Volkswagen New Beetle. Manual - part 1205

 

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Volkswagen New Beetle. Manual - part 1205

 

 

z

Match engine electronics control module to throttle valve control module. 

For engine code APH, see ENGINE CONTROL MODULE (ECM) TO THROTTLE VALVE 
CONTROL MODULE, ADAPTING
 . For engine codes AWP and AWV, see MOTRONIC ENGINE 
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, 
ADAPTING
 . 

If the DTC memory has been erased or the Engine Control Module separated from permanent (battery) 
positive, the readiness code must be generated again. 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) . 

Compression pressures, checking 

Special tools and equipment 

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3122 B Spark plug removal tool  

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VAG 1331 Torque wrench (5-50 N.m)  

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VAG 1763 Compression tester  

Fig. 90: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

Remove fuse 32. 

NOTE:

Removing fuse 32 interrupts the voltage supply to the injectors. Fuse 
block is behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Fig. 91: Removing Fuse 32 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test conditions 

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Engine oil temperature must be at least 30 °C.  

Work sequence 

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Remove engine cover.  

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Pull connector(s) off ignition coils.  

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Remove ignition coils.  

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Remove spark plugs with spark plug removal tool 3122B.  

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Fully open throttle valve. 

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Check compressions with compression tester VAG 1381 / VAG 1763.  

z

Operate starter until tester shows no further pressure increase.  

Compression pressure: 

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New: 10-14 bar  

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Wear limit: 7.0 bar  

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Permissible difference between all cylinders: 3 bar 

{

Thread in spark plugs with spark plug socket and extension 3122B and tighten to 30 N.m.  

Vehicles with engine code: APH 

z

Install ignition coils and tighten to 10 N.m. 

NOTE:

Using the compression tester. See Operating instructions.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

Vehicles with engine codes: AWP, AWV 

z

Install ignition coils. During this, make sure ignition coils are securely seated.  

Continued for all vehicles 

z

Check DTC memory. 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) . 

z

Read readiness code. 

See READINESS CODE . 

If the DTC memory has been erased or the Engine Control Module separated from permanent (battery) 
positive, the readiness code must be generated again. 

See GENERAL INFORMATION FOR ON BOARD DIAGNOSTIC (OBD) . 

VALVE GEAR, SERVICING 

1. 10 N.m  

2. Intake camshaft 

z

Checking axial clearance. See Checking Camshaft Axial Clearance  

z

Removing and installing. See VALVE GEAR, SERVICING 

Checking radial clearance with plastigage: 

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Wear limit: 0.1 mm  

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Run-out: max. 0.01 mm  

3. Drive chain 

z

Before removing mark direction of rotation (installation position). See CAMSHAFT, 
REMOVING AND INSTALLING 

NOTE:

z

Cylinder heads which have cracks between the valve seats or between 
valve seat inserts and the spark plug thread can be used further without 
reducing service life, provided the cracks do not exceed a maximum of 0.3 
mm in width, or when no more than the first four spark plug threads are 
cracked.  

z

After installing new hydraulic lifters, the engine must not be started for 
approx. 30 minutes (otherwise valves will strike pistons), then turn 
crankshaft two rotations.  

NOTE:

The following list refers to items in Fig. 92 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

4. 10 N.m  

5. O-ring 

z

Always replace  

z

Only for engine codes: AWP, AWV  

6. Camshaft adjustment valve (N205) 

z

Only for engine codes: AWP, AWV  

z

Check camshaft adjustment. See CAMSHAFT ADJUSTMENT, CHECKING .  

7. 3 N.m 

z

Only for engine codes: AWP, AWV  

8. Camshaft adjuster 

z

Only for engine codes: AWP, AWV  

z

For vehicles with engine code: APH; Chain tensioner  

z

Secure with 3366 before removing. See CAMSHAFT, REMOVING AND INSTALLING . 

z

Seal transition of hydraulic chain tensioner/cylinder head. See Sealing transition points 
between chain tensioner/cylinder head
  

z

Check camshaft adjustment. See CAMSHAFT ADJUSTMENT, CHECKING .  

9. Gasket 

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Rubber/metal seal  

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Replace  

10. Cylinder head 

z

Removing and installing. See CYLINDER HEAD, REMOVING AND INSTALLING .  

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Refacing valve seats. See VALVE SEATS, REFACING .  

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Reworking sealing surface. See Reworking Cylinder Head Sealing Surface .  

z

Sealing transition points. See Sealing transition points between double bearing cap and 
cylinder head
 and Sealing transition points between chain tensioner/cylinder head .  

11. Valves 

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Do not rework only grinding-in is permitted  

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Valve dimensions. See Valve Dimensions .  

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Sodium-filled exhaust valves: Observe disposal instructions. See VALVE SEATS, REFACING  

12. Oil seal 

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Replacing. See CAMSHAFT OIL SEAL, REPLACING .  

13. Hood 

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For Camshaft Position (CMP) sensor  

z

When installing note fixing arrangement  

14. Washer 

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Conical  

15. 25 N.m  

16. Camshaft Position (CMP) sensor -G40-

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

 

 

 

 

 

 

 

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