Volkswagen New Beetle. Manual - part 1176

 

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Volkswagen New Beetle. Manual - part 1176

 

 

z

Pistons must NOT be positioned at TDC. 

Fig. 114: Identifying Oil Seals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PTFE sealing rings 

z

Position oil seal with guide sleeve T10071 and press in onto limit stop with press sleeve T10071/1 and 
bolt T10071/2.  

Coil spring seals 

z

Position oil seal with guide sleeve 10-203 and press in onto limit stop with press sleeve and bolt from 10-
203. 

NOTE:

A PTFE seal (Teflon) -2 is gradually being introduced instead of the inner 
coil spring seal -1-. This has a wider sealing lip. PTFE oil seals are 
installed free of oil and grease. A radial shaft seal of older design (with coil 
spring) may be replaced with a PTFE oil seal, but not vice versa. When a 
PTFE oil seal is installed, then only such an oil seal may be installed as a 
replacement part!

NOTE:

Do not additionally oil or grease the oil seal sealing lip.

NOTE:

Oil or grease lightly the oil seal sealing lip.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 115: Installing Cam Shaft Oil Seal With Guide Sleeve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all seals 

z

Insert woodruff key in camshaft.  

z

Install camshaft pulley. To tighten securing bolt counter support camshaft pulley with 3415. 

Tightening torque: 100 N.m 

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

Fig. 116: Installing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing toothed belt and adjusting timing. See TOOTHED BELTS, REMOVING, INSTALLING 

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

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

  

AND TENSIONING . 

Camshaft, removing and installing 

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

z

3415 Counter support  

z

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

z

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

z

AMV174 004 01 Sealant  

Fig. 117: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove engine cover.  

z

Remove intake manifold upper part. See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING
 . 

z

Remove toothed belt guard, upper part.  

z

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

NOTE:

Seal the intake ports in the intake manifold lower section with clean cloths.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 118: 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 

Fig. 119: Removing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove woodruff key from camshaft.  

z

Remove cylinder head cover.  

z

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

Installing 

Requirements 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1174  1175  1176  1177   ..