Volkswagen New Beetle. Manual - part 1368

Fig. 4: Identifying Special Tools For Removing & Installing Diesel Injection Pump (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, continued 

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2068A Adj. gauge TDC  

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3035 Injector line wrench  

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

Fig. 5: Identifying Special Tools For Removing & Installing Diesel Injection Pump (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Diesel injection pump, removing 

WARNING:

Fire hazard! Do NOT have anything in the area that can ignite Diesel fuel.

 

2003 Volkswagen New Beetle GLS 

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

  

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Unbolt all fuel lines at fuel pump.  

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Cover openings with a clean cloth.  

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Remove connecting line between charge air cooler and intake manifold.  

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Remove upper toothed belt guard and valve cover.  

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Remove vacuum pump for brake servo.  

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Turn crankshaft to cyl. 1 TDC (arrow). 

Fig. 6: Turning Crankshaft To Cyl. 1 TDC (Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn crankshaft to cyl. 1 TDC (arrow) 

Fig. 7: Turning Crankshaft To Cyl. 1 TDC (Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Use 3035 tubing wrench to loosen the high pressure fuel lines.

 

2003 Volkswagen New Beetle GLS 

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

  

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for Automatic transmission  

With engine removed 

Vehicles with manual transmission 

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Install 2068 A TDC gauge as shown.  

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Set adjustment device to 96 mm (arrow -A-). 

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Left-hand notch of the vernier scale is the reference point.  

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Turn crankshaft until flywheel TDC marking aligns with point of setting device (arrow -B-). 

Fig. 8: Setting Adjustment Device & Turning Crankshaft Until Flywheel TDC Marking Aligns 
With Setting Device (Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with automatic transmission 

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Install 2068 A TDC gauge as shown.  

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Set adjustment device to 30 mm (arrow -A-). 

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Left-hand notch of the vernier scale is the reference point.  

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Turn crankshaft until TDC marking on drive plate aligns with point of setting device (arrow -B-). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 9: Setting Adjustment Device & Turning Crankshaft Until Flywheel TDC Marking Aligns With 
Setting Device (Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

All vehicles 

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Lock camshaft with setting bar. 

Fig. 10: Locking Camshaft With Setting Bar 3418 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Centralize setting bar as follows:  

Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge, establish the gap at 
the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and 
cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same 
thickness, at the other end between the setting bar and cylinder head. 

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Remove injection pump sprocket mounting bolts -1-. 

 

2003 Volkswagen New Beetle GLS 

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