Volkswagen New Beetle. Manual - part 1372

 

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Volkswagen New Beetle. Manual - part 1372

 

 

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Connect fuel injector to fuel injector test stand. 

Fig. 29: Connecting Fuel Injector To Fuel Injector Test Stand 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Move pump lever down slowly. When spray begins, record opening pressure for deviations from 
specification replace injector.  

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Specification (new injectors): 220 - 230 bar  

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Wear limit: 200 bar  

Fuel injectors, leak-checking 

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Pressure gauge on  

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Move pump lever down slowly and maintain a pressure of approx. 150 bar for 10 seconds.  

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No fuel should leak from the nozzle tip.  

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If any injector(s) leak, replace.  

Diesel injection pump timing cover O-ring, replacing 

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Place a clean cloth under the Diesel injection pump.  

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Remove cover screws -1- with commercially available tool for Torx socket head screws, e.g. Hazet 2115 
-T30.  

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Remove cover -2- and clean thoroughly.  

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Replace O-ring -3- and install cover using existing shims -4-. 

which could result in severe injuries.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 30: Removing Injection Pump Timing Cover Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

DIESEL FUEL INJECTION COMPONENTS AND FUNCTIONS, CHECKING 

Diesel injection system Voltage supply, checking 

Special tools 

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VAG1598/22 Test Box (MY 1999)  

WARNING:

Make sure that no electronic components are destroyed during testing by 
observing the following: 

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Switch the Fluke 83 multimeter to the appropriate units range before 
connecting measuring cables!  

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Always observe checking requirements!  

NOTE:

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Use the Fluke 83 multimeter and VAG1527B Voltage tester for electrical 
checking.  

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Specifications are valid for an ambient temperature range from: 0 to + 40 °
C (+32 to 104 °F).  

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If measured values deviate only slightly from the specifications, clean the 
sockets and plugs on the tester and measuring cables, then repeat check. 
Before replacing a component, check wiring and connections. In cases of 
specifications less than 10 ohm repeat the resistance measurement on the 
component.  

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To connect a tester to the Test Box, use jumper wires from the VW 1594 
adapter kit.  

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The terminal numbers of the plugs and the socket numbers on the Test 
Box are identical.  

 

2003 Volkswagen New Beetle GLS 

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

  

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VAG1598/31 Test Box (from MY 2000)  

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Fluke 83 multimeter  

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VW 1594 Adapter kit  

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Wiring diagram  

Test requirements 

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Battery Voltage OK.  

Test sequence 

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Switch OFF ignition.  

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Connect VAG1598/22 (or 1598/31) Test Box to ECM wiring harness. 

Fig. 31: Connecting VAG1598/22 Test Box To ECM Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Bridge sockets with jumper wires from VW 1594 kit.  

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Up to MY 1999: sockets 33 + 1  

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From 2000: sockets 18 + 4  

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Measure Voltage between following sockets:  

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Up to MY 1999: sockets 2 + 1, 28 + 1, 27 + 2 and 28 + 27  

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From 2000: sockets 1 + 4, 2 + 4, 1 + 5, 2 + 5  

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Specification: approx. battery Voltage  

If specification not obtained: 

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Check power supply relay -J31-, terminal 30. 

 

2003 Volkswagen New Beetle GLS 

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

  

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-J317- located on fuse relay panel above the central electric.  

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Check wiring for open circuit, short circuit and transfer resistance at terminals using Wiring diagram.  

If wiring and relay OK: 

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Replace Engine Control Module -J248-. See Engine Control Module (ECM), replacing .  

Engine speed (RPM) sensor -G28-, checking 

Engine speed (RPM) sensor -G28- serves dual purpose of speed and reference mark sensor. An inoperative 
sensor will stop engine. 

Special tools 

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VAG1598/22 Test Box (MY 1999)  

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VAG1598/31 Test Box (from MY 2000)  

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Fluke 83 multimeter  

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VW 1594 Adapter kit  

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Wiring diagram  

Test sequence 

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Switch OFF ignition.  

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Disconnect -G28- harness connector. See DIESEL INJECTION SYSTEM, COMPONENT 
LOCATIONS OVERVIEW
 .  

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Measure resistance between connector terminals 1 + 2. 

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Specification: 1000 to 1500 ohm  

Fig. 32: Identifying Engine RPM Sensor Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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