Volkswagen New Beetle. Manual - part 1282

 

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Volkswagen New Beetle. Manual - part 1282

 

 

Installation is performed in the reverse sequence. Note the following: 

z

Tightening torques. See EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND CATALYTIC 
CONVERTER WITH ATTACHMENTS
 and ENGINE CODES AVH, AZG, BDC, BEV, BGD 

{

Erase fault memory. See ENGINE CONTROL MODULE FAULT MEMORY, 
INTERROGATION AND ERASING
 .  

SECONDARY AIR SYSTEM 

FUNCTION 

z

The secondary air system blows air in behind the exhaust valve for a maximum of 100 seconds after the 
cold start (+5° C...+33° C coolant temperature). This produces an oxygen rich exhaust gas which initiates 
afterburning and reduces the heating-up phase of the catalytic converter.  

z

Activation occurs from Motronic Engine Control Module (ECM) -J220- via the Secondary Air Injection 
(AIR) pump relay -J229- to Secondary Air Injection (AIR) solenoid valve -N112-, change-over valve and 
combination valve. Only vehicles with engine code AEG up to Model Year 1999, 05.99.  

z

If the secondary air pump motor is activated it produces an overpressure and opens the combination valve 
at 60 to 70 mbar. Only vehicles with engine codes: AEG as of Model Year 1999, 06.99, AVH, AZG, 
BDC, BEV and BGD.  

z

Additionally after each subsequent engine start (up to max. 96 °C engine temperature) the secondary air 
system will switch in for 10 seconds during idling and will be checked by the self-diagnosis. When doing 
this the oxygen sensor regulation must be active.  

SECONDARY AIR SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Engine codes AEG up to Model Year 1999, 05.99 

z

Engine codes: AEG as of Model Year 1999, 06.99, AVH, AZG, BEV. See ENGINE CODES: AEG AS 
OF MODEL YEAR 1999 (06.99) - AVH, AZG AND BEV
 .  

z

Engine codes BDC, BGD. See ENGINE CODES: BDC, BGD .  

z

Replace all seals/gaskets and self-locking nuts.  

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

z

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

NOTE:

The following list refers to items in Fig. 12 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. Connector 

z

2-pin  

2. Secondary Air Injection (AIR) solenoid valve -N112-  

3. To union on pipe to brake servo  

4. Secondary Air Injection (AIR) pump relay -J299- 

z

In protective housing for relays. See Secondary Air Injection (AIR) pump relay -J299-  

z

In engine compartment (in cable guide next to brake master cylinder)  

5. O-ring 

z

Replace  

6. Pressure hose 

z

Check if seated securely  

z

Press together at front to release  

7. Intake hose 

z

From air cleaner upper part  

z

For secondary air injection pump  

z

Check if seated securely  

z

Press together at front to release  

8. Secondary Air Injection (AIR) pump motor -V101- 

z

Activation via AIR pump relay -J299-  

z

Checking function. See SECONDARY AIR INJECTION PUMP MOTOR, CHECKING  

9. 10 N.m  

10. Retainer 

z

For secondary air pump motor  

z

Fastened to intake manifold  

11. Connector 

z

2-pin  

12. 25 N.m  

13. Intake manifold lower part  

14. To union on exhaust manifold  

15. 40 N.m  

16. Connecting pipe  

17. Nuts/bolts, 60 N.m  

18. Warm air collector plate 

z

With mounting for combination valve  

19. Seal 

z

Replace  

20. Combination valve 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Checking. See COMBINATION VALVE, CHECKING  

z

Removing and installing. See COMBINATION VALVE, REMOVING AND INSTALLING  

Fig. 12: Exploded View Of Secondary Air System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes: AEG as of Model Year 1999 (06.99) - AVH, AZG and BEV 

1. Combination valve 

z

Checking. See COMBINATION VALVE, CHECKING  

z

Removing and installing. See COMBINATION VALVE, REMOVING AND INSTALLING  

2. Secondary Air Injection (AIR) pump relay -J299- 

z

In protective housing for relays. See Secondary Air Injection (AIR) pump relay -J299-  

z

In engine compartment (in cable guide next to brake master cylinder)  

3. O-ring 

z

Replace  

4. Pressure hose 

z

Check if seated securely  

z

Press together at front to release  

5. Intake hose 

z

From air cleaner upper part  

z

For secondary air injection pump  

z

Check if seated securely  

z

Press together at front to release  

6. Secondary Air Injection (AIR) pump motor -V101-

NOTE:

The following list refers to items in Fig. 13 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Activation via AIR pump relay -J299-  

z

Checking function. See SECONDARY AIR INJECTION PUMP MOTOR, CHECKING  

7. 10 N.m  

8. Retainer 

z

For secondary air injection pump motor  

z

Fastened to intake manifold  

9. Connector 

z

2-pin  

10. 25 N.m  

11. Intake manifold lower part  

12. To union on exhaust manifold  

13. 40 N.m  

14. Connecting pipe  

15. Nuts/bolts, 60 N.m  

16. Warm air collector plate 

z

With mounting for combination valve  

17. Seal 

z

Replace  

Fig. 13: Exploded View Of Secondary Air Injection (AIR) Pump Motor (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes: BDC, BGD 

1. Combination valve 

NOTE:

The following list refers to items in Fig. 14 .

 

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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