Volkswagen New Beetle. Manual - part 1135

 

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Volkswagen New Beetle. Manual - part 1135

 

 

Note offset. Before installing camshaft trial install the bearing caps and determine the correct position.

Valve dimensions 

Fig. 83: Identifying Valve Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

VALVE DIMENSION CHART 

Camshaft identification, valve timing 

Identification 

z

Cam base diameter: a = 38 mm diameter  

z

Camshaft is identified by stamped numbers and letters between intake and exhaust cams: 

CAMSHAFT IDENTIFICATION 

NOTE:

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

Dimension

Intake valve

Exhaust valve

diameter a mm

35.95

31.45

diameter b mm

6.963

6.943

c mm

96.85

96.85

"ALPHA ANGLE" °

45

45

Engine code

ALH

Cylinder 1 (arrow -A-)

38K

Cylinder 2 (arrow -B-)

DE

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 84: Identifying Camshaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve timing at 1 mm valve lift 

VALVE TIMING CHART 

Valve seats, reworking 

Special tools and equipment 

Engine code

ALH

Intake opens after TDC

16 °

Intake closes after BDC

25 °

Exhaust opens before BDC

28 °

Exhaust closes before TDC

19 °

 

2003 Volkswagen New Beetle GLS 

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

  

z

Depth gauge  

z

Valve seat refacing tool  

Maximum permissible reworking dimension, calculating: 

z

Insert valve and press firmly against seat.  

z

Measure distance -a- between end of valve stem and upper edge of cylinder head.  

z

Calculate maximum permissible reworking dimension from measured distance -a- and minimum 
dimension. 

NOTE:

z

When repairing engines with leaking valves, it is not always sufficient to 
merely reface or replace valve seats and valves. It is also necessary to 
check the valve guides for wear. This is particularly important on high 
mileage engines.  

z

The valve seats should only be reworked enough to produce a perfect 
seating pattern. The maximum permissible reworking dimension must be 
calculated before reworking starts. If this dimension is exceeded, the 
hydraulic lifter function can no longer be guaranteed and the cylinder head 
should be replaced.  

NOTE:

If the valve will be replaced as part of a repair, use the new valve for the 
calculation.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 85: Measuring Distance Between End Of Valve Stem And Upper Edge Of Cylinder Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Minimum dimension: 

Intake valve 35.8 mm 

Exhaust valve 36.1 mm 

Measured distance minus minimum dimension = Maximum permissible reworking dimension. 

Example: 

MAXIMUM PERMISSIBLE REWORKING DIMENSION (EXAMPLE) 

Dimension

Measurement

Measured distance

36.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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