Volkswagen New Beetle. Manual - part 1133

 

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Volkswagen New Beetle. Manual - part 1133

 

 

Fig. 76: Identifying Screw Guide Pins 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install new cylinder head gasket. 

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Lettering (Part No.) must be readable.  

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

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Remove guide pins with removal tool from 3070 by turning removal tool counter-clockwise until pins are 
free  

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Install remaining cylinder head bolts and tighten hand-tight.  

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Tighten cylinder head in following four stage sequence:  

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Tighten initially using torque wrench: 

Stage I = 40 N.m (30 ft lb) 

Stage II = 60 N.m (44 ft lb) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

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Turn further with a normal wrench: 

Stage III 1/4 turn (90°) 

Stage IV 1/4 turn (90°) 

Assembly is basically a reverse of the disassembly sequence. 

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

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Coolant, filling. See COOLING SYSTEM, DRAINING AND FILLING 

Fig. 77: Tightening Cylinder Head Bolts In Sequence 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Compression pressure, checking 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Special tools and equipment 

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3220 Hinged socket  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

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VAG 1381/12 Adaptor  

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VAG 1763 Compression tester 

Fig. 78: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirement 

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Engine oil temperature must be 30°C minimum.  

Test sequence 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

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Disconnect fuel cut-off valve on Diesel injection pump.  

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Disconnect Quantity adjuster harness connector on Diesel injection pump.  

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Remove all glow plugs using 3220 flexible wrench.  

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Screw in VAG 1381/12 adaptor in place of glow plugs. 

Fig. 79: Checking Compression With Compression Tester 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check compression using VAG 1763 compression tester.  

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Operate starter until tester display shows no further increase.  

Compression pressure: 

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New: 25 to 31 bar  

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Wear limit: 19 bar  

Permissible difference between all cylinders: 

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5 bar  

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Install glow plugs using 3220 flexible wrench 

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Tightening torque: 15 N.m (11 ft lb)  

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Check Diagnostic Trouble Code (DTC) memory: 

See DTC MEMORY, CHECKING 

VALVE TRAIN, SERVICING 

NOTE:

Trouble codes will be stored because the Diesel injection pump harness 
connector has been disconnected. Check and erase DTC memory.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

 

 

 

 

 

 

 

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