Volkswagen New Beetle. Manual - part 1364

 

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Volkswagen New Beetle. Manual - part 1364

 

 

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

z

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. 

z

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

z

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
 . 

z

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

z

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

z

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

z

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.  

z

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.  

z

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

  

z

Screw new securing bolt into scotch block until injector unit can still be turned lightly.  

z

Align injector unit at right angles to bearing pedestals of camshaft.  

z

Use a vernier gauge (measuring range at least 400 mm) and check dimension "a" from cylinder head 
outer edge to round surface of injector unit. See Fig. 13 and DIMENSION "A" FROM CYLINDER 
HEAD OUTER EDGE TO ROUND SURFACE OF INJECTOR UNIT
 . 

DIMENSION "A" FROM CYLINDER HEAD OUTER EDGE TO ROUND SURFACE OF 
INJECTOR UNIT
 

Fig. 13: Checking Dimension "a" From Cylinder Head Outer Edge To Round Surface Of Injector 
Unit
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Align injector unit again, if necessary, and tighten securing bolt as follows:  

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Tighten securing bolt to 12 N.m plus an additional 270° (3/4 turn). Turning further can be done in several 
stages.  

z

Position rocker shaft and tighten new securing bolts as follows: 

Cylinder

Dimension "a"

1

333.0 +/-0.8 mm

2

245.0 +/-0.8 mm

3

153.6 +/-0.8 mm

4

65.6 +/-0.8 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 14: Positioning Rocker Shaft And Tightening New Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Tighten inner bolts -2- first and then outer screws -1- hand-tight. Then in same sequence to: 

20 N.m and 90°(1/4 turn further). 

z

Install a dial gauge on injector unit adjustment screw as shown in Fig. 15 . 

Fig. 15: Installing Dial Gauge On Injector Unit Adjustment Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Turn crankshaft in engine direction of rotation, until rocker lever roller is positioned on actuating cam 
point. 

Roller side (arrow -A-) is at highest point 

Dial gauge (arrow -B-) is at lowest point 

z

Remove dial gauge.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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