Volkswagen New Beetle. Manual - part 1497

 

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Volkswagen New Beetle. Manual - part 1497

 

 

Fig. 4: Identifying V.A.G 1594 A Adapter Set 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

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Disconnect glow plug connectors from glow plugs.  

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Connect diode test lamp cable with clamps from adapter set to battery positive (+). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 1.9L 4-Cyl. - BEW

  

Fig. 5: Place Diode Test Lamp Test Pick On Every Glow Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place diode test lamp test pick on every glow plug one after another. 

Diode lights up: glow plug OK 

Diode does not light-up: replace glow plug. 

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Install and remove glow plugs with jointed spanner 3220. 

Tightening torque: 15 N.m 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 1.9L 4-Cyl. - BEW

  

1998-2004 ENGINE

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

IGNITION SYSTEM, SERVICING 

GENERAL NOTES ON IGNITION SYSTEM 

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Only the components which specifically relate to the ignition system are covered here. For the other 
components of the injection and ignition system, see MULTIPORT FUEL INJECTION (MFI) - 2.0L -
AEG, AVH, AZG, BDC, BEV & BGD)
 .  

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For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary.  

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Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the 
engine control module could be damaged.  

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During some checks it is possible that the control module will detect and store a fault. Therefore, after 
completing all checks and repairs the fault memory must be interrogated and, if necessary, erased. See 
ENGINE CONTROL MODULE FAULT MEMORY, INTERROGATING AND ERASING .  

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If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests, 
then the fault may lie with the immobilizer which is blocking the engine control unit. In such cases the 
control unit must be adapted. See COMPONENTS AND FUNCTIONS, ADAPTING .  

Safety precautions. See SAFETY PRECAUTIONS . 

Test data, spark plugs. See TEST DATA, SPARK PLUGS . 

IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Engine code AEG 

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Engine codes AVH, AZG, BDC, BEV, BGD. See ENGINE CODES AVH, AZG, BDC, BEV, BGD .  

1. 10 N.m  

2. Ignition wire 

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With RF suppression type connector and spark plug connector  

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Pull spark plug connector off with T10112  

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Check for continuity  

3. Spark plug 

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30 N.m  

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Remove and install with 3122B  

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Type and electrode gap. See TEST DATA, SPARK PLUGS  

4. 20 N.m 

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

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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Tightening torque influences knock sensor function  

5. Knock Sensor (KS) 2 -G66- 

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Sensor and connector terminals are gold-plated  

6. 3-pin harness connector 

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Terminals gold plated  

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Brown for KS 2 -G66-  

7. Knock Sensor (KS) 1 -G61- 

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Sensor and connector terminals are gold-plated  

8. 3-pin harness connector 

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Terminals gold plated  

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Black for KS 1 -G61-  

9. Camshaft Position (CMP) sensor -G40- 

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Location. See item - 17 - on ENGINE CODE AEG  

10. 3-pin harness connector 

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Black  

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For CMP sensor -G40-  

11. 4-pin harness connector 

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Black  

12. Ignition coils - N-, -N128- 

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Marked for ignition cables: A = Cylinder 1, B = Cylinder 2, C = Cylinder 3 and D = Cylinder 4  

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With Power output stage -N122-  

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Location. See item - 12 - on ENGINE CODE AEG 

 

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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