Volkswagen New Beetle. Manual - part 1252

 

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Volkswagen New Beetle. Manual - part 1252

 

 

12. 40 N.m  

Fig. 4: Removing And Installing Muffler With Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation Position Of Double Clamp 

Fig. 5: Identifying Installation Position Of Double Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

Position double clamp approx. 5 mm away from mark "A" (arrow -2-).  

Installation Position Of Mounting 

Angled side on base of mounting (arrow) points forward.

NOTE:

z

Mark "A" (arrow -2-) is valid for models with either a manual or an 
automatic transmission.  

z

Mark "S" (arrow -1-) is not valid for the engine codes in this manual.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 6: Identifying Installation Position Of Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Separating point on exhaust pipe 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

Body saw e.g. V.A.G 1523  

Fig. 7: Identifying Separating Point On Exhaust Pipe 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

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

z

When installing, position repair double clamp -4- at side markings (arrows -1- and -3-). Tighten torque: 
40 N.m  

Aligning Center Muffler Stress Free 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD)

  

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

Fig. 8: Aligning Center Muffler Stress Free 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

MUFFLER, REMOVING AND INSTALLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

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

Removing 

z

Remove engine cover.  

z

Unscrew wiper arms (M8 hex nuts = 20 N.m). 

See WIPER ARMS . 

z

Remove plenum chamber cover (outer) and plenum chamber sealing part. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 9: Identifying V.A.G 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

See PLENUM CHAMBER SEALING ASSEMBLY, REMOVING AND INSTALLING . 

z

Remove intake manifold upper part: See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING
 . 

z

Pull pressure and vacuum hoses off combination valve.  

z

Remove connecting pipe between combination valve and exhaust manifold.  

z

Remove insulation tray. 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

z

Remove right hand inner constant velocity joint protective cover from engine if installed.  

z

Remove engine/exhaust manifold support.  

z

Disconnect connector for oxygen sensor -1- and move wiring clear. 

NOTE:

Seal the intake ports in the intake manifold lower part with clean cloths.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 2.0L New Beetle (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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