Volkswagen New Beetle. Manual - part 2039

Fig. 12: Coolant Hose Routing Diagram (2.0L - Engine Code BDC) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

FUEL SYSTEM 

FUEL PRESSURE 

Specifications 

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

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FUEL PUMP PERFORMANCE & REGULATED FUEL PRESSURE(GASOLINE ENGINES) 

Fig. 13: Measuring Fuel Pump Delivery Volume 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

IGNITION SYSTEM 

FIRING ORDER 

Illustrations 

FIRING ORDER 

Application 

Pressure At Idle - psi 

(bar) 

(1)

 Volume In 30 

Seconds 

(4)

 Residual Pressure - psi 

(bar) 

All Engines 

(3)

 36.3 (2.5) 

(2)

29 (2.0) 

(1)

Volume is dependent upon battery voltage and should be checked with battery fully 
charged. See Fig. 13 .

(2)

Fuel pump volume depends on battery voltage at fuel pump. See Fig. 13 .

(3)

With vacuum hose disconnected at fuel pressure regulator, pressure is 43.5 psi (3.0 
bar).

(4)

Residual pressure is measured 10 minutes after engine or fuel pump is shut off.

Application 

Firing Order 

Beetle 

1.8L Turbo 

(1)

 1-3-4-2 

1.9L Turbo Diesel 

(2)

 1-3-4-2 

2.0L 

(3)

 1-3-4-2 

(1)

Coil-on-plug type ignition system is used. Cylinder No. 1 is at timing belt end of 
engine, and cylinder No. 4 is at flywheel end of engine.

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

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Fig. 14: Identifying Cylinder Numbers On Ignition Coil (2.0L - Engine Codes AVH & BDC) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

HIGH TENSION WIRES 

Resistance Specifications 

HIGH TENSION WIRE RESISTANCE 

IGNITION COIL 

(2)

Cylinder No. 1 is located at timing belt end of engine. Cylinder No. 4 is located at 
flywheel end of engine.

(3)

System uses a Distributorless Ignition System (DIS) with one ignition coil assembly. 
See Fig. 14 for cylinder No. to coil identification. Cylinder No. 1 is located at timing 
belt end of engine. Cylinder No. 4 is located at flywheel end of engine.

Application 

Ohms 

Beetle 

2.0L (Engine Codes AVH & BDC) 

(1)

 4,000-8,000 

(1)

Measured with suppression connector and spark plug connector installed.

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

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IGNITION TIMING 

SPARK PLUGS 

All Specifications 

SPARK PLUG TYPE 

SPARK PLUG SPECIFICATIONS 

STARTING SYSTEM 

STARTER 

Service Specifications 

SERVICE SPECIFICATIONS (STARTER) 

Torque Specifications 

TORQUE SPECIFICATIONS (STARTER) 

NOTE:

Ignition coil resistance is not available from manufacturer for any engine. 

NOTE:

All engines are equipped with DIS. Ignition timing is not adjustable. 

Application 

NGK No. 

Beetle 

1.8L Turbo (Engine Codes AWP) 

PFR 6 Q 

2.0L (Engine Codes AVH & BDC) 

PZFR 5 D-11 

Application 

Gap - In. (mm) 

Torque - Ft. Lbs. (N.m) 

Beetle 

1.8L Turbo (Engine Code AWP) 

.032 (.80), Maximum 

22 (30) 

2.0L (Engine Code AVH) 

.035-.043 (.9-1.1) 

22 (30) 

2.0L (Engine Code BDC) 

.039-.043 (1.0-1.1) 

18 (25) 

Application 

Rating 

1.8L & 2.0L Engines 

12V, 1.0 Kw 

1.9L Turbo Diesel 

12 V, 1.8 Kw 

Application 

Ft. Lbs. (N.m) 

All Engines 

Battery Cable Stud Nut On Solenoid 

10 (13) 

Starter Mounting Stud Nuts 

44 (60) 

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

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