Volkswagen New Beetle. Manual - part 1247

 

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Volkswagen New Beetle. Manual - part 1247

 

 

Fig. 28: Connecting Test Box VAG 1598/22 To ECM Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check wiring for open circuit between Test Box and harness connector using wiring diagram.  

Up to MY 1999 

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Socket 1 + terminals 2 + 28  

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Socket 2 + terminal 29  

From MY 2000 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

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Socket 1 + terminals 1 + 2  

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Socket 2 + terminal 61  

Wire resistance: 1.5 ohms maximum 

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Check wires for short to one another, to vehicle Ground and to battery Positive (+). 

Specification: "INFINITE" ohms 

If wiring OK: 

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Replace Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248: 

See Engine Control Module (ECM), Replacing .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

1998-2004 ENGINE

Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW 

EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING 

FRONT EXHAUST PIPE AND CATALYST WITH COMPONENTS 

1. From turbocharger  

2. Seal 

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Always replace  

3. 25 N.m 

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Always replace  

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Oil threaded studs with G 052 112 A3  

4. Front exhaust pipe with catalytic converter  

5. To rear muffler  

6. Connector 

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Connection in protective housing, on vehicle underside right side  

7. Mounting  

8. 25 N.m  

9. Heated Oxygen Sensor (HO2S) -G39-, 50 N.m 

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Grease only threads with hot bolt paste G 052 112 A3 (anti-seize compound). Grease must not get 
into slots on sensor body  

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Remove and install with 3337  

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To remove, separate connection and move wiring aside 

NOTE:

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Removing and installing exhaust manifold. See TURBOCHARGER 
SYSTEM COMPONENTS, REMOVING AND INSTALLING .  

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After working on the exhaust system make sure that the system is not 
under stress, and that there is 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.  

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Replace self-locking nuts.  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW

  

Fig. 1: Front Exhaust Pipe And Catalyst With Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

MUFFLER WITH MOUNTINGS 

1. From catalytic converter  

2. Double clamp 

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Note installation position. See Fig. 3 .  

3. 25 N.m  

4. Mounting 

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Note installation position. See Fig. 4 .  

5. Separating point 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - New Beetle, 1.9L 4-Cyl. - BEW

  

 

 

 

 

 

 

 

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