Volkswagen New Beetle. Manual - part 1367

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1365  1366  1367  1368   ..

 

 

Volkswagen New Beetle. Manual - part 1367

 

 

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Diesel injection pump, servicing 

z

Observe Rules of cleanliness. See RULES FOR CLEANLINESS .  

z

Removing and installing Diesel injection pump. See DIESEL INJECTION PUMP, REMOVING AND 
INSTALLING
 .  

z

Dynamically checking and adjusting Diesel injection pump. See START OF INJECTION, 
DYNAMICALLY CHECKING AND ADJUSTING
 .  

1. 20 Nm (15 ft lb) + 1/4 turn (90 °) further 

{

Always replace  

2. Injection pump sprocket 

z

Removing. See DIESEL INJECTION PUMP, REMOVING AND INSTALLING .  

3. Nut 

z

for hub  

4. Union 

z

25 Nm (18 ft lb)  

z

for supply line  

z

from fuel filter  

5. Diesel injection pump 

z

with Quantity adjuster (metering)  

z

with Quantity adjuster -N146-  

z

with Modulating piston displacement sensor -G149-  

z

with Fuel temperature sensor  

6. Fuel shut off valve 

z

40 Nm (30 ft lb)  

7. Union 

z

for return line  

8. Return line 

z

to control valve/fuel filter  

9. 25 Nm (18 ft lb)  

10. Fuel injector lines 

NOTE:

The following list refers to Fig. 2 .

CAUTION: Do not loosen nut or basic setting of pump may change. This cannot 

be reset using normal workshop equipment.

 

2003 Volkswagen New Beetle GLS 

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

  

z

25 Nm (18 ft lb) 

„

Remove with 3035  

„

Always remove fuel line cluster as an assembly  

„

Do not bend, kink or alter shape  

11. Union 

z

45 Nm (33 ft lb)  

z

with pressure valve  

12. 25 Nm (18 ft lb)  

13. 3rd cylinder Fuel injector 

z

includes Needle lift sensor -G80-  

z

Removing and installing. See FUEL INJECTORS, REMOVING AND INSTALLING .  

z

Servicing. See FUEL INJECTORS, SERVICING .  

14. 20 Nm (15 ft lb)  

15. Retainer  

16. Mounting  

17. Heat shield 

{

Always replace  

18. 10 Nm (7 ft lb)  

19. Cold Start injector -N108- 

z

Checking. See FUNCTION 03: OUTPUT DIAGNOSTIC TEST MODE, PERFORMING .  

20. Strainer  

21. O-ring 

{

Always replace  

22. 25 Nm (18 ft lb)  

23. Timing cover 

{

Replace O-ring if leaking. See DIESEL INJECTION PUMP TIMING COVER O-RING, 
REPLACING
 .  

24. Sleeve 

z

with nut  

25. Assembly bracket 

z

Removing and installing. See ENGINE, DISASSEMBLING AND ASSEMBLING .  

26. 25 Nm (18 ft lb) 

 

2003 Volkswagen New Beetle GLS 

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

  

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

  

 

 

 

 

 

 

 

Content   ..  1365  1366  1367  1368   ..