Volkswagen New Beetle. Manual - part 1134

1. Bearing cap 

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Installation position. See Camshaft bearing caps, installed position  

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Installation sequence. See CAMSHAFT, REMOVING AND INSTALLING  

2. 20 N.m (15 ft lb)  

3. Camshaft 

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Axial clearance, checking. See Camshaft axial clearance, checking  

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Removing and installing: See CAMSHAFT, REMOVING AND INSTALLING  

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Checking radial clearance with plastigage Wear limit: 0.11 mm  

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Run-out: max. 0.01 mm  

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Identification and valve timing. See Identification  

4. Hydraulic lifter 

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Do not interchange  

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Checking. See HYDRAULIC LIFTERS, CHECKING  

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Store with cam contact surface facing downward  

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Before installing, check camshaft axial clearance. See Camshaft axial clearance, checking  

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Oil contact surfaces  

5. Keepers  

6. Upper valve spring plate  

7. Valve spring 

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Removing and installing: With cylinder head removed Use 2037 With cylinder head installed. See 
VALVE STEM SEALS, REPLACING  

8. Valve stem seal 

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Replacing. See VALVE STEM SEALS, REPLACING  

9. Valve guide 

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Checking. See VALVE GUIDES, CHECKING  

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Replacing. See VALVE GUIDES, REPLACING  

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Service version with collar  

10. Oil seal 

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To remove and install, remove bearing cap  

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Toothed belt, removing and installing. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING  

11. Cylinder head 

NOTE:

Cylinder heads with cracks between the valve seats may be used without 
reducing engine life, provided the cracks are small and not more than 0.5 mm 
wide.

NOTE:

The following list refers to items in Fig. 80 .

 

2003 Volkswagen New Beetle GLS 

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

  

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See note. See VALVE TRAIN, SERVICING  

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Valve seats, reworking. See VALVE SEATS, REWORKING  

12. Valves 

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Valve dimensions. See Valve dimensions  

Fig. 80: Identifying Valve Train 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Camshaft axial clearance, checking 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 81: Checking Camshaft Axial Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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Dial gauge 

NOTE:

Check with hydraulic lifters removed and with first and last bearing caps 

 

2003 Volkswagen New Beetle GLS 

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

  

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Wear limit: max. 0.15 mm  

Camshaft bearing caps, installed position 

Fig. 82: Identifying Camshaft Bearing Caps Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

fitted.

 

2003 Volkswagen New Beetle GLS 

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