Volkswagen New Beetle. Manual - part 1230

 

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Volkswagen New Beetle. Manual - part 1230

 

 

z

Reduced performance or load change shudders  

z

Turbocharging noises during closing of throttle valve  

Test sequence 

z

Connect hand vacuum pump VAG 1390 to vacuum connection on charge pressure bypass valve. 

Fig. 27: Connecting Hand Vacuum Pump VAG 1390 To Vacuum Connection On Charge Pressure 
Bypass Valve
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Operate hand vacuum pump. 

NOTE:

The charge pressure bypass valve is located in front of the turbocharger. It is 
opened by vacuum pressure during the overrun phase and at idling speed.

 

2003 Volkswagen New Beetle GLS 

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

  

Charge pressure bypass valve must open in direction of -arrow-.

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Operate vent valve on hand vacuum pump. 

Valve must close -arrow-. 

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If valve does not open or close, replace valve. 

EXHAUST SYSTEM, EMISSION CONTROLS 

EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Checking catalyst. See CATALYST, CHECKING 

Special tools and equipment 

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3337 Ring spanner for oxygen sensor 

NOTE:

The charge pressure bypass valve connections are secured with screw-
type clamps.

NOTE:

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After working on the exhaust system ensure that the system is not under 
stress, and that it has sufficient clearance from the bodywork. If 
necessary, loosen double and single clamps and align muffler and 
exhaust pipe so that sufficient clearance is maintained to the bodywork 
and the support rings are evenly loaded.  

z

Always replace self-locking nuts.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 28: Identifying 3337 Ring Spanner For Oxygen Sensor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Exhaust manifold, front exhaust pipe and catalyst with attachments 

1. Turbocharger  

2. Gasket for front exhaust pipe 

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Always replace  

3. Front exhaust pipe with catalyst  

4. Oxygen sensor 1 before catalyst -G39-, 50 N.m 

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Grease only the threads with G 052 112 A3; G 052 112 A3 must not get into the slots on the probe 
body  

NOTE:

The following list refers to items in Fig. 29 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove and install with ring spanner 3337  

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Checking: 

See Oxygen Sensor And Oxygen Sensor Control Before Catalyst, Checking . 

5. 6-pin connector 

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Black  

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For oxygen sensor 1 before catalyst -G39- and oxygen sensor heating -Z19-  

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Right on underside of vehicle  

6. 4-pin connector 

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Brown  

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For oxygen sensor 2 after catalyst - G130- and oxygen sensor heating -Z29-  

7. Oxygen sensor 2 after catalyst -G130-, 50 N.m 

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Installation location: in catalyst  

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Grease only the threads with G 052 112 A3; G 052 112 A3 must not get into the slots on the probe 
body  

z

Remove and install with ring spanner 3337  

z

Checking: 

See Oxygen Sensor And Oxygen Sensor Control After Catalyst, Checking . 

8. To center muffler  

9. 40 N.m 

z

Always replace  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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