Volkswagen New Beetle. Manual - part 1735

 

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Volkswagen New Beetle. Manual - part 1735

 

 

Wire resistance: max. 1.5 ohm 

Fig. 10: Identifying Wastegate Bypass Regulator Valve Harness Connector Terminals (121-Pin 
ECM)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check the wire to terminal 1 according to wiring diagram. 

See appropriate System Wiring Diagram article. 

Continuation for all vehicles 

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Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Turbocharger, G-Charger - New Beetle

  

Specified value: INFINITY ohm 

If no malfunctions are found in wires: 

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Replace Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248-. See CONTROL 
MODULE FOR DIESEL-DIRECT FUEL INJECTION SYSTEM, REPLACING .  

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Erase DTC memory of control module for Diesel-Direct fuel injection system. See DIAGNOSTIC 
MODE 4: RESET/ERASE DIAGNOSTIC DATA
 .  

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Generate readiness code. See READINESS CODE, GENERATING 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Turbocharger, G-Charger - New Beetle

  

1998-2004 ENGINE

Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW 

CHARGE AIR SYSTEM WITH TURBOCHARGER 

SAFETY PRECAUTIONS 

Observe following if test and measuring instruments are required during a road test: 

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Test and measuring instruments must be secured to rear seat and operated by an assistant from this 
location.  

If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in an 
accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is 
triggered. 

RULES FOR CLEANLINESS 

When working on exhaust gas turbocharger, pay careful attention to the following rules: 

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Thoroughly clean all unions and adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

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Carefully cover opened components or seal if repairs cannot be performed immediately.  

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Only install clean components: 

Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored 
loose (e.g. in tool boxes etc.). 

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Only unpack and remove protective caps immediately prior to installation.  

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Clean oil from connection pieces and hose ends when repairing.  

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When the system is open: 

Do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely 
necessary. 

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 hoses/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 Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW

  

TURBOCHARGER SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Observe safety precautions, See CHARGE AIR SYSTEM WITH TURBOCHARGER . 

Observe rules for cleanliness, See RULES FOR CLEANLINESS . 

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Hoses are secured by clamps or retaining clips.  

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For installing the spring-type clips, assembly tool VAS 5024 A is recommended.  

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Charge air hoses and lines connections must be free of oil and grease before reinstalling.  

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Do not install hoses with lubricants, moisten hose only with water, if necessary.  

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Charge air system must be free of leaks.  

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Fill turbocharger with engine oil through oil connection before connecting the oil supply line  

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Allow the engine run for approx. 1 minute at idling speed after having installed the turbocharger and do 
not do not rev up immediately. This ensures the lubrication of the turbocharger.  

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Replace self-locking nuts. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Turbocharger, G-Charger - New Beetle, 1.9L 4-Cyl. - BEW

  

 

 

 

 

 

 

 

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