Volkswagen New Beetle. Manual - part 1214

 

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Volkswagen New Beetle. Manual - part 1214

 

 

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Repeat functional check.  

If the specification is not attained: 

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Check wiring for open/short circuit between Engine Control Module to camshaft adjuster solenoid valve 
using wiring diagram: 

See appropriate SYSTEM WIRING DIAGRAM article. 

If no wiring problem is detected: 

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Replace Engine Control Module: 

See REPLACING ENGINE CONTROL MODULE (ECM) . 

Valve guides, checking 

Special tools and equipment 

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VW 387 Universal dial indicator bracket  

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Dial indicator  

Fig. 133: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

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Insert new valve into guide until end of valve stem is flush with end of guide. Due to slight difference in 
stem dimensions, ensure that only an intake valve is used in intake guide and an exhaust valve in exhaust 
guide. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 134: Determining Valve Rock 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Determine valve rock. 

Wear limit: 0.8 mm 

If rock tolerance is exceeded: 

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Replace cylinder head.  

Valve guides, replacing 

Special tools and equipment 

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Press tool VW 411  

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Drift 3360  

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Support 3361  

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Hand reamer 3363 and cutting fluid 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 135: Identifying Press Tool VW 411 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Check whether valve seat insert rings and if necessary cylinder head sealing surface can be reworked. If 
not, then valve guide should not be replaced.  

First set the support as follows: 

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Install mount pins for cylinder head bolt holes -A- into threaded hole positions 2 and 3. 

Fig. 136: Installing Mount Pins For Cylinder Head Bolt Holes -A- Into Threaded Hole Positions 2 
And 3
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install pin -B- into relevant hole for valve angle. 

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Outer intake valves: 21.5°  

 

2003 Volkswagen New Beetle GLS 

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

  

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Center intake valve: 15°  

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Exhaust valve: 20°  

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Press worn valve guides out with drift 3360 from camshaft side. 

Fig. 137: Pressing Worn Valve Guides Out With Drift 3360 From Camshaft Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Coat new valve guides with oil and press with drift 3360 into cold cylinder head from camshaft side until 
shoulder makes contact.  

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Ream guides out with hand reamer 3363 using plenty of cutting fluid.  

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Rework valve seats. See VALVE SEATS, REFACING .  

Valve stem seals, replacing 

(with cylinder head installed) 

Special tools and equipment 

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VAG1331 Torque wrench (5-50 N.m)  

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VAG1332 Torque wrench (40-200 N.m)  

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3122B Spark plug removal tool  

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3364 Puller  

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VW 653/3 Pressure hose  

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3362 Valve spring compressor and press piece 3362/1 

NOTE:

When the shoulder on guide makes contact, the pressure must not exceed 10 
kN (approx. 1.0 t) otherwise shoulder may break off.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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