Volkswagen New Beetle. Manual - part 1270

3. to air filter  

4. Vacuum reservoir  

5. Reservoir for wastegate  

6. Turbocharger  

7. to Intake Manifold Change-over valve -N239-  

8. Return valve, with connection points to Wastegate Bypass regulator valve -N75-. 

Fig. 3: Exploded View Of Turbocharger, Hose And Pipe Connections 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Rules for cleanliness 

When working on the turbocharger and charge air pressure, pay careful attention to the following rules: 

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Thoroughly clean all unions and the adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover over. Do not use fluffy cloths!  

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Carefully cover opened components or seal, if the repair cannot be carried out immediately.  

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Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose (e.g. in tool boxes etc.).  

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When the system is open: Do not work with compressed air if it can be avoided. Do not move vehicle 
unless absolutely necessary.  

CHARGE AIR PRESSURE SYSTEM, CHECKING 

Special tools and equipment 

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VAG 1390 Vacuum pump  

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Fluke 83 Multimeter  

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VW 1594 Adaptor kit  

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VAG 1598/22 Test box  

 

2003 Volkswagen New Beetle GLS 

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

  

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VAG 1551/1552 with VAG 1551/3 adaptor cable  

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Wiring diagram 

Fig. 4: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking conditions 

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No DTCs stored in Diagnostic Trouble Code memory 

See DTC Memory, Checking . 

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No leaks from intake and exhaust systems.  

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No stored DTCs from engine and fuel injection system, e.g. start of injection, fuel injectors and 
compression pressure.  

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Engine oil temperature 80°C minimum.  

Test sequence 

Observe following if test and measuring instruments are required during a test drive: 

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Test and measuring instruments must be secured to the rear seat and operated by a 2nd person from this 
location.  

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Connect VAG 1551/1552 Scan Tool 

See VAG1551/1552 Scan Tool, Connecting .

CAUTION: If test and measuring instruments are operated from the front passenger 

seat and the vehicle is involved in an accident, there is a possibility that 
the person sitting in this seat could receive serious injuries when the 
airbag is triggered.

 

2003 Volkswagen New Beetle GLS 

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

  

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Start engine and let idle  

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Press 0 and 1 buttons to select Address word 01 "Engine electronics"  

Display will appear as shown in Fig. 5 . 

Fig. 5: Identifying VAG 1551/1552 Scan Tool Display (1 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press 0 and 8 buttons to select Function 08: "Read measuring value block"  

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Press Q button to enter input  

Display will appear as shown in Fig. 6 . 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 6: Identifying VAG 1551/1552 Scan Tool Display (2 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press 0, 1 and 1 buttons to select Display Group 11  

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Press Q button to enter input 

Read measuring value block 11 --> 840 RPM 938 mbar 978 mbar 92 % 

Display will appear as shown 

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Accelerate vehicle in 3rd gear from about 1500 RPM under Wide Open Throttle.  

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Press VAG 1551 PRINT button at approx. 3000 RPM. 

Read measuring value block 11 --> 3090 RPM 1866 mbar 1917 mbar 62% 

Specification: 1700 to 2200 mbar (in display zone 3)

 

2003 Volkswagen New Beetle GLS 

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