Volkswagen New Beetle. Manual - part 1290

 

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Volkswagen New Beetle. Manual - part 1290

 

 

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Ignition switched off.  

Test sequence 

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Remove front noise insulation.  

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Disconnect 2-pin connector from motor for secondary air pump (arrow). 

Fig. 16: Disconnecting 2-Pin Connector From Motor For Secondary Air Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Disconnect pressure hose at Secondary Air Injection (AIR) pump motor (arrow). 

Fig. 17: Disconnecting Pressure Hose At Secondary Air Injection Pump Motor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect Secondary Air Injection (AIR) Pump Motor to the B+ and Ground (GND) terminals of the 

NOTE:

To disengage, compress the buttons at the hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

battery using the respective adapter cables. 

The Secondary Air Injection (AIR) Pump Motor must start up and air must escape at compressed-air 
connection (arrow). 

Fig. 18: Connecting Secondary Air Injection Pump Motor To B+ And Ground Terminals Of 
Battery
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If the motor does not start up, or no air or only very little air escapes: 

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Disconnect connection between Secondary Air Injection (AIR) Pump Motor and battery.  

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Replace Secondary Air Injection (AIR) Pump Motor -V101-: 

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Vehicles with engine code AEG, AVH, AZG. See item 8 .  

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Vehicles with engine code BDC. See item 6 .  

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

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Generate readiness code. See READINESS CODE, GENERATING . 

If motor starts, and air escapes: 

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Disconnect connection between Secondary Air Injection (AIR) Pump Motor and battery.  

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Remove Secondary Air Injection (AIR) pump relay from relay carrier in protective housing for control 
modules:  

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Vehicles with engine code AEG, AVH, AZG. See item 4 .  

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Vehicles with engine code BDC. See Secondary Air Injection (AIR) pump relay -J299-* (arrow) .  

NOTE:

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Remove battery Ground (GND) strap if tools are necessary for removal of 

 

2003 Volkswagen New Beetle GLS 

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

  

Continuation for all vehicles 

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Check wire between terminal 2 of relay carrier and terminal 2 of 2-pin connector of Secondary Air 
Injection (AIR) Pump Motor for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohm 

Fig. 19: Identifying Secondary Air Injection Pump Motor Wiring Harness Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Also check the wire for short circuit to B+ and Ground (GND). Specified value: INFINITY ohm  

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Check wire between 2-pin connector terminal 1 and Ground (GND) for open circuit according to wiring 
diagram. Wire resistance: max. 1.5 ohm 

If no malfunctions are found in wires: 

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Replace Motronic Engine Control Module (ECM) -J220-. See REPLACING ENGINE CONTROL 
MODULE (ECM)
 .  

Combination valve, checking 

Vehicles with engine code AEG up to 05.99: 

Vehicles with engine code AEG as of 06.99, AVH, AZG, BDC. See Vehicles with engine code AEG as of 
06.99, AVH, AZG, BDC
 . 

Recommended special tools and equipment 

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VAG1390 Hand Vacuum Pump  

Test requirements 

relays or control modules from the relay carrier.  

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

 

2003 Volkswagen New Beetle GLS 

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

  

z

No leaks in vacuum lines or hose connections.  

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Vacuum hoses not clogged or kinked  

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Pressure hose for Secondary Air Injection (AIR) Pump Motor not clogged or kinked  

Test sequence 

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Remove front noise insulation.  

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Disconnect vacuum hose -1- from combination valve at Secondary Air Injection (AIR) solenoid valve 
(N112) -2-. See Fig. 20 . 

Fig. 20: Testing Combination Valve At Secondary Air Injection Solenoid Valve (Engine Code AEG: 
Up To 05.99)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect hand vacuum pump (VAG1390) at vacuum hose -1- to combination valve.  

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Disconnect pressure hose at Secondary Air Injection (AIR) pump motor (arrow) and blow into it with 
light pressure. Combination valve must close.  

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Operate vacuum pump. Combination valve must open. 

If the combination valve does not open or it is constantly open: 

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Replace combination valve. See item 20 .  

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

z

Generate readiness code. See READINESS CODE, GENERATING 

NOTE:

Do not use pressurized air for the following test!

NOTE:

To disengage, compress the buttons at the hose coupling.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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