Volkswagen New Beetle. Manual - part 1294

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification: approx. battery voltage 

If specification not obtained: 

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Switch ignition off.  

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Connect test box VAG 1598/22 to ECM wiring harness. 

Fig. 11: Connecting Test Box VAG 1598/22 To ECM Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check wiring for open circuit between Test Box and harness connector using Wiring diagram.  

Up to MY 1999 

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Terminal 1 + sockets 2 + 28  

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Terminal 2 + socket 15  

From MY 2000 

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Terminal 1 + sockets 1 + 2  

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Terminal 2 + socket 62  

Wire resistance: 1.5 ohms maximum 

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Check wires for short to one another, to vehicle Ground and to battery Plus. 

Specification: "INFINITE"ohms 

If wiring OK 

 

2003 Volkswagen New Beetle GLS 

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

  

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Replace Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248-: 

See Engine Control Module (ECM), Replacing . 

EXHAUST SYSTEM, EMISSION CONTROLS 

EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Front exhaust pipe and catalyst with attachments 

1. from turbocharger  

2. Gasket 

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Replace  

3. 25 N.m (18 ft lb)  

4. Catalyst  

5. to central muffler  

6. Mounting  

7. 25 N.m (18 ft lb)  

NOTE:

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

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After working on the exhaust system make sure that the system is not 
under stress, and that it has sufficient clearance from the bodywork. If 
necessary, loosen double and single clamps and align muffler and 
exhaust pipe so that sufficient clearance is maintained to the bodywork 
and the support rings are evenly loaded.  

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Replace self-locking nuts.  

NOTE:

The following list refers to items in Fig. 12 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 12: Identifying Front Exhaust Pipe And Catalyst With Attachments 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Muffler with mountings 

1. 40 N.m (30 ft lb)  

2. from catalyst  

3. Double clamp 

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Note installation position. See Double clamp installed position, checking  

4. 25 N.m (18 ft lb)  

5. Mounting 

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Note installation position. See Installation position of mounting  

6. Mounting 

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With retaining ring  

7. Bracket  

8. Mounting  

9. Rear muffler 

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Align rear muffler stress free. See Rear muffler, aligning free of stress .  

10. Separating point 

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For repairs  

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Marked by three impressions on circumference of exhaust pipe  

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In production, exhaust pipe and rear mufflers are installed as a single component. For repairs, the 
exhaust pipe and rear muffler are supplied individually with a double clamp to allow connecting 
together.  

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Cut through connecting pipe at right angle to separation point. See Exhaust pipe, separation 

NOTE:

The following list refers to items in Fig. 13 .

 

2003 Volkswagen New Beetle GLS 

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

  

point .  

11. 20 N.m (15 ft lb)  

12. Tunnel bridge  

Fig. 13: Identifying Muffler With Mountings 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Double clamp installed position, checking 

Fig. 14: Identifying Double Clamp Installed Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Position double clamp approx. 5 mm from mark A (arrow -1-). 

Installation position of mounting 

NOTE:

Mark -A- is valid for vehicles with either manual or automatic 
transmissions.

 

2003 Volkswagen New Beetle GLS 

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