Volkswagen New Beetle. Manual - part 1738

1. Vacuum unit 

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For variable intake manifold  

2. Vacuum unit 

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For bypass flap for exhaust gas recirculation cooler  

3. Vacuum unit 

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For charge pressure control  

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Integral part of turbocharger cannot be replaced  

4. Intake Manifold Runner Control (IMRC) valve -N316- 

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Installed position, See Fig. 8  

5. Non-return valve 

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White connection to distributor, item 8  

6. Wastegate bypass regulator valve N75- 

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Installed position, See Fig. 8  

7. Exhaust Gas Recirculation (EGR) cooler switch-over valve -N345- 

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Installed position, See Fig. 8  

8. Distributor  

9. Air cleaner  

10. Vacuum union 

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Between tandem pump and brake booster  

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With non-return valve  

11. Vacuum reservoir  

NOTE:

The following list refers to items in Fig. 7 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW

  

Fig. 7: Turbocharger Vacuum Hose Connection Diagram 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Solenoid valves, installed position  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW

  

The bracket with the solenoid valves is installed onto plenum chamber sealing cover right side.

The valve connectors are not coded, only the protective sleeves are different. 

Fig. 8: Identifying Solenoid Valves Installed Position 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Connector application 

SOLENOID VALVE CONNECTOR APPLICATION 

No.

Component

(1)

 Connector

1

Intake Manifold Runner Control (IMRC) Valve -N316-

with straight protective sleeve

2

Wastegate Bypass Regulator Valve -N75-

with rubber grommet

3

Exhaust Gas Recirculation (EGR) Cooler Switch-over Valve -N345-

with angled protective sleeve

(1)

To identify connectors, see Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW

  

CHARGE AIR COOLER, REMOVING AND INSTALLING

Removing 

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Remove upper charge air pipe -1- with connecting hose -2- by removing bolt/screw -3- and releasing 
connector (arrow). 

Fig. 9: Removing Upper Charge Air Pipe With Connecting Hose By Removing Bolt/Screw And 
Releasing Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove front turn signal, right side. 

See FRONT TURN SIGNAL LIGHTS, REMOVING AND INSTALLING . 

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Disconnect connector (arrow) from Manifold Absolute Pressure (MAP) sensor -G71- with Intake Air 
Temperature (IAT) sensor -G72-.  

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Remove front right wheelhouse liner. 

See FRONT WHEEL HOUSING LINER, ASSEMBLY OVERVIEW

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW