Volkswagen New Beetle. Manual - part 1071

 

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Volkswagen New Beetle. Manual - part 1071

 

 

Fig. 115: Installing Cam Shaft Oil Seal With Guide Sleeve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all seals 

z

Insert woodruff key in camshaft.  

z

Install camshaft pulley. To tighten securing bolt counter support camshaft pulley with 3415. 

Tightening torque: 100 N.m 

The rest of the assembly is basically in reverse order to the disassembly sequence. 

Fig. 116: Installing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

NOTE:

When the camshaft is turned, the crankshaft must not be at TDC. Danger 
of damage to valves or piston crowns.

 

2003 Volkswagen New Beetle GLS 

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

  

AND TENSIONING . 

Camshaft, removing and installing 

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

z

3415 Counter support  

z

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

z

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

z

AMV174 004 01 Sealant  

Fig. 117: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove engine cover.  

z

Remove intake manifold upper part. See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING
 . 

z

Remove toothed belt guard, upper part.  

z

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

NOTE:

Seal the intake ports in the intake manifold lower section with clean cloths.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 118: 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 

Fig. 119: Removing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove woodruff key from camshaft.  

z

Remove cylinder head cover.  

z

First remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally.  

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. 

Work sequence 

z

Oil running surfaces on camshaft.  

z

Install camshaft.  

z

Tighten bearing caps 2 and 4 alternately and diagonally to 20 N.m.  

z

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

z

Install bearing caps 3, 1 and 5 and also tighten to 20 N.m.  

z

Insert woodruff key in camshaft.  

z

Install camshaft pulley. To tighten securing bolt counter support camshaft pulley with 3415. 

Tightening torque: 100 N.m 

NOTE:

z

When installing the camshaft, the cam lobes for cylinder 1 must face 
upward.  

z

When installing the bearing cap note offset. Before installing camshaft fit 
bearing caps and determine installed position. 

Fig. 120: Identifying Correct Installation Of Camshaft Bearing Cap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

 

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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