Volkswagen New Beetle. Manual - part 1073

 

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Volkswagen New Beetle. Manual - part 1073

 

 

from combustion chamber side).  

Installing 

z

Press in new guides, moistened with oil, from camshaft side onto shoulder in cold cylinder head using 
drift 3121. 

z

Ream valve guide using hand reamer 3120. Always use cutting fluid when doing this.  

z

Reworking valve seats. See VALVE SEATS, REWORKING .  

Valve stem seals, replacing 

(with cylinder head installed) 

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

z

2036 Assembly device  

z

3047A Puller  

z

3122 B Spark plug wrench  

z

3129 Installation tool  

z

T10112 Installation tool  

z

V.A.G 1331 Torque wrench (5..50 N.m) 

Fig. 127: Identifying Special Tools (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VW 541/1A Lever  

NOTE:

When the shoulder on guide makes contact the pressure must not exceed 
10kN (approx. 1.0 t) otherwise the shoulder may break off.

 

2003 Volkswagen New Beetle GLS 

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

  

z

VW 541/5 Press piece  

z

VW 653/3 Pressure hose  

Fig. 128: Identifying Special Tools (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove camshaft. See CAMSHAFT, REMOVING AND INSTALLING .  

z

Take out hydraulic lifter and place down with running surface downward. Ensure hydraulic lifters are not 
interchanged when doing this.  

z

Disconnect spark plug connectors with tool T10112  

z

Remove spark plugs with spark plug wrench 3122B.  

z

Set piston of appropriate cylinder to "bottom dead centre (BDC)".  

z

Mount assembly device 2036 and adjust mountings to height of studs. 

Fig. 129: Mounting Assembly Device 2036, VW 653/3 & VW 541/1A 
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

  

z

Screw pressure hose VW 653/3 into spark plug thread.  

z

Connect pressure hose to compressed air supply of at least 6 bar.  

z

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

z

Pull off valve stem seals with 3047A. 

Fig. 130: Removing Valve Stem Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

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

Fig. 131: Installing Valve Stem Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Tight keepers can be loosened by tapping lightly on the lever.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Fit new valve stem seal into installation tool 3129.  

z

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

ENGINE - LUBRICATION 

LUBRICATION SYSTEM 

Lubrication system components, removing and installing 

Disassembling and assembling oil filter bracket. See Part II (Oil filter housing, disassembling and 
assembling)
 . 

Engine codes BDC, BGD 

Disassembling and assembling oil pump with balancer shaft gear assembly. See Oil pump with balancer shaft 
gear assembly, disassembling and assembling (Engine codes BDC, BGD)
 . 

Removing and installing oil pump with balancer shaft gear assembly. See OIL PUMP WITH BALANCER 
SHAFT GEAR ASSEMBLY, REMOVING AND INSTALLING
 . 

Continuation for all models 

Checking oil pressure and oil pressure switch. See OIL PRESSURE AND OIL PRESSURE SWITCH, 
CHECKING
 . 

Engine oil specifications 

Use engine oils which conform with VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-
grade and single grade oils conforming with API-SF and SG or ACE A A2/A3. 

NOTE:

z

Metal shavings or large amounts of small metal particles found in the 
engine oil during repairs may be caused by a partial seizure of the 
crankshaft or connecting rod bearings. Perform the following work 
sequences in this situation to prevent consequential damage once repairs 
are complete: 

{

Thoroughly clean oil passages  

{

Replace oil spray jets  

{

Replace oil cooler  

{

Replace oil filter  

z

The oil level must not be above the max. mark or there is a danger of 
damage to catalytic converter. For markings, see Fig. 136 .  

NOTE:

z

In the factory the engine is filled with engine oil conforming with VW 
standard 503 00. This engine oil is designed for long service intervals 

 

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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