Volkswagen New Beetle. Manual - part 1520

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test conditions 

z

All fuses must be OK. Fuse holder is located behind access panel at far left end of dash. 

Fig. 9: Locating Fuses 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Battery voltage must be at least 11.5 V  

z

Camshaft Position (CMP) sensor -G40- must be OK, checking, see CAMSHAFT POSITION (CMP) 
SENSOR -G40-, CHECKING  

z

Engine speed (RPM) sensor must be OK, checking, see ENGINE SPEED (RPM) SENSOR, 
CHECKING  

Test sequence 

z

Disconnect 4-pin connector -2- from ignition coil with power output stage to be checked -1-.. 

NOTE:

Ignition coils and power output stages are one component and cannot be 
replaced individually.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

Fig. 10: Disconnecting 4-Pin Connector From Ignition Coil 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking voltage supply 

z

Using multimeter and adapter cables from V.A.G 1594 C measure supply voltage between terminals 1 + 
2 and 1 + 4 of disconnected connector. 

Fig. 11: Identifying Ignition Coil 4-Pin Harness Connector Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Switch on ignition. 

Specification: Min. 11.5 V 

z

Switch off ignition.  

If no voltage is present: 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

z

Check wiring for open circuit between 4 -pin connector terminal 1 and current supply relay for Motronic 
(main relay) using Electrical Wiring Diagrams. 

Wire resistance: max. 1.5 ohm 

Fig. 12: Identifying Ignition Coil 4-Pin Harness Connector Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Check wiring between 4 -pin connector and Ground (GND) for open circuit according to Electrical 
Wiring Diagrams. 

z

Terminal 2 and Ground (GND)  

z

Terminal 4 and Ground (GND)  

Wire resistance: max. 1.5 ohm 

If there is no malfunction in the supply voltage: 

z

Check activation, see CHECKING ACTIVATION .  

Checking activation 

z

Pull fuse No. 32 out of fuse holder.  

WARNING:

During the following test do not touch the connecting parts of the ignition 
coils or test cables.

NOTE:

Removing fuse 32 interrupts the voltage supply to the fuel injectors. Fuse 
holder is located behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

Fig. 13: Locating Fuse 32 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Connect V.A.G 1527 B voltage tester with adapter cables from V.A.G 1594 C to terminals of 
disconnected connector 

Fig. 14: Identifying Ignition Coil 4-Pin Harness Connector Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Contacts 2 + 3  

z

Operate starter and check ignition signal from Engine Control Module. 

LED must flicker 

z

Switch off ignition.  

When the LED flickers and the supply voltage is OK: 

z

Using removal tool T40039, replace ignition coil with power output stage, see item 2 .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle