Volkswagen New Beetle. Manual - part 1239

 

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Volkswagen New Beetle. Manual - part 1239

 

 

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Fuse for secondary air injection pump relay -J299- -arrow- located in the main fuse box on the battery is 
OK. 

Fig. 54: Locating Fuse For Secondary Air Injection Pump Relay -J299 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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The battery voltage must be at least 11.5 V.  

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The suction hose for secondary air pump is not blocked or kinked  

Test sequence 

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Remove engine cover.  

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Disconnect pressure hose from secondary air injection pump motor. 

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Activate secondary air injection pump relay via Output Diagnostic Test Mode (DTM). 

See Output Diagnostic Test Mode (DTM) . 

Secondary air pump motor must run at intervals, and air must exit the outlet connections. 

If the motor runs, but no air exits: 

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Proceed with Output Diagnostic Test Mode (DTM) until completed.  

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

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Switch ignition off.  

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Replace secondary air injection pump motor.  

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Check DTC memory. 

See Diagnostic Trouble Code (DTC) Memory, Checking And Erasing .

NOTE:

To release, press together the buttons on the hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

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Read readiness code. 

See Readiness Code, Displaying . 

If the DTC memory has been erased or the engine control module separated from the permanent positive, the 
readiness code must be generated again. 

See Readiness Code, Displaying . 

If the secondary air injection pump motor does not run at intervals: 

z

Check activation of secondary air injection pump motor: 

See Output Diagnostic Test Mode (DTM) . 

Secondary air injection (AIR) solenoid valve -N112-, checking 

Special tools and equipment 

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Adapter set VAG1594 

Fig. 55: Identifying Adapter Set VAG1594 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Diode test lamp VAG1527B 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 56: Identifying Diode Test Lamp VAG1527B 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test conditions 

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Engine oil temperature 5 to 33° C  

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Secondary air injection pump motor OK  

Test sequence 

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Pull vacuum hose off combi-valve -arrow-. 

Fig. 57: Pulling Vacuum Hose Off Combi-Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Start engine and run at idling speed.  

When secondary air pump motor runs, vacuum must be perceptible at vacuum hose from secondary air injection 
solenoid valve. 

 

2003 Volkswagen New Beetle GLS 

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

  

If no intake manifold vacuum is perceptible:

z

Switch ignition off.  

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Check activation of AIR solenoid valve -N112-: 

See Output Diagnostic Test Mode (DTM) . 

Combi-valve, removing and installing 

Special tools and equipment 

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VAG1331 Torque wrench (5 to 50 N.m) 

Fig. 58: Identifying VAG1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Remove engine cover.  

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Remove intake air hose. 

See Air Cleaner, Disassembling And Assembling . 

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Remove pressure hose between combi-valve and secondary air pump at combi-valve. 

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Pull vacuum hose off combi-valve.  

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Unbolt combi-valve. For this, use flexible insert and 4 mm socket head from 3/8" socket set. 

NOTE:

Always replace all gaskets and O-rings.

NOTE:

To release, press together the buttons on the hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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