Volkswagen New Beetle. Manual - part 1059

 

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Volkswagen New Beetle. Manual - part 1059

 

 

9. Circlip  

10. Piston pin 

z

If difficult to remove, heat piston to 60° C  

z

Remove and install with VW 222a  

Fig. 59: Exploded View Of Piston And Connecting Rod Assembly (Older Type Connecting Rods) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Industrially fractured connecting rods 

1. Piston rings 

z

Offset gaps by 120°  

NOTE:

The following list refers to items in Fig. 60 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Use piston ring pliers to remove and install  

z

"TOP" faces piston crown  

z

Checking ring gap. See Fig. 61  

z

Checking ring to groove clearance. See Fig. 62  

z

Oil scraper ring 2- or 3-part  

2. Piston 

z

Checking. See Fig. 63  

z

Mark installation position and cylinder number  

z

Arrow on piston crown points to pulley end  

z

Install using piston ring clamp  

3. Floating piston pin 

z

If difficult to remove, heat piston to 60 °C  

z

Remove and install with VW 222A  

4. Snap ring  

5. Connecting rod 

z

With cracked bearing cap  

z

Only replace as a set  

z

Mark relationship to cylinder -B-  

z

Installation position: Marking -A- faces belt pulley end  

6. Bearing shell 

z

Observe installation position. See Fig. 64 .  

z

Insert bearing shells centrally  

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Do not interchange used bearing shells  

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Check if seated securely  

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Axial clearance, new: 0.10...0.35 mm; Wear limit: 0.4 mm  

z

Check radial clearance with Plastigage, new: 0.01...0.05 mm; Wear limit: 0.09 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 bearing cap 

z

Observe installing position  

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Caps only fit in one position and only on appropriate connecting rod due to breaking procedure 
(industrially fracturing) separating cap from connecting rod  

9. 30 N.m + 1/4 turn (90°) further 

z

Torx E 10  

z

Replace  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Oil thread and contact surface  

z

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

Fig. 60: Exploded View Of Piston And Connecting Rod Assembly (Industrially Fractured Connecting 
Rods)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Piston Ring Gap 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 61: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, testers, measuring instruments and auxiliary items required 

z

Feeler gauge  

Work sequence 

z

Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. 

PISTON RING END GAP SPECIFICATIONS 

Checking Ring To Groove Clearance 

Piston Ring

New

Wear limit

Compression mm rings

0.20...0.40

0.8

Oil scraper ring mm

0.25...0.50

0.8

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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