Volkswagen New Beetle. Manual - part 1518

 

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Volkswagen New Beetle. Manual - part 1518

 

 

1998-2004 ENGINE

Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle 

IGNITION/GLOW PLUG SYSTEM 

IGNITION SYSTEM, SERVICING 

General notes on ignition system 

Safety precautions, see SAFETY PRECAUTIONS 

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

Ignition system components, removing and installing 

The following list pertains to Fig. 1 . 

1. Connector 

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Black, 4 pin  

2. Ignition coils with power output stages (-N70-, -N127-, -N291-, -N292-) 

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Checking, see IGNITION COILS WITH POWER OUTPUT STAGE, CHECKING

NOTE:

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Only the components which specifically relate to the ignition system are 
dealt with here. For the other components of the fuel injection system, see 
MULTIPORT FUEL INJECTION (MFI) .  

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

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Components marked with * are checked via the On Board Diagnostic 
(OBD), see DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE 
(ECM) -J220-, CHECKING AND ERASING .  

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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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During some checks it is possible that the control module will recognize 
and store a DTC. Therefore after completing all checks and repairs the 
DTC memory must be checked and if necessary erased, see DTC MEMORY 
OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING 
AND ERASING .  

NOTE:

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Engine Control Module with connectors, see FUEL INJECTION SYSTEM 
COMPONENTS, REMOVING AND INSTALLING , item 6.  

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Components marked with * are checked via the On Board Diagnostic 
(OBD), see DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE 
(ECM) -J220-, CHECKING AND ERASING .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

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For removing use only removal tool T40039, see IGNITION COILS WITH POWER OUTPUT 
STAGE, CHECKING
  

3. Circlip 

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For ignition coil with power output stage ( -N70-, -N127-, -N291-, -N292-)  

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Replace if damaged  

4. Spark plug, 30 Nm 

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Remove and install with spark plug wrench 3122B  

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Type and electrode gap, see TEST DATA, SPARK PLUGS  

5. Connector 

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Black, 3-pin  

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For Camshaft Position (CMP) sensor -G40-  

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Sensor and connector terminals are gold-plated  

6. Bolt, 10 Nm  

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

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Component location, see COMPONENT LOCATIONS, OVERVIEW , engine compartment 
overview  

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Checking, see CAMSHAFT POSITION (CMP) SENSOR -G40-, CHECKING  

8. Bolt, 25 Nm  

9. Washer 

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Conical  

10. Hood 

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For Camshaft Position (CMP) sensor -G40-  

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When installing note fixing arrangement  

11. Bolt, 20 Nm 

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Tightening torque influences the function of the Knock Sensor (KS)  

12. Knock Sensor (KS) (KS) 1 -G61-* 

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Sensor and connector terminals are gold-plated  

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Component location: Cylinder block intake side  

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Checking, see KNOCK SENSORS (KS), CHECKING  

13. Knock Sensor (KS) 2 -G66-* 

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Sensor and connector terminals are gold-plated  

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Component location: Cylinder block intake side  

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Checking, see KNOCK SENSORS (KS), CHECKING  

14. Connector 

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2-pin  

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For Knock Sensor (KS) 1 -G61-  

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Sensor and connector terminals are gold-plated  

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Black for Knock Sensor (KS) 1 -G61-

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

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Black for Knock Sensor (KS) 2 -G66-  

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Mark connector before removing  

15. Ground (GND) wire 

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Only loosen or tighten with ignition switched off  

16. Bolt, 10 Nm 

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Only loosen or tighten with ignition switched off  

Fig. 1: Identifying Ignition System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Safety precautions 

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be 
noted: 

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Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.  

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The ignition must be switched off before connecting or disconnecting injection or ignition system wiring 
or tester cables.  

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If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull 
connector off output stage:  

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Disconnect all 4 -pin connectors -2- from ignition coils with power output stage -1-. 

WARNING:

When doing any repair work, especially in the engine compartment, due 
to the cramped conditions, pay attention to the following: 

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Route all sorts of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum lines and hoses) and 
electrical wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

Fig. 2: Disconnecting All Pin Connectors From Ignition Coils 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Pull fuse No. 32 out of fuse holder.  

Fig. 3: Locating Fuse 32 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Observe following if test and measuring instruments are required during a road test: 

NOTE:

Removing fuse 32 interrupts the voltage supply to the fuel injectors. Fuse 
holder is located behind access panel at far left end of dash.

WARNING:

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When driving or riding in an airbag -equipped vehicle, NEVER hold 
the scan tool or other test equipment in your hands or lap while in 
motion. Objects between you and the airbag increase the risk of 
injury in an accident.  

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During a road test in an airbag -equipped vehicle, test equipment 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

 

 

 

 

 

 

 

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