Volkswagen New Beetle. Manual - part 1362

 

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Volkswagen New Beetle. Manual - part 1362

 

 

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

  

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

VARIABLE INTAKE MANIFOLD, DISASSEMBLING AND ASSEMBLING 

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Remove variable intake manifold.  

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Loosen connecting bolts.  

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

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Clean contact surface.  

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Replace seal.  

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

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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.

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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  

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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 

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

8. O-ring 

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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

  

 

 

 

 

 

 

 

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