Volkswagen New Beetle. Manual - part 1493

 

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Volkswagen New Beetle. Manual - part 1493

 

 

Fig. 44: Measuring Kick Down Switch Resistance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Measure resistance at switch 

Specification: "INFINITY" ohms. 

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Press accelerator pedal slowly to floor. 

Shortly after kick down switch point resistance must drop at 0 ohm 

Accelerator pedal must be at point just before limit stop 

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Adjust accelerator cable by moving retainer on support bracket, so that throttle valve is fully open and 
kick-down switch clicks audibly.  

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Release accelerator pedal or remove speed regulator.  

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Once adjustments are complete check idling and wide open throttle limit stops on throttle valve.  

ELECTRONIC POWER CONTROL (EPC) 

ENGINE CODES AVH, AZG, BDC, BEV, BGD 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

1. Mounting  

2. Connector 

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Black, 6-pin  

3. 10 N.m  

4. Throttle Position (TP) sensor -G79- and Sender -2- for accelerator pedal position -G185- 

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On replacement, for models with automatic transmission, an adaptation must be performed. See 
COMPONENTS AND FUNCTIONS, ADAPTING .  

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When removing remove instrument panel/pedal cluster cover  

5. Retainer 

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For footwell cover  

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Clipped onto accelerator pedal  

Fig. 45: Exploded View Of Electronic Power Control (EPC) Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

FUNCTION OF EPC SYSTEM 

With the EPC system the throttle valve is not operated by the throttle pedal via a cable. There is no mechanical 

NOTE:

The following list refers to items in Fig. 45 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

connection between accelerator and throttle valve.

The position of the accelerator is transmitted to the engine control module by two accelerator position senders 
(variable resistors; mounted in one housing) which are connected to the accelerator pedal. 

The position of the accelerator (drivers requirement) is the main input value for the engine control module. 

The throttle valve is operated over the complete revolution and load range by an electric motor (throttle valve 
positioner) in the throttle valve control module. 

The throttle valve is operated by the throttle valve positioner which is controlled by the engine control module. 

When the engine is not running and the ignition is switched on the engine control module moves the throttle 
valve exactly as prescribed by the accelerator pedal position sender. This means that when the accelerator is 
depressed halfway the throttle valve positioner opens the throttle valve by the same amount, the throttle is then 
approximately half open. 

When the engine is running (under load) the engine control module can open or close the throttle valve 
independently of the accelerator pedal position sender. 

This means that the throttle valve can already be completely open even though the accelerator pedal is 
depressed half way. This also gives vastly improved consumption and exhaust emission levels at certain load 
conditions. 

After evaluating the torque requirements of various components (e.g. air conditioning system, automatic 
transmission, ABS/ESP and so on), the engine control module calculates the optimal throttle valve opening 
angle for the respective situation. 

This also gives vastly improved fuel consumption and exhaust emission levels at certain load conditions. 

EPC is a system comprising all components which contribute to determining, controlling or monitoring the 
position of the throttle valve, e.g. accelerator pedal position sender, the throttle valve control module, the EPC 
warning lamp, the engine control module and so on. 

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY 
SYSTEM
 . 

Observe rules for cleanliness. See RULES FOR CLEANLINESS . 

EVAPORATIVE EMISSIONS (EVAP) SYSTEM 

FUNCTION 

Depending on air pressure and ambient temperature, fuel vapor will form above the level of fuel in the tank. 

The EVAP system prevents these HC emissions from escaping into the atmosphere. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

In limited quantities, fuel vapors located at the highest point in the tank pass through a gravity valve (which 
closes at an angle of 45°) and through a pressure retention valve into the EVAP canister. 

The activated charcoal in the canister stores these vapors like a sponge. 

When the oxygen sensor control is active when driving (engine warm), the EVAP canister purge regulator valve 
-N80- is activated (pulsed) from the engine control module depending upon load and engine speed. The opening 
period is dependent on the input signals. 

Intake manifold vacuum draws fresh air through the vent opening on the underside of the EVAP canister during 
the purging procedure (regenerating the activated charcoal). The fuel vapors stored in the activated charcoal and 
fresh air are fed for combustion in dosed quantities. 

The pressure retention valve prevents fuel vapors from being drawn from the tank when the solenoid valve is 
open and an intake manifold vacuum is present. It therefore ensures that the evacuation of the EVAP canister 
has priority. 

When no voltage is applied (e.g. wiring open circuit), the solenoid valve is closed. The EVAP canister will not 
be purged. 

The vacuum line from the throttle valve control module to the EVAP canister has an additional bypass which is 
connected with the crankcase breather valve. The non-return valve integrated in the crankcase breather valve 
prevents the intake air gassing into the crankcase during some partial load ranges. This improves the overall 
crankcase breathing. The bypass guarantees the crankcase breathing. 

Functional description of leak diagnosis 

The EVAP system (including the fuel tank) is equipped with a leak diagnosis. This diagnosis system detects 
leaks in breather system. 

This diagnosis is based on the pressure principle and should detect leaks with a circumference larger than 1 mm.

During the diagnosis the Leak Detection Pump (LDP) -V144- creates a pressure of 30 mbar in the EVAP 
system. When the pressure is attained the pump switches off. If the pressure drops below a predetermined value 
the pump switches on again. The self-diagnosis monitors the switching periods and sets a fault in the fault 
memory when the period is too short. 

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY 
SYSTEM
 . 

Observe rules for cleanliness. See RULES FOR CLEANLINESS . 

EVAP system components, servicing. See EVAP SYSTEM COMPONENTS, SERVICING . 

EVAP system, assembly overview. See EVAPORATIVE EMISSIONS (EVAP) SYSTEM, ASSEMBLY 
OVERVIEW
 . 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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