Volkswagen New Beetle. Manual - part 1301

 

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Volkswagen New Beetle. Manual - part 1301

 

 

All vehicles 

z

Lock camshaft with setting bar. 

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

z

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. 

z

Remove injection pump sprocket mounting bolts -1-. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 11: Injection Pump Sprocket Mounting Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

z

Remove tensioning roller nut.  

z

Relieve tooth belt tension then remove camshaft and injection pump sprockets.  

z

Disconnect Quantity adjuster harness connector and unclip connector from retainer.  

z

Remove mounting bolts from assembly bracket -1-. 

CAUTION: Do not loosen hub nut -2- for ANY reason. Otherwise, the Diesel 

injection pump basic setting will be altered and cannot be reset with 
normal workshop equipment.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 12: Assembly Bracket Mounting Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

z

Remove bolt from rear support (arrow). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Diesel Injection Pump Rear Support Bolt 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

z

Remove Diesel injection pump.  

DIESEL INJECTION PUMP, INSTALLING 

z

Insert injection pump into assembly bracket then tighten mounting bolt on rear support with conical nut 
first.  

z

Insert front mounting bolts. 

z

tighten to 25 Nm (18 ft lb)  

z

Install new bolts (arrows) to mount injection pump sprocket to hub but do not tighten. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1299  1300  1301  1302   ..