Volkswagen New Beetle. Manual - part 1300

 

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Volkswagen New Beetle. Manual - part 1300

 

 

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

Fig. 4: Identifying Special Tools (1 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 5: Identifying Special Tools (2 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DIESEL INJECTION PUMP, REMOVING 

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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. 

WARNING:

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

NOTE:

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

 

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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Turn crankshaft to cyl. 1 TDC (arrow). 

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

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Turn crankshaft to cyl. 1 TDC (arrow) 

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for automatic transmission 

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

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-). 

 

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

Fig. 8: Installing 2068 A TDC Gauge On Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

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.  

Fig. 9: Installing Adjustment Device On Flywheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

  

 

 

 

 

 

 

 

Content   ..  1298  1299  1300  1301   ..