Volkswagen New Beetle. Manual - part 1741

1. Support for turbocharger - cylinder block  

2. 40 Nm  

3. Connection, 40 Nm  

4. Oil return line with union nut 

Tighten to 30 Nm on cylinder block 

5. 15 Nm  

6. Gasket 

replace 

7. 25 Nm  

Fig. 3: Identifying Oil Return Line And Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Parts of charge air cooler, removing and installing 

1. Connection hose  

2. Connection tube 

NOTE:

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All hose connections are secured with clamps. 

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Charge air system must be properly sealed.  

NOTE:

The following list refers to Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Charge air cooler/intake manifold  

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To remove, remove right headlight  

3. O-ring 

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Replace if damaged  

4. Intake Air Temperature (IAT) Sensor -G72- 

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Vehicles of model year 2000 and up at charge air cooler  

5. 5 Nm  

6. Connection hose 

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Connection pipe/intake manifold  

7. Connection hose 

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Charge air pipe/turbocharger  

8. 10 Nm  

9. Charge air pipe  

10. Connection hose  

11. Bracket  

12. Charge air cooler  

Fig. 4: Identifying Parts Of Charge Air Cooler Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Line connections of turbocharger 

 

2003 Volkswagen New Beetle GLS 

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

  

1. Wastegate Bypass Regulator Valve -N75-  

2. To EGR Vacuum Regulator Solenoid Valve -N18-  

3. To air filter  

4. Vacuum reservoir  

5. Vacuum diaphragm for charge pressure regulator valve  

6. Turbocharger  

7. To Change-over valve for intake manifold flap -N239-  

8. Check valve, white connection faces toward Wastegate Bypass Regulator Valve -N75- 

NOTE:

The following list refers to Fig. 5 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 5: Identifying Line Connections Of Turbocharger
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Rules of cleanliness 

When working on turbocharger, carefully observe the following "5 Rules of Cleanliness": 

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Thoroughly clean all connections and the surrounding area before disconnecting.  

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Place parts that have been removed on a clean surface and cover them. Use lint-free cloths only!  

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Carefully cover opened components or seal, if repairs are not 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 without packaging (in tool boxes etc.)  

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When the system is open: Avoid working with compressed air. Do not move vehicle unless absolutely 
necessary.  

Safety precautions 

If test and measuring equipment is required during road test, note the following: 

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Test equipment must always be secured to the rear seat and operated from there by a second person.  

If test and measuring equipment is operated from the passenger seat, the person seated there could be injured in 
the event of an accident involving deployment of the passenger-side airbag. 

BOOST PRESSURE SYSTEM, CHECKING 

Wastegate bypass regulator valve, checking 

Recommended special tools and equipment: 

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VAG1526 multimeter or VAG1715 multimeter  

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VAG1594 connector test kit  

Test sequence 

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Switch ignition off.  

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Disconnect connector (arrow) from wastegate bypass regulator valve. 

WARNING:

Observe the following for all installations, especially in engine 
compartment due to dense construction: 

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Route lines of all types (e.g. for fuel, hydraulics, coolant and 
refrigerant, brake fluid, vacuum) and electrical wiring so that the 
original path is re-established.  

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Watch for sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

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