Volkswagen New Beetle. Manual - part 1302

 

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Volkswagen New Beetle. Manual - part 1302

 

 

Fig. 14: Installing Injection Pump Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Align injection pump sprocket to central position in elongated holes.  

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Lock injection pump sprocket using 3359 pin.  

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Loosen camshaft sprocket mounting bolt a half turn.  

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Place a drift through hole in rear of toothed belt guard and release camshaft sprocket from camshaft taper 
with blow from hammer. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 15: Installing Drift Through Hole In Rear Of Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove camshaft sprocket.  

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Check whether TDC mark on flywheel and reference mark are aligned.  

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Place tooth belt on injection pump sprocket and tensioning roller.  

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Install camshaft sprocket into toothed belt and secure sprocket such that the camshaft can still turn.  

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Tension toothed belt using pin wrench (e.g. Matra V159) on eccentric and turning clockwise until notch 
and raised mark align (arrows). 

Fig. 16: Tightening Lock Nut On Tensioning Roller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

Make sure retaining hook is correctly seated in toothed belt guard.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 17: Installing Timing Belt Tensioner Retaining Hook 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Tighten mounting nut. 

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20 Nm (15 ft lb)  

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Check TDC mark on flywheel again.  

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Tighten new mounting bolts for injection pump sprocket. 

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20 Nm (15 ft lb)  

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Tighten camshaft sprocket mounting bolt. 

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45 Nm (33 ft lb)  

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Remove 3359 locking pin.  

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Remove 3418 setting bar from camshaft.  

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Turn crankshaft two rotations in direction of engine rotation until crankshaft is set to cyl. 1 TDC again.  

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Reconnect injection lines, fuel supply line and electrical wiring. 

NOTE:

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After dynamically checking the injection timing, tighten the bolts an 
additional 1/4 turn (90°).  

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The mounting bolts (stretch design) may only be used once.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fill injection pump with Diesel fuel as follows.

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Screw 1318/10 adapter into injection pump return/supply opening.  

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Connect VAG1390 hand vacuum pump to adapter using approx. 40 inches of transparent plastic hose. 

 

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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