Volkswagen New Beetle. Manual - part 1309

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Screw new securing bolt into scotch block until injector unit can still be turned lightly.  

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Align injector unit at right angles to bearing pedestals of camshaft.  

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Use a vernier gauge (measuring range at least 400 mm) and check dimension "a" from cylinder head 
outer edge to round surface of injector unit. See Fig. 13 and DIMENSION "A" FROM CYLINDER 
HEAD OUTER EDGE TO ROUND SURFACE OF INJECTOR UNIT . 

DIMENSION "A" FROM CYLINDER HEAD OUTER EDGE TO ROUND SURFACE OF 
INJECTOR UNIT 

Fig. 13: Checking Dimension "a" From Cylinder Head Outer Edge To Round Surface Of Injector 
Unit 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Align injector unit again, if necessary, and tighten securing bolt as follows:  

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Tighten securing bolt to 12 N.m plus an additional 270° (3/4 turn). Turning further can be done in several 
stages.  

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Position rocker shaft and tighten new securing bolts as follows: 

Cylinder

Dimension "a"

1

333.0 +/-0.8 mm

2

245.0 +/-0.8 mm

3

153.6 +/-0.8 mm

4

65.6 +/-0.8 mm

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

Fig. 14: Positioning Rocker Shaft And Tightening New Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten inner bolts -2- first and then outer screws -1- hand-tight. Then in same sequence to: 

20 N.m and 90°(1/4 turn further). 

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Install a dial gauge on injector unit adjustment screw as shown in Fig. 15 . 

Fig. 15: Installing Dial Gauge On Injector Unit Adjustment Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft in engine direction of rotation, until rocker lever roller is positioned on actuating cam 
point. 

Roller side (arrow -A-) is at highest point 

Dial gauge (arrow -B-) is at lowest point 

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Remove dial gauge.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

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Install adjustment screw into rocker lever until a considerable resistance can be felt (injector element is 
onto limit stop).  

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Turn adjustment screw back from top around 225°.  

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Hold adjustment screw in this position and tighten lock nut to 30 N.m. 

Fig. 16: Holding Adjustment Screw In Position And Tightening Lock Nut 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Position injector unit connector and install cylinder head cover and toothed belt guard, upper part. See 
CYLINDER HEAD, REMOVING AND INSTALLING .  

ENGINE CONTROL MODULE 

ENGINE CONTROL MODULE, REMOVING AND INSTALLING 

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Before removing engine control module check control module identification and thereby previous control 
module coding, See ENGINE CONTROL MODULE (DTC) MEMORY, READING AND 
ERASING .  

Removing 

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Switch ignition off.  

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Remove inner cover on left hand side of plenum chamber. 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING . 

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Carefully press off retaining tab (arrow). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

Fig. 17: Pressing Off Engine Control Module Retaining Tab 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Unlock engine control module connector and remove.  

Installing 

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Install new control module and press to left.  

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Connect connector and lock in position.  

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Check previous coding and code new control module, See COMPONENTS, ADAPTING .  

ENGINE CONTROL MODULE (DTC) MEMORY, READING AND ERASING 

Special tools and equipment 

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VAS 5051 Vehicle Diagnosis, Testing and Information System 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW