Volkswagen New Beetle. Manual - part 1369

 

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Volkswagen New Beetle. Manual - part 1369

 

 

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

z

Remove tensioning roller nut.  

z

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

z

Disconnect Quantity adjuster harness connector and unclip connector from retainer.  

z

Remove mounting bolts from assembly bracket -1-. 

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

z

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. 

z

Remove Diesel injection pump.  

Diesel injection pump, installing 

z

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

z

Insert front mounting bolts.  

z

tighten to 25 Nm (18 ft lb)  

z

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. 

z

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

  

z

Lock injection pump sprocket using 3359 pin.  

z

Loosen camshaft sprocket mounting bolt a half turn.  

z

Place a drift through hole in rear of toothed belt guard and release camshaft sprocket from camshaft taper 
with blow from hammer. 

Fig. 15: Placing Drift Through Hole In Rear Of Toothed Belt Guard & Releasing Camshaft 
Sprocket Using Hammer
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove camshaft sprocket.  

z

Check whether TDC mark on flywheel and reference mark are aligned.  

z

Place tooth belt on injection pump sprocket and tensioning roller.  

z

Install camshaft sprocket into toothed belt and secure sprocket such that the camshaft can still turn.  

z

Tension toothed belt using pin wrench (e.g. Matra V159) on eccentric and turning clockwise until notch 
and raised mark align (arrows). 

Fig. 16: Tensioning Toothed Belt Using Pin Wrench & Aligning Notch & Raised Mark 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 17: Ensuring Retaining Hook Is Correctly Seated In Toothed Belt Guard 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Tighten mounting nut. 

z

20 Nm (15 ft lb)  

z

Check TDC mark on flywheel again.  

z

Tighten new mounting bolts for injection pump sprocket. 

z

20 Nm (15 ft lb)  

z

Tighten camshaft sprocket mounting bolt. 

z

45 Nm (33 ft lb)  

z

Remove 3359 locking pin.  

z

Remove 3418 setting bar from camshaft.  

z

Turn crankshaft two rotations in direction of engine rotation until crankshaft is set to cyl. 1 TDC again.  

z

Reconnect injection lines, fuel supply line and electrical wiring.  

Fill injection pump with Diesel fuel as follows. 

z

Screw 1318/10 adapter into injection pump return/supply opening.  

z

Connect VAG1390 hand vacuum pump to adapter using approx. 40 inches of transparent plastic hose. 

NOTE:

Make sure retaining hook is correctly seated in toothed belt guard.

NOTE:

z

After dynamically checking the injection timing, tighten the bolts an 
additional 1/4 turn (90 °).  

z

The mounting bolts (stretch design) may only be used once.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1367  1368  1369  1370   ..