Volkswagen New Beetle. Manual - part 1095

 

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Volkswagen New Beetle. Manual - part 1095

 

 

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Checking ring to groove clearance. See Checking Ring To Groove Clearance  

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2 or 3 part oil scraper ring, mixed installations permissible  

2. Piston 

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Checking. See Checking Piston  

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Mark installation position and cylinder number  

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Arrow on piston crown points to pulley end  

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Install using piston ring clamp  

3. Connecting rod 

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Only replace as a set  

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Mark cylinder number -B-  

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Installation position: Marking -A- faces toward pulley end  

4. Connecting rod bearing cap 

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Note installation position  

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Installation position: Marking -A- faces towards pulley end  

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Mark cylinder number -B-  

5. 30 N.m + 1/4 turn (90°) further 

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Always replace  

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Oil threads and contact surface  

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

6. Pressure relief valve, 27 N.m 

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Opening pressure: 1.3 to 1.6 bar  

7. Oil spray jet 

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For piston cooling  

8. Bearing shell 

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Note installation position  

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Do not interchange used bearing shells  

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Ensure retaining lugs fit tightly in recesses  

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Axial clearance New: 0.10-0.31 mm Wear limit: 0.40 mm 

Check radial clearance with Plastigage: 

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New: 0.01-0.05 mm  

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Wear limit: 0.09 mm  

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Do not rotate crankshaft when checking radial clearance  

9. Cylinder block 

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Checking cylinder bores. See Checking Cylinder Bores  

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Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS (ENGINE 
CODE: APH)
  

 

2003 Volkswagen New Beetle GLS 

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

  

10. Connecting rod bolt 

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Always replace  

11. Circlip  

12. Piston pin 

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If difficult to remove, heat piston to 60° C  

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Remove and install with VW 222a  

Fig. 67: Exploded View Of Pistons And Connecting Rods (Engine Code APH) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Piston Ring Gap 

Fig. 68: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

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Feeler gauges  

 

2003 Volkswagen New Beetle GLS 

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

  

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

PISTON RING END GAP (ENGINE CODE APH) 

Checking Ring To Groove Clearance 

Fig. 69: Checking Ring To Groove Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

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Feeler gauges  

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Clean groove before check.  

PISTON RING-TO-GROOVE CLEARANCE (ENGINE CODE APH) 

Checking Piston 

Special tools and equipment 

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Micrometer 75-100 mm  

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Measure pistons approx. 10 mm from lower edge of skirt, at 90° to piston pin axis. 

Piston ring

Gap

New

Wear limit

Compression mm rings

0.15-0.40

0.8

Oil scraper ring mm

0.25-0.50

1.0

 

Clearance

Piston ring

New

Wear limit

Compression rings mm

0.02-0.07

0.12

Oil scraper ring mm

0.02-0.06

0.12

 

2003 Volkswagen New Beetle GLS 

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

  

Deviation from nominal dimension max.: 0.04 mm

Fig. 70: Checking Piston Skirt Diameter 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Cylinder Bores 

Special tools and equipment 

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Internal dial indicator 50-100 mm  

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

Deviation from nominal dimension max.: 0.10 mm 

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.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1093  1094  1095  1096   ..