Volkswagen New Beetle. Manual - part 1280

 

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Volkswagen New Beetle. Manual - part 1280

 

 

Fig. 2: Removing And Installing Exhaust Manifold, Front Exhaust Pipe And Catalytic Converter (Engine 
Code AEG)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes AVH, AZG, BDC, BEV, BGD 

1. Warm air collector plate 

z

With intake manifold support  

z

With mounting for combination valve  

2. Heated Oxygen Sensor (HO2S) -G39- 

z

50 N.m  

z

Grease only threads with hot bolt paste G 052 112 A3. Paste must not get into slots on sensor body 

z

Remove and install with 3337  

3. Connector 

z

Black, 6-pin  

z

Gold plated contacts  

z

For oxygen and oxygen sensor heating  

4. Combination valve 

z

Checking. See COMBINATION VALVE, CHECKING  

z

Removing and installing. See COMBINATION VALVE, REMOVING AND INSTALLING  

5. 10 N.m  

6. 25 N.m  

7. 25 N.m 

z

Replace  

8. 40 N.m  

9. Connecting pipe 

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

For secondary air inlet  

10. Bolts, 60 N.m  

11. 25 N.m  

12. Retainer  

13. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC)-G130- 

z

50 N.m  

z

Grease only threads with hot bolt paste G 052 112 A3. Paste must not get into slots on sensor body 

z

Remove and install with 3337  

14. 4-pin connector 

z

Brown  

z

Contacts 3 and 4 are gold plated  

z

For oxygen and oxygen sensor heating  

15. Front exhaust pipe with catalytic converter 

z

With anti-vibration element  

16. 10 N.m  

17. To center muffler  

18. Heat shield 

z

For catalytic converter  

19. 5 N.m  

20. Speed nut 

z

Install from rear and press forward onto limit stop  

21. 25 N.m 

z

Replace  

22. Seal 

z

Replace  

23. Exhaust manifold 

z

Removing and installing. See MUFFLER, REMOVING AND INSTALLING  

24. Seal 

z

Replace  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 3: Removing And Installing Exhaust Manifold, Front Exhaust Pipe And Catalytic Converter (Engine 
Codes AVH, AZG, BDC, BEV And BGD)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

MUFFLER WITH MOUNTINGS 

1. From catalytic converter  

2. Double clamp 

z

Observe installing position. See Installation Position Of Double Clamp  

3. 25 N.m  

4. Hangers/mountings 

z

Observe installed position. See Installation Position Of Mounting  

5. Forward muffler 

z

Aligning. See Aligning Center Muffler Stress Free  

6. Separating point 

z

For repair cases  

z

As standard, front and rear mufflers are installed as a single component. In repair cases front and 
rear mufflers are supplied individually with a double clamp for connecting together.  

z

Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at separating point. See 
Separating point on exhaust pipe  

7. 20 N.m  

8. Hangers/mountings  

9. Rear muffler  

10. Hangers/mountings 

z

With retaining ring  

11. Tunnel bridge  

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

12. 40 N.m  

Fig. 4: Removing And Installing Muffler With Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation Position Of Double Clamp 

Fig. 5: Identifying Installation Position Of Double Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

Position double clamp approx. 5 mm away from mark "A" (arrow -2-).  

Installation Position Of Mounting 

Angled side on base of mounting (arrow) points forward.

NOTE:

z

Mark "A" (arrow -2-) is valid for models with either a manual or an 
automatic transmission.  

z

Mark "S" (arrow -1-) is not valid for the engine codes in this manual.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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