The New Beetle TDI shares its platform with the MkIV Jetta and MkIV Golf, called the A4 platform.
In the model years of 2004-2005 the New Beetle TDI was powered by a 1.9 liter turbocharged direct injection diesel with a more modern injection system. Designed as a collaboration between Bosch and Volkswagen AG, this system was termed “Pumpe Düse, or “PD”, as each individual injector had its own high pressure fuel pump.
Engine
Engine Code: BEW
Horsepower: 100 @ 4000 RPM
Torque: 177 lb/ft @1800 RPM
Injection Pump Type: PD, “Pumpe Düse”, Unit Injectors (Unit Injector on Wikipedia)
The vehicle uses three fuel pumps in total: a very low pressure in-tank “lift” pump that pushes fuel from the tank to the engine bay; a standard rotary style pump attached to the camshaft which sent higher pressure fuel to the injectors; each individual injector set the final fuel pressure depending on load and engine speed.
These PD injectors also had a fully electronic injection timing using piezo technology.
Transmission
The 2004-2005 New Beetle TDI BEW was one of the first VWs, and one of the first production vehicles, to be available with the 6-speed “Direct Shift Gearbox”, or DSG, and it was also available as a 5-speed manual.
The 5-speed manual was equipped with a dual-mass flywheel and clutch design. The clutch was hydraulically operated with a slave cylinder operating a lever to disengage the clutch. The dual-mass flywheel design is prone to failure, so most owners opt to replace their dual-mass design with the more durable single-mass flywheel from the G60/VR6.
Maintenance
See the Complete BEW TDI Service Schedule
VW Oil Requirement: VW/AUDI 505.01
Timing Belt Interval: The BEW engine originally used a timing belt interval of 100,000 miles. Later on, Volkswagen revised the interval to 80,000 miles, presumably due to the extra strain that the injection system put on the timing belt components. There is some debate as to which cars this revision applies to as there was a seemingly insignificant VIN split in the announcement.
DSG Transmission Fluid & Filter: every 40,000 miles
Common Replacement Parts for 2004-2005 Jetta TDI – Sponsored By IDParts.com
Oil Change Kit
Engine Filter Pack
505.01 Approved Oils
DSG Fluid & Service Kit
Timing Belt Replacement Kit
Clutch Replacement Kit
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