Volkswagen New Beetle. Manual - part 1732

3. From charge air cooler  

4. Gasket 

z

replace  

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Coating (bead) to intake manifold  

5. 25 Nm  

6. Gasket 

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Note installed position  

7. Bracket 

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For shielding plate, item no. 9  

8. Washer  

9. Heat shield 

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Engages in bracket, item no. 7  

10. Turbocharger 

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Replace as complete unit with exhaust manifold only  

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To remove the exhaust turbocharger, disconnect right drive axle from transmission:  

See FRONT AXLE SHAFT . 

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After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. 
This ensures adequate oil supply to the turbocharger.  

11. Vacuum diaphragm 

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For boost pressure regulation  

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Part of turbocharger, cannot be replaced  

12. From air filter  

13. Gasket 

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replace  

14. Seal 

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replace  

15. Oil return line 

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to cylinder block  

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new version. See New version of oil return line and support .  

16. Banjo fitting, 40 Nm  

17. 15 Nm  

18. 40 Nm  

19. Brace 

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Turbocharger - cylinder block  

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new version. See New version of oil return line and support .  

20. 25 Nm  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Turbocharger, G-Charger - New Beetle

  

21. Gasket 

z

replace  

22. Front exhaust pipe  

23. Connecting piece 

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Coat threads and bolt head contact surface with G 052 112 A3  

24. 10 Nm  

25. Oil supply line 

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Before installing, fill turbocharger with oil at connection of oil supply line  

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Tighten to 22 Nm  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Turbocharger, G-Charger - New Beetle

  

Fig. 2: Exploded View Of Turbo Charger & Exhaust Manifold Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

New version of oil return line and support 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Turbocharger, G-Charger - New Beetle

  

1. Support for turbocharger - cylinder block  

2. 40 Nm  

3. Connection, 40 Nm  

4. Oil return line with union nut 

Tighten to 30 Nm on cylinder block 

5. 15 Nm  

6. Gasket 

replace 

7. 25 Nm  

Fig. 3: Identifying Oil Return Line And Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Parts of charge air cooler, removing and installing 

1. Connection hose  

2. Connection tube 

NOTE:

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All hose connections are secured with clamps. 

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Charge air system must be properly sealed.  

NOTE:

The following list refers to Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Turbocharger, G-Charger - New Beetle