Volkswagen New Beetle. Manual - part 1363

 

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Volkswagen New Beetle. Manual - part 1363

 

 

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.  

z

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

  

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

z

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. 

z

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

z

Remove assembly sleeve.  

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

z

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

INJECTOR UNIT, REMOVING AND INSTALLING 

Special tools and equipment 

z

VW 387 Universal dial gauge bracket  

z

3410 Socket  

 

2003 Volkswagen New Beetle GLS 

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

  

z

T10054 Socket  

z

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 

z

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

z

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

z

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

z

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

z

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

  

 

 

 

 

 

 

 

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