Volkswagen New Beetle. Manual - part 1299

 

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Volkswagen New Beetle. Manual - part 1299

 

 

14. 20 Nm (15 ft lb)  

15. Retainer  

16. Mounting  

17. Heat shield 

z

Always replace  

18. 10 Nm (7 ft lb)  

19. Cold Start injector -N108-, see OUTPUT DIAGNOSTIC TEST MODE (DTM) (FUNCTION 03).  

20. Strainer  

21. O-ring 

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Always replace  

22. 25 Nm (18 ft lb)  

23. Timing cover 

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Replace O-ring if leaking. See DIESEL INJECTION PUMP TIMING COVER O-RING, 
REPLACING
 .  

24. Sleeve 

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with nut  

25. Assembly bracket 

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Removing and installing. See 1.9L4-CYLINDER TDI ENGINE .  

26. 25 Nm (18 ft lb)  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 2: Diesel Injection Pump Components 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

INTAKE MANIFOLD CHANGE-OVER VALVE, SERVICING 

The intake manifold change-over flap is closed for approx. 3 seconds when engine stops and then opens again 
which reduces the stop jolt. 

Intake manifold change-over valve.  

 

2003 Volkswagen New Beetle GLS 

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

  

1. Intake manifold  

2. 10 Nm (7 ft lb)  

3. O-ring 

z

Always replace  

4. Connecting flange 

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with EGR valve and change-over flap  

5. 10 Nm (7 ft lb)  

6. Gasket 

z

Always replace  

7. Connecting line 

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to exhaust manifold  

8. 25 Nm (18 ft lb)  

9. Vacuum control element  

10. Intake Manifold Flap Change-over valve -N239- 

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Checking  

11. Vacuum supply 

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from vacuum pump  

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 3: Intake Manifold Change-Over Valve Components 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DIESEL INJECTION PUMP, REMOVING AND INSTALLING 

Special Tools 

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3098 Lever camber adjustment  

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V159 Pin wrench  

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3359 Rig pin  

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VAG1318/10 Adapter  

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3418 Adjustment guide  

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VAG1390 Hand vacuum pump  

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2068A Adj. gauge TDC  

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3035 Injector line wrench  

 

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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