Volkswagen New Beetle. Manual - part 1715

 

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Volkswagen New Beetle. Manual - part 1715

 

 

Fig. 1: Locating TDC Mark on Flywheel/Flexplate 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:59 AM

Page 3 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 2: Locking Camshaft With Setting Bar 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

7. Lock injection pump in place using Lock Pin (3359). See Fig. 3 .  

8.  

Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Replace these bolts with 
NEW bolts during installation. Attach Engine Support (10-222A) with legs (10-222A/1) or equivalent. 
Remove coolant reservoir bottle and power steering reservoir, and leaving hoses attached set aside.  

9.  

Remove engine mount from timing belt end of engine. Remove 4 crankshaft pulley socket-head bolts and 
remove crankshaft pulley (it is not necessary to remove center bolt). Remove middle and lower timing 

CAUTION: DO NOT loosen diesel injection pump center hub nut. This will alter 

injection pump basic setting. 

CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt. This bolt 

MUST be replaced if loosened or removed. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:59 AM

Page 4 

© 2004 Mitchell Repair Information Company, LLC. 

belt covers. Remove engine mount bracket.  

10.  

If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Loosen timing 
belt tensioner lock nut. Turn tensioner to release belt and remove timing belt.  

Fig. 3: Locking Diesel Fuel Injection Pump Sprocket 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Removal (New Beetle) 

1. Remove tube between charge air cooler and air intake pipe. Disconnect and plug fuel supply and return 

lines at fuel filter. Remove fuel filter from bracket.  

2.  

Remove upper timing belt cover. Remove valve cover. Remove brake booster vacuum pump. Remove 
pipe between charge air cooler and turbocharger. 

CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. 

CAUTION: The valve cover has an integrated, vulcanized gasket. If gasket is 

damaged or leaking, replace the valve cover. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:59 AM

Page 5 

© 2004 Mitchell Repair Information Company, LLC. 

3. If serpentine belt is to be reused, mark rotational direction of belt. Using a 16 mm box wrench, rotate 

serpentine belt tensioner clockwise to relieve belt tension, and remove serpentine belt. Remove serpentine 
belt tensioner.  

4. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed 

through access hole in engine-to-transmission mating flange. See Fig. 1 .  

5. Lock camshaft in place with Camshaft Setting Bar (3418) installed on rear of camshaft. See Fig. 2 . 

Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler 
gauge, measure distance between other end of setting bar and cylinder head.  

6. Divide this dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head 

dimension between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. 
Place second feeler gauge of same dimension between other end of bar and cylinder head.  

7. Lock the injection pump in place using Lock Pin (3359). See Fig. 3 .  

8.  

Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Manufacturer 
recommends replacing these torque-to-yield bolts during final assembly. Support engine weight from 
above or below with floor jack.  

9.  

Remove engine mount from timing belt end of engine.  

10.  

Remove 4 crankshaft pulley socket-head bolts, and remove crankshaft pulley (it is not necessary to 
remove center bolt). Remove timing belt covers.  

11.  

If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Loosen timing 
belt tensioner lock nut. Turn tensioner to release belt and remove timing belt.  

Installation (All Models) 

CAUTION: DO NOT loosen diesel injection pump center hub nut. This will alter 

injection pump basic setting. 

NOTE:

The 3 diesel injection pump bolts are torque-to-yield type. Manufacturer 
recommends replacing bolts during final assembly. 

NOTE:

On New Beetle, engine mount bolts are torque-to-yield type. Manufacturer 
recommends replacing bolts if they are loosened or removed. 

CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt. This bolt 

MUST be replaced if loosened or removed. 

CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. 

 

2003 Volkswagen New Beetle GLS 

VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:40:59 AM

Page 6 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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