Volkswagen New Beetle. Manual - part 1278

Fig. 6: Positioning Double Clamp On Side Markings While Installing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Aligning rear muffler free of stress 

Fig. 7: Aligning Rear Muffler Free Of Stress 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The mounting pins on exhaust pipe must run parallel with tunnel bridge (dimension -x- on left and right the 
same). 

EXHAUST GAS RECIRCULATION SYSTEM 

NOTE:

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The function/control of the exhaust gas recirculation system is undertaken 
by Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- 
via EGR Vacuum Regulator Solenoid Valve -N18-.  

 

2003 Volkswagen New Beetle GLS 

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

  

EXHAUST GAS RECIRCULATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

1. Bracket 

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For bypass flap for exhaust gas recirculation cooler  

2. 22 N.m  

3. 5 N.m  

4. Intake manifold 

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With Motor for intake flap -V157-  

5. O-ring 

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Always replace  

6. EGR Vacuum Regulator Solenoid Valve -N18- 

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Removing and installing. See EGR VACUUM REGULATOR SOLENOID VALVE -N18-
,REMOVING AND INSTALLING  

7. 10 N.m  

8. Seal 

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Always replace  

9. Connecting pipe  

10. Radiator 

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For exhaust gas recirculation  

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Installing. See EXHAUST GAS RECIRCULATION COOLER, INSTALLING .  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM .  

11. Exhaust manifold 

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Can only be replaced completely with turbocharger  

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Removing and installing. See TURBOCHARGER SYSTEM COMPONENTS, REMOVING 
AND INSTALLING .  

12. Seal 

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Always replace  

13. Connecting pipe  

14. Seal 

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Always replace  

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Pulsed control makes every conceivable valve position possible.  

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Replace self-locking nuts.  

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Vacuum hose connection diagram. See VACUUM HOSE CONNECTION 
DIAGRAM .  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION 
DIAGRAM .  

NOTE:

The following list refers to items in Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

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

  

15. Bypass flap 

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Vacuum hoses for connection diagram. See VACUUM HOSE CONNECTION DIAGRAM .  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM .  

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Installing. See EXHAUST GAS RECIRCULATION COOLER, INSTALLING .  

Fig. 8: Exploded View Of Intake Manifold, Exhaust Manifold & Exhaust Gas Recirculation System 
Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

EXHAUST GAS RECIRCULATION COOLER, INSTALLING 

Special tools and equipment 

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

Fig. 9: Identifying V.A.G 1331 Torque Wrench

NOTE:

Description of repair must be observed in order to avoid damages caused 
by stress.

 

2003 Volkswagen New Beetle GLS 

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

  

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