Volkswagen New Beetle. Manual - part 987

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  985  986  987  988   ..

 

 

Volkswagen New Beetle. Manual - part 987

 

 

Special tools and equipment 

z

Kukko 21/2 and Kukko 22/1  

z

3176 Centering mandrel 

or 

z

Mandrel 207 c 

Fig. 45: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Pull off with extractor -A-, e.g. Kukko 21/2 and Kukko 22/1.  

NOTE:

Check whether the needle bearing is installed in the crankshaft when installing 
the engine. Install the needle bearing, if necessary.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 46: Removing Needle Bearing From Crankshaft Using Extractor
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

Installing 

z

Drive in using punch 207c or centering mandrel 3176. 

z

Inscription side of needle bearing must be able to be read when it is installed  

Fig. 47: Driving In Needle Bearing Using Punch 207C 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Locating distance of needle bearing 

z

Dimension a = 1.7 mm +/- 0.5 mm 

Fig. 48: Locating Needle Bearing Installed Distance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Crankshaft dimensions 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

CRANKSHAFT DIMENSIONS 

PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING 

1. Piston rings 

z

Offset ring gaps by 120°  

z

Position oil scraper ring gap in tight winded spring area  

z

Use piston ring pliers to remove and install  

z

"TOP" faces toward piston crown  

z

Checking ring gap. See Fig. 50  

z

Checking ring to groove clearance. See Fig. 51  

2. Piston 

z

With combustion chamber  

z

Mark installation position and cylinder number.  

z

Mark installation position and application piston/cylinder. See Fig. 53  

z

Arrow on piston crown points to belt pulley end.  

z

Install using piston ring clamp.  

z

Cracks on piston skirt, replace piston  

z

Checking piston projection at TDC. See PISTON PROJECTION AT TDC, CHECKING  

3. Piston pin 

z

If difficult to remove, heat piston to 60 °C  

z

Remove and install with drift VW 222a  

4. Circlip  

NOTE:

For CRANKSHAFT DIMENSIONS , all dimensions are in mm.

Honing dimension

Main journal diameter

Connecting rod journal diameter

Basic dimension

-0.022 

54.00 

-0.042

-0.022

47.80

-0.042

1st undersize

-0.022 

53.75 

-0.042

-0.022

47.55

-0.042

2nd undersize

-0.022 

53.50 

-0.042

-0.022

47.30

-0.042

3rd undersize

-0.022 

53.25 

-0.042

-0.022

47.05

-0.042

NOTE:

The following list refers to items in Fig. 49 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

5. Connecting rod 

z

Mark cylinder number -A- with colored pen  

z

Installed position: Marking -B- faces pulley end  

z

With industrially cracked bearing caps.  

6. Bearing shell 

z

Note installed position. See Fig. 54  

z

Note versions:  

z

Upper bearing shell (to piston) made out of more hard-wearing material  

z

Distinguishing features: Black line on contact surface in separating area  

z

Do not interchange used bearing shells.  

z

Insert bearing shells centrally. See Fig. 54  

z

Check for secure seating  

z

Axial clearance. Wear limit: 0.37 mm  

z

Check radial clearance with Plastigage, Wear limit: 0.08 mm  

z

Do not rotate crankshaft when checking radial clearance  

7. Cylinder block 

z

Checking cylinder bores. See Fig. 52  

z

Piston and cylinder dimensions. See PISTON AND CYLINDER DIMENSIONS  

8. Connecting rod bearing cap 

z

Note installed position.  

z

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

9. Oil spray jet 

z

For piston cooling.  

10. 25 N.m 

z

Insert without sealant  

11. Connecting rod bolt, 30 N.m plus an additional 1/4 turn (90°) 

z

Always replace  

z

Oil threads and contact surfaces.  

z

To measure radial clearance use old bolts 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

 

 

 

 

 

 

 

Content   ..  985  986  987  988   ..