Volkswagen New Beetle. Manual - part 1579

 

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Volkswagen New Beetle. Manual - part 1579

 

 

Fig. 22: Identifying 3094 Hose Clamps 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

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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.  

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Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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With ignition switched off disconnect battery Ground strap.  

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Remove engine cover. 

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Release pressure in coolant circuit by opening coolant expansion tank cap.  

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Remove air cleaner with intake hose and Mass Air Flow (MAF) sensor -G70-. See AIR CLEANER, 
DISASSEMBLING AND ASSEMBLING
 .  

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Clamp off coolant hose from Throttle valve control module -J338- (with for example V.A.G 3094).  

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Ensure following components are disconnected from coolant hoses: 

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Top of expansion tank  

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Throttle valve control module -J338-  

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Ensure following components are disconnected from electrical connections:  

Engine codes BDC, BGD 

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Intake manifold change-over valve -N156-  

Continuation for all engines 

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Positive Crankcase Ventilation (PCV) heating element -N79-  

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Throttle valve control module -J338-  

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Ensure following components are disconnected from breather or vacuum hoses:  

Engine codes BDC, BGD 

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Intake manifold change-over valve -N156-  

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Vacuum line T-piece from Intake manifold changeover valve -N156-  

Continuation for all engines 

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EVAP canister purge regulator valve -N80- to intake manifold upper part  

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EVAP canister to intake manifold upper part  

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Injector breather lines  

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Brake servo vacuum line  

NOTE:

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During the further course of work the battery Ground strap must be 
disconnected. Therefore, please check whether a coded radio is installed. 
Obtain the radio code first if necessary.  

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Observe the notes on COOLING SYSTEM, SERVICING .  

WARNING:

Steam can be released when removing the cap from the expansion 
tank. Cover the cap with a cloth and open it carefully.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Engine codes AEG, AVH, AZG, BDC 

z

On fuel pressure regulator  

Engine codes BDC, BGD 

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Remove bolts (arrows) from intake manifold upper part -1- on intake manifold support of warm air 
collector -2-. See Fig. 23 . See Fig. 9 , item - 14 -. 

Fig. 23: Removing Bolts From Intake Manifold Upper Part On Intake Manifold Support Of Warm 
Air Collector (Engine codes BDC, BGD)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove upper bolts on intake manifold (arrows). See Fig. 24 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 24: Removing Upper Bolts From Intake Manifold (Engine codes BDC, BGD) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove spreader (split) rivets. See Fig. 9 , item - 9 -.  

z

Press tabs -1- as illustrated in Fig. 25 , carefully outward so that pins for spreader (split) rivet mounting -
2- are free. Simultaneously, move intake manifold upper part back and forth until it can be disconnected 
on exhaust side. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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