Volkswagen New Beetle. Manual - part 1256

 

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Volkswagen New Beetle. Manual - part 1256

 

 

INTERROGATION AND ERASING 

z

Fuse for Secondary Air Injection (AIR) pump relay -J299- located in the main fuse box on the battery is 
OK. 

Fig. 22: Identifying Fuses Of Secondary Air Injection (AIR) Pump Relay Located In Main Fuse 
Box
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Secondary air injection pump vacuum lines and hose connections free of leaks.  

z

Secondary air injection pump vacuum lines not blocked/kinked.  

Work sequence 

z

Remove engine cover.  

z

Remove pressure hose (arrow) from secondary air injection pump motor. 

Fig. 23: Removing Pressure Hose From Secondary Air Injection Pump Motor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Activate secondary air injection pump relay via final control diagnosis. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 . 

z

Secondary air injection pump motor must run and air must exit outlet connection  

If the motor runs, but no air exits: 

z

Replace secondary air injection pump motor.  

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

z

Activate secondary air injection pump relay via final control diagnosis. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 .  

z

Check activation of secondary air injection pump motor. See COMPONENTS AND FUNCTIONS, 
ADAPTING
 .  

SECONDARY AIR INJECTION SOLENOID VALVE, CHECKING 

Only engine code AEG up to Model Year 1999, 05.99 

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

z

Adapter set V.A.G 1594 

Fig. 24: Identifying Adapter Set V.A.G 1594 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

V.A.G 1527 B Diode test lamp  

z

Wiring diagram 

NOTE:

To release, press buttons together on hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 25: Identifying V.A.G 1527 B Diode Test Lamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

Coolant temperature 5...33° C  

z

Secondary air injection pump motor OK  

Work sequence 

z

Pull upper vacuum hose (arrow) off secondary air injection solenoid valve -1-. 

Fig. 26: Disconnecting Upper Vacuum Hose From Secondary Air Injection Solenoid Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Start engine and run at idling speed. 

z

When secondary air injection pump motor runs, a vacuum must be detectable at secondary air 
injection pump union.  

 

2003 Volkswagen New Beetle GLS 

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

  

If a vacuum cannot be detected: 

z

Switch off ignition.  

z

Disconnect 2-pin connector from secondary air injection solenoid valve.  

z

Connect diode test lamp V.A.G 1527 B to disconnected connector using adapter cables from V.A.G 1594 
C. 

Fig. 27: Connecting Diode Test Lamp V.A.G 1527 B To Disconnected Secondary Air Injection 
Solenoid Valve Connector
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Start engine and run at idling speed. 

z

LED must light up  

LED lights up (voltage supply OK): 

z

Replace secondary air injection solenoid valve.  

LED does not light up: 

z

Connect 2-pin connector.  

z

Check activation of valve. See COMPONENTS AND FUNCTIONS, ADAPTING .  

z

Check wiring connections plate according to wiring diagram. 

See appropriate WIRING DIAGRAMS article. 

z

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

z

Read readiness code. See COMPONENTS AND FUNCTIONS, ADAPTING .  

z

If fault memory has been erased or engine control module separated from permanent positive power 
supply, generate readiness code again. See COMPONENTS AND FUNCTIONS, ADAPTING 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1254  1255  1256  1257   ..