Volkswagen New Beetle. Manual - part 1307

 

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Volkswagen New Beetle. Manual - part 1307

 

 

Fig. 2: Exploded View Of Variable Intake Manifold 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

VARIABLE INTAKE MANIFOLD, DISASSEMBLING AND ASSEMBLING 

z

Remove variable intake manifold.  

z

Loosen connecting bolts.  

z

Disconnect upper and lower part of intake manifold. Separate both parts with light blows of a rubber 
headed hammer if necessary.  

z

Clean contact surface.  

z

Replace seal.  

z

Put upper and lower part of intake manifold together and tighten all connecting bolts hand-tight.  

z

Tighten all securing bolts in indicated sequence to 10 N.m. 

Fig. 3: Tightening Sequence Of Upper & Lower Intake Manifold Securing Bolts 

NOTE:

To avoid distortion of the variable intake manifold it must only be tightened in 
the described sequence:

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z

Install variable intake manifold.  

INJECTOR UNIT, SERVICING 

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Observe rules for cleanliness. See RULES FOR CLEANLINESS .  

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Always replace sealing and O-rings.  

1. 20 N.m plus an additional 1/4 turn (90°) 

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Always replace  

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Note sequence when loosening and tightening. See INJECTOR UNIT, REMOVING AND 
INSTALLING
 .  

2. Rocker shaft 

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With rocker lever  

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Removing and installing, See INJECTOR UNIT, REMOVING AND INSTALLING .  

3. Lock nut, 30 N.m  

4. Adjustment screw 

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Replace when installing a new injector unit or if worn  

z

Adjusting, see INJECTOR UNIT, REMOVING AND INSTALLING  

5. Unit injector 

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Check ball pin for wear, replace if necessary  

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Removing and installing, see INJECTOR UNIT, REMOVING AND INSTALLING  

6. O-ring 

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Replacing, See O-RINGS FOR INJECTOR UNIT, REMOVING AND INSTALLING  

7. O-ring 

z

Replacing, See O-RINGS FOR INJECTOR UNIT, REMOVING AND INSTALLING  

8. O-ring 

z

Replacing, See O-RINGS FOR INJECTOR UNIT, REMOVING AND INSTALLING  

9. Heat protection gasket 

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Always replace  

10. Circlip  

11. Cylinder head  

12. Scotch block  

13. 12 N.m plus an additional 3/4 turn (270°) 

z

Always replace  

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 4: Injector Unit Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

O-RINGS FOR INJECTOR UNIT, REMOVING AND INSTALLING 

Special tools and equipment 

z

T10056 Assembly sleeves Removing 

Fig. 5: Identifying T10056 Assembly Sleeves 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove injector unit, See INJECTOR UNIT, REMOVING AND INSTALLING .  

z

Carefully remove old O-rings from injector unit.  

Installing 

NOTE:

z

Always use assembly sleeves to install the O-rings. Otherwise the O-rings 
will be damaged.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Pull heat protection gasket off together with safety ring.  

z

Carefully clean contact surfaces for O-rings at injector unit.  

z

Install assembly sleeve T10056/1 on injector unit onto limit stop. 

Fig. 6: Installing Assembly Sleeve T10056/1 On Injector Unit Onto Limit Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Carefully slide upper thicker O-ring on assembly sleeve and in injector unit seat.  

z

Remove assembly sleeve.  

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Install assembly sleeve T10056/2 on injector unit onto limit stop.  

z

Carefully slide center thinner O-ring on assembly sleeve and in injector unit seat.  

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Remove assembly sleeve. 

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Gradual introduction of O-rings without different color identification. 
Observe correct application of the O-rings to the grooves: the ring 
thickness decreases towards the injector.  

z

Avoid rolling movements when sliding onto the O-rings. The O-rings must 
not be twisted in the injector unit seat.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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