Volkswagen New Beetle. Manual - part 1023

 

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Volkswagen New Beetle. Manual - part 1023

 

 

Fig. 62: Identifying Piston Installation Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Piston for cylinder 1 and 2: marked 1/2  

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Piston for cylinder 3 and 4: marked 3/4  

Piston projection at TDC, checking 

Special tools and equipment 

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VW 382/7 

NOTE:

New piston/cylinder allocations are shown by a colored mark on the piston 
crown.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 63: Identifying VW 382/7 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VW 385/17 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 64: Identifying VW 385/17 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

Piston projection at TDC must be measured when installing new pistons or a short block. Depending upon 
piston projection, install the corresponding cylinder head gasket using the following table: 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 65: Measuring Piston Projection At TDC 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PISTON PROJECTION IDENTIFICATION 

Cylinder head gasket, identification 

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 - 1.9L 4-Cyl. - ALH, New Beetle

  

 

 

 

 

 

 

 

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