Volkswagen New Beetle. Manual - part 1260

 

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Volkswagen New Beetle. Manual - part 1260

 

 

Fig. 9: Identifying Parts Of Secondary Air Injection System (Vehicles With Engine Code BDC) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Secondary Air Injection (AIR) pump relay -J299-* (arrow) 

In protective housing for relays in engine compartment (inserted in wiring beside master brake cylinder). 

Fig. 10: Identifying Secondary Air Injection (Air) Pump Relay -J299- 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Secondary Air Injection (AIR) system, checking for proper seal 

Function test 

NOTE:

z

Remove battery Ground (GND) strap if tools are necessary for removal of 
relays or control modules from the relay carrier.  

z

Obtain radio code for radios with anti-theft coding before disconnecting 
battery.  

z

Checking relay activation:  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Select the measuring value "Test-ID 03: Secondary Air Injection (AIR) system" and check whether the 
specified values are being reached. See DIAGNOSTIC MODE 6: CHECK TEST RESULTS OF 
COMPONENTS THAT ARE NOT CONTINUOUSLY MONITORED
 .  

z

End diagnosis and switch ignition off.  

If the specified values are not reached: 

Checking Proper Seal 

z

Check the connection pipes and hoses between Secondary Air Injection (AIR) pump motor and 
combination valve for proper seal. 

Secondary Air Injection (AIR) system components, removing and installing: 

z

Vehicles with engine code AEG, AVH, AZG. See PARTS OF SECONDARY AIR INJECTION 
(AIR) SYSTEM, REMOVING AND INSTALLING (VEHICLES WITH ENGINE CODE 
AEG, AVH, AZG)
 .  

z

Vehicles with engine code BDC. See PARTS OF SECONDARY AIR INJECTION (AIR) 
SYSTEM, REMOVING AND INSTALLING (VEHICLES WITH ENGINE CODE BDC)
 .  

z

Repeat function test.  

z

Check hoses and hose connections for secure seating.  

z

Repeat function test.  

If malfunction is no longer present: 

z

Erase DTC memory of Engine Control Module (ECM). See DIAGNOSTIC MODE 6: CHECK TEST 
RESULTS OF COMPONENTS THAT ARE NOT CONTINUOUSLY MONITORED
 .  

z

Generate readiness code. See READINESS CODE, GENERATING .  

Secondary Air Injection (AIR) Solenoid Valve (Vehicles with engine code AEG up to 05.99), checking 

Solenoid valve is closed when no voltage is present. 

Recommended special tools and equipment 

z

VAG1526 multimeter or VAG1715 multimeter  

z

VAG1594 connector test kit  

z

Wiring diagram  

Test requirements 

z

Main fuses must be OK. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 11: Identifying Main Fuses (Secondary Air Injection Solenoid Valve: Engine Code AEG Up To 
05.99)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Ignition switched off.  

Test sequence 

z

Disconnect 2-pin connector from Secondary Air Injection (AIR) Solenoid Valve -N112- (arrow). 

Fig. 12: Disconnecting 2-Pin Connector From Secondary Air Injection Solenoid Valve -N112- 
(Engine Code AEG: Up To 05.99)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Measure resistance between terminals of solenoid valve. 

Specified value: 25,0...35,0 ohm 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Measuring Resistance Between Terminals Of Secondary Air Injection Solenoid Valve 
(Engine Code AEG: Up To 05.99)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If specified value is not obtained: 

z

Replace Secondary Air Injection (AIR) Solenoid Valve -N112-. See item 2 .  

z

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

z

Generate readiness code. See READINESS CODE, GENERATING . 

If specified value is obtained: 

z

Connect test box to control module wiring harness. See TEST BOX FOR WIRING TEST, 
CONNECTING
 .  

z

Check wire between test box socket 33 + 2-pin connector terminal 2 for open circuit according to wiring 
diagram. Wire resistance: max. 1.5 ohm 

Fig. 14: Identifying Secondary Air Injection Solenoid Valve 2-Pin Harness Connector Terminals 
(Engine Code AEG: Up To 05.99)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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