Volkswagen New Beetle. Manual - part 1744

 

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Volkswagen New Beetle. Manual - part 1744

 

 

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

  

Fig. 1: Identifying VAS 5024 A Assembly Tool
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

Hoses with quick release coupling 

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Unlock quick release coupling by pulling securing clamp (arrow). Separate hose/tube without assistance 
of tools. 

Fig. 2: Unlocking Quick Release Coupling By Pulling Securing Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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When installing check for secure fit of tabs -A-.  

NOTE:

All hoses of the charge air system are secured with hose clips or with quick 
release couplings. When using quick release couplings the following points 
must be observed:

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. Oil supply line 

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From oil filter bracket. See PART 2: DISASSEMBLING OIL FILTER BRACKET .  

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Fill with engine oil through oil connection before connecting oil supply line.  

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Removing and installing, See PART 3: REMOVING AND INSTALLING OIL RETURN 
LINE
 .  

2. Union nut 

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Prescribed torque, see PART 3: REMOVING AND INSTALLING OIL RETURN LINE .  

3. 22 N.m  

4. Pipe union, 30 N.m 

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Always replace  

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Oil threads and contact surfaces with G 052 112 A3.  

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

5. Bolt/screw 

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Prescribed torque, See PART 3: REMOVING AND INSTALLING OIL RETURN LINE .  

6. Banjo bolt 

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Prescribed torque, See PART 3: REMOVING AND INSTALLING OIL RETURN LINE .  

7. Seal 

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Always replace  

8. Intake manifold  

9. Seal 

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Always replace  

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Note installed position.  

10. Washer  

11. 25 N.m 

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Always replace  

12. Bracket 

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Between turbocharger and cylinder block  

13. 40 N.m 

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Hand-tighten all bolts first  

14. Connecting line 

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Air filter/turbocharger  

15. Transition piece  

16. Turbocharger 

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Only replace as assembly  

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Removing: remove right axle shaft at transmission: 

See FRONT AXLE SHAFT . 

 

2003 Volkswagen New Beetle GLS 

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

  

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Allow engine to run for approx.1 minute at idling speed after installing turbocharger; to ensure oil 
supply is guaranteed, do not rev up immediately  

17. Seal 

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Always replace  

18. Pipe union, 40 N.m  

19. Oil return line 

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To cylinder block  

20. 17 N.m  

21. Connector 

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For Turbocharger (TC) Vane Position Sensor -G500-  

22. Vacuum hose 

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to Wastegate Bypass Regulator Valve -N75-  

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Vacuum hoses for connection diagram, See VACUUM HOSE CONNECTION DIAGRAM .  

23. 20 N.m 

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Hand-tighten all bolts first  

24. 20 N.m 

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Always replace  

25. Heat shield  

26. Front exhaust pipe  

27. Bracket 

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For oil return line item 1  

28. 22 N.m 

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Always replace  

29. Connecting line 

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To bypass flap for exhaust gas recirculation, see EXHAUST GAS RECIRCULATION SYSTEM 
COMPONENTS, REMOVING AND INSTALLING
 .  

30. Connecting line 

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From bypass flap for exhaust gas recirculation, see EXHAUST GAS RECIRCULATION 
SYSTEM COMPONENTS, REMOVING AND INSTALLING 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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