Volkswagen New Beetle. Manual - part 1296

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Remove engine cover.  

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Disconnect pipe between Charge Air cooler and intake manifold at intake manifold.  

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Disconnect vacuum hose from EGR valve.  

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Connect VAG 1390 hand vacuum pump to EGR valve.  

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Operate pump and observe membrane rod. 

Membrane rod must move in direction of arrow. 

Fig. 21: Locating Hand Vacuum Pump Membrane Rod 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Disconnect hand vacuum pump hose from EGR valve. 

Membrane rod must move back against direction of arrow to its original position. 

Exhaust Gas Recirculation (EGR), checking 

Special tools and equipment 

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Fluke 83 multimeter  

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VW 1594 Adaptor kit  

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VAG 1598/22 Test Box  

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VAG 1551/1552 Scan Tool with VAG 1551/3 adaptor cable  

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Wiring diagram 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 22: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

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Connect VAG 1551/1552 Scan Tool: 

See VAG1551/1552 Scan Tool, Connecting . 

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Start engine and let idle.  

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Press 0 and 1 buttons to select Address word 01 "Engine electronics": 

See DTC Memory, Checking . 

Indicated on display 

NOTE:

The EGR return function is checked via Function 04 (Basic Setting). Through 
this procedure the valve for EGR is metered every 10 seconds, so that in 
measured value block 003 the extreme values for the EGR (air mass sensor) in 
display field 3 can be read.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 23: Identifying Special Tools Display (1 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press 0 and 4 buttons to select Function 04: "Basic setting".  

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Press Q button to enter input.  

Indicated on display 

Fig. 24: Identifying Special Tools Display (2 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press 0, 0 and 3 buttons to select "Display group 3".  

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Press Q button to enter input.  

Indicated on display: (1 to 4 - Display zones)

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 25: Identifying Special Tools Display (3 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Display in field 2 must fluctuate every 10 seconds between EGR active or EGR inactive (n.aktiv). 

Displays in display zones 3 and 4 must fluctuate within following control range: 

See Mass Air Flow (MAF) Sensor -G70-, Checking . 

If EGR NOT active: 

Specification display zone 3: 420 to 560 mg/stroke 

Specification display zone 4: 0 to 5% 

If EGR active: 

Specification display zone 3: 170 to 340 mg/stroke 

Specification display zone 4: 95 to 100% 

If specifications not obtained: 

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Check mechanical EGR valve. See EXHAUST GAS RECIRCULATION (EGR) VALVE, 
CHECKING .  

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Check vacuum hoses. See VACUUM HOSE CONNECTIONS, DIAGRAM .  

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Check EGR Vacuum Regulator solenoid valve as follows: 

NOTE:

If a constant value of 550 mg/H is indicated in display zone 3, check Mass Air 
Flow sensor.

 

2003 Volkswagen New Beetle GLS 

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