Volkswagen New Beetle. Manual - part 1313

 

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Volkswagen New Beetle. Manual - part 1313

 

 

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for Automatic transmission  

With engine removed 

Vehicles with manual transmission 

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Install 2068 A TDC gauge as shown.  

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Set adjustment device to 96 mm (arrow -A-). 

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Left-hand notch of the vernier scale is the reference point.  

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Turn crankshaft until flywheel TDC marking aligns with point of setting device (arrow -B-). 

Fig. 8: Setting Adjustment Device & Turning Crankshaft Until Flywheel TDC Marking Aligns 
With Setting Device (Manual Transmission)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with automatic transmission 

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Install 2068 A TDC gauge as shown.  

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Set adjustment device to 30 mm (arrow -A-). 

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Left-hand notch of the vernier scale is the reference point.  

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Turn crankshaft until TDC marking on drive plate aligns with point of setting device (arrow -B-). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 9: Setting Adjustment Device & Turning Crankshaft Until Flywheel TDC Marking Aligns With 
Setting Device (Automatic Transmission)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

All vehicles 

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Lock camshaft with setting bar. 

Fig. 10: Locking Camshaft With Setting Bar 3418 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Centralize setting bar as follows:  

Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge, establish the gap at 
the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and 
cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same 
thickness, at the other end between the setting bar and cylinder head. 

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Remove injection pump sprocket mounting bolts -1-. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 11: Removing Injection Pump Sprocket Mounting Bolts & Hub Nut 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove tensioning roller nut.  

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Relieve tooth belt tension then remove camshaft and injection pump sprockets.  

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Disconnect Quantity adjuster harness connector and unclip connector from retainer.  

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Remove mounting bolts from assembly bracket -1-. 

Fig. 12: Removing Mounting Bolts From Assembly Bracket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove bolt from rear support (arrow). 

CAUTION: Do not loosen hub nut -2- for ANY reason. Otherwise, the Diesel injection 

pump basic setting will be altered and cannot be reset with normal 
workshop equipment.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Removing Bolt From Rear Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove Diesel injection pump.  

Diesel injection pump, installing 

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Insert injection pump into assembly bracket then tighten mounting bolt on rear support with conical nut 
first.  

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Insert front mounting bolts.  

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tighten to 25 Nm (18 ft lb)  

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Install new bolts (arrows) to mount injection pump sprocket to hub but do not tighten. 

Fig. 14: Installing New Bolts To Mount Injection Pump Sprocket To Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Align injection pump sprocket to central position in elongated holes. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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