Volkswagen New Beetle. Manual - part 1022

Piston ring gap, checking 

z

Squarely insert ring into top of cylinder and push it down to approx. 15 mm from lower edge of cylinder. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 59: Checking Piston Ring Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PISTON RING END GAP DIMENSIONS 

Ring to groove clearance, checking 

Clean groove before checking.

Piston ring 
Dimensions in mm

New

Wear limit

1st compression ring

0.20 to 0.40

1.0

2nd compression ring

0.20 to 0.40

1.0

Oil scraper ring

0.25 to 0.50

1.0

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 60: Checking Ring To Groove Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

RING TO GROOVE CLEARANCE DIMENSIONS 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle

  

Cylinder bores, checking 

Special tools and equipment 

z

Internal dial gauge 50 to 100 mm  

z

Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. 

z

Deviation from nominal dimension: 0.10 mm maximum  

Fig. 61: Checking Cylinder Bores 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston installation position and piston/cylinder allocation 

Piston in cylinders 1 and 2: 

Larger intake valve chamber points toward flywheel (arrows) 

Piston in cylinders 3 and 4: 

Larger intake valve chamber points toward belt pulley side (arrows).

Piston ring 
Dimensions in mm

New

Wear limit

1st compression ring

0.06 to 0.09

0.25

2nd compression ring

0.05 to 0.08

0.25

Oil scraper ring

0.03 to 0.06

0.15

NOTE:

Do NOT measure the cylinder bores when the block is mounted on a repair 
stand using the VW 540 adaptor bracket. Bending stresses resulting from 
the mass overhang will make incorrect measurements likely.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - 1.9L 4-Cyl. - ALH, New Beetle