Volkswagen New Beetle. Manual - part 1201

 

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Volkswagen New Beetle. Manual - part 1201

 

 

Deviation from nominal dimension max.: 0.04 mm

Fig. 70: Checking Piston Skirt Diameter 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Cylinder Bores 

Special tools and equipment 

z

Internal dial indicator 50-100 mm  

z

Measure bores at 3 locations in both directions -A- across engine and -B- in line with crankshaft. 

Deviation from nominal dimension max.: 0.10 mm 

NOTE:

Measuring the cylinder bores must not be done when the cylinder block is 
mounted on a repair stand with adapter bracket VW 540, as incorrect 
measurements would then be possible.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 71: Checking Cylinder Bores 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston and cylinder dimensions (engine code: APH) 

PISTON AND CYLINDER DIMENSIONS (ENGINE CODE APH) 

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  

z

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

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. Piston pin 

z

If difficult to remove, heat piston to 60 °C  

z

Remove and install with VW 222a  

4. Circlip  

5. Connecting rod 

z

Only replace as a set  

z

Mark cylinder number -B-  

z

Installation position: Marking -A- faces toward pulley end  

6. Bearing shell 

z

Note installation position  

z

Do not interchange used bearing shells  

z

Axial clearance 

Honing dimension

Piston diameter

Cylinder bore diameter

Basic dimen. mm

80.965 

(1)

81.01

1st oversize mm

81.465 

(1)

81.51

(1)

Dimension without graphite coating (thickness 0.02 mm). The graphite coating wears away.

NOTE:

The following list refers to items in Fig. 72 .

 

2003 Volkswagen New Beetle GLS 

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

  

New: 0.05 to 0.31 mm 

Wear limit: 0.37 mm 

z

Check radial clearance with Plastigage: 

New: 0.01 to 0.06 mm 

Wear limit: 0.09 mm 

z

Do not rotate crankshaft when checking radial clearance  

7. Cylinder block 

z

Checking cylinder bores. See Bearing Shells - Mount  

z

Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS (ENGINE 
CODES: AWP, AWV)
  

8. Connecting rod bearing cap 

z

Note installation position  

9. Oil spray jet 

z

For piston cooling  

10. Pressure relief valve, 27 N.m 

z

Opening pressure: 1.3 to 1.6 bar  

11. Connecting rod bolt, 30 N.m + 1/4 turn (90°) further 

z

Always replace  

z

Oil threads and contact surface  

z

To measure radial clearance use old bolts  

z

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

Fig. 72: Identifying Piston Components - Vehicles With Engine Code AWP, AWV 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Checking Piston Ring Gap 

Fig. 73: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Feeler gauges  

z

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

PISTON RING END GAP (ENGINE CODE AWP, AWV) 

Checking Ring To Groove Clearance 

Piston ring

Gap

 

New

Wear limit

Compression rings mm

0.20 to 0.40

0.8

Oil scraper ring mm

0.25 to 0.50

0.8

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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