Volkswagen New Beetle. Manual - part 1304

C. Specified range for Start of injection  

Fig. 24: Start Of Diesel Fuel Injection Graph 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Example: 

Value 90 in Display zone 9 (B) corresponds to a numerical range from 35 to 74 in Display zone 2 (A). 

If Start of injection is outside specification, adjust as follows:  

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Remove connecting line between charge air cooler and intake manifold.  

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Remove upper toothed belt guard.  

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Loosen two injection pump sprocket mounting bolts -1-.  

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Place 22 mm box wrench onto hub nut -2- to counter-hold pump shaft. 

NOTE:

If, when checking Start of injection, the specifications are within zone -C-, no 
adjustment is required. After repairs, e.g. removing and installing injection 
pump or adjusting timing, Start of injection must be set to the mean value 
(dashed line) in zone -C-.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH

  

Fig. 25: Injection Pump Sprocket Mounting Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

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Loosen 3rd injection pump sprocket mounting bolt and slightly turn pump shaft 

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Left = advance Start of injection  

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Right = retard Start of injection  

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Tighten new mounting bolts for injection pump sprocket. 

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20 Nm (15 ft lb)  

CAUTION: Do not loosen hub nut -2- for ANY reason. Otherwise, the Diesel 

injection pump basic setting will be altered and cannot be reset with 
normal workshop equipment. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH

  

If injection pump has not previously been removed and installed

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Screw in new injection pump sprocket mounting bolts one after the other.  

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Observe values in zone 2 and adjust again, if necessary, until the mean value for specification zone -C- is 
displayed.  

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Tighten injection pump sprockets 1/ 4 turn (90°) additional.  

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Press "right arrow" button. 

Display will appear as shown: 

Fig. 26: Scan Tool Display Screen 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

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Press -0- and -6- buttons to select Function 06: "End output".  

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Press -Q- button to enter input.  

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Erase DTC memory and set the readiness code CLEARING DIAGNOSTIC TROUBLE CODES 
(FUNCTION 0 .  

FUEL INJECTORS, REMOVING AND INSTALLING 

Special tools 

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VAG1331 Torque wrench (5 to 50 Nm) or equivalent 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH

  

Fig. 27: Identifying Torque Wrench VAG 1331 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

z

3035 Injector line wrench 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH