Volkswagen New Beetle. Manual - part 1211

 

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Volkswagen New Beetle. Manual - part 1211

 

 

Fig. 115: Pushing Hydraulic Lifter Down Lightly With Wooden Or Plastic Wedge 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Camshaft, removing and installing 

(with cylinder head installed) 

Special tools and equipment 

z

3036 Counter hold tool  

z

3366 Retainer  

z

VAG 1331 Torque wrench (5 to 50 N.m)  

z

VAG 1332 Torque wrench (40 to 200 N.m)  

z

AMV174 004 01 Sealant  

z

D454 300A2 Sealant 

NOTE:

After installing new lifters the engine must not be started for approx. 30 
minutes. Hydraulic compensation elements must settle (otherwise valves will 
strike pistons).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 116: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Remove engine cover.  

z

Remove toothed belt guard (upper part).  

z

Set camshaft sprocket to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft sprocket must 
align with mark on cylinder head cover. 

Fig. 117: Aligning Mark On Camshaft Sprocket With Mark On Cylinder Head Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove cylinder head cover.  

z

Take toothed belt off camshaft toothed belt sprocket. See REMOVING .  

z

Turn crankshaft back slightly.  

z

Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove woodruff key from camshaft.  

z

Remove Camshaft Position (CMP) sensor housing.  

z

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

z

Clean drive chain and camshaft chain sprocket in area of arrows on bearing caps and mark installation 
position with a colored mark. 

Fig. 118: Cleaning Drive Chain And Camshaft Chain Sprocket In Area Of Arrows On Bearing 
Caps
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Secure chain tensioner with retainer for chain tensioner 3366. 

Fig. 119: Securing Chain Tensioner With Retainer For Chain Tensioner 3366 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

z

Do not mark chain with a punched mark, notch or similar.  

z

The distance between both arrows or the colored marks equals 16 
rollers on the drive chain.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove intake and exhaust camshafts 3rd and 5th bearing caps. 

Fig. 120: Identifying Intake And Exhaust Camshaft Bearing Cap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove double bearing cap.  

z

Remove both bearing caps at chain sprockets on intake and exhaust camshafts.  

z

Remove chain tensioner securing bolts.  

z

Remove intake and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence.  

z

Remove chain tensioner for intake and exhaust camshafts and retainer for chain tensioner 3366.  

Installing 

z

Install drive chain onto both camshafts relevant to colored markings. 

NOTE:

Hydraulic chain tensioner can be damaged if chain tensioner retainer is 
overtightened.

NOTE:

z

When installing the camshafts the cams for No. 1 Cyl. must point upward.  

z

When installing the bearing caps, ensure that the cap markings can be 
read from the inlet side of the cylinder head.  

NOTE:

z

When using a new timing chain, the distance between notches -A- 
and -B- at the camshaft equals 16 rollers on the drive chain.  

z

The figure shows where on the sprockets the 1st and 16th rollers 
must be placed.  

z

Notch -A- is slightly offset toward inside to chain roller 1.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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