Volkswagen New Beetle. Manual - part 1306

 

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Volkswagen New Beetle. Manual - part 1306

 

 

1998-2004 ENGINE

Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW 

DIESEL DIRECT INJECTION SYSTEM, SERVICING 

The diesel direct injection system control module is equipped with a fault memory. Check the fault memory 
before/after performing repairs or adjustments, See ENGINE CONTROL MODULE (DTC) MEMORY, 
READING AND ERASING
 . 

Safety precautions, See SAFETY PRECAUTIONS . 

Rules for cleanliness, See RULES FOR CLEANLINESS . 

SAFETY PRECAUTIONS 

To prevent injuries to persons and/or damage to the fuel injection and glow plug system, observe the following: 

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The ignition must be switched off before connecting or disconnecting the glow plug system or injection 
system wiring or tester cables.  

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If the engine is to be turned over at starter speed without starting, e.g. for compression pressure test, 
separate connection for injector unit at cylinder head.  

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Before disconnecting the battery Ground (GND) strap obtain the code for radios with anti-theft coding.  

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Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the 
diesel direct injection system control module could be damaged.  

Observe the following if test and measuring instruments are required during a road test: 

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Test and measuring instruments must be secured to rear seat and operated by an assistant from this 
location.  

If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in an 
accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is 
triggered. 

RULES FOR CLEANLINESS 

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

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Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

When working on the fuel supply/injection system, pay careful attention to the following rules:

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Thoroughly clean all unions and adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

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Carefully cover opened components or seal if repairs cannot be carried out immediately.  

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Only install clean components: 

Only unpack replacement parts immediately prior to installation. 

Do not use parts that have been stored loose (e.g. in tool boxes etc.). 

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When system is open: 

Do not work with compressed air if this can be avoided. 

Do not move vehicle unless absolutely necessary. 

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Make sure that no diesel fuel runs onto the coolant hoses. Immediately clean any accidental hose 
contamination. Affected hoses must be replaced.  

DIESEL DIRECT INJECTION SYSTEM, COMPONENT LOCATIONS OVERVIEW 

A. Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection) -F47- 

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In footwell on brake pedal  

B. Brake light switch -F- 

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In footwell on brake pedal  

C. Throttle Position (TP) sensor -G79- 

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In footwell on accelerator pedal  

1. Engine Coolant Temperature (ECT) sensor -G62- 

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For engine control module.  

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With Engine Coolant Temperature (ECT) Sensor -G2-  

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If necessary, release pressure in cooling system before removing.  

2. Intake manifold flap 

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With Motor for intake flap -V157-  

3. EGR Vacuum Regulator Solenoid Valve -N18-  

4. Positive Crankcase Ventilation (PCV) Heating Element -N79-

NOTE:

The following list refers to items in Fig. 1 . The components A to C are not 
shown on the illustration.

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

5. Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- 

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With Barometric Pressure (BARO) Sensor -F96-  

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Replacing, See ENGINE CONTROL MODULE  

6. Intake Manifold Runner Control (IMRC) Valve -N316-  

7. Exhaust Gas Recirculation (EGR) Cooler Switch-over Valve -N345-  

8. Wastegate Bypass Regulator Valve -N75-  

9. Mass Air Flow (MAF) Sensor -G70-  

10. Connector 

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For injector unit (-N240- to -243-)  

11. Engine Speed (RPM) Sensor -G28-  

12. Fuel Temperature Sensor -G81-  

13. Connector 

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For Engine Speed (RPM) Sensor -G28-  

14. Connector 

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For Camshaft Position (CMP) Sensor -G40-,  

15. Camshaft Position (CMP) Sensor -G40- 

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For camshaft position  

16. Manifold Absolute Pressure (MAP) Sensor -G71- with Intake Air Temperature (IAT) Sensor -G72-

Fig. 1: Diesel Direct Injection System Component Locations Overview 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

VARIABLE INTAKE MANIFOLD, SERVICING 

The variable intake manifold is switched depending on engine speed and accelerator pedal position. 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

1. 22 N.m  

2. Connecting pipe 

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From cooler for exhaust gas recirculation. See EXHAUST GAS RECIRCULATION SYSTEM 
COMPONENTS, REMOVING AND INSTALLING
 .  

3. Seal 

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Always replace  

4. Intake manifold upper part  

5. O-ring 

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Always replace  

6. EGR Vacuum Regulator Solenoid Valve -N18-  

7. 10 N.m  

8. O-ring 

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Always replace  

9. Intake manifold flap 

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With Motor for intake flap -V157-  

10. 10 N.m  

11. Seal 

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Always replace  

12. Seal 

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Always replace.  

13. Intake manifold lower part 

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with selector shaft  

14. 10 N.m 

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Note tightening sequence. See VARIABLE INTAKE MANIFOLD, DISASSEMBLING AND 
ASSEMBLING
  

15. Bracket  

16. 10 N.m  

17. Vacuum actuator  

18. Vacuum hose  

19. Intake Manifold Runner Control (IMRC) Valve -N316- 

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Vacuum hoses for connection diagram. See VACUUM HOSE CONNECTION DIAGRAM 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

 

 

 

 

 

 

 

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