Volkswagen New Beetle. Manual - part 1745

 

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Volkswagen New Beetle. Manual - part 1745

 

 

Fig. 3: Exploded View Of Turbocharger & Intake Manifold Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

CHARGE AIR COOLING COMPONENTS, REMOVING AND INSTALLING 

 

2003 Volkswagen New Beetle GLS 

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

  

Observe safety precautions, See CHARGE AIR SYSTEM WITH TURBOCHARGER . 

Observe rules for cleanliness, See RULES FOR CLEANLINESS . 

z

Unlock connection by pulling securing clamp (arrow). 

Fig. 4: Unlocking Connection By Pulling Securing Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove hose/tube without assistance of tools.  

z

When installing check for secure fit of tabs -A-. See Fig. 4 .  

z

Use assembly tool VAS 5024 A to install spring-type clips. 

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:

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 5: Installing Spring-Type Clips Using VAS 5024 A Assembly Tool 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Air duct  

2. Charge air cooler 

z

Removing and installing, See CHARGE AIR COOLER, REMOVING AND INSTALLING  

3. 5 N.m  

NOTE:

z

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

z

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

z

Charge air system must be free of leaks.  

NOTE:

The following list refers to items in Fig. 6 .

 

2003 Volkswagen New Beetle GLS 

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

  

4. Manifold Absolute Pressure (MAP) sensor -G71- with Intake Air Temperature (IAT) sensor -G72-  

5. O-ring 

z

Replace if damaged.  

6. 10 N.m  

7. Tube connection piece  

8. Upper charge air pipe  

9. Connecting hose 

z

Upper charge air pipe/intake manifold flap  

10. To intake manifold flap  

11. From air cleaner  

12. From crankcase ventilation/ cylinder head cover  

13. Rear charge air line 

z

With Positive Crankcase Ventilation (PCV) heating element -N79-  

14. Connecting hose 

z

Rear charge air pipe/exhaust turbocharger  

15. Bracket  

16. Connecting hose 

z

Exhaust turbocharger/lower charge air line  

17. Turbocharger  

18. Lower charge air pipe 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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