Volkswagen New Beetle. Manual - part 1096

 

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Volkswagen New Beetle. Manual - part 1096

 

 

Fig. 71: Checking Cylinder Bores 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston and cylinder dimensions (engine code: APH) 

PISTON AND CYLINDER DIMENSIONS (ENGINE CODE APH) 

Vehicles with engine code AWP, AWV 

1. Piston ring 

z

Offset gaps by 120°  

z

Remove and install with piston ring pliers  

z

"TOP" faces toward piston crown  

z

Checking ring gap. See Checking Piston Ring Gap  

z

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

2. Piston 

z

Checking. See Checking Piston  

z

Mark installation position and cylinder number  

z

Arrow on piston crown points to pulley end  

z

Install using piston ring clamp  

3. Piston pin 

z

If difficult to remove, heat piston to 60 °C  

z

Remove and install with VW 222a  

4. Circlip  

5. Connecting rod 

z

Only replace as a set  

z

Mark cylinder number -B-  

z

Installation position: Marking -A- faces toward pulley end  

6. Bearing shell 

z

Note installation position  

z

Do not interchange used bearing shells  

z

Axial clearance 

Honing dimension

Piston diameter

Cylinder bore diameter

Basic dimen. mm

80.965 

(1)

81.01

1st oversize mm

81.465 

(1)

81.51

(1)

Dimension without graphite coating (thickness 0.02 mm). The graphite coating wears away.

NOTE:

The following list refers to items in Fig. 72 .

 

2003 Volkswagen New Beetle GLS 

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

  

New: 0.05 to 0.31 mm 

Wear limit: 0.37 mm 

z

Check radial clearance with Plastigage: 

New: 0.01 to 0.06 mm 

Wear limit: 0.09 mm 

z

Do not rotate crankshaft when checking radial clearance  

7. Cylinder block 

z

Checking cylinder bores. See Bearing Shells - Mount  

z

Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS (ENGINE 
CODES: AWP, AWV)
  

8. Connecting rod bearing cap 

z

Note installation position  

9. Oil spray jet 

z

For piston cooling  

10. Pressure relief valve, 27 N.m 

z

Opening pressure: 1.3 to 1.6 bar  

11. Connecting rod bolt, 30 N.m + 1/4 turn (90°) further 

z

Always replace  

z

Oil threads and contact surface  

z

To measure radial clearance use old bolts  

z

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

Fig. 72: Identifying Piston Components - Vehicles With Engine Code AWP, AWV 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Checking Piston Ring Gap 

Fig. 73: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Feeler gauges  

z

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

PISTON RING END GAP (ENGINE CODE AWP, AWV) 

Checking Ring To Groove Clearance 

Piston ring

Gap

 

New

Wear limit

Compression rings mm

0.20 to 0.40

0.8

Oil scraper ring mm

0.25 to 0.50

0.8

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 74: Checking Ring To Groove Clearance
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

Special tools and equipment 

z

Feeler gauges  

Clean groove before check. 

PISTON RING CLEARANCE (ENGINE CODE AWP, AWV) 

Checking Piston 

Fig. 75: Checking Piston Skirt Diameter (Engine Code AWP, AWV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Micrometer 75 to 100 mm  

z

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

Deviation from nominal dimension: max. 0.04 mm 

Bearing Shells - Mount 

Piston ring

Clearance

 

New

Wear limit

Compression rings mm

0.06 to 0.09

0.20

Oil scraper ring mm

0.03 to 0.06

0.15

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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