Volkswagen New Beetle. Manual - part 1537

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

z

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. 

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe 
the following: 

z

Do not touch or disconnect ignition wires when engine is running or turning at starting RPM.  

z

Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition 
is switched off.  

z

If engine is to be cranked at starting RPM without starting:  

Vehicles with engine code APH 

z

Disconnect all 4-pin connectors -2- from the ignition coils -1-. 

z

Watch for sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L Generic Scan Tool - New Beetle

  

Fig. 4: Disconnecting 4-Pin Connectors From Ignition Coils (Engine Code APH) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with engine code AWP, AWV 

z

Disconnect all 4-pin connectors -2- from the ignition coils -1-. 

Fig. 5: Disconnecting 4-Pin Connectors From Ignition Coils (Engine Code AWP, AWV) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all vehicles 

z

Remove fuse 32  

NOTE:

By removing fuse 32, voltage supply to the fuel injectors is interrupted. Fuse 
holder is located behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L Generic Scan Tool - New Beetle

  

Fig. 6: Locating Fuse 32 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test Data, Spark Plugs 

TEST DATA, SPARK PLUGS SPECIFICATIONS 

Engine code

APH

AWP

AWV

Ignition sequence

1-3-4-2

1-3-4-2

1-3-4-2

Spark plugs
VW/Audi

101,000,063 AA

101,000,063 AA

101,000,063 AA

Manufacturer code

PFR 6 Q

PFR 6 Q

PFR 6 Q

Tightening torque

30 Nm

30 Nm

30 Nm

Spark plug gap

max. 0.8 mm

max. 0.8 mm

max. 0.8 mm

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L Generic Scan Tool - New Beetle

  

Check Camshaft Position (CMP) sensor 

Recommended special tools and equipment 

z

VAG1526 multimeter or VAG1715 multimeter  

z

VAG1594 connector test kit  

z

Wiring diagram  

Test requirements 

z

The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Fuse holder is 
located behind access panel at far left end of dash. 

Engine Control Module (ECM)

(1)

System identification

Motronic ME7.5

Motronic ME7.5

Motronic ME7.5

Terminals at Engine Control Module (ECM)

121

121

121

Part number

See Parts Catalog

See Parts Catalog

See Parts Catalog

Engine speed (RPM) limitation RPM

from approx. 6500 from approx. 6800 from approx. 6800

(1)

Replacing Engine Control Module (ECM), see REPLACING ENGINE CONTROL MODULE 
(ECM).

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L Generic Scan Tool - New Beetle