Volkswagen New Beetle. Manual - part 1254

z

Activation via AIR pump relay -J299-  

z

Checking function. See SECONDARY AIR INJECTION PUMP MOTOR, CHECKING  

7. 10 N.m  

8. Retainer 

z

For secondary air injection pump motor  

z

Fastened to intake manifold  

9. Connector 

z

2-pin  

10. 25 N.m  

11. Intake manifold lower part  

12. To union on exhaust manifold  

13. 40 N.m  

14. Connecting pipe  

15. Nuts/bolts, 60 N.m  

16. Warm air collector plate 

z

With mounting for combination valve  

17. Seal 

z

Replace  

Fig. 13: Exploded View Of Secondary Air Injection (AIR) Pump Motor (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes: BDC, BGD 

1. Combination valve 

NOTE:

The following list refers to items in Fig. 14 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Checking. See COMBINATION VALVE, CHECKING  

z

To replace, remove warm air collector plate  

z

Removing and installing. See COMBINATION VALVE, REMOVING AND INSTALLING  

2. O-ring 

z

Replace  

3. Pressure hose 

z

Check if seated securely  

z

Press together at front to release  

4. Intake hose 

z

For secondary air injection pump  

z

Check if seated securely  

z

Press together at front to release  

5. To air cleaner  

6. Secondary Air Injection (AIR) pump motor -V101- 

z

Activation via AIR pump relay -J299-. See Secondary Air Injection (AIR) pump relay -J299-  

z

Checking function. See SECONDARY AIR INJECTION PUMP MOTOR, CHECKING  

7. Connector 

z

2-pin  

8. 10 N.m  

9. 25 N.m  

10. 15 N.m  

11. Retainer 

z

For secondary air injection pump motor  

z

Secured to intake manifold  

12. Intake manifold lower part  

13. 10 N.m  

14. To union on exhaust manifold  

15. 40 N.m  

16. Connecting pipe  

17. Nuts/bolts, 60 N.m  

18. Warm air collector plate 

z

With intake manifold support  

z

With mounting for combination valve  

19. Seal 

z

Replace  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 14: Exploded View Of Secondary Air Injection (AIR) Pump Motor (Engine Codes BDC And BGD) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Secondary Air Injection (AIR) pump relay -J299- 

Fig. 15: Identifying Secondary Air Injection (AIR) Pump Relay 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Location: in protective housing for relays in engine compartment (pushed into cable guide next to brake master 
cylinder). 

Distinguishing features: Control number 100 

NOTE:

z

The relay locations may differ depending on the level of vehicle 
equipment. For the latest control numbers and installation locations: 

See appropriate WIRING DIAGRAMS articles. 

 

2003 Volkswagen New Beetle GLS 

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

  

COMBINATION VALVE, CHECKING 

Checking combination valve with vacuum connection, up to Model Year 1999, 05.99 

Checking combination valve without vacuum connection, from Model Year 2000, 06.99. See CHECKING 
COMBINATION VALVE WITHOUT VACUUM CONNECTION, FROM MODEL YEAR 2000, 06.99 

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

z

V.A.G 1390 Hand vacuum pump 

Fig. 16: Identifying V.A.G 1390 Hand Vacuum Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

No fault stored in fault memory. See ENGINE CONTROL MODULE FAULT MEMORY, 
INTERROGATION AND ERASING .  

z

Perform final control diagnosis. See COMPONENTS AND FUNCTIONS, ADAPTING .  

z

Vacuum lines and hose connections free of leaks.  

z

Vacuum lines not blocked/kinked.  

Work sequence 

z

Remove engine cover.  

z

Pull vacuum hose -1- off at Secondary Air Injection (AIR) solenoid valve -N112- -2-. 

z

Disconnect the battery Ground strap first if tools are required to pull relays 
or control modules out of the relay plate.  

z

Before disconnecting the battery Ground strap obtain the code for radios 
with anti-theft coding.  

 

2003 Volkswagen New Beetle GLS 

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