Volkswagen New Beetle. Manual - part 1207

 

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Volkswagen New Beetle. Manual - part 1207

 

 

Fig. 96: Identifying Sealing Transition Points Between Double Bearing Cap And Cylinder Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully apply a thin coat of sealant D 454 300 A2 to both edges of sealing surfaces between double 
bearing cap and cylinder head -arrows- using a small screwdriver.  

Sealing transition points between chain tensioner/cylinder head

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 97: Identifying Sealing Transition Points Between Chain Tensioner/Cylinder Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between camshaft 
adjuster and cylinder head -arrows- using a small screwdriver.  

Valve seats, refacing 

Special tools and equipment 

z

Depth gauge  

z

Valve seat refacing tool  

NOTE:

z

When repairing engines with leaking valves, it is not sufficient to replace 
or replace valve seats and valves. It is also necessary to check the valve 
guides for wear. This particularly important on high mileage engines. See 

VALVE GUIDES, CHECKING

 .  

z

The valve seats should only be reworked just enough to produce a perfect 
seating pattern. The maximum permissible reworking dimension must be 
calculated before reworking commences. If the reworking dimension is 
exceeded, the function of the hydraulic lifters can no longer be guaranteed 
and the cylinder head should be replaced.  

 

2003 Volkswagen New Beetle GLS 

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

  

The max. permissible reworking dimension is calculated as follows:

z

Insert valve and press firmly against seat. 

z

Measure distance between end of valve stem and upper edge of cylinder head. 

Fig. 98: Measuring Distance Between End Of Valve Stem And Upper Edge Of Cylinder Head 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Calculate max. permissible reworking dimension from measured distance and minimum dimension. 

Minimum dimension: 

Outer intake valves: 34.0 mm 

Center intake valve: 33.7 mm 

Exhaust valve: 34.4 mm 

Measured distance minus minimum dimension = max. permissible reworking dimension. 

Example: 

CALCULATING PERMISSIBLE REWORKING DIMENSION 

NOTE:

If the valve is to be replaced as part of a repair, use a new valve for the 
calculation.

Measured distance

34.4 mm

- Minimum dimension

34.0 mm

= max. perm. rework dimension 

(1)

0.4 mm

(1)

The max. permissible reworking dimension is shown on illustrations for refacing valve seats as 

 

2003 Volkswagen New Beetle GLS 

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

  

Reworking intake valve seat 

Fig. 99: Reworking Valve Seat Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

a = 26.2 mm diameter 

b = Max. permissible reworking dimension 

c = 1.5- 1.8 mm 

Z = Cylinder head lower edge 

"ALPHA" = 45° valve seat angle 

"BETA" = 30° upper correction angle 

"GAMMA" = 60° lower correction angle 

Reworking exhaust valve seat 

a = 29.0 mm diameter 

dimension "b."

NOTE:

Calculating max. permissible reworking dimension. See VALVE SEATS, 
REFACING .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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