Volkswagen New Beetle. Manual - part 1253

 

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Volkswagen New Beetle. Manual - part 1253

 

 

Fig. 10: Disconnecting Connector From Oxygen Sensor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove warm air collector plate.  

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Remove securing bolts -2- from exhaust pipe on exhaust manifold. 

Fig. 11: Removing Securing Bolts From Exhaust Pipe On Exhaust Manifold 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Unbolt four upper nuts -1- as well as four lower from exhaust manifold to cylinder head.  

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Remove exhaust manifold upward.  

Installing 

NOTE:

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To prevent exhaust gases escaping, the contact surfaces between the 
exhaust manifold, exhaust pipe and cylinder head must be bolted together 
correctly.  

 

2003 Volkswagen New Beetle GLS 

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

  

Installation is performed in the reverse sequence. Note the following: 

z

Tightening torques. See EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND CATALYTIC 
CONVERTER WITH ATTACHMENTS
 and ENGINE CODES AVH, AZG, BDC, BEV, BGD 

{

Erase fault memory. See ENGINE CONTROL MODULE FAULT MEMORY, 
INTERROGATION AND ERASING
 .  

SECONDARY AIR SYSTEM 

FUNCTION 

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The secondary air system blows air in behind the exhaust valve for a maximum of 100 seconds after the 
cold start (+5° C...+33° C coolant temperature). This produces an oxygen rich exhaust gas which initiates 
afterburning and reduces the heating-up phase of the catalytic converter.  

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Activation occurs from Motronic Engine Control Module (ECM) -J220- via the Secondary Air Injection 
(AIR) pump relay -J229- to Secondary Air Injection (AIR) solenoid valve -N112-, change-over valve and 
combination valve. Only vehicles with engine code AEG up to Model Year 1999, 05.99.  

z

If the secondary air pump motor is activated it produces an overpressure and opens the combination valve 
at 60 to 70 mbar. Only vehicles with engine codes: AEG as of Model Year 1999, 06.99, AVH, AZG, 
BDC, BEV and BGD.  

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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 self-diagnosis. When doing 
this the oxygen sensor regulation must be active.  

SECONDARY AIR SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Engine codes AEG up to Model Year 1999, 05.99 

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Engine codes: AEG as of Model Year 1999, 06.99, AVH, AZG, BEV. See ENGINE CODES: AEG AS 
OF MODEL YEAR 1999 (06.99) - AVH, AZG AND BEV
 .  

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Engine codes BDC, BGD. See ENGINE CODES: BDC, BGD .  

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Replace all seals/gaskets and self-locking nuts.  

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

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Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

NOTE:

The following list refers to items in Fig. 12 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. Connector 

z

2-pin  

2. Secondary Air Injection (AIR) solenoid valve -N112-  

3. To union on pipe to brake servo  

4. Secondary Air Injection (AIR) pump relay -J299- 

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In protective housing for relays. See Secondary Air Injection (AIR) pump relay -J299-  

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In engine compartment (in cable guide next to brake master cylinder)  

5. O-ring 

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Replace  

6. Pressure hose 

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Check if seated securely  

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Press together at front to release  

7. Intake hose 

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From air cleaner upper part  

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For secondary air injection pump  

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Check if seated securely  

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Press together at front to release  

8. Secondary Air Injection (AIR) pump motor -V101- 

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Activation via AIR pump relay -J299-  

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Checking function. See SECONDARY AIR INJECTION PUMP MOTOR, CHECKING  

9. 10 N.m  

10. Retainer 

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For secondary air pump motor  

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Fastened to intake manifold  

11. Connector 

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2-pin  

12. 25 N.m  

13. Intake manifold lower part  

14. To union on exhaust manifold  

15. 40 N.m  

16. Connecting pipe  

17. Nuts/bolts, 60 N.m  

18. Warm air collector plate 

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With mounting for combination valve  

19. Seal 

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Replace  

20. Combination valve 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Checking. See COMBINATION VALVE, CHECKING  

z

Removing and installing. See COMBINATION VALVE, REMOVING AND INSTALLING  

Fig. 12: Exploded View Of Secondary Air System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes: AEG as of Model Year 1999 (06.99) - AVH, AZG and BEV 

1. Combination valve 

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Checking. See COMBINATION VALVE, CHECKING  

z

Removing and installing. See COMBINATION VALVE, REMOVING AND INSTALLING  

2. Secondary Air Injection (AIR) pump relay -J299- 

z

In protective housing for relays. See Secondary Air Injection (AIR) pump relay -J299-  

z

In engine compartment (in cable guide next to brake master cylinder)  

3. O-ring 

z

Replace  

4. Pressure hose 

z

Check if seated securely  

z

Press together at front to release  

5. Intake hose 

z

From air cleaner upper part  

z

For secondary air injection pump  

z

Check if seated securely  

z

Press together at front to release  

6. Secondary Air Injection (AIR) pump motor -V101-

NOTE:

The following list refers to items in Fig. 13 .

 

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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