Volkswagen New Beetle. Manual - part 990

 

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Volkswagen New Beetle. Manual - part 990

 

 

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With bracket for engine cover  

22. Cylinder head gasket 

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Always replace  

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Note marking. See Fig. 61  

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After replacing, replace entire coolant  

23. 20 N.m  

24. Cylinder head 

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Check for distortion. See Fig. 60  

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Removing and installing. See CYLINDER HEAD, REMOVING AND INSTALLING .  

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After replacing, replace entire quantity of coolant.  

25. 10 N.m 

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Always replace  

26. Camshaft Position (CMP) Sensor-G40- 

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For camshaft position  

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To remove, unclip sealing grommet from rear toothed belt guard  

27. Glow plug 

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15 N.m  

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Checking. See GLOW PLUGS, CHECKING .  

28. Unit injector 

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Removing and installing. See INJECTOR UNIT, REMOVING AND INSTALLING .  

29. Cylinder head bolt 

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Note sequence when loosening and tightening. See CYLINDER HEAD, REMOVING AND 
INSTALLING
 .  

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Before installing, set washers in cylinder head. See SPECIAL TOOLS AND EQUIPMENT . 
item 4, Servicing valve gear  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 59: Exploded View Of Cylinder Head Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cylinder head distortion, checking 

Fig. 60: Checking Cylinder Head Distortion 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

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Straight edge  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

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Feeler gauges  

Max. permissible distortion: 0.1 mm (minimum distance between linear measurements: 100 mm) 

Cylinder head gasket identification 

Fig. 61: Identifying Cylinder Head Gasket Control Code And Hole 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Part No. = arrow -1-  

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Control code = arrow -2- (not significant!)  

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Hole(s) = arrow -3-  

Cylinder head cover, removing and installing 

Special tools and equipment 

NOTE:

Reworking diesel cylinder heads is not permissible.

NOTE:

Different thicknesses of cylinder head gasket are installed depending on the 
piston projection dimension. When replacing the cylinder head gasket, install a 
new gasket with the same identification.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 62: Identifying Special Tools And Equipment (V.A.G 1331) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1331 Torque wrench (5 to 50 N.m)  

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Sealant AMV 174 004 01  

Removing 

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Remove engine cover. 

Fig. 63: Removing Engine Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

{

Pull front engine cover abruptly upward (arrow -A-) and then pull forward out of rear securing 
elements (arrow -B-).  

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Remove exhaust gas recirculation valve. See EGR VACUUM REGULATOR SOLENOID VALVE -
N18-,REMOVING AND INSTALLING
 .  

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Remove toothed belt guard upper part.  

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Separate crankcase breather hose at union on rear charge air pipe. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

 

 

 

 

 

 

 

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