Volkswagen New Beetle. Manual - part 1298

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Place removed parts on a clean surface and cover over but do NOT use fluffy cloths (lint contamination)! 

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Carefully cover opened components or seal over, if the repair cannot be carried out immediately.  

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Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose e.g. in tool boxes.  

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When the system is open: Do not work with compressed air if it can be avoided. Do not move the vehicle 
unless absolutely necessary.  

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Make sure that no Diesel fuel runs onto the coolant hoses. Clean contaminated hoses immediately. 
Always replace affected hoses.  

DIESEL INJECTION SYSTEM, COMPONENT LOCATIONS OVERVIEW 

Components A, B and C are not shown in Fig. 1 . 

A. Brake vacuum vent valve switch for cruise control/diesel fuel injection -F47- and Brake light switch -

F63- 

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Together in one housing in footwell on brake pedal  

B. Throttle Position (TP) Sensor -G79- 

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in footwell on throttle pedal. See THROTTLE POSITION SENSOR, CHECKING .  

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In case of malfunction it is displayed as Throttle Position sensor -G69-  

C. Clutch vacuum vent valve switch -F36- 

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in footwell on throttle pedal  

1. EGR Valve  

2. Change-over valve for intake manifold flap -N239-  

3. Needle Lift Sensor -G80-  

4. EGR vacuum regulator solenoid valve -N18-  

5. Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- 

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with Barometric Pressure (BARO) sensor -F96-  

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tighten nut for ground wire (located forward of ECM) to 9 +/- 1 Nm (80 +/- 9 in. lb)  

6. Wastegate bypass regulator valve -N75-  

7. Mass Air Flow (MAF) Sensor -G70-  

8. Engine Coolant Temperature (ECT) Sensor -G62-  

9. Engine speed (RPM) sensor -G28-  

10. Harness connector 

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for Needle lift sensor -G80-  

11. Harness connector 

NOTE:

The following list refers to items in Fig. 1 .

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

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for Engine Speed sensor- G28-  

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for Cold Start injector -N108-  

12. Harness connector 

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for Fuel temperature sensor -G81-  

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for Quantity adjuster -N146-  

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for Modulating piston displacement sensor -G149-  

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for Fuel shut-off valve -N109-  

13. Cold start injector -N108-  

14. Fuel shut-off valve -N109-  

15. Injection pump Quantity adjuster -N146- 

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with Fuel temperature sensor  

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with Quantity adjuster -N146-  

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with Modulating piston displacement sensor -G149-  

16. Manifold Absolute Pressure (MAP) sensor -G71- and Intake Air Temperature (IAT) sensor -G72-

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 1: Diesel Injection System Components 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DIESEL INJECTION PUMP, SERVICING 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. 20 Nm (15 ft lb) + 1/4 turn (90°) further 

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Always replace  

2. Injection pump sprocket  

3. Nut 

4. Union 

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25 Nm (18 ft lb)  

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for supply line  

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from fuel filter  

5. Diesel injection pump 

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with Quantity adjuster (metering)  

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with Quantity adjuster -N146-  

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with Modulating piston displacement sensor -G149-  

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with Fuel temperature sensor  

6. Fuel shut off valve 

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40 Nm (30 ft lb)  

7. Union 

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for return line  

8. Return line 

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to control valve/fuel filter  

9. 25 Nm (18 ft lb)  

10. Fuel injector lines 

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25 Nm (18 ft lb) 

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Remove with 3035  

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Always remove fuel line cluster as an assembly  

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Do not bend, kink or alter shape  

11. Union 

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45 Nm (33 ft lb)  

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with pressure valve  

12. 25 Nm (18 ft lb)  

13. 3rd cylinder Fuel injector 

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includes Needle lift sensor -G80-  

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Removing and installing, see FUEL INJECTORS, REMOVING AND INSTALLING .  

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Servicing, see FUEL INJECTORS, SERVICING . 

CAUTION: Do not loosen nut or basic setting of pump may change. This cannot 

be reset using normal workshop equipment.

 

2003 Volkswagen New Beetle GLS 

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