Volkswagen New Beetle. Manual - part 1312

 

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Volkswagen New Beetle. Manual - part 1312

 

 

Fig. 2: Identifying Diesel Injection Pump Components (1.9L ALH) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Intake manifold change-over valve, servicing 

The intake manifold change-over flap is closed for approx. 3 seconds when engine stops and then opens again 
which reduces the stop jolt. 

Intake manifold change-over valve, checking. See CHANGE-OVER VALVE FOR INTAKE MANIFOLD 
FLAP -N239-, CHECKING
 . 

1. Intake manifold  

2. 10 Nm (7 ft lb)  

3. O-ring 

{

Always replace  

4. Connecting flange 

z

with EGR valve and change-over flap  

5. 10 Nm (7 ft lb)  

6. Gasket 

{

Always replace  

7. Connecting line 

z

to exhaust manifold  

8. 25 Nm (18 ft lb)  

NOTE:

The following list refers to Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

9. Vacuum control element  

10. Intake Manifold Flap Change-over valve -N239- 

z

Checking. See CHANGE-OVER VALVE FOR INTAKE MANIFOLD FLAP -N239-, 
CHECKING
 .  

11. Vacuum supply 

z

from vacuum pump  

Fig. 3: Identifying Intake Manifold Change-Over Valve Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Diesel injection pump, removing and installing 

Special tools 

z

3098 Lever camber adjustment  

z

V159 Pin wrench  

z

3359 Rig pin  

z

VAG1318/10 Adapter  

z

3418 Adjustment guide  

z

VAG1390 Hand vacuum pump 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

Fig. 4: Identifying Special Tools For Removing & Installing Diesel Injection Pump (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools, continued 

z

2068A Adj. gauge TDC  

z

3035 Injector line wrench  

z

VAG1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb) or equivalent 

Fig. 5: Identifying Special Tools For Removing & Installing Diesel Injection Pump (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Diesel injection pump, removing 

WARNING:

Fire hazard! Do NOT have anything in the area that can ignite Diesel fuel.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

z

Unbolt all fuel lines at fuel pump.  

z

Cover openings with a clean cloth.  

z

Remove connecting line between charge air cooler and intake manifold.  

z

Remove upper toothed belt guard and valve cover.  

z

Remove vacuum pump for brake servo.  

z

Turn crankshaft to cyl. 1 TDC (arrow). 

Fig. 6: Turning Crankshaft To Cyl. 1 TDC (Manual Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft to cyl. 1 TDC (arrow) 

Fig. 7: Turning Crankshaft To Cyl. 1 TDC (Automatic Transmission) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Use 3035 tubing wrench to loosen the high pressure fuel lines.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

 

 

 

 

 

 

 

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