Volkswagen New Beetle. Manual - part 1126

 

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Volkswagen New Beetle. Manual - part 1126

 

 

z

For Engine Speed sensor  

7. 10 N.m (7 ft lb) plus additional 1/4 turn (90°) 

z

Always replace  

8. Fitted pin 

z

Checking projection from crankshaft. See Crankshaft dowel pin projection, checking  

9. Crankshaft 

z

Axial clearance new: 0.07 to 0.17 mm Wear limit: 0.37 mm  

z

Check radial clearance with Plastigage New: 0.03 to 0.08 mm Wear limit: 0.17 mm  

z

Do not rotate crankshaft when checking radial clearance  

z

Crankshaft dimensions. See CRANKSHAFT DIMENSIONS (MM)  

10. Thrust washer  

11. For engine block, bearing 3  

Fig. 56: Exploded View Of Crankshaft & Main Bearing Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Crankshaft dowel pin projection, checking 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 57: Checking Crankshaft Dowel Pin Projection 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Dowel pin projection -3- out of crankshaft a = 2.5 to 3.0 mm 

Crankshaft dimensions (mm) 

CRANKSHAFT DIMENSIONS CHART 

Honing dimension

Main journal diameter

Con-rod journal diameter

Basic 
dimension

-0.022 

54.00 

-0.042

-0.022

47.80

-0.042

1st undersize

-0.022 

53.75 

-0.042

-0.022

47.55

-0.042

2nd undersize

-0.022 

53.50 

-0.022

47.30

 

2003 Volkswagen New Beetle GLS 

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

  

PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING 

1. Piston ring 

z

Offset ring gaps 120°  

z

Remove and install using piston ring pliers  

z

"TOP" faces towards crown  

z

Ring gap, checking: See Piston ring gap, checking  

z

Ring to groove clearance. See Ring to groove clearance, checking  

2. Piston 

z

Mark installation position and cylinder number  

z

Arrow on piston crown points to: pulley end  

z

Install using piston ring tool  

z

If any cracks on piston skirt, replace piston  

z

Piston projection at TDC, checking. See PISTON PROJECTION AT TDC, CHECKING  

3. Piston pin 

z

If difficult to remove, heat piston to 60 °C  

z

Remove and install using VW 222A  

4. Circlip  

5. Connecting rod 

z

Only replace as a set  

z

Mark cylinder number -A-  

z

Installed position: Marking -B- faces pulley end  

6. Fitted pin 

z

Pin must seat securely in connecting rod, not in bearing cap  

7. Bearing shell 

z

Note installed position  

z

Do not interchange used bearing shells  

z

Make sure retaining lugs fit tightly in recesses  

z

Axial clearance Wear limit: 0.37 mm  

z

Check radial clearance with Plastigage: Wear limit: 0.08 mm Do not rotate crankshaft while 
checking.  

8. Cylinder block 

-0.042

-0.042

3rd undersize

-0.022 

53.25 

-0.042

-0.022

47.05

-0.042

NOTE:

The following list refers to items in Fig. 58 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Checking cylinder bores. See Cylinder bores, checking  

z

Piston and cylinder dimensions: See PISTON AND CYLINDER DIMENSIONS IN MM  

9. Connecting rod bearing cap 

z

Note installed position  

10. Oil spray jet 

z

For piston cooling  

11. 25 N.m (18 ft lb) 

z

Install without sealant  

12. Connecting rod bolt 

z

30 N.m (22 ft lb) plus additional 1/4 turn (90°)  

z

Always replace  

z

Oil the threads and contact surfaces  

z

Use old bolts to measure radial clearance 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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