Volkswagen New Beetle. Manual - part 1263

 

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Volkswagen New Beetle. Manual - part 1263

 

 

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Charge air pressure control, checking. See CHARGE AIR PRESSURE SYSTEM, 
CHECKING
 .  

11. Pressure unit 

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For charge air pressure control valve  

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Integral part of turbocharger; cannot be replaced  

12. From Air Cleaner  

13. Gasket 

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Replace  

14. Sealing ring 

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Replace  

15. Oil return pipe 

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To cylinder block  

16. Banjo bolt 

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25 N.m (18 ft lb)  

17. 15 N.m (11 ft lb)  

18. 40 N.m (30 ft lb)  

19. Bracket  

20. 25 N.m (18 ft lb)  

21. Gasket 

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Replace  

22. Front exhaust pipe  

23. Connection  

24. 10 N.m (7 ft lb)  

25. Oil supply pipe  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 1: Exploded View Of Turbocharger System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Charge air cooler components, removing and installing 

1. Charge air cooler  

2. 10 N.m (7 ft lb)  

3. Connecting hose  

4. Connecting pipe 

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Charge air cooler/intake manifold  

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Lower pipe  

5. Connecting hose  

6. Connecting pipe 

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Charge air cooler/intake manifold  

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Upper pipe  

7. O-ring 

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Replace if damaged  

8. Intake Air Temperature sensor -G72-  

9. 5 N.m (3.7 ft lb)  

10. Connecting hose 

NOTE:

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All hose connections are secured by clips. 

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Charge air pressure must be free of leaks. 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

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Charge air cooler/intake manifold  

11. Connecting hose 

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Charge air cooler/turbocharger  

12. Charge air cooler  

13. Bracket  

Fig. 2: Exploded View Of Charge Air Cooler Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Turbocharger, hose and pipe connections 

Vacuum hose diagram 

1. Solenoid valve for Wastegate Bypass regulator valve -N75-  

2. to EGR vacuum regulator solenoid valve -N18-  

3. to air filter  

4. Vacuum reservoir  

5. Reservoir for wastegate  

6. Turbocharger  

7. to Intake Manifold Change-over valve -N239-  

8. Return valve, with connection points to Wastegate Bypass regulator valve -N75-. 

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 3: Exploded View Of Turbocharger, Hose And Pipe Connections 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Rules for cleanliness 

When working on the turbocharger and charge air pressure, pay careful attention to the following rules: 

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Thoroughly clean all unions and the adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover over. Do not use fluffy cloths!  

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Carefully cover opened components or seal, if the repair cannot be carried out immediately.  

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Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose (e.g. in tool boxes etc.).  

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When the system is open: Do not work with compressed air if it can be avoided. Do not move vehicle 
unless absolutely necessary.  

CHARGE AIR PRESSURE SYSTEM, CHECKING 

Special tools and equipment 

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VAG 1390 Vacuum pump  

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Fluke 83 Multimeter  

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VW 1594 Adaptor kit  

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VAG 1598/22 Test box  

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VAG 1551/1552 with VAG 1551/3 adaptor cable  

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Wiring diagram 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

 

 

 

 

 

 

 

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