Volkswagen New Beetle. Manual - part 1058

Fig. 57: Locating Upper Crankshaft Bearing Identification Marks 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

In the factory the upper bearing caps are allocated with the correct thickness for the cylinder block. Colored 
marks are used to identify the thickness of the bearing shells. See CRANKSHAFT BEARING COLOR 
MARKINGS . 

Which thickness of shell should be installed to which location is marked by a letter on the lower sealing surface 
of the cylinder block -x-. 

Arrow indicates direction of travel (forward). 

Crankshaft bearing color markings 

CRANKSHAFT BEARING COLOR MARKINGS SPECIFICATIONS 

Letter on cylinder block

Color of bearing

S =

Black

R =

Red

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Crankshaft dimensions 

Dimensions in mm. 

CRANKSHAFT DIMENSIONS SPECIFICATIONS 

PISTON AND CONNECTING ROD, DISASSEMBLING AND ASSEMBLING 

Gradual introduction of "industrially fractured" connecting rods.

G =

Yellow

NOTE:

z

If the colored marks have not been stamped or are no longer legible, use 
the average bearing shell (red).  

z

The lower crankshaft bearing shells are always supplied as a spare part 
with the color marking "yellow".  

Grinding dimension

(1)

Crankshaft bearing journal diameter

Connecting rod journal diameter

Basic dimension

-0.017 

54.00 

-0.037

-0.022

47.80

-0.042

1st undersize

-0.017 

53.75 

-0.037

-0.022

47.55

-0.042

2nd undersize

-0.017 

53.50 

-0.037

-0.022

47.30

-0.042

3rd undersize

-0.017 

53.25 

-0.037

-0.022

47.05

-0.042

(1)

All dimensions are in mm.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 58: Identifying "Industrially Fractured" Connecting Rods 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Distinguishing features: 

A. Older type connecting rods (smooth joint along contact surface)  

B. Industrially fractured connecting rods (rough joint along contact surface)  

z

Disassembling and assembling piston and older type connecting rod. See OLDER TYPE 
CONNECTING RODS  

z

Disassembling and assembling piston and industrially fractured connecting rod. See INDUSTRIALLY 
FRACTURED CONNECTING RODS  

Older type connecting rods 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

1. Piston rings 

z

Offset gaps by 120°  

z

Use piston ring pliers to remove and install  

z

"TOP" faces piston crown  

z

Checking ring gap. See Fig. 61  

z

2-part oil scraper ring  

2. Piston 

z

Checking. See Fig. 63  

z

Mark installation position and cylinder number  

z

Arrow on piston crown points to belt pulley end  

z

Checking ring to groove clearance. See Fig. 62  

z

Install using piston ring clamp  

3. Connecting rod 

z

Only replace as a set  

z

Mark allocation to cylinder -B-  

z

Installation position: Marking -A- faces belt pulley end  

4. Connecting rod bearing cap 

z

Mark allocation to cylinder -B-  

z

Installation position: Marking -A- faces belt pulley end  

5. 30 N.m + 1/4 turn (90°) further 

z

Replace  

z

Oil thread and contact surface  

z

To measure radial clearance tighten to 30 N.m, but do not turn further  

6. Bearing shell 

z

Observe installing position  

z

Do not interchange used bearing shells  

z

Ensure retaining lugs fit tightly in recesses  

z

Upper bearing shell with oil drilling for piston pin lubrication  

z

Axial clearance, new: 0.05 ... 0.31 mm; Wear limit: 0.37 mm  

z

Check radial clearance with Plastigage, new: 0.01 ... 0.06 mm; Wear limit: 0.12 mm  

z

Do not rotate crankshaft when checking radial clearance  

7. Cylinder block 

z

Checking cylinder bore. See Fig. 65  

z

Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS  

8. Connecting rod bolt  

NOTE:

The following list refers to items in Fig. 59 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD