Volkswagen New Beetle. Manual - part 1101

 

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Volkswagen New Beetle. Manual - part 1101

 

 

30. Exhaust camshaft 

z

Checking axial clearance. See Checking Camshaft Axial Clearance  

z

Removing and installing. See CAMSHAFT, REMOVING AND INSTALLING . 

Checking radial clearance with plastigage: 

z

Wear limit: 0.1 mm  

z

Run-out: max.: 0.01 mm  

Fig. 92: Exploded View Of Valve Train Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Reworking Cylinder Head Sealing Surface 

Fig. 93: Measuring Point For Reworking Cylinder Head Sealing Surface 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The dimension for reworking is measured through the holes for the cylinder head bolts. 

 

2003 Volkswagen New Beetle GLS 

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

  

-a- = minimum 139.2 mm 

Checking Camshaft Axial Clearance 

Special tools and equipment 

z

Universal dial indicator bracket VW 387  

z

Dial indicator  

Check with hydraulic lifters and chain removed and No. 2 and 4 bearing caps installed. 

Wear limit: max. 0.2 mm 

Fig. 94: Checking Camshaft Axial Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve Dimensions 

NOTE:

Valves must not be reworked. Only lapping-in is permitted.

NOTE:

The following table refers to items in Fig. 95 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 95: Valve Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

VALVE DIMENSIONS 

Sealing transition points between double bearing cap and cylinder head 

Dimension

Intake valve

Exhaust valve

dia. a (mm)

26.9

29.9

dia. b (mm)

5.963

5.943

c (mm)

104.84 - 105.34

103.64 - 104.14

Angle a (angle °)

45

45

NOTE:

Care must be taken when disposing of old sodium filled valves. They must be 
cut through in the center of the stem with a hacksaw. When doing this they 
must be perfectly dry. The valves prepared in this way can then be thrown into a 
bucket of water a maximum of ten at a time. When doing this step back quickly 
because a sudden chemical reaction causes the sodium filling to burn. After 
this treatment, the valves can be put in with the normal scrap.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 96: Identifying Sealing Transition Points Between Double Bearing Cap And Cylinder Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully apply a thin coat of sealant D 454 300 A2 to both edges of sealing surfaces between double 
bearing cap and cylinder head -arrows- using a small screwdriver.  

Sealing transition points between chain tensioner/cylinder head

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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