Volkswagen New Beetle. Manual - part 1219

5. Circlip  

6. Turbocharger 

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Checking charge air pressure control. See CHARGE AIR PRESSURE SYSTEM, CHECKING  

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Charge air pressure control valve and charge air pressure control valve vacuum unit are 
components of the turbocharger and cannot be replaced individually  

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Fill turbocharger with oil via connection before connecting oil supply pipe  

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After installing turbocharger run engine at idling speed for approx. 1 minute and do not rev up, to 
ensure oil supply for turbocharger.  

7. O-ring 

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Always replace  

8. 10 N.m  

9. Intake pipe  

10. Gasket 

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Always replace  

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Note installation position  

11. 20 N.m  

12. Heat shield  

13. 10 N.m  

14. Banjo bolt, 30 N.m  

15. Oil supply pipe  

16. 30 N.m 

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Always replace  

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Coat threads and bolt head seating surface with G 052 112 A3  

17. Exhaust manifold  

18. Gasket 

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Always replace  

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Note installation position  

19. 20 N.m  

20. Banjo bolt, 30 N.m  

21. 25 N.m 

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Always replace  

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Coat threads with G 052 112 A3  

22. Banjo bolt, 35 N.m  

23. Coolant return pipe  

24. 25 N.m  

25. Spacer sleeve  

26. Banjo bolt, 35 N.m  

27. 10 N.m  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)

  

28. Coolant supply pipe  

29. Banjo bolt, 35 N.m  

30. 30 N.m 

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Only use genuine bolt from parts catalog  

31. Support bracket 

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Between turbocharger and cylinder block  

32. 25 N.m  

33. Gasket 

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Always replace  

34. Gasket 

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Always replace  

35. 10 N.m  

36. Oil return pipe 

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To oil pan  

37. 10 N.m  

38. 10 N.m 

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Do not alter setting  

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Must not be loosened  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)

  

Fig. 1: Removing And Installing Turbocharger With Attachments - Part I
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Turbocharger with attachments, removing and installing Part II 

Only for engine code APH 

Engine codes AWP, AWV. See ENGINE CODES AWP, AWV . 

1. Charge pressure bypass valve 

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Checking charge air pressure regulation. See CHARGE AIR PRESSURE SYSTEM, 
CHECKING  

2. Connecting pipe/hose 

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Recirculating valve for turbocharger - N249-*/**. See 16  

3. Pressure regulator valve 

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For crankcase ventilation  

4. Connecting pipe/hose 

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From charge pressure bypass valve to upper air duct  

5. To crankcase ventilation  

6. From air filter  

7. Upper air guiding duct 

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Vehicles with engine code APH, with screw clamp  

8. Bracket  

9. 25 N.m  

10. 10 N.m  

11. From exhaust turbocharger-exhaust connection  

12. Connecting pipe/hose  

NOTE:

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Components marked with an * are checked by the On Board Diagnostic 
(OBD). 

See On Board Diagnostic (OBD) . 

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Components marked with ** are checked by the Output Diagnostic Test 
Mode (DTM). 

See Output Diagnostic Test Mode (DTM) . 

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Observe installed position of heat protection mats  

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)