Volkswagen New Beetle. Manual - part 1308

 

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Volkswagen New Beetle. Manual - part 1308

 

 

Fig. 7: Installing Assembly Sleeve T10056/2 On Injector Unit Onto Limit Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install assembly sleeve T10056/3 on injector unit onto limit stop. 

Fig. 8: Installing Assembly Sleeve T10056/3 On Injector Unit Onto Limit Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

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Remove assembly sleeve.  

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Slide on a new heat protection gasket together with safety ring.  

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

INJECTOR UNIT, REMOVING AND INSTALLING 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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3410 Socket  

 

2003 Volkswagen New Beetle GLS 

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

  

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T10054 Socket  

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T10055 Puller  

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V.A.G1331 Torque wrench (5 to 50 N.m)  

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Dial gauge 

Fig. 9: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove toothed belt upper part and cylinder head cover. See CYLINDER HEAD, REMOVING AND 
INSTALLING
 .  

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Turn crankshaft until cam pair of injector unit to be installed/removed points evenly upward.  

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Loosen adjustment screw lock nuts -1- and unscrew adjustment screws until respective locker lever lies 
on injector unit spring. See Fig. 10 .  

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Loosen securing bolts -2- for rocker shaft (starting on outside and working inward) with socket insert 
3410 and take rocker shaft off.  

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Loosen scotch block securing bolt -3- with socket insert T10054 and remove scotch block. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 10: Removing Scotch Block 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Pry up unit injector connector with a screwdriver. To avoid canting support other side of connector with 
light finger pressure. 

Fig. 11: Prying Up Unit Injector Connector With Screwdriver 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Insert puller instead of scotch block into slot of injector unit.  

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Pull injector unit off by knocking it outward of cylinder head seat. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 12: Removing Injector Unit 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

If the old injector unit is installed, the O-rings and heat protection gasket must be replaced, See O-RINGS FOR 
INJECTOR UNIT, REMOVING AND INSTALLING
 . 

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Check correct seat of three O-rings, heat protection gasket and safety ring before installing injector unit. 

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Oil O-rings and insert injector unit with greatest care in cylinder head seat.  

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Install injector unit into cylinder head seat onto limit stop by pressing it evenly.  

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Insert scotch block into slot of injector unit. 

Align injector unit as follows: 

NOTE:

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If a new injector unit is installed, the respective adjustment screw in the 
rocker lever must also be replaced.  

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For every repair which requires an adjustment of the injector unit, the 
locker lever adjustment screw and the injector unit ball pin must be 
cleaned and checked for wear. If worn replace the ball pin and adjustment 
screw.  

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New injector units are supplied with O-rings and heat protection gasket.  

NOTE:

The O-rings must not be twisted.

NOTE:

If the injector unit is not positioned at right angles to the scotch block the 
securing bolt could loosen and cause damage to the injector unit or the 
cylinder head.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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