Volkswagen New Beetle. Manual - part 1500

 

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Volkswagen New Beetle. Manual - part 1500

 

 

location.  

If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in 
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the 
airbag is triggered. 

z

Erase engine control module fault memory because pulling connectors off injector will have caused a 
fault to be recorded. See ENGINE CONTROL MODULE FAULT MEMORY, INTERROGATING 
AND ERASING
 .  

z

Generate readiness code if fault memory has been erased. See COMPONENTS AND FUNCTIONS, 
ADAPTING
 .  

TEST DATA, SPARK PLUGS 

SPARK PLUGS TEST DATA 

Engine code

AEG

AVH, AZG, BEV

BDC, BGD

Firing order

1-3-4-2

1-3-4-2

1-3-4-2

Spark Plugs 

(1)

 , 

(2)

VW

101 000 033 AA

101 000 062 

AB

101 000 062 

AB

Manufacturer's 

designation

BKR6ET-10

PZFR5D-11

PZFR 5D-11

Electrode gap

0.9 to 1.1 mm (0.035 to 

0.043 in.)

1.0 to 1.1 mm

1.0 to 1.1 mm

Torque setting

30 N.m (22 ft lb)

25 N.m

25 N.m

(1)

For spark plug change intervals, see maintenance schedule in owners manual.

(2)

Use tool T10112 for disconnecting and connecting spark plug connector. Remove and install spark 
plugs using tool 3122B.

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE PERFORMANCE

Ignition-Glow Plug System, 1.8L Generic Scan Tool - New Beetle 

IGNITION GLOW PLUG SYSTEM 

IGNITION, SERVICING 

General notes on ignition system 

z

This section deals specifically with ignition - related components. The other components of the injection 
and ignition system, see MULTIPORT FUEL INJECTION (MFI) .  

z

For the electric components to work properly, a voltage of at least 11.5 V is required.  

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The battery must only be disconnected and connected with the ignition switched off, since the Engine 
Control Module (ECM) can otherwise be damaged.  

z

The Engine Control Module (ECM) is equipped with an On Board Diagnostic (OBD)  

z

Components marked with * are tested via On Board Diagnostic (OBD), see DIAGNOSTIC MODE 3: 
CHECK DTC MEMORY
 .  

z

It is possible that the control module will recognize a malfunction and store a DTC during some tests. 
Therefore the following work steps must be performed in the mentioned sequence after ending all tests 
and repairs.  

z

Check DTC memory, see DIAGNOSTIC MODE 3: CHECK DTC MEMORY .  

z

Erase DTC memory, see DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA  

z

For completion, generate readiness code, see READINESS CODE, GENERATING .  

Parts of ignition, removing and installing: 

z

Vehicles with engine code APH, see PARTS OF THE IGNITION, REMOVING AND INSTALLING 
(VEHICLES WITH ENGINE CODE APH)
 .  

z

Vehicles with engine code AWP, AWV, see PARTS OF THE IGNITION, REMOVING AND 
INSTALLING (VEHICLES WITH ENGINE CODE AWP, AWV)
 .  

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Safety precautions, see SAFETY PRECAUTIONS .  

z

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

Parts of the ignition, removing and installing (Vehicles with engine code APH) 

The following list pertains to Fig. 1 . 

1. Connector 

z

Black, 4-pin  

2. Ignition Coil 1 with Power Output Stage -N70-, Ignition Coil 2 with Power Output Stage -N127-, 

Ignition Coil 3 with Power Output Stage - N291-, Ignition Coil 4 with Power Output Stage -N292-

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Checking, see IGNITION COILS WITH POWER OUTPUT STAGES, CHECKING  

3. Seal 

z

Replace if damaged  

4. Spark plug, 30 Nm 

z

remove and install with 3122 B  

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Type and spark plug gap, see TEST DATA, SPARK PLUGS  

5. Connector 

z

black, 3-pin  

6. 10 Nm  

7. Camshaft Position (CMP) Sensor -G40-* 

z

Checking, see CHECK CAMSHAFT POSITION (CMP) SENSOR  

8. 25 Nm  

9. Washer 

z

Conical  

10. Face plate 

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For Camshaft Position (CMP) Sensor -G40-  

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note position when installing  

11. 20 Nm 

z

Tightening torque affects function of Knock Sensor (KS)  

12. Knock Sensor (KS) 1 -G61-* 

z

Terminals of sensor and connector are gold-plated  

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Checking, see CHECK KNOCK SENSORS  

13. 3-pin harness connector 

z

Terminals are gold-plated  

z

Brown for Knock Sensor (KS) 1 -G61-  

14. Ground (GND) wire 

z

Do not loosen or tighten unless ignition is switched off.  

15. 10 Nm 

z

Do not loosen or tighten unless ignition is switched off.  

16. 3-pin harness connector 

z

Terminals are gold-plated  

z

Black for Knock Sensor (KS) 2 -G66-  

17. Knock Sensor (KS) 2 -G66-* 

z

Terminals of sensor and connector are gold-plated  

z

Checking, see CHECK KNOCK SENSORS

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 1: Identifying Parts Of Ignition (Vehicles With Engine Code APH) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Parts of the ignition, removing and installing (Vehicles with engine code AWP, AWV) 

The following list pertains to Fig. 2 . 

1. Connector 

z

Black, 4-pin  

2. Ignition Coil 1 with Power Output Stage -N70-, Ignition Coil 2 with Power Output Stage -N127-, 

Ignition Coil 3 with Power Output Stage -N291-, Ignition Coil 4 with Power Output Stage -N292- 

z

Checking, see IGNITION COILS WITH POWER OUTPUT STAGES, CHECKING

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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