Volkswagen New Beetle. Manual - part 1167

 

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Volkswagen New Beetle. Manual - part 1167

 

 

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Only engine codes BDC, BGD to Positive Crankcase Ventilation (PCV) heating element -N79-  

5. Shaped hose 

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Engine codes AVH, AZG through Model Year 2001  

6. Shaped hose 

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Engine codes AVH, AZG from Model Year 2002  

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Engine codes BDC, BEV and BGD  

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Do not remove union between intake manifold hose and shaped hose.  

7. To intake manifold upper part 

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Only Model Year from 2002  

8. Seal 

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Replace  

9. Sealing plug, 15 N.m 

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Replace  

10. Cylinder head bolt 

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Replace  

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Remove and install Polydrive cylinder head bolt with 3452  

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

11. Connecting unions 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

12. 10 N.m  

13. Seal 

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Replace  

14. 20 N.m  

15. Lifting eye  

16. Cylinder head gasket 

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Replace  

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After replacement replace entire coolant amount  

17. 15 N.m  

18. 20 N.m  

19. Rear toothed belt guard  

20. Toothed belt 

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Mark direction of rotation before removing  

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Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELTS, REMOVING, INSTALLING 
AND TENSIONING
  

21. Cylinder head 

 

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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Check for distortion. See Fig. 68  

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Reworking sealing surface. See Fig. 102  

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Removing and installing. See CYLINDER HEAD, REMOVING AND INSTALLING  

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After replacement replace entire coolant amount  

22. Oil deflector  

23. Cylinder head cover gasket 

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Replace if damaged  

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

24. Cylinder head cover 

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With cable guide  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 67: Exploded View Of Cylinder Head Cylinder Head (Aluminum Cylinder Head Cover) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Cylinder Head For Distortion 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 68: Checking Cylinder Head For Distortion 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Max. permissible distortion: 0.1 mm 

Toothed belts, removing, installing and tensioning 

 

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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