Volkswagen New Beetle. Manual - part 1177

 

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Volkswagen New Beetle. Manual - part 1177

 

 

z

Pistons must not be positioned at TDC. 

Work sequence 

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Oil running surfaces on camshaft.  

z

Install camshaft.  

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Tighten bearing caps 2 and 4 alternately and diagonally to 20 N.m.  

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Coat contact surfaces of bearing cap 1 lightly with sealing compound AMV 174 004 01.  

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Install bearing caps 3, 1 and 5 and also tighten to 20 N.m.  

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Insert woodruff key in camshaft.  

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

Tightening torque: 100 N.m 

NOTE:

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When installing the camshaft, the cam lobes for cylinder 1 must face 
upward.  

z

When installing the bearing cap note offset. Before installing camshaft fit 
bearing caps and determine installed position. 

Fig. 120: Identifying Correct Installation Of Camshaft Bearing Cap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 121: Installing Camshaft Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

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

Hydraulic lifters, checking 

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

z

Feeler gauge  

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Wooden or plastic wedge 

Work sequence 

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Start engine and run until coolant fan has switched on once.  

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Increase engine speed to about 2500 RPM for approx. 2 minutes. 

NOTE:

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

NOTE:

When new lifters have been installed the engine must not be started for 
about 30 minutes. The hydraulic compensation elements must settle 
(otherwise valves will strike pistons).

NOTE:

z

Replace faulty hydraulic lifters complete only (can not be adjusted or 
serviced).  

z

Irregular valve noises when starting engine are normal.  

 

2003 Volkswagen New Beetle GLS 

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

  

If the hydraulic lifters are still noisy, locate faulty lifters as follows:

z

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

z

Remove cylinder head cover.  

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Rotate crankshaft clockwise, until cam of lifter to be checked is pointing upward.  

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Determine clearance between cam lobe and hydraulic lifter.  

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If clearance is greater than 0.2 mm, replace hydraulic lifter. If clearance is less than 0.1 mm or no 
clearance exists, then proceed with check as follows:  

z

Push hydraulic lifter down lightly with a wooden or plastic wedge. If when hydraulic lifter is pushed 
down a 0.2 mm thick feeler gauge can be inserted between camshaft and hydraulic lifter, lifter is to be 
replaced. 

Fig. 122: Pushing Hydraulic Lifter 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve guides, checking 

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

z

VW 387 Universal dial gauge bracket  

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Dial gauge  

NOTE:

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

NOTE:

When new lifters have been installed the engine must not be started for 
about 30 minutes. The hydraulic compensation elements must settle 
(otherwise valves will strike pistons).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 123: Identifying Special Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

Insert a new valve into guide. End of valve stem must be flush with guide. Due to slight difference in 
stem diameters, ensure that only an intake valve is used in intake guide and an exhaust valve in exhaust 
guide. 

Fig. 124: Checking Valve Guide Wear (Valve Rock) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Determine rock. 

Wear limit: 

Intake valve guide = 1.0 mm 

Exhaust valve guide = 1.3 mm 

 

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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