Volkswagen New Beetle. Manual - part 1218

 

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Volkswagen New Beetle. Manual - part 1218

 

 

Fig. 151: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAG 1342 Oil pressure tester  

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VAG 1527 BLED test light  

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VAG 1594 A Adapter set  

Function of the dynamic oil pressure warning indicator 

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When not under pressure, the oil pressure switch is open and will close when the operating pressure is 
attained.  

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The oil pressure warning will be activated approx. 10 seconds after switching the ignition on.  

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Switch-in delay of oil pressure warning: approx. 3 seconds.  

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Switch-off delay of oil pressure warning: approx. 5 seconds. 

See appropriate WIRING DIAGRAM article. 

Checking warning lamp 

After switching on the ignition without engine started, the oil pressure warning lamp in instrument cluster must 
light for approx. 3 seconds and then go out. The test will be terminated if the engine is running. 

Criteria for warning 

Switching on the optical oil pressure warning (the oil pressure warning lamp flashes) and the buzzer sounding 
three times for the acoustical warning will occur under one of the following conditions: 

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"Ignition on," engine stationary, oil pressure switch closed 

NOTE:

Functional check and servicing the optical and acoustic oil pressure 
warning:

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

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Engine speed above 1500 RPM, oil pressure switch open 

Test conditions 

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Engine oil level OK. See PART II  

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Oil Pressure Warning Lamp -K3- must light up for approx. 3 seconds when ignition is switched on  

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Engine oil temperature at least 80° C (radiator fan must have run once)  

Test sequence 

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Remove Oil Pressure Switch -F1- and screw into tester. 

Fig. 152: Removing Oil Pressure Switch -F1- And Screwing Into Tester 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Screw tester into oil filter bracket in place of oil pressure switch.  

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Connect brown wire of tester to Ground (-).  

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Connect LED test light VAG 1527 B using aux. cables from VAG 1594 A to battery positive (+) and oil 

NOTE:

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If the oil pressure switch is closed, the warning lamp will remain 
switched on if the engine speed is above 5000 RPM. The warning 
lamp will be switched off again if the engine speed is below 5000 
RPM.  

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If the oil pressure switch is open for 0.3-3.0 seconds when the engine 
speed is above 1500 RPM, it will be stored in the combi-processor in 
the instrument cluster. If this condition occurs three times when the 
engine is running, the oil pressure warning will be activated and will 
not be cancelled even below 1500 RPM. The oil pressure warning will 
be cancelled when the oil pressure switch is closed for longer than 5 
seconds at an engine speed above 1500 RPM, or when the ignition is 
switched off.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

pressure switch. 

LED must not light up. 

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If LED lights up, replace 1.4 bar Oil Pressure Switch -F1-.  

When the LED does not light up: 

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Start engine and run at idling speed: 

At 1.2-1.6 bar LED must light up, otherwise replace oil pressure switch. 

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Check oil pressure at different RPMs: 

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Idle: at least 2.0 bar  

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2000 RPM: 2.7 to 4.5 bar  

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Above 2000 RPM: maximum 7.0 bar  

If the specifications are not obtained: 

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Repair mechanical damage (e.g. bearing damage).  

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Replace oil filter bracket with pressure relief valve (see OIL PAN, REMOVING AND INSTALLING , 
item 23) or replace oil pump (see PART II , item 21).  

At higher engine speeds the oil pressure must not exceed 7.0 bar. 

If the specification is exceeded: 

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Check oil galleys.  

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If necessary, replace oil filter bracket with pressure relief valve. See OIL PAN, REMOVING AND 
INSTALLING
 , item 23.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 1.8 L 4-Cyl. (APH, AWV, AWP)

  

1998-2004 ENGINE

Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP) 

TURBOCHARGER, G-CHARGER 

CHARGE AIR SYSTEM WITH TURBOCHARGER 

Removing and installing turbocharger with attachments. See TURBOCHARGER WITH ATTACHMENTS, 
REMOVING AND INSTALLING
 . 

Removing and installing parts of charge air cooler. See CHARGE AIR COOLING COMPONENTS, 
REMOVING AND INSTALLING
 . 

Observe rules of cleanliness. See RULES OF CLEANLINESS . 

Observe safety precautions. See SAFETY PRECAUTIONS . 

Checking charge air pressure system. See CHARGE AIR PRESSURE SYSTEM, CHECKING . 

Turbocharger with attachments, removing and installing (Part I) 

1. 40 N.m 

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Coat threads with G 052 112 A3  

2. Seal 

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Always replace  

3. 10 N.m 

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Must not be loosened  

4. Pressure unit 

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For charge pressure regulator valve in turbocharger  

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Checking charge pressure regulation. See CHARGE AIR PRESSURE SYSTEM, CHECKING  

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Can only be replaced in conjunction with turbocharger 

NOTE:

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All hose connections are secured with clamps.  

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Charge air system must be free of leaks.  

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Always replace self-locking nuts.  

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Charge air pressure hose and all the respective connections must be free 
of grease etc. before installing.  

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Assembly tool VAS 5024 or hose clip pliers VAG 1921 are recommended 
for installing spring-type clips.  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.8L (APH, AWV & AWP)

  

 

 

 

 

 

 

 

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