Volkswagen New Beetle. Manual - part 1305

Fig. 28: Identifying 3035 Injector Line Wrench 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

NOTE:

Faulty injectors can cause the following malfunctions: 

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Misfiring  

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Knocking in one or more cylinders  

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Engine over-heating  

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Loss of power  

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Excessive black exhaust smoke  

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Higher fuel consumption  

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Excessive blue smoke when starting with cold engine 

NOTE:

Faulty injectors can be located by loosening the high pressure line connection 
on each injector in turn with the engine running at a fast idle. If engine speed 
remains constant after loosening a line connection, this would indicate a faulty 

 

2003 Volkswagen New Beetle GLS 

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

  

FUEL INJECTORS, REMOVING 

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Remove injection lines using 3035 tubing wrench. 

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Remove mounting nut, retainer and pull out fuel injector.  

FUEL INJECTORS, INSTALLING 

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Insert fuel injector.  

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Make sure mount is seated correctly in cylinder head and install retainer. 

Tightening torques:  

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Injection lines = 25 Nm (18 ft lb)  

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Retainer screw = 20 Nm (15 ft lb)  

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Erase DTC memory and set the readiness.  

FUEL INJECTORS, SERVICING 

The AHL engine is equipped with dual spring design injectors. Fuel is injected in 2 stages. These fuel injectors 
must be replaced if malfunctions occur because neither servicing nor pressure adjustment is possible. 

Special tools 

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VAG1322 Injector test stand with VAG1322/2 pressure line  

Checking requirements 

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Pressure gauge on  

FUEL INJECTION PRESSURE, CHECKING 

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Connect fuel injector to fuel injector test stand. 

injector.

NOTE:

Always remove fuel lines in a complete set. Do not alter line shape.

NOTE:

Always replace heat shield between cylinder head and fuel injectors.

WARNING:

When testing fuel injectors, make sure that the stream of fuel does not 
contact your hands. The high pressure fuel delivery can penetrate skin 
which could result in severe injuries.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 29: Identifying V.A.G. 1322 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

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Move pump lever down slowly. When spray begins, record opening pressure for deviations from 
specification replace injector. 

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Specification (new injectors): 220 - 230 bar  

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Wear limit: 200 bar  

FUEL INJECTORS, LEAK-CHECKING 

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Pressure gauge on 

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Move pump lever down slowly and maintain a pressure of approx. 150 bar for 10 seconds.  

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No fuel should leak from the nozzle tip. 

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If any injector(s) leak, replace. 

 

2003 Volkswagen New Beetle GLS 

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

  

DIESEL INJECTION PUMP TIMING COVER O-RING, REPLACING

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Place a clean cloth under the Diesel injection pump.  

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Remove cover screws -1- with commercially available tool for Torx socket head screws, e.g. Hazet 2115-
T30.  

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Remove cover -2- and clean thoroughly.  

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Replace O-ring -3- and install cover using existing shims -4-.  

Fig. 30: Diesel Injection Pump Timing Cover Components 
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