Volkswagen New Beetle. Manual - part 1138

 

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Volkswagen New Beetle. Manual - part 1138

 

 

Camshaft, removing and installing 

Special tools and equipment 

z

3359 Rig pin  

z

3418 Adjustment guide  

z

V159 Nut wrench  

z

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

Fig. 96: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove connecting pipe between charge air cooler and intake hose. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
  

z

Remove toothed belt guard, upper section.  

z

Remove valve cover.  

z

Remove brake booster vacuum pump.  

Vehicles with manual transmission: 

z

Turn crankshaft to cyl. 1 TDC. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 97: Identifying Mark (Vehicles With Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with automatic transmission: 

z

Turn crankshaft to cyl. 1 TDC. 

Fig. 98: Identifying Mark (Vehicles With Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Lock camshaft with setting bar. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 99: Installing Setting Bar On Camshaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Release tensioning roller and take toothed belt off camshaft sprocket.  

z

Loosen camshaft sprocket mounting bolt 1/2 turn.  

z

Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear 
toothed belt guard opening).  

z

Take off camshaft sprocket.  

z

First remove bearing caps 5, 1 and 3. Then loosen bearing caps 2 and 4 alternately and diagonally.  

Installing 

NOTE:

z

When installing the camshaft, No. 1 cylinder cams must point upward.  

z

When installing the bearing cap, note offset before installing camshaft, 
install bearing caps and determine installed position. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Oil camshaft contact surfaces.  

z

Install camshaft.  

z

Tighten bearing caps: 2 and 4 alternately and diagonally 

z

20 N.m (15 ft lb)  

z

Install bearing caps: 5, 1 and 3. 

z

20 N.m (15 ft lb)  

z

Position bearing cap 5 by gently tapping on end of camshaft.  

z

Install camshaft sprocket.  

z

Install toothed belt and tension. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
 . 

Assembly is basically a reverse of the disassembly sequence. 

Hydraulic lifters, checking 

Special tools and equipment 

z

Feeler gauge  

z

Wood or plastic wedge 

Test sequence 

z

Start engine and run until engine oil temperature is 80° C minimum  

z

Increase engine speed to 2500 RPM for approx. 2 minutes.  

If lifters are still noisy, locate faulty lifter(s) as follows: 

z

Remove valve cover.  

z

Rotate crankshaft clockwise, until cam of lifter to be checked is pointing upward.  

z

Measure play between cam and lifter.  

If play is in excess of 0.1 mm 

Fig. 100: Identifying Bearing Caps Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

Do NOT start the engine for approx. 30 minutes after new lifters have been 
installed. Hydraulic compensation elements must settle (otherwise the 
valves will strike pistons).

NOTE:

z

Replace faulty lifter assembly (cannot be adjusted or repaired). 

z

Irregular valve noises are normal when starting the engine.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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