Volkswagen New Beetle. Manual - part 1200

 

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Volkswagen New Beetle. Manual - part 1200

 

 

CRANKSHAFT BEARING COLOR MARKINGS

The lower crankshaft bearing shells are always supplied as a replacement part with the color marking "yellow". 

Crankshaft dimensions 

(in mm) 

CRANKSHAFT DIMENSIONS 

PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING 

Vehicles with engine code APH 

For vehicles with engine code AWP or AWV, see VEHICLES WITH ENGINE CODE AWP, AWV . 

1. Piston ring 

z

Offset gaps by 120°  

z

Remove and install with piston ring pliers  

z

"TOP" faces toward piston crown  

z

Checking ring gap. See Checking Piston Ring Gap

Letter in cylinder block

Bearing color

S =

black

R =

red

G =

yellow

Honing dimension

Main journal diameter (mm)

Connecting rod journal diameter (mm)

Basic dimension

-0.017 

54.00 

-0.037

-0.022

47.80

-0.042

1st undersize

-0.017 

53.75 

-0.037

-0.022

47.55

-0.042

2nd undersize

-0.017 

53.50 

-0.037

-0.022

47.30

-0.042

3rd undersize

-0.017 

53.25 

-0.037

-0.022

47.05

-0.042

NOTE:

Secure engine to engine bracket VW 540 on assembly stand when 
dissembling/assembling engine.

NOTE:

The following list refers to items in Fig. 67 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

z

Checking ring to groove clearance. See Checking Ring To Groove Clearance  

z

2 or 3 part oil scraper ring, mixed installations permissible  

2. Piston 

z

Checking. See Checking Piston  

z

Mark installation position and cylinder number  

z

Arrow on piston crown points to pulley end  

z

Install using piston ring clamp  

3. Connecting rod 

z

Only replace as a set  

z

Mark cylinder number -B-  

z

Installation position: Marking -A- faces toward pulley end  

4. Connecting rod bearing cap 

z

Note installation position  

z

Installation position: Marking -A- faces towards pulley end  

z

Mark cylinder number -B-  

5. 30 N.m + 1/4 turn (90°) further 

z

Always replace  

z

Oil threads and contact surface  

z

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

6. Pressure relief valve, 27 N.m 

z

Opening pressure: 1.3 to 1.6 bar  

7. Oil spray jet 

z

For piston cooling  

8. Bearing shell 

z

Note installation position  

z

Do not interchange used bearing shells  

z

Ensure retaining lugs fit tightly in recesses  

z

Axial clearance New: 0.10-0.31 mm Wear limit: 0.40 mm 

Check radial clearance with Plastigage: 

z

New: 0.01-0.05 mm  

z

Wear limit: 0.09 mm  

z

Do not rotate crankshaft when checking radial clearance  

9. Cylinder block 

z

Checking cylinder bores. See Checking Cylinder Bores  

z

Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS (ENGINE 
CODE: APH)
  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

10. Connecting rod bolt 

z

Always replace  

11. Circlip  

12. Piston pin 

z

If difficult to remove, heat piston to 60° C  

z

Remove and install with VW 222a  

Fig. 67: Exploded View Of Pistons And Connecting Rods (Engine Code APH) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Piston Ring Gap 

Fig. 68: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Feeler gauges  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

z

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

PISTON RING END GAP (ENGINE CODE APH) 

Checking Ring To Groove Clearance 

Fig. 69: Checking Ring To Groove Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Feeler gauges  

z

Clean groove before check.  

PISTON RING-TO-GROOVE CLEARANCE (ENGINE CODE APH) 

Checking Piston 

Special tools and equipment 

z

Micrometer 75-100 mm  

z

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

Piston ring

Gap

New

Wear limit

Compression mm rings

0.15-0.40

0.8

Oil scraper ring mm

0.25-0.50

1.0

 

Clearance

Piston ring

New

Wear limit

Compression rings mm

0.02-0.07

0.12

Oil scraper ring mm

0.02-0.06

0.12

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

 

 

 

 

 

 

 

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