Volkswagen New Beetle. Manual - part 1165

 

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Volkswagen New Beetle. Manual - part 1165

 

 

Fig. 61: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, testers, measuring instruments and auxiliary items required 

z

Feeler gauge  

Work sequence 

z

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

PISTON RING END GAP SPECIFICATIONS 

Checking Ring To Groove Clearance 

Piston Ring

New

Wear limit

Compression mm rings

0.20...0.40

0.8

Oil scraper ring mm

0.25...0.50

0.8

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 62: Checking Ring To Groove Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, testers, measuring instruments and auxiliary items required 

z

Feeler gauge  

Work sequence 

Clean groove before checking. 

PISTON RING TO GROOVE CLEARANCE SPECIFICATIONS 

Piston Ring

New

Wear limit

Compression rings 
mm

0.06...0.09

0.20

Oil scraper ring 

0.03...0.06

0.15

 

2003 Volkswagen New Beetle GLS 

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

  

Measuring Piston Lower Edge Of Skirt 

Fig. 63: Measuring Piston Lower Edge Of Skirt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, testers, measuring instruments and auxiliary items required 

z

External micrometer 75...100 mm  

Work sequence 

z

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

Deviation from nominal dimension: max. 0.04 mm

mm

 

2003 Volkswagen New Beetle GLS 

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

  

Installation Position Of Bearing Shells 

Fig. 64: Identifying Installation Position Of Connecting Rod Bearing Shells 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bearing shell -1- with oil channel (arrow) for connecting rod 

Bearing shell -2- without oil channel connecting rod bearing cap 

z

Insert bearing shells and connecting rod bearing cap centrally. 

Dimension -a- must be same on both left and right side, maximum deviation 0.2 mm 

Checking Cylinder Bores 

 

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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