Volkswagen New Beetle. Manual - part 1221

 

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Volkswagen New Beetle. Manual - part 1221

 

 

Charge air cooling components, removing and installing

1. Air ducting 

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Clip in at charge air cooler  

2. 10 N.m  

3. Charge Air Pressure Sensor -G31- 

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

4. O-ring 

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Always replace  

5. Rubber grommet 

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With sleeve  

6. 10 N.m  

7. Intake hose 

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Between intake manifold and charge air cooler  

8. Heat protection mat 

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Must enclose upper hose clamp  

9. Screw-type clip 

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Only vehicles with engine code APH  

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Vehicles with engine codes AWP, AWV, with quick release connection (with O-ring and securing 
brace)  

10. Connecting pipe/hose 

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Between upper and lower air guiding ducts  

11. Air duct  

12. Bracket  

13. Connecting pipe/hose  

14. Charge air cooler 

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Installation location: in front of wheelhousing, right front 

NOTE:

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All hose connections secured by clamps.  

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Charge air system must be free of leaks.  

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When installing observe markings on hoses and components. 

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Observe installed position of heat protection mats  

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 4: Removing And Installing Charge Air Cooling Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Turbocharging diagram 

Only engine code APH 

Engine codes AWP, AWV. See ENGINE CODES AWP, AWV 

1. Connecting pipe/hose 

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From gravity valve on fuel tank. See EVAPORATIVE EMISSION (EVAP) SYSTEM 
COMPONENTS, SERVICING
 , Item 1  

2. Vacuum reservoir 

NOTE:

The following list refers to items in Fig. 5 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Below rear right wheelhousing  

3. Non-return valve 

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For Evaporative Emission (EVAP) system  

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Observe installation position: arrows point in direction of flow  

4. Turbocharger  

5. Pressure unit 

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For charge pressure regulator valve in turbocharger  

6. Charge pressure bypass valve 

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

7. Wastegate Bypass Regulator Valve -N75-*/** 

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The valve will be activated from engine control module (pulsed)  

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Checking activation with output Diagnostic Test Mode (DTM) 

See Output Diagnostic Test Mode (DTM) 

8. Brake servo  

9. Air cleaner with Mass Air Flow (MAF) sensor -G70-  

10. Crankcase breather pressure regulating valve  

11. Vacuum booster  

12. Fuel pressure regulator  

13. Crankcase breather  

14. Intake pipe  

15. Non-return valve 

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Observe installation position: arrows point in direction of flow  

16. Recirculating valve for turbocharger -N249-*/** 

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Checking. See RECIRCULATING VALVE FOR TURBOCHARGER -N249-, CHECKING  

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Output Diagnostic Test Mode (DTM) 

See Output Diagnostic Test Mode (DTM) 

17. Vacuum reservoir 

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Bolted onto cylinder head cover  

18. Secondary air injection (AIR) solenoid valve -N112-*/** 

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Checking. See SECONDARY AIR INJECTION (AIR) SOLENOID VALVE -N112-, 
CHECKING
  

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Output Diagnostic Test Mode (DTM) 

See Output Diagnostic Test Mode (DTM) 

19. Charge air cooler  

 

2003 Volkswagen New Beetle GLS 

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

  

20. EVAP canister purge regulator valve -N80-*/** 

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On right side of engine compartment above wheelhousing liner  

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Checking. See EVAP CANISTER PURGE REGULATOR VALVE -N80-, CHECKING  

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Output Diagnostic Test Mode (DTM) 

See Output Diagnostic Test Mode (DTM) 

Fig. 5: Turbocharging Diagram - Engine Code APH 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes AWP, AWV 

1. Connecting pipe/hose 

NOTE:

The following list refers to items in Fig. 6 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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