Volkswagen New Beetle. Manual - part 1291

Vehicles with engine code AEG as of 06.99, AVH, AZG, BDC

Test requirements 

z

Pressure hose for Secondary Air Injection (AIR) Pump Motor not clogged or kinked  

z

Hose connections must be properly sealed.  

Test sequence 

z

Remove front noise insulation.  

z

Disconnect pressure hose (arrow) from Secondary Air Injection (AIR) pump motor. 

Fig. 21: Disconnecting Pressure Hose From Secondary Air Injection Pump Motor (Engine Code 
AEG From 06.99, And Engine Codes AVH, AZG, BDC) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Blow with light pressure into pressure hose to combination valve. Combination valve must close.  

z

Blow with high pressure into pressure hose to combination valve. Combination valve must open.  

If the combination valve does not open or it is constantly open: 

z

Replace the combination valve: 

z

Vehicles with engine code AEG, AVH, AZG. See item 20 .  

z

Vehicles with engine code BDC. See item 1 .  

z

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

NOTE:

Do not use pressurized air for the following test!

NOTE:

To disengage, compress the buttons at the hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Generate readiness code. See READINESS CODE, GENERATING . 

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

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

TURBOCHARGER, G-CHARGER 

CHARGE AIR PRESSURE WITH TURBOCHARGER 

Turbocharger system components, removing and installing 

Observe rules for cleanliness. See RULES FOR CLEANLINESS . 

1. Exhaust manifold 

z

With turbocharger  

z

Only replace as assembly  

2. Intake manifold  

3. from charge air cooler  

4. Gasket 

z

Replace  

z

Coating (beading) toward intake manifold  

5. 25 N.m (18 ft lb)  

6. Gasket 

z

Note installation position  

7. Bracket 

z

For heat shield (item -9-)  

8. Washer  

9. Heat shield 

z

Engage in bracket (item -7-)  

10. Turbocharger 

z

Only replace as assembly  

z

Removing: remove right drive shaft at transmission: 

See FRONT AXLE SHAFT . 

NOTE:

z

All hose connections are secured with clips. 

z

Charge air pressure must be leak free.  

z

Replace self-locking nuts.  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Charge air pressure control, checking. See CHARGE AIR PRESSURE SYSTEM, 
CHECKING .  

11. Pressure unit 

z

For charge air pressure control valve  

z

Integral part of turbocharger; cannot be replaced  

12. From Air Cleaner  

13. Gasket 

z

Replace  

14. Sealing ring 

z

Replace  

15. Oil return pipe 

z

To cylinder block  

16. Banjo bolt 

z

25 N.m (18 ft lb)  

17. 15 N.m (11 ft lb)  

18. 40 N.m (30 ft lb)  

19. Bracket  

20. 25 N.m (18 ft lb)  

21. Gasket 

z

Replace  

22. Front exhaust pipe  

23. Connection  

24. 10 N.m (7 ft lb)  

25. Oil supply pipe  

 

2003 Volkswagen New Beetle GLS 

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