Volkswagen New Beetle. Manual - part 1128

 

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Volkswagen New Beetle. Manual - part 1128

 

 

Cylinder bores, checking 

Special tools and equipment 

z

Internal dial gauge 50 to 100 mm  

z

Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. 

z

Deviation from nominal dimension: 0.10 mm maximum  

Fig. 61: Checking Cylinder Bores 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston installation position and piston/cylinder allocation 

Piston in cylinders 1 and 2: 

Larger intake valve chamber points toward flywheel (arrows) 

Piston in cylinders 3 and 4: 

Larger intake valve chamber points toward belt pulley side (arrows).

Piston ring 
Dimensions in mm

New

Wear limit

1st compression ring

0.06 to 0.09

0.25

2nd compression ring

0.05 to 0.08

0.25

Oil scraper ring

0.03 to 0.06

0.15

NOTE:

Do NOT measure the cylinder bores when the block is mounted on a repair 
stand using the VW 540 adaptor bracket. Bending stresses resulting from 
the mass overhang will make incorrect measurements likely.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 62: Identifying Piston Installation Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Piston for cylinder 1 and 2: marked 1/2  

z

Piston for cylinder 3 and 4: marked 3/4  

Piston projection at TDC, checking 

Special tools and equipment 

z

VW 382/7 

NOTE:

New piston/cylinder allocations are shown by a colored mark on the piston 
crown.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 63: Identifying VW 382/7 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VW 385/17 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 64: Identifying VW 385/17 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

Piston projection at TDC must be measured when installing new pistons or a short block. Depending upon 
piston projection, install the corresponding cylinder head gasket using the following table: 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1126  1127  1128  1129   ..