Volkswagen New Beetle. Manual - part 988

Fig. 49: Disassembling And Assembling View Of Pistons And Connecting Rods 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking piston ring gap 

Fig. 50: Checking Piston Ring End Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Feeler gauges  

z

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

z

1 gap with feeler gauge. 

RING GAP DETERMINING 

Checking ring to groove clearance 

Piston ring end gap (in mm)

New

Wear limit

1. Compression ring

0.20 to 0.40

1.0

2. Compression ring

0.20 to 0.40

1.0

Oil scraper ring

0.25 to 0.50

1.0

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 51: Checking Ring To Groove Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Feeler gauges  

z

Clean ring groove before checking.  

z

Determine clearance with feeler gauge. 

RING TO GROOVE CLEARANCE 

Cylinder bores, checking 

Special tools and equipment 

z

Internal dial gauge 50 to 100 mm  

z

Take measurements at 3 positions in both lateral -A- and longitudinal -B- planes, as illustrated. Deviation 
from nominal dimension max. 0.10 mm 

Piston ring to groove ( in mm)

New

Wear limit

1. Compression ring

0.06 to 0.09

0.25

2. Compression ring

0.05 to 0.08

0.25

Oil scraper ring

0.03 to 0.06

0.15

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 52: Checking Cylinder Bores Dimensions 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston installed position and piston/cylinder application 

Piston in cylinders 1 and 2: 

Larger intake valve chamber toward flywheel (arrows). See Fig. 53 . 

Fig. 53: Locating Larger Intake Valve Chamber Toward Flywheel And Belt Pulley Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Piston in cylinders 3 and 4: 

Larger intake valve chamber toward belt pulley side (arrows).

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 be possible.

 

2003 Volkswagen New Beetle GLS 

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

  

Installed position of bearing shells 

Fig. 54: Identifying Connecting Rod Bearing Cap Shells Dimension -a- 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Center bearing shells when inserting into connecting rod and connecting rod bearing cap. 

Dimension -a- must be equal on both left and right sides 

Max. deviation: 0.2 mm 

Piston projection at TDC, checking 

Special tools and equipment 

z

VW 382/7 Measuring device 

NOTE:

New piston/cylinder allocations are shown by a colored marking on the piston 
crown. 

z

Piston for cylinder 1 and 2: marked 1/2  

z

Piston for cylinder 3 and 4: marked 3/4  

 

2003 Volkswagen New Beetle GLS 

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