Volkswagen New Beetle. Manual - part 1316

Fig. 27: Identifying VAG 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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3035 Injector line wrench 

Fig. 28: Identifying 3035 Injector Line Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

Faulty injectors can cause the following malfunctions: 

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Misfiring  

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Knocking in one or more cylinders  

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Engine over-heating  

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Loss of power  

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Excessive black exhaust smoke  

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Higher fuel consumption  

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Excessive blue smoke when starting with cold engine 

 

2003 Volkswagen New Beetle GLS 

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

  

Fuel Injectors, removing 

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Remove injection lines using 3035 tubing wrench.  

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Remove mounting nut, retainer and pull out fuel injector.  

Fuel injectors, installing 

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Insert fuel injector.  

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Make sure mount is seated correctly in cylinder head and install retainer.  

Tightening torques: 

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Injection lines = 25 Nm (18 ft lb)  

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Retainer screw = 20 Nm (15 ft lb)  

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Erase DTC memory. See DTC MEMORY, ERASING . Set the readiness code. See READINESS 
CODE, SETTING .  

Fuel injectors, servicing 

The AHL engine is equipped with dual spring design injectors. Fuel is injected in 2 stages. These fuel injectors 
must be replaced if malfunctions occur because neither servicing nor pressure adjustment is possible. 

Special tools 

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VAG1322 Injector test stand with VAG1322/2 pressure line  

Checking requirements 

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Pressure gauge on  

Fuel injection pressure, checking 

NOTE:

Faulty injectors can be located by loosening the high pressure line connection 
on each injector in turn with the engine running at a fast idle. If engine speed 
remains constant after loosening a line connection, this would indicate a faulty 
injector.

NOTE:

Always remove fuel lines in a complete set. Do not alter line shape.

NOTE:

Always replace heat shield between cylinder head and fuel injectors.

WARNING:

When testing fuel injectors, make sure that the stream of fuel does not 
contact your hands. The high pressure fuel delivery can penetrate skin 

 

2003 Volkswagen New Beetle GLS 

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

  

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Connect fuel injector to fuel injector test stand. 

Fig. 29: Connecting Fuel Injector To Fuel Injector Test Stand 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Move pump lever down slowly. When spray begins, record opening pressure for deviations from 
specification replace injector.  

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Specification (new injectors): 220 - 230 bar  

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Wear limit: 200 bar  

Fuel injectors, leak-checking 

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Pressure gauge on  

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Move pump lever down slowly and maintain a pressure of approx. 150 bar for 10 seconds.  

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No fuel should leak from the nozzle tip.  

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If any injector(s) leak, replace.  

Diesel injection pump timing cover O-ring, replacing 

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Place a clean cloth under the Diesel injection pump.  

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Remove cover screws -1- with commercially available tool for Torx socket head screws, e.g. Hazet 2115 
-T30.  

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Remove cover -2- and clean thoroughly.  

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Replace O-ring -3- and install cover using existing shims -4-. 

which could result in severe injuries.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 30: Removing Injection Pump Timing Cover Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

DIESEL FUEL INJECTION COMPONENTS AND FUNCTIONS, CHECKING 

Diesel injection system Voltage supply, checking 

Special tools 

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VAG1598/22 Test Box (MY 1999)  

WARNING:

Make sure that no electronic components are destroyed during testing by 
observing the following: 

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Switch the Fluke 83 multimeter to the appropriate units range before 
connecting measuring cables!  

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Always observe checking requirements!  

NOTE:

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Use the Fluke 83 multimeter and VAG1527B Voltage tester for electrical 
checking.  

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Specifications are valid for an ambient temperature range from: 0 to + 40 °
C (+32 to 104 °F).  

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If measured values deviate only slightly from the specifications, clean the 
sockets and plugs on the tester and measuring cables, then repeat check. 
Before replacing a component, check wiring and connections. In cases of 
specifications less than 10 ohm repeat the resistance measurement on the 
component.  

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To connect a tester to the Test Box, use jumper wires from the VW 1594 
adapter kit.  

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The terminal numbers of the plugs and the socket numbers on the Test 
Box are identical.  

 

2003 Volkswagen New Beetle GLS 

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