Volkswagen New Beetle. Manual - part 1222

 

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Volkswagen New Beetle. Manual - part 1222

 

 

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From Leak detection pump (LDP) -V144-  

2. Vacuum reservoir 

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Under right rear wheel well liner  

3. Non-return valve 

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Observe installation position: arrows point in direction of flow  

4. Turbocharger  

5. Pressure unit 

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For charge air pressure control valve  

6. Crankcase breather pressure regulating valve  

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: 

See Output Diagnostic Test Mode (DTM) 

8. Brake servo  

9. Combi-valve 

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For secondary air system  

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Checking. See COMBI-VALVE, CHECKING  

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

11. Non-return valve 

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Observe installation position.  

12. Charge pressure bypass valve 

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

13. Secondary air injection pump motor -V101- 

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Checking function. See SECONDARY AIR INJECTION (AIR) PUMP MOTOR -V101-, 
CHECKING
  

14. Vacuum booster  

15. Crankcase breather  

16. Fuel pressure regulator  

17. Intake pipe  

18. Recirculating valve for turbocharger -N249-  

19. Vacuum reservoir  

20. Secondary air injection (AIR) solenoid valve -N112- 

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

21. Charge air pressure sensor -G31- 

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Replace O-ring if damaged  

 

2003 Volkswagen New Beetle GLS 

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

  

22. Charge air cooler  

23. Evaporative emission (EVAP) canister purge regulator valve -N80- 

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Checking activation: 

See Output Diagnostic Test Mode (DTM) 

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

24. Connecting hose 

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To EVAP canister  

Fig. 6: Turbocharging Diagram - Engine Code AWP, AWV 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Rules of cleanliness 

 

2003 Volkswagen New Beetle GLS 

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

  

When working on the exhaust gas turbocharger, pay careful attention to the following 5 rules: 

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Thoroughly clean all unions and the adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

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Carefully cover opened components or seal if the repair cannot be carried out immediately.  

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Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose (e.g. in tool boxes etc.).  

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When the system is open: Do not work with compressed air if this can be avoided. Do not move vehicle 
unless absolutely necessary.  

Safety precautions 

Observe the following if test and measuring instruments are required during a test drive: 

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Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this 
location.  

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If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in 
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the 
airbag is triggered.  

CHARGE AIR PRESSURE SYSTEM, CHECKING 

Charge air pressure regulation, checking (APH) 

Engine codes AWP, AWV. See Charge air pressure regulation, checking (AWP, AWV) . 

Special tools and equipment 

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VAG 1397 A Turbocharger tester  

WARNING:

When doing any repair work, especially in the engine compartment, due 
to the cramped conditions, pay attention to the following: 

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Route all sorts of lines/hoses (e.g. for fuel, hydraulics, evaporative 
emissions system, coolant, refrigerant, brake fluid and vacuum lines 
and hoses) and electrical wiring so that the original positions are 
restored.  

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Make sure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 7: Identifying VAG 1397 A Turbocharger Tester 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Check conditions 

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No leaks on intake and exhaust systems  

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Engine oil temperature min. 60° C  

Test sequence 

Measure the charge pressure under full load, while driving or on a rolling road. Test duration per measurement 
max. 10 seconds. 

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Pull off connecting hose running between intake manifold and fuel pressure regulator at intake manifold 
and connect in turbocharger tester VAG 1397 A using T-piece. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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