Volkswagen New Beetle. Manual - part 1129

 

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Volkswagen New Beetle. Manual - part 1129

 

 

Fig. 65: Measuring Piston Projection At TDC 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

PISTON PROJECTION IDENTIFICATION 

Cylinder head gasket, identification 

Piston projection

Identification: holes / notches

0.91 mm to 1.00 mm

1

1.01 mm to 1.10 mm

2

1.11 mm to 1.20 mm

3

 

2003 Volkswagen New Beetle GLS 

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

  

z

Part No. = arrow -1-  

z

Production control code = arrow -2- (can be disregarded)  

z

Holes = arrow -3- 

NOTE:

If different values are obtained from the piston projection measurements, 
use the largest measurement to select the proper gasket.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 66: Identifying Cylinder Head Gasket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston and cylinder dimensions in mm 

 

2003 Volkswagen New Beetle GLS 

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

  

PISTON AND CYLINDER DIMENSIONS

ENGINE - CYLINDER HEAD, VALVETRAIN 

CYLINDER HEAD, REMOVING AND INSTALLING 

Compression checking COMPRESSION PRESSURE, CHECKING 

1. Toothed belt guard, upper section  

2. Toothed belt 

z

Mark direction of engine rotation before removing  

z

Check for wear  

z

Do not kink  

z

Removing and installing. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
  

3. 20 N.m (15 ft lb)  

4. 20 N.m (15 ft lb)  

5. 45 N.m (33 ft lb)  

6. Camshaft sprocket 

z

Drive off of camshaft taper using hammer and drift through toothed belt guard openings  

7. Tensioning roller (semiautomatic, toothed belt) 

z

Checking: See SEMI-AUTOMATIC TOOTHED BELT TENSIONING ROLLER, 
CHECKING
  

8. Idler roller  

9. Toothed belt guard, rear  

10. 10 N.m (7 ft lb)  

Honing dimension

Piston diameter

Cylinder bore diameter

Basic dimen., mm

79.47

79.51

1st oversize, mm

79.72

79.76

2nd oversize, mm

79.97

80.01

NOTE:

z

When installing an exchange cylinder head (complete with installed 
camshafts): Oil the contact surfaces between the lifters and the cam lobes 
before installing the valve cover.  

z

Do NOT remove the plastic packing pieces which protect the open valves 
until immediately before installing the cylinder head.  

z

If the cylinder head is replaced: 

{

Replace the entire engine coolant.  

NOTE:

The following list refers to items in Fig. 67 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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