Volkswagen New Beetle. Manual - part 1164

 

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Volkswagen New Beetle. Manual - part 1164

 

 

1. Piston rings 

z

Offset gaps by 120°  

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Use piston ring pliers to remove and install  

z

"TOP" faces piston crown  

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Checking ring gap. See Fig. 61  

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2-part oil scraper ring  

2. Piston 

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Checking. See Fig. 63  

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Mark installation position and cylinder number  

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Arrow on piston crown points to belt pulley end  

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Checking ring to groove clearance. See Fig. 62  

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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 allocation to cylinder -B-  

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Installation position: Marking -A- faces belt pulley end  

4. Connecting rod bearing cap 

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Mark allocation to cylinder -B-  

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Installation position: Marking -A- faces belt pulley end  

5. 30 N.m + 1/4 turn (90°) further 

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Replace  

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Oil thread and contact surface  

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

6. Bearing shell 

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Observe installing 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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Upper bearing shell with oil drilling for piston pin lubrication  

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Axial clearance, new: 0.05 ... 0.31 mm; Wear limit: 0.37 mm  

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Check radial clearance with Plastigage, new: 0.01 ... 0.06 mm; Wear limit: 0.12 mm  

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Do not rotate crankshaft when checking radial clearance  

7. Cylinder block 

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Checking cylinder bore. See Fig. 65  

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Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS  

8. Connecting rod bolt  

NOTE:

The following list refers to items in Fig. 59 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

9. Circlip  

10. Piston pin 

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If difficult to remove, heat piston to 60° C  

z

Remove and install with VW 222a  

Fig. 59: Exploded View Of Piston And Connecting Rod Assembly (Older Type Connecting Rods) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Industrially fractured connecting rods 

1. Piston rings 

z

Offset gaps by 120°  

NOTE:

The following list refers to items in Fig. 60 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

z

Use piston ring pliers to remove and install  

z

"TOP" faces piston crown  

z

Checking ring gap. See Fig. 61  

z

Checking ring to groove clearance. See Fig. 62  

z

Oil scraper ring 2- or 3-part  

2. Piston 

z

Checking. See Fig. 63  

z

Mark installation position and cylinder number  

z

Arrow on piston crown points to pulley end  

z

Install using piston ring clamp  

3. Floating piston pin 

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If difficult to remove, heat piston to 60 °C  

z

Remove and install with VW 222A  

4. Snap ring  

5. Connecting rod 

z

With cracked bearing cap  

z

Only replace as a set  

z

Mark relationship to cylinder -B-  

z

Installation position: Marking -A- faces belt pulley end  

6. Bearing shell 

z

Observe installation position. See Fig. 64 .  

z

Insert bearing shells centrally  

z

Do not interchange used bearing shells  

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Check if seated securely  

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Axial clearance, new: 0.10...0.35 mm; Wear limit: 0.4 mm  

z

Check radial clearance with Plastigage, new: 0.01...0.05 mm; Wear limit: 0.09 mm  

z

Do not rotate crankshaft when checking radial clearance  

7. Cylinder block 

z

Checking cylinder bore. See Fig. 65  

z

Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS  

8. Connecting rod bearing cap 

z

Observe installing position  

z

Caps only fit in one position and only on appropriate connecting rod due to breaking procedure 
(industrially fracturing) separating cap from connecting rod  

9. 30 N.m + 1/4 turn (90°) further 

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Torx E 10  

z

Replace  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

z

Oil thread and contact surface  

z

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

Fig. 60: Exploded View Of Piston And Connecting Rod Assembly (Industrially Fractured Connecting 
Rods)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Piston Ring Gap 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

 

 

 

 

 

 

 

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