Volkswagen New Beetle. Manual - part 1215

 

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Volkswagen New Beetle. Manual - part 1215

 

 

Fig. 138: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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3365 Fitting tool 

Fig. 139: Identifying 3365 Fitting Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove camshafts. See CAMSHAFT, REMOVING AND INSTALLING .  

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Remove hydraulic lifters and place them with contact surface downward. When doing this ensure that 
lifters are not interchanged.  

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Remove spark plugs with spark plug removal tool3122B.  

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Set piston of appropriate cylinder to BDC (bottom dead center).  

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Screw pressure hose VW 653/3 into spark plug thread.  

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Mount fitting tool 3362 on cylinder head with fitting tool securing bolts. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 140: Mounting Fitting Tool 3362 On Cylinder Head With Fitting Tool Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Position fitting tool for compressing valve springs to one of following positions: 

Outer intake valves: lower position 

Center intake valve: upper position 

Exhaust valve: lower position 

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Connect pressure hose to compressed air system supplying at least 6 bar and remove valve springs.  

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Pull off valve stem seals with 3364. 

Fig. 141: Pulling Off Valve Stem Seals With 3364 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Place plastic sleeve -A- supplied on appropriate valve stem. This will prevent new valve stem seal being 
damaged. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 142: Placing Plastic Sleeve -A- Supplied On Appropriate Valve Stem 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place new valve stem seal in fitting tool 3365.  

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Oil sealing lip of valve stem seal -B- insert in installation tool 3365 and press carefully onto valve guide. 

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

ENGINE - LUBRICATION 

LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Checking oil pressure and oil pressure switch. See OIL PRESSURE AND OIL PRESSURE SWITCH, 
CHECKING
 . 

Oil system capacity: 

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Without oil filter: 4.0 liters  

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With oil filter: 4.5 liters (4.8 qt.)  

NOTE:

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If large quantities of metal particles or other deposits (caused, for 
example, by partial seizure of the crankshaft or connecting rod bearings) 
are found in the engine oil when performing repairs, clean the oil passages 
thoroughly and replace the oil cooler in order to prevent further damage 
from occurring later.  

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The oil level must not be above the max. mark, or there is danger of 
damage to the catalyst! Marking. See Markings On Oil Dipstick . 

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Thoroughly clean oil passages  

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Replace oil spray jets, oil cooler, and oil filter  

 

2003 Volkswagen New Beetle GLS 

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

  

Oil Capacities up to MY 2000 

Checking oil pressure. See OIL PRESSURE AND OIL PRESSURE SWITCH, CHECKING . 

Engine oil specifications: 

The following terms must appear on the oil container singly or in combination with other designations: 

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VW 502 00 or VW500 00 or VW501 01  

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ACEA A2 or ACEA A3  

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API-SJ or API-SL  

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Engine oils are graded according to their viscosity. The proper grade to be used in your engine depends 
on existing climatic or seasonal conditions.  

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The engine oil which was first put into your engine has a viscosity grade of SAE 5W-40. You can use this 
oil over all temperature ranges for normal driving. If engine oil viscosity grade SAE 5W-40 is not 
available, you can also use SAE 5W-30.  

Part I 

Part II, disassembly oil filter bracket. See PART II . 

1. 15 N.m  

2. Sealing flange 

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Must be located on dowel sleeves  

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Clean sealing surface before installing  

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Insert with silicone sealant D 176 404 A2. See FRONT SEALING FLANGE, REMOVING 
AND INSTALLING
 .  

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Replacing crankshaft oil seal (pulley end). See CRANKSHAFT OIL SEAL (BELT PULLEY 
END), REPLACING
 .  

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Removing and installing. See FRONT SEALING FLANGE, REMOVING AND 
INSTALLING
 .  

3. Chain tensioner with tensioning rail, 15 N.m 

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Check for wear  

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When installing, pretension spring and install  

4. Chain sprocket 

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For oil pump drive  

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Check for wear  

5. Cylinder block 

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Removing and installing crankshaft. See CRANKSHAFT, REMOVING AND INSTALLING 

NOTE:

The following list refers to items in Fig. 143 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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