Volkswagen New Beetle. Manual - part 1740

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1738  1739  1740  1741   ..

 

 

Volkswagen New Beetle. Manual - part 1740

 

 

Assembly overview 

1. Exhaust manifold 

z

with turbocharger  

z

Replace as complete unit only  

2. Intake manifold  

Fig. 1: Identifying Special Tool VAS5024A 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Charge air system must be properly sealed.  

z

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

z

Always replace self-locking nuts.  

NOTE:

The following list refers to Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

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

  

3. From charge air cooler  

4. Gasket 

z

replace  

z

Coating (bead) to intake manifold  

5. 25 Nm  

6. Gasket 

z

Note installed position  

7. Bracket 

z

For shielding plate, item no. 9  

8. Washer  

9. Heat shield 

z

Engages in bracket, item no. 7  

10. Turbocharger 

z

Replace as complete unit with exhaust manifold only  

z

To remove the exhaust turbocharger, disconnect right drive axle from transmission:  

See FRONT AXLE SHAFT . 

z

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

11. Vacuum diaphragm 

z

For boost pressure regulation  

z

Part of turbocharger, cannot be replaced  

12. From air filter  

13. Gasket 

z

replace  

14. Seal 

z

replace  

15. Oil return line 

z

to cylinder block  

z

new version. See New version of oil return line and support .  

16. Banjo fitting, 40 Nm  

17. 15 Nm  

18. 40 Nm  

19. Brace 

z

Turbocharger - cylinder block  

z

new version. See New version of oil return line and support .  

20. 25 Nm  

 

2003 Volkswagen New Beetle GLS 

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

  

21. Gasket 

z

replace  

22. Front exhaust pipe  

23. Connecting piece 

z

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

24. 10 Nm  

25. Oil supply line 

z

Before installing, fill turbocharger with oil at connection of oil supply line  

z

Tighten to 22 Nm  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 2: Exploded View Of Turbo Charger & Exhaust Manifold Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

New version of oil return line and support 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1738  1739  1740  1741   ..