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Welcome! With your first post you now have access to the entire site. Normally I would delete such a short introduction but it sounds like you might be a French speaker so I'll let it go. If you have any questions, feel free to ask in the mk4 subforum since that is what the new beetle ALH engine is classified with.
 

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Welcome to the forum Romeo.

Well you don't state the year only new Beetle. Autodata list an ALH engine code for the Beetle 1.9 TDI from 1998 to 2004 so I wouldn't say it was new, lol.

Is that correct? ;)
 

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Welcome to the forum Romeo.

Well you don't state the year only new Beetle. Autodata list an ALH engine code for the Beetle 1.9 TDI from 1998 to 2004 so I wouldn't say it was new, lol.

Is that correct? ;)
LOL, used New Beetle? The US only got the ALH until 2003.
 

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Ok I've made a Word file for you. Have a read and have fun.

Volkswagen_Beetle.zip:
Your file of 251.9 KB bytes exceeds the forum's limit of 97.7 KB for this filetype.

Oh yet another upload thats failed and I can't make it any smaller.

If you PM me with your email address I'll mail it to you. Or Chitty do you want me to mail it to you again? ;)

Ok I'll try it this way.

Volkswagen Beetle 1,9D TDI 1998-04 Engine code : ALH, AGR

Replacement intervals:
We have highlighted important information from the manufacturers' service schedules covering the intervals for checks and replacements. Be sure that you make the vehicle owner aware of this information.

Please refer to Important note to assist in explaining this to your customer.

Important note:
IMPORTANT: All service items are vital to the smooth running and reliability of a vehicle, none more so than the timing belt and its associated components. For this reason we have highlighted important information from the manufacturers' service schedules covering the intervals for checks and replacements. Be sure that you make the vehicle owner aware of this information. Industry best practice is to ensure that the vehicle owner is made aware of the importance of replacing the timing belt and its associated components according to the manufacturers' specification. The service history and the use of the vehicle must be considered when deciding the correct course of action. If there is any doubt to the serviceability of the belt and its components, they should be replaced.

Timing belt replacement intervals:
MY 1999
• Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt.
• Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there are several other factors which must be considered when checking a timing belt:
1. Is the belt an original or a replacement?
2. When was the belt last replaced and was it at the correct mileage?
3. Is the service history of the vehicle known?
4. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval?
5. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected?
6. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due?
7. If the belt does fail, have you considered the consequences? If the engine is an INTERFERENCE type then considerable expensive damage may well be the result.
8. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences.
9. If in doubt about the condition of the belt - RENEW it.
10. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating conditions, inspection and service replacement.

Timing belt - Check/report
Every 10000 miles or 12 months

Timing belt - Renew
Every 60000 miles or 48 months


MY 2002:
Timing belt - Check/report
At 10000 miles or 12 months and then every 20000 miles or 24 months

Timing belt - Renew
Every 80000 miles or 48 months


MY 2003:
Timing belt - Check/report
At 10000 miles or 12 months and then every 20000 miles or 24 months.

Timing belt - Renew
Every 100000 miles or 48 months

Check for Engine Damage:
CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Check and adjust: 0.30
Remove and install: 3.30

Special Tools:
• Camshaft setting bar - No.3418/T10098.
• Injection pump locking pin - No.3359.
• Sprocket holding tool - No.3036.
• Two-pin wrench - Matra V.159 - TDI.
• Puller - No.T40001.

Removal:
1. Raise and support front of vehicle.
2. Remove:
 RH headlamp (Golf/Bora).
 Coolant expansion tank. DO NOT disconnect hoses (Golf/Bora).
 PAS reservoir. DO NOT disconnect hoses (Golf/Bora).
 RH engine undershield (Golf/Bora).
 Fuel filter and bracket (Beetle).
 Engine undershield (Beetle).
 Intercooler to intake manifold hose.
 Timing belt upper cover [1].
 Vacuum pump.
 Engine undershield (if fitted).
 Auxiliary drive belt.
3. Remove – if using camshaft setting bar No.3418:
 Polo Classic/Caddy SDI: Inlet manifold upper chamber.
 Cylinder head cover.
4. Turn crankshaft to TDC on No.1 cylinder.
5. Ensure timing marks aligned. MT: [2]. AT: [3].
6. Fit setting bar to rear of camshaft:
 Tool No.3418 4. Centralise camshaft using feeler gauges.
 Or tool No.T10098 [20].
7. Lock injection pump. Use tool No.3359 [5].
8. Slacken injection pump sprocket bolts [6].

NOTE: DO NOT slacken injection pump hub nut.

9. Golf/Bora/Beetle: Support engine.
10. Golf/Bora/Beetle: Remove:
 RH engine mounting bolts 7, 8 & 9.
 RH engine mounting.
 Engine mounting bracket bolts [10].
 Engine mounting bracket.
11. Remove:
 Crankshaft pulley bolts [11].
 Crankshaft pulley [12].
 Timing belt centre cover [13].
 Timing belt lower cover [14].
12. Slacken tensioner nut [15].
13. SDI: Turn tensioner anti-clockwise away from belt. Use Allen key.
14. TDI: Turn tensioner anti-clockwise away from belt. Use wrench Matra V.159.
15. Lightly tighten tensioner nut [15].
16. Remove timing belt.

NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation:

IMPORTANT: DO NOT reuse old belt if width is less than 22 mm.

1. Ensure timing marks aligned. MT: [2]. AT: [3].
2. Ensure camshaft setting bar fitted correctly [4] or [20].
3. Ensure locking pin located correctly in injection pump [5].
4. Hold camshaft sprocket. Use tool No.3036.
5. Slacken camshaft sprocket bolt one turn [16].

NOTE: DO NOT use setting bar to hold camshaft when slackening sprocket bolt.

6. Loosen sprocket from taper.
 Method 1: Use drift through hole in timing belt rear cover.
 Method 2: Use puller. Tool No.T40001.
7. Remove:
 Camshaft sprocket bolt [16].
 Camshaft sprocket.
8. Remove bolts from injection pump sprocket [6]. Proceed as follows:
 Injection pump sprocket 038 130 111A: Bolts with pointed ends - type A. Fit new bolts.
 Injection pump sprocket 038 130 111B: Bolts with flat ends - type B. Bolts can be re-used.
9. Align injection pump sprocket with bolts in centre of slotted holes.
10. Fit timing belt in following order:
 Crankshaft sprocket.
 Guide pulley G1.
 Water pump sprocket.
 Injection pump sprocket.
 Guide pulley G2 - TDI.
 Tensioner pulley.
 Guide pulley G3.

NOTE: Turn injection pump sprocket slightly to engage timing belt teeth.

11. Ensure belt is taut between sprockets.
12. Fit camshaft sprocket to belt, then install camshaft sprocket with belt onto end of camshaft.
13. Fit camshaft sprocket bolt [16].
14. Lightly tighten camshaft sprocket bolt [16]. Sprocket should turn freely without tilting.
15. Slacken tensioner nut [15].
16. SDI: Turn tensioner pulley clockwise until pointer and notch in baseplate aligned [17]. Use Allen key.
17. TDI: Turn tensioner pulley clockwise as follows:
 ALH, AT: Pointer and raised section of tensioner baseplate aligned [18]. Use Allen key.
 Except ALH, AT: Notch and raised mark on tensioner aligned [19]. Use wrench Matra V.159.
18. If tensioner pulley turned too far: Turn fully anti-clockwise and repeat tensioning procedure.
19. Tighten tensioner nut to 20 Nm [15].

NOTE: Ensure tensioner retaining lug is properly engaged.

20. Ensure timing marks aligned. MT: [2]. AT: [3].
21. Hold camshaft sprocket. Use tool No.3036.
22. Tighten camshaft sprocket bolt to 45 Nm (33 lb/ft).
23. Tighten injection pump sprocket bolts [6].
Type A: Temporarily to 20 Nm (15 lb/ft).
NOTE: Tighten bolts a further 90° after checking pump timing using diagnostic equipment.
Type B: Tighten to 25 Nm (18 lb/ft).
24. Remove:
Camshaft setting bar [4] or [20]. Tool No.3418/T10098.
Injection pump locking pin [5], Tool No.3359.
25. Turn crankshaft two turns clockwise until timing marks are aligned: MT: [2]. AT: [3].
26. Ensure camshaft setting bar can be fitted [4] or [20].
27. Ensure locking pin can be inserted in injection pump [5].
28. SDI: Ensure pointer aligned with notch [17] in baseplate.
29. TDI: ALH, AT: Pointer and raised section of tensioner baseplate aligned [18]. Except ALH, AT: Ensure notch and raised mark on tensioner are aligned [19].
30. If not repeat tensioning procedure.
31. Apply firm thumb pressure to belt. Tensioner marks should move out of alignment [17], [18] or [19].
32. Release thumb pressure on belt. Tensioner marks should follow movement of belt.
33. Install components in reverse order of removal.
34. Tighten crankshaft pulley bolts [11]. Tightening torque 10 Nm + 90° (7 lb/ft + 90°).
35. Golf/Bora/Beetle: Tighten RH engine mounting bracket bolts to 45 Nm (33 lb/ft).
36. Golf/Bora/Beetle: Fit and align RH engine mounting.
Engine mounting clearance: 14 mm [21].
Engine mounting clearance: 10 mm [22].
Ensure engine mounting bolts [7] aligned with edge of mounting [23].
37. Golf/Bora/Beetle: Tighten:
Engine mounting bolts [9]. Tightening torque 40 Nm + 90° (30 lb/ft + 90°).
Engine mounting bolts [8]. Tightening torque 25 Nm (18 lb/ft).
Engine mounting bolts [7]. Tightening torque 100 Nm (74 lb/ft).

Its not good but its the best your going to get on here. :)
 

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