Volkswagen New Beetle. Manual - part 1273

 

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Volkswagen New Beetle. Manual - part 1273

 

 

Fig. 17: Rear Muffler, Aligning Free Stress 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

EXHAUST GAS RECIRCULATION (EGR) SYSTEM, OVERVIEW 

Exhaust Gas Recirculation (EGR) system components, removing and installing 

1. Intake manifold  

2. O-ring 

z

Replace  

3. Throttle valve 

z

With EGR valve and control flap  

4. Exhaust Gas Recirculation (EGR) valve 

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Component of intake support  

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Can only be replaced with intake support assembly  

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Checking: See EXHAUST GAS RECIRCULATION (EGR) VALVE, CHECKING 

NOTE:

Mounting pins on exhaust pipe must run parallel with tunnel bridge (dimension 
-x- on left and right = the same).

NOTE:

z

The function/control of the Exhaust Gas Recirculation (EGR) system is 
managed by the Diesel Direct Fuel Injection (DFI) Engine Control Module 
(ECM) -J248- via the EGR Vacuum Regulator solenoid valve -N18-.  

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The cone shaped plunger in the mechanical EGR valve ensures that 
various cross sectional openings are possible at different plunger heights. 

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Every possible valve position is provided via pulsed control.  

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Replace self-locking nuts.  

NOTE:

The following list refers to items in Fig. 18 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Control, checking:  

See Function 03: Output Diagnostic Test Mode, Performing . 

5. 10 N.m (7 ft lb)  

6. from Air Cleaner  

7. Gasket 

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Replace  

8. 25 N.m (18 ft lb)  

9. Connecting pipe 

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EGR cooler to intake support  

10. Connecting pipe 

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EGR cooler to exhaust elbow  

11. Exhaust manifold  

12. 25 N.m (18 ft lb)  

13. to heat exchanger  

14. EGR cooler  

15. Connection 

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Heater  

16. to Coolant expansion tank  

Fig. 18: Exploded View Of Exhaust Gas Recirculation (EGR) System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vacuum hose connections, diagram 

1. EGR valve  

NOTE:

The following list refers to items in Fig. 19 .

 

2003 Volkswagen New Beetle GLS 

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

  

2. EGR Vacuum Regulator solenoid valve -N18-  

3. Check valve  

4. Brake servo  

5. Air Cleaner  

6. Vacuum pump  

Fig. 19: Identifying Vacuum Hose Connections 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Exhaust Gas Recirculation (EGR) valve, checking 

Special tools and equipment 

z

VAG 1390 Hand vacuum pump  

Fig. 20: Identifying VAG 1390 Hand Vacuum Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove engine cover.  

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Disconnect pipe between Charge Air cooler and intake manifold at intake manifold.  

z

Disconnect vacuum hose from EGR valve.  

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Connect VAG 1390 hand vacuum pump to EGR valve.  

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Operate pump and observe membrane rod. 

Membrane rod must move in direction of arrow. 

Fig. 21: Locating Hand Vacuum Pump Membrane Rod 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Disconnect hand vacuum pump hose from EGR valve. 

Membrane rod must move back against direction of arrow to its original position. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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