Volkswagen New Beetle. Manual - part 1314

Lock injection pump sprocket using 3359 pin.

Loosen camshaft sprocket mounting bolt a half turn.

Place a drift through hole in rear of toothed belt guard and release camshaft sprocket from camshaft taper
with blow from hammer.

Fig. 15: Placing Drift Through Hole In Rear Of Toothed Belt Guard & Releasing Camshaft
Sprocket Using Hammer
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Remove camshaft sprocket.

Check whether TDC mark on flywheel and reference mark are aligned.

Place tooth belt on injection pump sprocket and tensioning roller.

Install camshaft sprocket into toothed belt and secure sprocket such that the camshaft can still turn.

Tension toothed belt using pin wrench (e.g. Matra V159) on eccentric and turning clockwise until notch
and raised mark align (arrows).

Fig. 16: Tensioning Toothed Belt Using Pin Wrench & Aligning Notch & Raised Mark
Courtesy of VOLKSWAGEN OF AMERICA, INC.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

Fig. 17: Ensuring Retaining Hook Is Correctly Seated In Toothed Belt Guard
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Tighten mounting nut.

20 Nm (15 ft lb)

Check TDC mark on flywheel again.

Tighten new mounting bolts for injection pump sprocket.

20 Nm (15 ft lb)

Tighten camshaft sprocket mounting bolt.

45 Nm (33 ft lb)

Remove 3359 locking pin.

Remove 3418 setting bar from camshaft.

Turn crankshaft two rotations in direction of engine rotation until crankshaft is set to cyl. 1 TDC again.

Reconnect injection lines, fuel supply line and electrical wiring.

Fill injection pump with Diesel fuel as follows.

Screw 1318/10 adapter into injection pump return/supply opening.

Connect VAG1390 hand vacuum pump to adapter using approx. 40 inches of transparent plastic hose.

NOTE:

Make sure retaining hook is correctly seated in toothed belt guard.

NOTE:

After dynamically checking the injection timing, tighten the bolts an
additional 1/4 turn (90 °).

The mounting bolts (stretch design) may only be used once.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

Fig. 18: Connecting VAG1390 Hand Vacuum Pump To Injection Pump
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Operate vacuum pump until fuel flows out of return/supply opening.

Do not draw fuel into vacuum pump.

Remove adapter and connect return/supply line.

Install valve cover and vacuum pump.

Dynamically check Start of injection and adjust if necessary. See START OF INJECTION,
DYNAMICALLY CHECKING AND ADJUSTING .

Start of injection, dynamically checking and adjusting

Special tools

VAG1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb) or equivalent

Fig. 19: Identifying Special Tool VAG 1331
Courtesy of VOLKSWAGEN OF AMERICA, INC.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

VAG1551/1552 Scan Tool using VAG1551/3 Adapter cable

3035 Injection line wrench

Checking and adjustment conditions

Mechanical engine settings OK.

Toothed belt tension OK.

Work sequence

Connect VAG1551/1552 Scan Tool. See VAG1551/1552 SCAN TOOL, CONNECTING .

Start engine and let idle.

Press -0- and -1- buttons to select Address word 01: "Engine electronics"

Display will appear as shown (example only)

Fig. 20: Scan Tool Display - Start Of Injection (1 Of 5)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Press --> button.

Display will appear as shown

NOTE:

Dynamically checking and correcting Start of injection is only possible in
Function 04, "Basic setting".

Start of injection must always be checked after replacing the toothed belt
or loosening the injection pump bolts or toothed belt sprockets and if
necessary, adjusted.

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

Content .. 1312 1313 1314 1315 ..