New Beetle L4-1.9L DSL Turbo (BEW) (2006)
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Upper bearing shell (toward piston) is made of material which is more resistant to wear. Identification characteristics: black line on running
surface in separating area
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Do not interchange used bearing shells
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Insert bearing shells centrally
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Check for secure seating
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Measuring axial clearance
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Wear limit: 0.37 mm
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Check radial clearance with Plastigage:
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Wear limit: 0.08 mm (Do not rotate crankshaft when checking radial clearance)
7 - Cylinder block
8 - Connecting rod bearing cap
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Note installation position
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Caps only fit in one position and only on appropriate connecting rod due to breaking procedure (industrial cracking) separating cap from
connecting rod
9 - Oil spray jet
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For piston cooling
10 - 25 Nm
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Insert without sealant
11 - Connecting rod bolt, 30 Nm plus 1/4 turn (90°)
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Replace
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Oil threads and contact surfaces
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To measure radial clearance use old bolts
Checking piston ring gap
Special tools, testers and auxiliary items required
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Feeler gauge (commercial type)
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Push ring squarely from above down to approximately 15 mm from bottom end of cylinder.
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Determine ring gap with feeler gauge.