Volkswagen New Beetle. Manual - part 1235

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1233  1234  1235  1236   ..

 

 

Volkswagen New Beetle. Manual - part 1235

 

 

See Readiness Code, Displaying . 

If the display indicates as described: 

z

Remove engine speed adjuster VAG1788/10 from accelerator pedal.  

z

Press --> key.  

Indicated on display: 

Fig. 41: V.A.G 1551 Scan Tool Display - Checking Catalyst (6 Of 6) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.  

z

Switch ignition off.  

 

2003 Volkswagen New Beetle GLS 

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

  

SECONDARY AIR SYSTEM 

Function 

The secondary air system blows air in behind the exhaust valve for 100 seconds during a cold start (+5° C to 
+33° C coolant temperature). This produces an oxygen rich exhaust gas, causes afterburning and reduces the 
heating-up phase of the catalyst. Activation occurs from the Motronic control module (ECM) -J220- via the 
Secondary air injection (AIR) pump relay -J299- to secondary air inlet valve (-N112-, change-over valve) and 
combi-valve. 

Additionally, after each subsequent engine start (up to max. 96° C engine temperature), the secondary air 
system will switch in for 10 seconds during idling and will be checked by the On Board Diagnostic (OBD). 
When this occurs, the oxygen sensor control must be active. 

Secondary air system components, removing and installing 

1. Gasket 

z

Replace  

2. Combi-valve 

z

Checking. See COMBI-VALVE, CHECKING

WARNING:

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

z

Route all sorts of lines (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.  

z

Make sure sufficient clearance to all moving or hot components.  

NOTE:

z

Components marked with an * are checked by the On Board Diagnostic 
(OBD). 

See On Board Diagnostic (OBD) . 

z

Components marked with ** are checked by the Output Diagnostic Test 
Mode (DTM). 

See Output Diagnostic Test Mode (DTM) . 

z

Secondary air injection pump relay -J299-**. See Secondary Air Injection 
(AIR) Pump Relay - J299  

NOTE:

The following list refers to items in Fig. 42 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Removing and installing. See COMBI-VALVE, REMOVING AND INSTALLING  

3. Connecting pipe/hose 

z

To distributor piece at vacuum reservoir on cylinder head cover  

z

Check Turbocharging diagram: 

Engine code APH: See TURBOCHARGING DIAGRAM . 

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

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

z

Secured to bracket with 6 N.m  

z

Bracket secured to cylinder head cover  

z

Resistance: 21-24 ohms  

z

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

5. Connector 

z

Black, 2-pin  

6. O-Ring 

z

Replace  

7. Secondary air injection (AIR) pump relay -J299-*/** 

z

In relay/fuse box (pushed into cable guide next to brake master cylinder). See Secondary Air 
Injection (AIR) Pump Relay - J299
  

8. Pressure hose 

z

Ensure seated tightly  

z

Press together at front to release  

9. 10 N.m  

10. Bracket  

11. Retaining clip  

12. Intake hose 

z

From upper air filter housing  

z

Ensure seated tightly  

z

Press together at front to release  

13. Secondary air injection (AIR) pump motor -V101-** 

z

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

14. Bracket 

z

For secondary air injection pump motor  

z

Secured to intake manifold  

15. 25 N.m  

16. Intake pipe  

 

2003 Volkswagen New Beetle GLS 

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

  

17. Cylinder head  

18. 10 N.m  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1233  1234  1235  1236   ..