Volkswagen New Beetle. Manual - part 1175

 

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Volkswagen New Beetle. Manual - part 1175

 

 

Fig. 107: Reworking Intake Valve Seat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Reworking exhaust valve seat 

EXHAUST VALVE SEAT DIMENSION SPECIFICATIONS 

Z

Cylinder head lower edge

45°

Valve seat angle

30°

Upper correction angle

Dimension

Exhaust valve seat

Dia. a - mm

32.4

Dia. b - mm

max. permissible reworking dimension

c - mm

2.2...2.6

Z

Cylinder head lower edge

45°

Valve seat angle

30°

Upper correction angle

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 108: Reworking Exhaust Valve Seat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Camshaft oil seal, replacing 

For coil spring seals: 

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

z

10-203 Puller  

z

2085 Oil seal extractor  

z

3415 Counterhold  

z

V.A.G1331 Torque wrench (5 ... 50 N.m)  

z

V.A.G 1332 Torque wrench (40 ... 200 N.m)  

Fig. 109: Identifying Special Tools (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

For PTFE seals: 

z

2085 Oil seal extractor  

z

3415 Counter support  

z

T10071 Puller  

z

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

z

V.A.G 1332 Torque wrench (40...200 N.m) 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 110: Identifying Special Tools (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove toothed belt guard, upper part.  

z

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

Fig. 111: Aligning Mark On Camshaft Sprocket With Arrow On Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

z

Release tensioning roller and take toothed belt off camshaft pulley.  

z

Turn crankshaft back slightly.  

z

Remove camshaft pulley. To loosen camshaft pulley securing bolt, hold pulley with counter support 3415 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 112: Removing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove woodruff key from camshaft.  

z

Screw camshaft pulley securing bolt fully into camshaft onto limit stop.  

z

Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of outer part and lock in 
position with knurled screw.  

z

Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into 
oil seal as far as possible. 

Fig. 113: Removing Camshaft Oil Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.  

z

Clamp flats of oil seal extractor in a vice. Remove oil seal with pliers.  

Installing 

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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