Volkswagen New Beetle. Manual - part 1533

Fig. 1: Exploded View Of Ignition System Components (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes AVH, AZG, BDC, BEV, BGD 

1. H.T. cable 

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4...8 kohm  

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With suppression connector and spark plug connector  

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Check for continuity  

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Pull spark plug connector off with T10112. 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

2. Ignition coils with final output stages -N70-, -N127-, -N291-, -N292- 

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With marks for H.T. cables: HV1 = Cylinder 1, HV2 = Cylinder 2, HV3 = Cylinder 3, HV4 = 
Cylinder 4  

3. 10 N.m  

4. 6-pin connector  

5. Knock Sensor (KS) 1 -G61- 

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Gold plated contacts  

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Location: Cylinder block intake side  

6. 2-pin connector 

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For KS 1 -G61-  

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Gold plated contacts  

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Do not interchange  

7. Knock Sensor (KS) 2 -G66- 

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Gold plated contacts  

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Next to ignition transformer  

8. 2-pin connector 

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For KS2 -G66-  

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Gold plated contacts  

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Do not interchange  

9. 20 N.m 

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Torque setting influences the function of knock sensor  

10. Spark plug, 25 N.m 

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Type and electrode gap. See TEST DATA, SPARK PLUGS  

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To remove and install pull off connectors for outer injectors  

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Remove and install with 3122 B  

11. Connector 

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Gold plated contacts  

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3-pin  

12. 10 N.m  

13. 100 N.m 

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Use counter support tool 3415 to loosen and tighten  

14. Camshaft pulley 

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With rotor for camshaft position sensor  

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Removing and installing. See VALVE GEAR, SERVICING  

15. Camshaft Position (CMP) sensor -G40-  

16. Retainer 

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For camshaft position sensor  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 2: Exploded View Of Ignition System Components (Engine Code AVH, AZG, BDC, BEV AND BGD)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

SAFETY PRECAUTIONS 

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be 
observed: 

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

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Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.  

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The ignition must be switched off before connecting or disconnecting injection or ignition system wiring 
or tester cables.  

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If the engine is to be turned at starter speed, without starting:  

Engine code AEG 

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Disconnect 4-pin harness connector -1- from ignition coil power output stage -2-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)