Volkswagen New Beetle. Manual - part 989

Fig. 55: Identifying Special Tools And Equipment (VW 382/7) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VW 385/17 Final measurement plate  

z

Dial gauge 

Fig. 56: Identifying Special Tools And Equipment (VW 385/17) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

When installing new pistons or a reconditioned engine, the piston projection of all pistons must be checked at 
TDC. Depending on the piston projection determine the relevant cylinder head gasket to be installed from the 
following table: 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 57: Measuring Piston Projection At TDC  
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PISTON PROJECTION SPECIFICATIONS 

Cylinder head gasket identification 

NOTE:

To measure piston projection at TDC turn engine clockwise.

Piston projection

Identification holes/notches

0.91 mm to 1.00 mm

1

1.01 mm to 1.10 mm

2

1.11 mm to 1.20 mm

3

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 58: Cylinder Head Gasket Identification Marks
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Part No. = arrow -1-  

z

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

z

Hole(s) = arrow -3-  

Piston and cylinder dimensions 

PISTON AND CYLINDER DIMENSIONS 

ENGINE - CYLINDER HEAD, VALVETRAIN 

CYLINDER HEAD, SERVICING 

Checking compression. See COMPRESSION PRESSURE, CHECKING . 

1. Cylinder head cover 

z

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

2. Pressure regulating valve 

z

For crankcase breather  

3. Vent hose 

z

Via rear charge air pipe to exhaust turbocharger  

4. Cap 

z

Replace seal if damaged  

NOTE:

If differing figures are obtained when measuring the piston projection, the 
highest figure should be taken when selecting the gasket.

Honing Dimension (mm)

Piston diameter

Cylinder bore diameter

Basic dimension

79.47

79.51

1st oversize

79.72

79.76

2nd oversize

79.97

80.01

NOTE:

z

When installing an exchange cylinder head (complete with installed 
camshafts): Oil the contact surfaces between the lifters and the cam lobes 
before installing the valve cover.  

z

Do NOT remove the plastic packing pieces which protect the open valves 
until immediately before installing the cylinder head.  

z

If the cylinder head is replaced, replace all the coolant in the system.  

NOTE:

The following list refers to items in Fig. 59 .

 

2003 Volkswagen New Beetle GLS 

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

  

5. Seal 

z

Replace if damaged.  

6. 10 N.m 

z

Observe tightening sequence. See CYLINDER HEAD COVER, REMOVING AND 
INSTALLING .  

7. Cylinder head cover gasket 

z

Replace if damaged or leaking  

z

Seal with AMV 174 004 01 before installing. See CYLINDER HEAD COVER, REMOVING 
AND INSTALLING .  

z

Insert nubs in cylinder head holes.  

8. 20 N.m  

9. Lifting eye  

10. Central connector 

z

For unit injector  

11. 10 N.m  

12. From brake booster  

13. Tandem pump 

z

For fuel and vacuum supply  

z

Checking. See TANDEM PUMP, CHECKING .  

z

Removing and installing, see TANDEM PUMP, REMOVING AND INSTALLING .  

14. 25 N.m  

15. Supply hose 

z

From fuel filter, see FUEL TANK, REMOVING AND INSTALLING .  

z

White or with white marking  

z

Check for secure seating  

z

Secure with spring-type clips  

16. Return hose 

z

To fuel filter. See FUEL FILTER, SERVICING .  

z

Blue or with blue marking  

z

Check for secure seating  

z

Secure with spring-type clips  

17. Seal 

z

Always replace  

18. 20 N.m  

19. Ball head bolt, 8 N.m  

20. Bracket 

z

For engine cover  

21. Lifting eye 

 

2003 Volkswagen New Beetle GLS 

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