurled screw.  

z

Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into 
oil seal as far as possible. 

Fig. 113: Removing Camshaft Oil Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.  

z

Clamp flats of oil seal extractor in a vice. Remove oil seal with pliers.  

Installing 

Requirements 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Pistons must NOT be positioned at TDC. 

Fig. 114: Identifying Oil Seals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PTFE sealing rings 

z

Position oil seal with guide sleeve T10071 and press in onto limit stop with press sleeve T10071/1 and 
bolt T10071/2.  

Coil spring seals 

z

Position oil seal with guide sleeve 10-203 and press in onto limit stop with press sleeve and bolt from 10-
203. 

NOTE:

A PTFE seal (Teflon) -2 is gradually being introduced instead of the inner 
coil spring seal -1-. This has a wider sealing lip. PTFE oil seals are 
installed free of oil and grease. A radial shaft seal of older design (with coil 
spring) may be replaced with a PTFE oil seal, but not vice versa. When a 
PTFE oil seal is installed, then only such an oil seal may be installed as a 
replacement part!

NOTE:

Do not additionally oil or grease the oil seal sealing lip.

NOTE:

Oil or grease lightly the oil seal sealing lip.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1068  1069  1070  1071   ..