Volkswagen New Beetle. Manual - part 999

 

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Volkswagen New Beetle. Manual - part 999

 

 

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3220 Jointed wrench  

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V.A.G 1331 Torque wrench (5 to 50 N.m)  

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V.A.G 1381/12 Adapter  

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V.A.G 1763 Compression tester 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 105: Identifying Special Tools And Equipment

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Requirement 

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Engine oil temperature must be min. 30°C  

Work sequence 

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Remove engine cover.  

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Remove central connector for unit injectors -1-.  

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Disconnect connector strip -2- from glow plugs.  

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Remove all glow plugs -3- using jointed wrench 3220. 

Fig. 106: Removing Unit Injector Central Connector, Connector Strip And Glow Plugs 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Thread in adapter V.A.G 1381/12 in place of glow plugs. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

Fig. 107: Checking Compression Pressure
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Check compression pressure using compression tester V.A.G 1763. 

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Operate starter until tester shows no further pressure increase.  

Compression pressures 

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New: 25 to 31 bar  

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Wear limit: 19 bar  

Permissible difference between all cylinders: 5 bar 

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Install glow plugs with jointed spanner 3220 

Tightening torque: 15 N.m 

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Check DTC memory. See ENGINE CONTROL MODULE (DTC) MEMORY, READING AND 
ERASING
 .  

VALVE TRAIN, SERVICING 

Fig. 108: Exploded View Of Valve Train Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Using the compression tester --> tester operating instructions.

NOTE:

Trouble codes will be stored because the diesel injection pump harness 
connector has been disconnected. Check and erase DTC memory.

NOTE:

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Cylinder heads with cracks between the valve seats may be used without 
reducing engine life, provided the cracks are small and not more than 0.5 
mm wide.  

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Do not rework valve seats. Only lapping-in of valves is permitted.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.9L 4-Cyl. (Engine Code BEW)

  

 

 

 

 

 

 

 

Content   ..  997  998  999  1000   ..