Volkswagen New Beetle. Manual - part 991

 

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Volkswagen New Beetle. Manual - part 991

 

 

z

Remove cylinder head cover.  

Installing 

Installation is performed in reverse sequence of removal. Note the following: 

z

Thoroughly clean sealing surfaces using clean cloth.  

z

Apply a drop of sealant AMV 174 004 01 (diameter approx. 5 mm) to both forward edges of bearing 
cap/cylinder head sealing surface (arrows). 

Fig. 64: Identifying Forward Edges Of Bearing Cap/Cylinder Head Sealing Surface 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Apply a drop of sealant AMV 174 004 01 (diameter approx. 5 mm) to both back edges of bearing 
cap/cylinder head sealing surface (arrows). 

Fig. 65: Identifying Back Edges Of Bearing Cap/Cylinder Head Sealing Surface 

NOTE:

Replace cylinder head cover and seals for bolts if damaged.

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z

Position cylinder head.  

z

Tighten cylinder head cover bolts hand tight in sequence -1- to -13-.  

z

Tighten bolts in sequence -1- to -13- to 10 N.m. 

Fig. 66: Cylinder Head Cover Bolt Tightening Sequence 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

Toothed belt, removing and installing 

Special tools and equipment 

z

3359 Pin  

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T10004 Two-hole pin wrench (or T10020)  

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T10115 Pin  

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T10050 Crankshaft stop  

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

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V.A.G 1332 Torque wrench (40 to 200 N.m)  

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10-222A support element with adapter 10-222A/8 (modifying guide 10-222 A/21. See MODIFYING 
GUIDE 10-222 A/21 FROM SUPPORT DEVICE 10-222 A
 .  

z

T10004 Two-hole pin wrench (or T10020)  

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T10172 Counter-bracket  

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T10172/4 Pin 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 67: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Fig. 68: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Modifying guide 10-222 A/21 from support device 10-222 A 

NOTE:

A new tensioning roller is gradually being introduced. The tensioning roller has 
an additional hex bit (arrow). Use a hex key to tighten/loosen toothed belt 
instead of the two-hole pin wrench T10020 or T10004. This does not change the 
work sequence.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 69: Identifying Revised Tensioning Roller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Support device 10-222A is required to support engine/transmission assembly. 

A new hole is required on guide 10-222 A/21 to secure adapter 10-222 A/8. 

Fig. 70: Identifying Guide 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Dimensions given are in mm. 

z

Drill a 12.5 mm diameter hole (arrow) in guide 10-222 A/21.  

Removing 

NOTE:

Adjustment work on toothed belts must be performed on cold engines only. The 
tensioning element indicator position is dependent upon the engine 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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