Volkswagen New Beetle. Manual - part 1255

Fig. 17: Pulling Vacuum Hose From Secondary Air Injection (AIR) Solenoid Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect hand vacuum pump V.A.G 1390 to vacuum hose -1-. 

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Remove pressure hose at secondary air pump motor and blow in lightly (arrow). 

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Combination valve must be closed  

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Operate hand vacuum pump. 

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Combination valve must open  

If the combination valve does not open: 

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Replace combination valve.  

Checking combination valve without vacuum connection, from Model Year 2000, 06.99 

Requirements 

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

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

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Hose unions must not leak  

Work sequence 

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Remove engine cover.  

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Remove pressure hose (arrow) from secondary air injection pump motor. 

NOTE:

Do not use compressed air during the following check!

NOTE:

Do not use compressed air during the following check!

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 18: Removing Pressure Hose From Secondary Air Injection Pump Motor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Blow lightly into pressure hose to combination valve. 

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Combination valve must be closed.  

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Blow strongly into pressure hose to combination valve. 

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Combination valve must open.  

When the combination valve does not open or is continuously open: 

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Replace combination valve.  

COMBINATION VALVE, REMOVING AND INSTALLING 

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

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

NOTE:

To release, press buttons together on hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 19: Identifying V.A.G 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAS 5085 Step ladder 

Fig. 20: Identifying VAS 5085 Step Ladder 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

From above: 

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Remove engine cover.  

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Remove intake manifold upper part. See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING .  

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Pull pressure and vacuum hoses off combination valve.  

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Loosen screwed on connections on connection pipe and remove pipe. 

NOTE:

Always replace seals, gaskets and O-rings.

 

2003 Volkswagen New Beetle GLS 

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

  

From below: 

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Remove middle insulation tray. 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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Disconnect connector for Heated Oxygen Sensor (HO2S) -G39-.  

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Remove right side inner constant velocity joint protective cover from engine if installed.  

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Unbolt connecting pipe on exhaust manifold.  

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Remove warm air collector plate with combination valve. 

Fig. 21: Removing Warm Air Collector Plate With Combination Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Guide a 5 mm hex bit from 3/8"drive socket set into holes -3- of warm air collector plate -1- and remove 
bolts -4- for combination valve -2-.  

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Remove combination valve.  

Installing 

The rest of the assembly is basically in reverse order to the disassembly sequence. 

SECONDARY AIR INJECTION PUMP MOTOR, CHECKING 

Requirements 

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

NOTE:

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Thoroughly clean contact surfaces between combination valve and warm 
air collector plate.  

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Replace seal.  

 

2003 Volkswagen New Beetle GLS 

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