Volkswagen New Beetle. Manual - part 1166

 

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Volkswagen New Beetle. Manual - part 1166

 

 

Fig. 65: Checking Cylinder Bores 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, testers, measuring instruments and auxiliary items required

NOTE:

Measuring the cylinder bores must not be done when the cylinder block is 
mounted on a repair stand with adapter bracket VW 540, as incorrect 
measurements would then be possible.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

z

Internal dial gauge 50...100 mm  

z

Measure bores at 3 locations in both directions -A- across engine and -B- in line with crankshaft. 

Deviation from nominal dimension: max. 0.08 mm 

Piston and cylinder dimensions 

PISTON AND CYLINDER DIMENSIONS SPECIFICATIONS 

ENGINE - CYLINDER HEAD, VALVETRAIN 

CYLINDER HEAD, REMOVING AND INSTALLING CYLINDER HEAD 

Checking compression. See Compression pressures, checking . 

Engines with steel cylinder head cover: 

z

Engine code AEG. See ENGINES WITH STEEL CYLINDER HEAD COVER 

Engines with aluminum cylinder head cover. 

z

Engine codes AVH, AZG, BDC, BEV, BGD. See ENGINES WITH ALUMINUM CYLINDER 
HEAD COVER
  

Engines with steel cylinder head cover 

Honing dimension

Piston diameter

Cylinder bore diameter

Basic dimension 
mm

82.465

(1)

82.51

1st oversize 
mm

82.965

(1)

83.01

(1)

Dimensions without graphite coating (thickness 0.02 mm). Graphite coating wears away

NOTE:

z

When installing an exchange cylinder head with fitted camshaft, lubricate 
the running contact surfaces between the bucket tappets and the camshaft 
cam surfaces before installing the cylinder head cover.  

z

The plastic packing pieces for protecting the open valves must not be 
removed until immediately before installing the cylinder head.  

z

If the cylinder head is replaced, all the coolant in the system must also be 
replaced.  

z

Removing and installing intake manifold. See INTAKE MANIFOLD UPPER 
PART, DISASSEMBLING AND .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

1. Cover  

2. Seal  

3. Breather housing 

z

Turn to right to remove  

4. 10 N.m  

5. Seal 

z

Replace if damaged  

6. Retainer  

7. Sealing plug, 15 N.m 

z

Replace  

8. Seal 

z

Replace  

9. Union 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

10. Lifting eye  

11. 20 N.m  

12. Cylinder head gasket 

z

Replace  

z

After replacement replace entire coolant amount  

13. 15 N.m  

14. Rear toothed belt guard  

15. Cylinder head 

z

Check for distortion. See Fig. 68  

z

Reworking sealing surface. See Fig. 68  

z

Removing and installing. See CYLINDER HEAD, REMOVING AND INSTALLING  

z

After replacement replace entire coolant amount  

16. Cylinder head bolt 

z

Replace  

z

Remove and install Polydrive cylinder head bolt with 3452  

z

Sequence when loosening and tightening. See CYLINDER HEAD, REMOVING AND 
INSTALLING
  

17. Oil deflector  

18. Cylinder head cover gasket 

z

Replace if damaged  

z

Coat cylinder head/bearing cap transition points with D 454 300 A2 before installing  

19. Cylinder head cover  

NOTE:

The following list refers to items in Fig. 66 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

20. Reinforcing strip  

21. Rear toothed belt guard, upper part  

Fig. 66: Exploded View Of Cylinder Head Cylinder Head (Steel Cylinder Head Cover) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engines with aluminum cylinder head cover 

1. Cover  

2. Seal  

3. 10 N.m  

4. To intake manifold 

NOTE:

The following list refers to items in Fig. 67 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

 

 

 

 

 

 

 

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