Volkswagen New Beetle. Manual - part 1249

 

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Volkswagen New Beetle. Manual - part 1249

 

 

Fig. 5: Identifying Exhaust Pipe, Separating Point 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Special tools and equipment 

z

Body saw e.g. V.A.G 1523 

{

Separate exhaust pipe at right angles at separating point (arrow -2-).  

{

When installing, position double clamp -4- on side markings (arrows -1- and -3-). 

Tightening torque: 40 N.m 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 6: Positioning Double Clamp On Side Markings While Installing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Aligning rear muffler free of stress 

Fig. 7: Aligning Rear Muffler Free Of Stress 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The mounting pins on exhaust pipe must run parallel with tunnel bridge (dimension -x- on left and right the 
same). 

EXHAUST GAS RECIRCULATION SYSTEM 

NOTE:

z

The function/control of the exhaust gas recirculation system is undertaken 
by Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- 
via EGR Vacuum Regulator Solenoid Valve -N18-.  

 

2003 Volkswagen New Beetle GLS 

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

  

EXHAUST GAS RECIRCULATION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

1. Bracket 

z

For bypass flap for exhaust gas recirculation cooler  

2. 22 N.m  

3. 5 N.m  

4. Intake manifold 

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With Motor for intake flap -V157-  

5. O-ring 

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Always replace  

6. EGR Vacuum Regulator Solenoid Valve -N18- 

z

Removing and installing. See EGR VACUUM REGULATOR SOLENOID VALVE -N18-
,REMOVING AND INSTALLING
  

7. 10 N.m  

8. Seal 

z

Always replace  

9. Connecting pipe  

10. Radiator 

z

For exhaust gas recirculation  

z

Installing. See EXHAUST GAS RECIRCULATION COOLER, INSTALLING .  

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM .  

11. Exhaust manifold 

z

Can only be replaced completely with turbocharger  

z

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

12. Seal 

z

Always replace  

13. Connecting pipe  

14. Seal 

z

Always replace  

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Pulsed control makes every conceivable valve position possible.  

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Replace self-locking nuts.  

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Vacuum hose connection diagram. See VACUUM HOSE CONNECTION 
DIAGRAM .  

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION 
DIAGRAM .  

NOTE:

The following list refers to items in Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

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

  

15. Bypass flap 

z

Vacuum hoses for connection diagram. See VACUUM HOSE CONNECTION DIAGRAM .  

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM .  

z

Installing. See EXHAUST GAS RECIRCULATION COOLER, INSTALLING .  

Fig. 8: Exploded View Of Intake Manifold, Exhaust Manifold & Exhaust Gas Recirculation System 
Components
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

EXHAUST GAS RECIRCULATION COOLER, INSTALLING 

Special tools and equipment 

z

V.A.G 1331 Torque wrench (5 to 50 N.m) 

Fig. 9: Identifying V.A.G 1331 Torque Wrench

NOTE:

Description of repair must be observed in order to avoid damages caused 
by stress.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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