Volkswagen New Beetle. Manual - part 1723

 

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Volkswagen New Beetle. Manual - part 1723

 

 

1998-2004 ENGINE

Turbocharger, G - Charger, 1.8L Generic Scan Tool - New Beetle 

TURBOCHARGER G-CHARGER 

CHARGE AIR SYSTEM WITH TURBOCHARGER 

Removing and installing turbocharger with attachments, see TURBOCHARGER WITH ATTACHMENTS, 
REMOVING AND INSTALLING
 . 

Removing and installing parts of charge air cooler, see PARTS OF CHARGE AIR COOLER, REMOVING 
AND INSTALLING
 . 

Overview plan of exhaust turbocharging system: 

z

Vehicles with engine code APH, see OVERVIEW PLAN OF EXHAUST TURBOCHARGING 
SYSTEM (VEHICLES WITH ENGINE CODE APH)
  

z

Vehicles with engine code AWP, AWV, see OVERVIEW PLAN OF EXHAUST 
TURBOCHARGING SYSTEM (VEHICLES WITH ENGINE CODE AWP, AWV)
 .  

Observe rules for cleanliness, see RULES OF CLEANLINESS . 

Observe safety precautions, see SAFETY PRECAUTIONS . 

Turbocharger with attachments, removing and installing 

NOTE:

z

All hose connections are secured with clamps.  

z

Charge air system must be properly sealed.  

z

Always replace self-locking nuts.  

z

Charge pressure hoses and their connections must be free of grease 
before re-installation.  

z

VAS5024 assembly tool or VAG1921 pliers are recommended for installing 
spring clips.  

NOTE:

z

All hose connections are secured with clamps.  

z

Charge air system must be properly sealed.  

z

Always replace self-locking nuts.  

z

Charge pressure hoses and their connections must be free of grease 
before re-installation.  

z

Components marked with * are tested via On Board Diagnostic (OBD), see 
DIAGNOSTIC MODE 3: CHECK DTC MEMORY .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G - Charger, 1.8L Generic Scan Tool - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G - Charger, 1.8L Generic Scan Tool - New Beetle

  

Part I 

The following list pertains to Fig. 1 . 

1. 40 Nm 

z

Coat threads with G 052 112 A3  

2. Seal 

z

replace  

3. 10 Nm 

z

Must not be loosened  

4. Vacuum diaphragm 

z

For boost pressure regulator valve  

z

Can only be replaced together with turbocharger  

z

Boost pressure regulation, checking, see BOOST PRESSURE SYSTEM, CHECKING  

5. Fuse  

6. Turbocharger 

z

Boost pressure regulation, checking, see BOOST PRESSURE SYSTEM, CHECKING  

z

The boost pressure regulator valve and vacuum diaphragm for boost pressure regulator valve are 
part of the exhaust turbocharger and cannot be replaced individually.  

z

Before connecting oil supply line, fill turbocharger with oil at filler tube  

z

After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. 
This ensures adequate oil supply to the turbocharger.  

7. O-ring 

z

replace  

8. 10 Nm  

9. Intake manifold  

10. Seal 

z

replace  

z

Note installed position  

11. 20 Nm  

12. Heat shield  

13. 10 Nm  

14. Banjo fitting, 30 Nm  

15. Oil supply line  

16. 30 Nm 

z

replace  

z

Coat threads and bolt head contact surface with G 052 112 A3  

17. Exhaust manifold  

18. Seal 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G - Charger, 1.8L Generic Scan Tool - New Beetle

  

z

replace  

z

Note installed position  

19. 20 Nm  

20. Banjo fitting, 30 Nm  

21. 25 Nm 

z

replace  

z

Coat threads with G 052 112 A3  

22. Banjo fitting, 35 Nm  

23. Coolant return line  

24. 25 Nm  

25. Spacer sleeve  

26. Banjo fitting, 35 Nm  

27. 10 Nm  

28. Coolant supply line  

29. Banjo fitting, 35 Nm  

30. 30 Nm 

z

use only original bolts from parts catalog  

31. Bracket 

z

Between turbocharger and cylinder block  

32. 25 Nm  

33. Seal 

z

replace  

34. Seal 

z

replace  

35. 10 Nm  

36. Oil return line 

z

To oil pan  

37. 10 Nm  

38. 10 Nm 

z

Do not change orientation  

z

Must not be loosened  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G - Charger, 1.8L Generic Scan Tool - New Beetle

  

Fig. 1: Exploded View Of Turbocharger With Attachments 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Part II 

Vehicles with engine code APH 

Vehicles with engine code AWP, AWV, see VEHICLES WITH ENGINE CODE AWP, AWV 

The following list pertains to Fig. 2 . 

1. Deceleration shut-off valve 

z

Checking, see DECELERATION SHUT-OFF VALVE, CHECKING  

2. Connection hose 

z

To Recirculating valve for turbocharger -N249-* 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G - Charger, 1.8L Generic Scan Tool - New Beetle

  

 

 

 

 

 

 

 

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