Volkswagen New Beetle. Manual - part 1097

Fig. 76: Bearing Shells - Mounting In Connecting Rods 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bearing shell -1- for connecting rod (with hole -arrow- for oil channel). 

Bearing shell -2- for connecting rod (without hole for oil channel). 

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Place bearing shells on the middle of connecting rod and connecting rod bearing cap. 

Measure -a- must be the same at right and left, max. deviation: 0.2 mm 

Checking Cylinder Bores 

Fig. 77: Checking Cylinder Bores 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

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Internal dial gauge 50 to 100 mm  

 

2003 Volkswagen New Beetle GLS 

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

  

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Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft. 

Deviation from nominal dimension: max. 0.08 mm 

Piston and cylinder dimensions (engine codes: AWP, AWV) 

PISTON AND CYLINDER DIMENSIONS (ENGINE CODES: AWP, AWV) 

ENGINE - CYLINDER HEAD, VALVETRAIN 

CYLINDER HEAD, REMOVING AND INSTALLING 

Checking compression. See COMPRESSION PRESSURES, CHECKING . 

Cylinder head overview 

1. Cap 

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Replace seal if damaged  

2. 10 N.m  

NOTE:

Measuring the cylinder bores must not be done when the cylinder block is 
mounted on a repair stand with adapter bracket VW 540, as incorrect 
measurements would then be possible.

Honing dimension

Piston diameter

Cylinder bore diameter

Basic dimen. mm

80.965 

(1)

81.01

1st oversize mm

81.465 

(1)

81.51

(1)

Dimension without graphite coating (thickness 0.02 mm). The graphite coating wears away.

NOTE:

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When installing an replacement cylinder head with installed camshaft, the 
contact surfaces between the hydraulic lifters and the cam must be oiled 
before installing the cylinder head cover.  

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The plastic packing pieces for protecting the open valves must not be 
removed until immediately before installing cylinder head.  

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If the cylinder head is replaced, all the coolant in the system must also be 
replaced.  

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Removing and installing intake manifold: 

For engine code APH, see FUEL INJECTION SYSTEM COMPONENTS, 
REMOVING AND INSTALLING . For engine codes AWP and AWV, see 
FUEL INJECTION SYSTEM COMPONENTS, REMOVING AND INSTALLING . 

NOTE:

The following list refers to items in Fig. 78 .

 

2003 Volkswagen New Beetle GLS 

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

  

3. Cylinder head cover  

4. Cylinder head cover gasket 

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Replace if damaged  

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Before installing, coat transition from bearing cap e.g. camshaft adjuster/chain tightener to cylinder 
head with D 454 300 A2. See Sealing transition points between double bearing cap and 
cylinder head and Sealing transition points between chain tensioner/cylinder head .  

5. Oil deflector 

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Note installation position: above intake camshaft  

6. Cylinder head 

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Check for distortion. See Reworking Cylinder Head Sealing Surface  

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Reworking sealing surface. See Reworking Cylinder Head Sealing Surface .  

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

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After replacing completely replace coolant  

7. Intake manifold gasket 

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Always replace  

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Note installation position  

8. Cylinder head gasket 

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Always replace  

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Metal gasket  

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If replaced completely replace coolant  

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Note installation position: Identification: Part No. must be readable from intake side  

9. Toothed (Timing) belt 

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Mark direction of rotation before removing  

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Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING .  

10. Exhaust manifold gasket 

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Always replace  

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Note installation position  

11. Cylinder head bolt 

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Always replace  

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Removing and installing Polydrive cylinder head bolt with 3452  

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

12. Gasket 

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Replace if damaged  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 78: Exploded View Of Cylinder Head Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Cylinder Head For Distortion 

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required 

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Straight edge  

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Feeler gauges  

Max. permissible distortion: 0.1 mm 

Fig. 79: Checking Cylinder Head For Distortion 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cylinder head, removing and installing 

Special tools and equipment 

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VAG 1306 Drip tray  

 

2003 Volkswagen New Beetle GLS 

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