Volkswagen New Beetle. Manual - part 1287

11. 20 Nm  

12. Tunnel bridge  

13. 40 Nm  

14. Washer 

Fig. 3: Identifying Mufflers With Mounts Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation position of double clamp 

Fig. 4: Identifying Installation Position Of Double Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work procedure 

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Position new double clamp as shown with approx. 5 mm distance to marking -A- and tighten it. 
Tightening torque 40 Nm 

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Marking A (arrow 1) for vehicles with automatic transmission 

 

2003 Volkswagen New Beetle GLS 

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

  

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Marking S (arrow 2) for vehicles with manual transmission  

Installation position of muffler suspension 

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Angled side at foot of suspension (arrow) faces front of vehicle.  

Fig. 5: Identifying Installation Position Of Muffler Suspension 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Separation point at exhaust pipe 

Fig. 6: Identifying Separation Point At Exhaust Pipe 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Recommended special tools and equipment 

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Body saw, e.g. VAG1523  

Work procedure 

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Separate exhaust pipe at right angle to separation point (arrow 2).  

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Position replacement double clamp -4- in installation position at the edge markings (arrows 1 and 3) as 
shown when installing. Tightening torque 40 Nm 

 

2003 Volkswagen New Beetle GLS 

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

  

Aligning front muffler parallel 

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Mounting bolt at exhaust pipe must be parallel to tunnel bridge (dimension -x- same at left and right). 

Fig. 7: Aligning Front Muffler Parallel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Catalytic converter, checking 

Function test 

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Select the measuring value "Test-ID 01: Catalytic converter" and check whether the specified values are 
being reached. See DIAGNOSTIC MODE 6: CHECK TEST RESULTS OF COMPONENTS THAT 
ARE NOT CONTINUOUSLY MONITORED .  

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End diagnosis and switch ignition off. 

If the specified values are exceeded: 

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Replace the front exhaust pipe with catalytic converter:  

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Vehicles with engine code AEG. See item 13 .  

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Vehicles with engine code AVH, AZG, BDC. See item 10 .  

Continuation for all vehicles 

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Erase DTC memory of Engine Control Module (ECM). See DIAGNOSTIC MODE 4: RESET/ERASE 
DIAGNOSTIC DATA .  

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Generate readiness code. See READINESS CODE, GENERATING .  

SECONDARY AIR INJECTION (AIR) SYSTEM 

WARNING:

Observe the following for all installations, especially in engine 

 

2003 Volkswagen New Beetle GLS 

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

  

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