Volkswagen New Beetle. Manual - part 1258

 

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Volkswagen New Beetle. Manual - part 1258

 

 

Fig. 2: Identifying Exhaust Manifold, Front Exhaust Pipe With Three Way Catalytic Converter And 
Attachments (Vehicles With Engine Code AVH, AZG, BDC)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Mufflers with mounts 

1. From Three Way Catalytic Converter (TWC)  

2. Double clamp 

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replace  

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Note installed position. See Installation position of double clamp .  

3. 25 Nm  

4. Suspended mount 

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Note installed position. See Installation position of muffler suspension .  

5. Front muffler 

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At factory, front and rear mufflers are installed as a single component. Replacement front and rear 
mufflers are supplied separately, with replacement double clamp for connecting joint.  

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Install front muffler parallel. See Aligning front muffler parallel .  

6. Separating point 

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Separation point at exhaust pipe. See Separation point at exhaust pipe .  

7. Suspended mount  

8. Bracket  

9. Rear muffler 

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At factory, front and rear mufflers are installed as a single component. Replacement front and rear 
mufflers are supplied separately, with replacement double clamp for connecting joint.  

10. Suspended mount 

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With retainer ring  

NOTE:

The following list refers to Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

11. 20 Nm  

12. Tunnel bridge  

13. 40 Nm  

14. Washer 

Fig. 3: Identifying Mufflers With Mounts Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation position of double clamp 

Fig. 4: Identifying Installation Position Of Double Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work procedure 

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Position new double clamp as shown with approx. 5 mm distance to marking -A- and tighten it. 
Tightening torque 40 Nm 

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Marking A (arrow 1) for vehicles with automatic transmission 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

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Marking S (arrow 2) for vehicles with manual transmission  

Installation position of muffler suspension 

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Angled side at foot of suspension (arrow) faces front of vehicle.  

Fig. 5: Identifying Installation Position Of Muffler Suspension 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Separation point at exhaust pipe 

Fig. 6: Identifying Separation Point At Exhaust Pipe 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Recommended special tools and equipment 

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Body saw, e.g. VAG1523  

Work procedure 

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Separate exhaust pipe at right angle to separation point (arrow 2).  

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Position replacement double clamp -4- in installation position at the edge markings (arrows 1 and 3) as 
shown when installing. Tightening torque 40 Nm 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

Aligning front muffler parallel 

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Mounting bolt at exhaust pipe must be parallel to tunnel bridge (dimension -x- same at left and right). 

Fig. 7: Aligning Front Muffler Parallel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Catalytic converter, checking 

Function test 

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Select the measuring value "Test-ID 01: Catalytic converter" and check whether the specified values are 
being reached. See DIAGNOSTIC MODE 6: CHECK TEST RESULTS OF COMPONENTS THAT 
ARE NOT CONTINUOUSLY MONITORED
 .  

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End diagnosis and switch ignition off. 

If the specified values are exceeded: 

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Replace the front exhaust pipe with catalytic converter:  

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Vehicles with engine code AEG. See item 13 .  

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Vehicles with engine code AVH, AZG, BDC. See item 10 .  

Continuation for all vehicles 

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Erase DTC memory of Engine Control Module (ECM). See DIAGNOSTIC MODE 4: RESET/ERASE 
DIAGNOSTIC DATA
 .  

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Generate readiness code. See READINESS CODE, GENERATING .  

SECONDARY AIR INJECTION (AIR) SYSTEM 

WARNING:

Observe the following for all installations, especially in engine 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Exhaust System Emission Controls, 2.0L Generic Scan Tool - New Beetle

  

 

 

 

 

 

 

 

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