Volkswagen New Beetle. Manual - part 1259

Function 

Air is blown behind the exhaust valves by the Secondary Air Injection (AIR) system during a cold start. 
Thereby, the emission gas is enriched with oxygen, initiating a secondary combustion and thereby shortening 
the warm-up phase of the catalytic converter. Activation occurs from Motronic Engine Control Module (ECM) -
J220- via Secondary Air Injection (AIR) Pump Relay -J299- to combination valve. 

Secondary Air Injection (AIR) system components, removing and installing: 

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Vehicles with engine code AEG, AVH, AZG. See PARTS OF SECONDARY AIR INJECTION (AIR) 
SYSTEM, REMOVING AND INSTALLING (VEHICLES WITH ENGINE CODE AEG, AVH, 
AZG) .  

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Vehicles with engine code BDC. See PARTS OF SECONDARY AIR INJECTION (AIR) SYSTEM, 
REMOVING AND INSTALLING (VEHICLES WITH ENGINE CODE BDC) .  

Check secondary air system for proper seal. See SECONDARY AIR INJECTION (AIR) SYSTEM, 
CHECKING FOR PROPER SEAL . 

Parts of Secondary Air Injection (AIR) system, removing and installing (Vehicles with engine code AEG, AVH, AZG) 

1. Connector 

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only for vehicles with engine code AEG up to 05.99  

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black, 2-pin  

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for Secondary Air Injection (AIR) solenoid valve  

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before disconnecting, mark allocation to component  

2. Secondary Air Injection (AIR) Solenoid Valve -N112-* 

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only for vehicles with engine code AEG up to 05.99  

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Checking. See SECONDARY AIR INJECTION (AIR) SOLENOID VALVE (VEHICLES 
WITH ENGINE CODE AEG UP TO 05.99), CHECKING .  

3. to fork of vacuum line for brake booster 

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only for vehicles with engine code AEG up to 05.99 

compartment due to lack of room: 

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Route lines of all types (e.g. for fuel, hydraulic, EVAP canister 
system, coolant and refrigerant, brake fluid, vacuum) and electrical 
wiring so that the original path is followed.  

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Watch for sufficient clearance to all moving or hot components.  

NOTE:

Components marked with * are tested via On Board Diagnostic (OBD). See 
DIAGNOSTIC MODE 3: CHECK DTC MEMORY .

NOTE:

The following list refers to Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

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Check for secure fitting  

4. Secondary Air Injection (AIR) Pump Relay -J299-*  

5. O-ring 

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Replace if damaged  

6. Pressure hose 

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Check for secure fitting  

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To disengage, squeeze together at front  

7. Intake hose 

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Check for secure fitting  

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To disengage, squeeze together at front  

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from upper air filter housing. See item 6 in AIR FILTER, DISASSEMBLING AND 
ASSEMBLING (VEHICLES WITH ENGINE CODE AEG, AVH, AZG) .  

8. Secondary Air Injection (AIR) Pump Motor -V101-* 

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Checking. See SECONDARY AIR INJECTION (AIR) PUMP MOTOR, CHECKING .  

9. 10 Nm  

10. Bracket 

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For Secondary Air Injection (AIR) pump motor  

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secured to lower part of intake manifold at bottom  

11. Connector 

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2-pin  

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For Secondary Air Injection (AIR) pump motor  

12. 25 Nm  

13. Lower part of intake manifold  

14. to connecting piece at exhaust manifold 

Vehicles with engine code AEG: 

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See item 7 . 

Vehicles with engine code AVH; AZG: 

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See item 7 .  

15. 30 Nm  

16. Connection tube  

17. Connecting piece, 35 Nm  

18. Heat shield  

19. Seal 

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replace  

20. Combination valve 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

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Checking. See COMBINATION VALVE, CHECKING . 

Vehicles with engine code AEG as of 06.99: 

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without vacuum connection to Secondary Air Injection (AIR) solenoid valve -N112-  

Fig. 8: Identifying Parts Of Secondary Air Injection System (Vehicles With Engine Code AEG, AVH, 
AZG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Parts of Secondary Air Injection (AIR) system, removing and installing (Vehicles with engine code BDC) 

1. Combination valve 

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Checking. See COMBINATION VALVE, CHECKING .  

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To replace, remove warm air collector plate  

2. O-ring 

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Replace if damaged  

3. Pressure hose 

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Check for secure fitting  

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to disengage, squeeze together at front  

4. Intake hose 

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Check for secure fitting  

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To disengage, squeeze together at front  

5. To upper part of air filter 

NOTE:

Components marked with * are tested via On Board Diagnostic (OBD). See 
DIAGNOSTIC MODE 3: CHECK DTC MEMORY .

NOTE:

The following list refers to Fig. 9 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

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See item 3 in AIR FILTER, DISASSEMBLING AND ASSEMBLING (VEHICLES WITH 
ENGINE CODE BDC) .  

6. Secondary Air Injection (AIR) Pump Motor -V101-* 

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Checking. See SECONDARY AIR INJECTION (AIR) PUMP MOTOR, CHECKING .  

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Activation via Secondary Air Injection (AIR) Pump Relay -J299-*. See Secondary Air Injection 
(AIR) pump relay -J299-* (arrow) .  

7. Connector 

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2-pin  

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For Secondary Air Injection (AIR) pump motor  

8. 10 Nm  

9. 25 Nm  

10. 15 Nm  

11. Bracket 

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For Secondary Air Injection (AIR) pump motor  

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secured to lower part of intake manifold at bottom  

12. Lower part of intake manifold  

13. 10 Nm  

14. to connecting piece at exhaust manifold 

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See item 7 .  

15. 30 Nm  

16. Connection tube  

17. Connecting piece, 35 Nm  

18. Warm air collector plate 

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With intake manifold support  

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With mount for combination valve  

19. Seal 

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replace  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle