Volkswagen New Beetle. Manual - part 1137

 

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Volkswagen New Beetle. Manual - part 1137

 

 

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Insert new valve into guide until end of valve stem is flush with end of guide. Due to slight differences in 
stem dimensions, make sure that an intake valve is used in intake guide and an exhaust valve in exhaust 
guide. 

z

Rock: 1.3 mm maximum  

Fig. 89: Measuring Valve Rock 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve guides, replacing 

Special tools and equipment 

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3121 Drift 

Fig. 90: Identifying 3121 Drift 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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3120 Reamer and cutting fluid 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 91: Identifying 3120 Reamer And Cutting Fluid 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Clean and check cylinder head. 

z

Press out worn valve guides using 3121 from camshaft side (valve guides with shoulder service version 
from combustion chamber side).  

Installing 

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Press new guides in up to shoulder (moistened with oil) from camshaft side in cold cylinder head using 
3121 drift. 

z

Ream out guides with 3120 hand reamer and plenty of cutting fluid.  

z

Rework valve seats. See VALVE SEATS, REWORKING  

Valve stem seals, replacing 

Special tools and equipment 

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2036 Adjustable rod  

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3047A Slide hammer  

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3129 Seal driver  

NOTE:

Do not replace the valve guides in cylinder heads where the valve seats 
can no longer be reworked, or cylinder heads which have already been 
machined to the minimum dimension.

NOTE:

When the valve guide shoulder makes contact, do NOT allow the pressure 
to exceed 2000 psi or shoulder could break off.

 

2003 Volkswagen New Beetle GLS 

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

  

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VW 541/1A Valve spring lever  

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VW 541/5 Thrust piece 

Fig. 92: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

(with cylinder head installed) 

z

Remove camshaft. See CAMSHAFT, REMOVING AND INSTALLING  

z

Remove hydraulic lifters and set them with contact surfaces facing down. Make sure lifters are not 
interchanged in process.  

z

Set piston of respective cylinder to Top Dead Center.  

z

Install 2036 adjustable rod and adjust mountings to height of studs. 

Fig. 93: Installing 2036 Adjustable Rod And Adjust Mountings 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove valve springs with VW 541/1A lever and VW 541/5 press piece. 

z

Remove valve stem seals using 3047A. 

Fig. 94: Removing Valve Stem Seals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

Place plastic sleeve supplied on appropriate valve stem. This will prevent new valve stem seal from being 
damaged.  

z

Insert new valve stem seal in 3129 installation tool.  

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Oil valve stem seal sealing lip and press carefully onto valve guide. 

Fig. 95: Installing Plastic Sleeve On Valve Stem 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

The valves are supported by the piston crown.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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