Volkswagen New Beetle. Manual - part 1250

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Assemble bypass flap -1- with sealing ring -2- and two screws -5- with exhaust gas heat exchanger -3- 
and tighten these screws.  

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Install four screws -4- and tighten all screws to 10 N.m. 

Fig. 10: Assembling Bypass Flap With Sealing Ring And Two Screws 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Hand-tighten exhaust gas recirculation radiator -7- with three screws -8- to intake manifold -6- (exhaust 
gas recirculation radiator must lie against and must be moveable in threaded joints).  

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Install screws -9- and tighten to 10 N.m.  

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Tighten bolts/screws -8- to 10 N.m. 

Fig. 11: Hand-Tightening Exhaust Gas Recirculation Radiator With Three Screws To Intake 
Manifold 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Hand-tighten connecting pipe -15- with seals, two screws -14- and screw -16-. See Fig. 12 .  

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Hand-tighten bracket -12- with screws -11 - and -13- to bypass-flap.  

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Install bracket -12- with screw -10- to intake manifold and tighten screw to 10 N.m.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW

  

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Tighten screw -11 - to 22 N.m.  

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Tighten screw -13- to 5 N.m.  

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Tighten screws -14- and -16- to 22 N.m. 

Fig. 12: Hand-Tightening Connecting Pipe With Seals, Two Screws And Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install connecting pipe -18- from heat exchanger for exhaust gas recirculation -16- to exhaust manifold -
17-.  

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Tighten bolts and nuts to 22 N.m. 

Fig. 13: Installing Connecting Pipe From Heat Exchanger For Exhaust Gas Recirculation To 
Exhaust Manifold 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

EGR VACUUM REGULATOR SOLENOID VALVE -N18-, REMOVING AND INSTALLING 

Special tools and equipment 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW

  

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

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VAS 5128 Wet and dry cleaner  

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Brush with plastic bristles 

Fig. 14: Identifying V.A.G 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Disconnect connector from exhaust gas recirculation valve and remove securing bolts.  

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Pull valve carefully out of seat. 

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Clean sooted surfaces with a plastic brush. Afterward, remove loose soot with a cloth.  

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Clean exhaust gas recirculation valve seat in intake manifold with a plastic brush and a cloth. Make sure 
that no soot particles enter intake manifold.  

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Take cloth out of intake manifold and clean intake manifold with a vacuum cleaner, if necessary.  

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Replace O-ring.  

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Insert valve carefully into seat in intake manifold and tighten screws to 10 N.m.  

NOTE:

To avoid damage to exhaust gas recirculation valve do not use solvents, 
fuel or sharp-edged tools or tools made out of metal to clean.

NOTE:

For protection against soot particles, cover intake manifold inner part with 
a lint-free cloth.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW

  

1998-2004 ENGINE

Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD) 

EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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3337 Ring spanner for oxygen sensor  

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

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V.A.G 1332 Torque wrench (40...200 N.m) 

Fig. 1: Identifying Exhaust System Special Tools And Measuring Instruments 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND CATALYTIC CONVERTER WITH 
ATTACHMENTS 

Engine code: AEG 

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Engine codes AVH, AZG, BDC, BEV, BGD. See ENGINE CODES AVH, AZG, BDC, BEV, BGD .  

NOTE:

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After working on the exhaust system ensure that the system is not under 
stress, and that it has sufficient clearance to the bodywork. If necessary, 
loosen double clamp(s) and align muffler and exhaust pipe so that 
sufficient clearance is maintained to the bodywork and the support rings 
are evenly loaded.  

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Replace self-locking nuts.  

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD)