Volkswagen New Beetle. Manual - part 998

 

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Volkswagen New Beetle. Manual - part 998

 

 

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Turn crankshaft to TDC marking before installing cylinder head.  

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Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed 
below TDC.  

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Note cylinder head gasket identification. 

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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- 

Fig. 101: Identifying Cylinder Head Gasket Control Code And Hole 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Charge pressure hoses and line connections must be free of oil and 
grease before reinstalling.  

NOTE:

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If the cylinder head gasket or the cylinder head are replaced, 
use a new cylinder head gasket with same number of holes as 
the old gasket.  

 

2003 Volkswagen New Beetle GLS 

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

  

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Install cylinder head sealant. 

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Observe center sleeves (arrows) in cylinder block. 

Fig. 102: Locating Center Sleeves In Cylinder Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Observe head gasket installation position, identification "above" or Part No. must show to cylinder 
head.  

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Install cylinder head and cylinder head bolts, and tighten by hand.  

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Tighten cylinder head in four stages in sequence shown as follows:  

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Tighten initially with torque wrench: 

Stage I = 40 N.m 

Stage II = 60 N.m 

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Turn further with normal spanner: 

Stage III = 1/4 turn (90°) 

Stage IV = 1/4 turn (90°) 

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If components of the crankshaft system have been replaced the 
new cylinder head gasket must be re-selected by measuring the 
piston projection in TDC. See PISTON PROJECTION AT TDC, 
CHECKING .  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 103: Cylinder Head Bolt Tightening Sequence 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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After tightening cylinder head, turn camshaft hub so cam lobes for cylinder No. 1 point evenly upward 
(arrows). 

Install in reverse order. 

NOTE:

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It is not necessary to retighten cylinder head bolts after completing 
the repairs.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 104: Cam Lobes For Cylinder No. 1 Pointing Upward 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Observe tightening sequence for securing bolts when installing oil return line. See PART 3: 
REMOVING AND INSTALLING OIL RETURN LINE TO TURBOCHARGER
 .  

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Before installing toothed belt, turn crankshaft in direction of engine rotation to TDC and lock in position 
using crankshaft stop T10050.  

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Perform a road test and check DTC memory. See ENGINE CONTROL MODULE (DTC) MEMORY, 
READING AND ERASING
 .  

Compression pressure, checking 

Special tools and equipment 

CAUTION: When performing repair work, especially due to the confined 

conditions in the engine compartment, pay attention to the following: 

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Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP 
system, coolant, refrigerant, brake fluid and vacuum) as well as 
electrical wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  996  997  998  999   ..