Volkswagen New Beetle. Manual - part 1589

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Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 (connection -B-).  

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Connect vacuum hose (to actuator) to vacuum tester V.A.G 1368 (connection -A-). 

Fig. 60: Connecting Vacuum Hose To Vacuum Tester V.A.G 1368 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set vacuum tester to -A/B- position.  

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Operate V.A.G 1390 several times. Create a vacuum of maximum 500 millibar. 

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Vacuum must not drop  

If the vacuum drops: 

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Replace intake manifold upper part. See INTAKE MANIFOLD UPPER PART, DISASSEMBLING 
AND ASSEMBLING .  

Checking vacuum actuator in intake manifold lower part for leaks 

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Pull vacuum hose to variable intake manifold actuator (arrow), off intake manifold tuning valve -1-.  

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Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 (connection -B-). 

manifold and is therefore not visible from the outside.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 61: Disconnecting Intake Manifold Tuning Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect vacuum hose (to actuator) to vacuum tester V.A.G 1368 (connection -A-). 

Fig. 62: Connecting Vacuum Hose (To Actuator) To Vacuum Tester V.A.G 1368 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set vacuum tester to -A/B- position.  

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Operate V.A.G 1390 several times. Create a vacuum of maximum 500 millibar. 

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Vacuum must not drop  

If the vacuum drops: 

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Replace intake manifold lower part. See INTAKE MANIFOLD LOWER PART, DISASSEMBLING 
AND ASSEMBLING .  

If the vacuum does not drop at either of the vacuum actuators:

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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Check change-over mechanics in intake manifold for freedom of movement.  

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Remove intake manifold upper part.  

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Repeat leak tests on both vacuum actuators. Check that change-over flaps move.  

If fault is detected: 

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Replace intake manifold upper part or intake manifold lower part.  

ENGINE CONTROL MODULE 

ENGINE CONTROL MODULE, REPLACING 

Work sequence 

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Print out control module identification and thereby previous control module coding. See ENGINE 
CONTROL MODULE FAULT MEMORY, INTERROGATING AND ERASING .  

Removing 

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Switch off ignition.  

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Remove inner cover on left side of plenum chamber: 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

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Carefully press off retaining tab (arrow). 

Fig. 63: Pressing Off Retaining Tab And Disconnecting Connector From Control Module 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

Replace the control module if the control module version displayed does not 
correspond to the vehicle. For the latest engine control module part number: 
See Parts catalog

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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Release and disconnect connector from control module.  

Installing 

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Install new control module and press it to left.  

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Install control module connector and lock.  

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If fault memory has been erased or engine control module was disconnected from permanent positive, 
adapt respective components to engine control module, and generate readiness code again. See 
COMPONENTS AND FUNCTIONS, ADAPTING .  

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Adapt control module to electronic immobilizer and throttle valve control module. Adapt for cruise 
control system function if necessary. See COMPONENTS AND FUNCTIONS, ADAPTING .  

Vehicles with automatic transmission 

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Adapt transmission to learn kick-down point. See COMPONENTS AND FUNCTIONS, ADAPTING . 

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Adapt control module for automatic transmission. See COMPONENTS AND FUNCTIONS, 
ADAPTING .  

Continued for all vehicles 

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Interrogate fault memory of new engine control module and erase fault memory if necessary. See 
ENGINE CONTROL MODULE FAULT MEMORY, INTERROGATING AND ERASING .  

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Road test vehicle and interrogate all fault memories: 

See Diagnostic tester VAS 5051; Guided fault finding; Vehicle system test 

Observe the valid safety precautions when performing a road test. See SAFETY PRECAUTIONS . 

During the road test the following operating conditions must be fulfilled: 

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Coolant temperature must exceed 80 °C.  

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When the temperature is reached, the operating conditions  

Idling 

Part throttle 

Enrichment 

Wide open throttle 

Overrun 

must be attained several times. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)