Volkswagen New Beetle. Manual - part 1580

 

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Volkswagen New Beetle. Manual - part 1580

 

 

Fig. 25: Pressing Tabs Outward For Releasing Pins For Spreader Rivet Mounting 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove cylinder head cover. See ENGINES WITH STEEL CYLINDER HEAD COVER or see 
ENGINES WITH ALUMINUM CYLINDER HEAD COVER .  

Continuation for all engines 

z

Remove rear bolts from warm air deflector plate and front bolts of intake manifold lower part.  

z

Carefully remove intake manifold upper part.  

NOTE:

The intake manifold upper part complete with throttle valve control module 
can only be removed when the cylinder head cover has been removed.

NOTE:

z

Seal the intake ports in the intake manifold lower section with clean cloths. 

 

2003 Volkswagen New Beetle GLS 

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

  

Installing 

Installation is performed in the reverse order. When installing, note the following: 

z

Carefully seat intake manifold upper part onto its original position on warm air collector plate.  

Engine codes BDC, BGD 

z

Install cylinder head cover; tightening torques. See ENGINES WITH STEEL CYLINDER HEAD 
COVER
 or see ENGINES WITH ALUMINUM CYLINDER HEAD COVER .  

z

Slide intake manifold upper part carefully onto intake manifold supports on intake manifold lower part.  

z

Press tabs -1- carefully outward. Then press intake manifold upper part back onto intake manifold lower 
part by moving it back and forth until it seats on limit stop. 

z

To remove the intake manifold upper part, remove the throttle valve 
control module and vacuum hoses from the brake servo.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 26: Pressing Tabs Outward And Intake Manifold Upper Part Back Onto Intake Manifold 
Lower Part
 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

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

z

Install bolts to intake manifold upper part on intake manifold support of warm air collector (arrows); 
tightening torques. See Fig. 9 , item -14-. 

Fig. 27: Tightening Bolts To Intake Manifold Upper Part On Intake Manifold Support Of Warm 
Air Collector
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install upper bolts on intake manifold (arrows), tightening torques. 

 

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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