Volkswagen New Beetle. Manual - part 1285

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Activate secondary air injection pump relay via final control diagnosis. See COMPONENTS AND 
FUNCTIONS, ADAPTING . 

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Secondary air injection pump motor must run and air must exit outlet connection  

If the motor runs, but no air exits: 

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Replace secondary air injection pump motor.  

If the secondary air injection pump motor does not run at intervals: 

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Activate secondary air injection pump relay via final control diagnosis. See COMPONENTS AND 
FUNCTIONS, ADAPTING .  

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Check activation of secondary air injection pump motor. See COMPONENTS AND FUNCTIONS, 
ADAPTING .  

SECONDARY AIR INJECTION SOLENOID VALVE, CHECKING 

Only engine code AEG up to Model Year 1999, 05.99 

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

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Adapter set V.A.G 1594 

Fig. 24: Identifying Adapter Set V.A.G 1594 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1527 B Diode test lamp  

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Wiring diagram 

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. 25: Identifying V.A.G 1527 B Diode Test Lamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Coolant temperature 5...33° C  

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Secondary air injection pump motor OK  

Work sequence 

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Pull upper vacuum hose (arrow) off secondary air injection solenoid valve -1-. 

Fig. 26: Disconnecting Upper Vacuum Hose From Secondary Air Injection Solenoid Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Start engine and run at idling speed. 

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When secondary air injection pump motor runs, a vacuum must be detectable at secondary air 
injection pump union.  

 

2003 Volkswagen New Beetle GLS 

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

  

If a vacuum cannot be detected: 

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Switch off ignition.  

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Disconnect 2-pin connector from secondary air injection solenoid valve.  

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Connect diode test lamp V.A.G 1527 B to disconnected connector using adapter cables from V.A.G 1594 
C. 

Fig. 27: Connecting Diode Test Lamp V.A.G 1527 B To Disconnected Secondary Air Injection 
Solenoid Valve Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Start engine and run at idling speed. 

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LED must light up  

LED lights up (voltage supply OK): 

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Replace secondary air injection solenoid valve.  

LED does not light up: 

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Connect 2-pin connector.  

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Check activation of valve. See COMPONENTS AND FUNCTIONS, ADAPTING .  

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Check wiring connections plate according to wiring diagram. 

See appropriate WIRING DIAGRAMS article. 

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Interrogate fault memory. See ENGINE CONTROL MODULE FAULT MEMORY, 
INTERROGATION AND ERASING .  

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Read readiness code. See COMPONENTS AND FUNCTIONS, ADAPTING .  

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If fault memory has been erased or engine control module separated from permanent positive power 
supply, generate readiness code again. See COMPONENTS AND FUNCTIONS, ADAPTING . 

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE PERFORMANCE

Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle 

EXHAUST SYSTEM EMISSION CONTROLS 

EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Exhaust manifold, front exhaust pipe with Three Way Catalytic Converter (TWC) and attachments: 

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Vehicles with engine code AEG. See EXHAUST MANIFOLD, FRONT EXHAUST PIPE WITH 
THREE WAY CATALYTIC CONVERTER (TWC) AND ATTACHMENTS (VEHICLES WITH 
ENGINE CODE AVH, AZG, BDC) .  

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Vehicles with engine code AVH, AZG, BDC EXHAUST MANIFOLD, FRONT EXHAUST PIPE 
WITH THREE WAY CATALYTIC CONVERTER (TWC) AND ATTACHMENTS (VEHICLES 
WITH ENGINE CODE AVH, AZG, BDC) .  

Mufflers with mounts. See MUFFLERS WITH MOUNTS . 

Check catalytic converter. See CATALYTIC CONVERTER, CHECKING . 

Exhaust manifold, front exhaust pipe with Three Way Catalytic Converter (TWC) and attachments (vehicles with 
engine code AEG) 

1. Combination valve 

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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-  

2. 10 Nm  

NOTE:

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After exhaust system repairs, make sure exhaust system is not under 
stress and that it has sufficient clearance from the bodywork. If necessary, 
loosen double clamps and align muffler and exhaust pipe so that sufficient 
clearance is maintained to the bodywork and mounts carry uniform loads.  

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Do not use any silicone sealant. Traces of silicone components which are 
sucked into the engine are not burned there, and they damage the oxygen 
sensor.  

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Always replace self-locking nuts.  

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

NOTE:

The following list refers to Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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