Volkswagen New Beetle. Manual - part 1172

 

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Volkswagen New Beetle. Manual - part 1172

 

 

z

Remove bracket (item - 4 -. See PART I ) on tensioning element for ribbed belt.  

z

Remove toothed belt guard, upper part.  

z

Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. 

Mark on camshaft sprocket must align with arrow on toothed belt guard 

Fig. 93: Aligning Mark On Camshaft Sprocket With Arrow On Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Release tensioning roller and take toothed belt off camshaft pulley.  

z

Turn crankshaft back slightly.  

z

Remove cylinder head cover.  

z

Remove upper rear toothed belt guard bolt.  

z

Loosen socket head bolts in sequence given and then remove complete. 

Fig. 94: Loosening Sequence Of Cylinder Head Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully lift cylinder head off.  

NOTE:

Use tool 3452 for Polydrive cylinder head bolts.

 

2003 Volkswagen New Beetle GLS 

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

  

Installing 

z

Place a clean cloth into cylinders so that no dirt or emery cloth particles can get in between cylinder wall 
and piston.  

z

Prevent dirt and emery cloth particles from getting into coolant.  

z

Carefully clean cylinder head and cylinder block sealing surfaces. Please ensure that no scoring or 
scratches are formed (when using abrasive paper grade must not be less than 100).  

z

Carefully remove metal particles, emery remains and cleaning cloths.  

z

If crankshaft has been turned: Set No. 1 cylinder piston to top dead center and then turn crankshaft back 
slightly.  

z

To centralize, screw guide pins from 3450/2A into front outer holes for cylinder head bolts. 

Fig. 95: Centralizing Guide Pins 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install new cylinder head gasket. 

z

Install cylinder head, thread in 8 remaining cylinder head bolts and tighten by hand.  

z

Remove guide pins through bolt holes with extractor 3450/3. Extractor must be turned to left (counter-
clock wise) until pins are free.  

z

Install remaining cylinder head bolts and tighten hand-tight.  

z

Tighten cylinder head bolts in prescribed tightening sequence as follows: 

{

Pretighten all bolts to 40 N.m.  

{

Then tighten all bolts 1/4 turn (90°) turn further with a rigid wrench. 

NOTE:

z

Always replace cylinder head bolts.  

z

There must be no oil or coolant in the cylinder head bolt pockets in the 
cylinder head.  

z

Only remove the new cylinder head gasket from its packing immediately 
before installing.  

z

Handle the new gasket with extreme care. Damage will lead to leaks.  

NOTE:

Lettering (part number) must be readable.

 

2003 Volkswagen New Beetle GLS 

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

  

{

Then tighten all bolts again 1/4 turn (90°) further. 

Fig. 96: Tightening Sequence Of Cylinder Head Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The rest of the assembly is basically in reverse order to the disassembly sequence. 

z

Install cylinder head cover and tighten nuts. 

Tightening torque: 10 N.m 

z

Install toothed belt and adjust timing. See TOOTHED BELTS, REMOVING, INSTALLING AND 
TENSIONING
 .  

z

Install ribbed belt tensioning element. 

Tightening torque: 25 N.m 

z

Install ribbed belt. See RIBBED BELT, REMOVING AND INSTALLING . 

z

Fill with new coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

z

Connect battery Ground (GND) strap.  

Vehicles without EPC 

z

Adjust accelerator cable. See ACCELERATOR MECHANISM, SERVICING .  

NOTE:

When the camshaft is turned, the crankshaft must not be at TDC. Danger 
of damage to valves or piston crowns.

NOTE:

All cable ties which are opened or cut open to remove the cylinder head 
must be replaced in the same position when re-installing the cylinder 
head.

 

2003 Volkswagen New Beetle GLS 

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

  

Continuation for all models 

z

Adapt (match) engine control module to throttle valve control module. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 .  

z

Road test vehicle and interrogate all fault memories: 

Observe the valid safety precautions when performing a road test. See SAFETY PRECAUTIONS . 

z

If fault memory has been erased or engine control module was disconnected from permanent positive, 
respective components must be adapted to engine control module and readiness code generated again. See 
COMPONENTS AND FUNCTIONS, ADAPTING .  

z

Read readiness code.  

Vehicles with automatic transmission 

z

Adapt transmission control module: 

For 01M, see BASIC SETTING, INITIATING . 

For 09G, see BASIC SETTING, INITIATING . 

z

Test drive vehicle and interrogate fault memory.  

COMPRESSION PRESSURES, CHECKING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

3122 B Spark plug wrench  

z

T10112 Removal tool  

z

V.A.G 1331 Torque wrench (5..50 N.m)  

z

V.A.G 1763 Compression tester  

Fig. 97: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

 

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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