Volkswagen New Beetle. Manual - part 1371

 

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Volkswagen New Beetle. Manual - part 1371

 

 

Example: 

Value 90 in Display zone 9 (B) corresponds to a numerical range from 35 to 74 in Display zone 2 (A). 

If Start of injection is outside specification, adjust as follows: 

z

Remove connecting line between charge air cooler and intake manifold.  

z

Remove upper toothed belt guard.  

z

Loosen two injection pump sprocket mounting bolts -1-. 

Fig. 25: Locating Injection Pump Sprocket Mounting Bolts & Hub Nut 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Place 22 mm box wrench onto hub nut -2- to counter-hold pump shaft. DO NOT loosen hub nut.  

z

Loosen 3rd injection pump sprocket mounting bolt and slightly turn pump shaft  

z

Left = advance Start of injection  

z

Right = retard Start of injection  

z

Tighten new mounting bolts for injection pump sprocket. 

z

20 Nm (15 ft lb)  

NOTE:

If, when checking Start of injection, the specifications are within zone -C-, no 
adjustment is required. After repairs, e.g. removing and installing injection 
pump or adjusting timing, Start of injection must be set to the mean value 
(dashed line) in zone -C-.

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

  

If injection pump has not previously been removed and installed

z

Screw in new injection pump sprocket mounting bolts one after the other.  

z

Observe values in zone 2 and adjust again, if necessary, until the mean value for specification zone -C- is 
displayed.  

z

Tighten injection pump sprockets 1/ 4 turn (90 °) additional.  

z

Press --> button.  

Display will appear as shown: 

Fig. 26: Scan Tool Display - Start Of Injection (5 Of 5) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press -0- and -6- buttons to select Function 06: "End output".  

z

Press -Q- button to enter input.  

z

Erase DTC memory. See DTC MEMORY, ERASING . Set the readiness code. See READINESS 
CODE, SETTING
 .  

Fuel injectors, removing and installing 

Special tools 

z

VAG1331 Torque wrench (5 to 50 Nm) or equivalent 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 27: Identifying VAG 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

3035 Injector line wrench 

Fig. 28: Identifying 3035 Injector Line Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

Faulty injectors can cause the following malfunctions: 

z

Misfiring  

z

Knocking in one or more cylinders  

z

Engine over-heating  

z

Loss of power  

z

Excessive black exhaust smoke  

z

Higher fuel consumption  

z

Excessive blue smoke when starting with cold engine 

 

2003 Volkswagen New Beetle GLS 

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

  

Fuel Injectors, removing 

z

Remove injection lines using 3035 tubing wrench.  

z

Remove mounting nut, retainer and pull out fuel injector.  

Fuel injectors, installing 

z

Insert fuel injector.  

z

Make sure mount is seated correctly in cylinder head and install retainer.  

Tightening torques: 

z

Injection lines = 25 Nm (18 ft lb)  

z

Retainer screw = 20 Nm (15 ft lb)  

z

Erase DTC memory. See DTC MEMORY, ERASING . Set the readiness code. See READINESS 
CODE, SETTING
 .  

Fuel injectors, servicing 

The AHL engine is equipped with dual spring design injectors. Fuel is injected in 2 stages. These fuel injectors 
must be replaced if malfunctions occur because neither servicing nor pressure adjustment is possible. 

Special tools 

z

VAG1322 Injector test stand with VAG1322/2 pressure line  

Checking requirements 

z

Pressure gauge on  

Fuel injection pressure, checking 

NOTE:

Faulty injectors can be located by loosening the high pressure line connection 
on each injector in turn with the engine running at a fast idle. If engine speed 
remains constant after loosening a line connection, this would indicate a faulty 
injector.

NOTE:

Always remove fuel lines in a complete set. Do not alter line shape.

NOTE:

Always replace heat shield between cylinder head and fuel injectors.

WARNING:

When testing fuel injectors, make sure that the stream of fuel does not 
contact your hands. The high pressure fuel delivery can penetrate skin 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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