Volkswagen New Beetle. Manual - part 1099

 

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Volkswagen New Beetle. Manual - part 1099

 

 

Installing 

z

Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall 
and piston. Also prevent dirt and emery cloth particles from getting into coolant  

z

Carefully clean cylinder head and cylinder block sealing surfaces. Ensure that no scoring or scratches are 
formed (when using abrasive paper the grade must not be less than 100).  

z

Carefully remove metal particles, emery remains and cloths.  

z

Turn crankshaft to TDC No. 1 cylinder. 

Fig. 86: Turning Crankshaft To TDC Of No. 1 Cylinder 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft back slightly.  

z

Loosen bolts 1 and 2 at bracket for turbocharger approx. 2 revolutions in order to avoid tension when 
installing cylinder head. 

NOTE:

z

There must be no oil or coolant in the cylinder head bolt pockets in the 
cylinder head.  

z

Only remove the new cylinder head gasket from its packing immediately 
before installing.  

z

Handle the new gasket with extreme care. Damaging will lead to leaks.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 87: Loosening Bolts 1 And 2 At Bracket For Turbocharger 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Center screw guide pins from 3070 into holes for cylinder head bolts 8 and 10. 

Fig. 88: Installing Cylinder Head Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install new cylinder head gasket. Lettering (Part No.) must be readable.  

z

Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.  

z

Remove guide pins with removal tool from 3070. To do this turn removal tool counterclockwise, until 
pins are free.  

z

Install remaining cylinder head bolts and tighten hand-tight.  

z

Tighten cylinder head in tightening sequence as follows: 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 89: Cylinder Head Bolt Tightening Sequence 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pretighten all bolts to 40 N.m.  

z

Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.  

z

Then tighten all bolts again 1/4 turn (90°) further. 

z

Install gasket between turbocharger/exhaust manifold and bolt turbocharger as well as bracket to cylinder 
head.  

z

Install toothed belt and adjust valve timing. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING
 .  

Filling with new coolant. See COOLING SYSTEM, DRAINING AND FILLING . 

The rest of the assembly is basically a reverse of the disassembling sequence. 

z

Perform work sequence "Procedure after voltage supply open circuit". 

For engine code APH see PROCEDURE AFTER CORRECTING VOLTAGE SUPPLY OPEN 
CIRCUIT
 . For engine codes AWP and AWV, see PROCEDURE AFTER CORRECTING 
VOLTAGE SUPPLY OPEN CIRCUIT
 . 

z

Check DTC memory. 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) . 

z

Read readiness code. 

See READINESS CODE . 

NOTE:

There is no requirement to retighten the cylinder head bolts after repairs.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

z

Match engine electronics control module to throttle valve control module. 

For engine code APH, see ENGINE CONTROL MODULE (ECM) TO THROTTLE VALVE 
CONTROL MODULE, ADAPTING
 . For engine codes AWP and AWV, see MOTRONIC ENGINE 
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, 
ADAPTING
 . 

If the DTC memory has been erased or the Engine Control Module separated from permanent (battery) 
positive, the readiness code must be generated again. 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) . 

Compression pressures, checking 

Special tools and equipment 

z

3122 B Spark plug removal tool  

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VAG 1331 Torque wrench (5-50 N.m)  

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VAG 1763 Compression tester  

Fig. 90: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

Remove fuse 32. 

NOTE:

Removing fuse 32 interrupts the voltage supply to the injectors. Fuse 
block is behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

 

 

 

 

 

 

 

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