Volkswagen New Beetle. Manual - part 1209

 

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Volkswagen New Beetle. Manual - part 1209

 

 

Fig. 103: Removing Oil Seal Using Special Tool 2085 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Before installing, remove oil remains from crankshaft journal with a clean cloth.  

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Install guide sleeve 3241/2 onto camshaft journal. 

NOTE:

Gradual introduction of PTFE (Teflon) oil seal (identifying characteristics: no 
annular spring, sealing lip wider). The sealing lip of this oil ring must not be 
oiled or lubricated. A plain encased seal of older construction (with annular 
spring) may be replaced with a PTFE oil seal, but not vice versa.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 104: Installing Guide Sleeve 3241/2 Onto Camshaft Journal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Slide oil seal over guide sleeve.  

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Press seal in onto stop with press sleeve 3241/1 and bolt 3241/5. 

Fig. 105: Pressing Seal In Onto Stop With Press Sleeve 3241/1 And Bolt 3241/5 

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

The rest of the assembly is basically a reverse of the disassembling sequence. 

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

Oil seal on Camshaft Position (CMP) sensor, removing 

Special tools and equipment 

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2085 Oil seal extractor  

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3241 Seal installer (for seal in standard version with annular spring)  

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T10071 Puller (for seal in PTFE-version)  

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VAG1331 Torque wrench (5 to 50 N.m)  

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VAG1332 Torque wrench (40 to 200 N.m)  

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Bolt M8 X 60  

Fig. 106: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

 

2003 Volkswagen New Beetle GLS 

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

  

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Pull connector off Camshaft Position (CMP) sensor -G40- -arrow-. 

Fig. 107: Pulling Connector Off Camshaft Position Sensor G40 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove toothed belt guard (upper part).  

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Remove housing for Camshaft Position (CMP) sensor.  

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Remove washer and hood for Camshaft Position (CMP) sensor.  

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Screw bolt 2085/1 into camshaft onto stop by hand, to guide seal extractor. 

Fig. 108: Screwing Bolt 2085/1 Into Camshaft Onto Stop By Hand To Guiding Seal Extractor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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