Volkswagen New Beetle. Manual - part 1526

 

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Volkswagen New Beetle. Manual - part 1526

 

 

Fig. 5: Locating Fuse 32 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test Data, Spark Plugs 

SPARK PLUGS TEST DATA 

Check Camshaft Position (CMP) sensor 

NOTE:

By removing fuse 32, voltage supply to the fuel injectors is interrupted.

NOTE:

Fuse holder is located behind access panel at far left end of dash.

Engine Code

AEG

AVH, AZG, BDC

Ignition sequence

1-3-4-2

1-3-4-2

Spark plugs

 

 

VW/Audi

101 000 033 AA

101 000 062 AB

Manufacturer code

BKUR 6ET-10

PZF R5D-11

Tightening torque

30 Nm

30 Nm

Spark plug gap

max. 0.9 to 1.1 mm

max. 0.9 to 1.1 mm

Engine Control Module (ECM)

(1)

System identification

Motronic M5.9.2

Motronic ME7.5

Terminals at Engine Control Module 
(ECM)

80

121

Part number

See Parts catalog

See Parts catalog

Engine speed (RPM) limitation

starting at approx. 6300 

RPM

starting at approx. 6300 

RPM

.

(1)

Replacing Engine Control Module (ECM). See REPLACING ENGINE CONTROL MODULE 
(ECM)

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 2.0L Generic Scan Tool - New Beetle

  

Recommended special tools and equipment 

z

VAG1526 multimeter or VAG1715 multimeter  

z

VAG1594 connector test kit  

z

Wiring diagram  

Test requirements 

z

The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. 

Fig. 6: Identifying Fuses 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Battery voltage must be at least 11.5 volts.  

z

All electrical consumers such as, for example, lights and rear window defroster must be switched off.  

z

Parking brake must be engaged or else daylight driving lights will be switched on.  

z

Ground (GND) connections between engine and chassis must be OK.  

Test sequence (Vehicles with engine code AEG) 

Test sequence (Vehicles with engine code AVH, AZG, BDC). See TEST SEQUENCE (VEHICLES WITH 
ENGINE CODE AVH, AZG, BDC)
 . 

z

Remove engine cover.  

z

Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor -G40- (arrow). 

NOTE:

Fuse holder is located behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 2.0L Generic Scan Tool - New Beetle

  

Fig. 7: Disconnecting 3-Pin Connector From Camshaft Position Sensor -G40- (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) 
sensor for voltage measurement. 

Fig. 8: Connecting Multimeter To ECT Sensor Harness Connector Terminal 1 And 3 Of (Engine 
Code AEG)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Switch ignition on. Specified value: at least 4.5 V  

z

Switch ignition off. 

If there is no voltage: 

z

Connect test box to control module wiring harness. See TEST BOX FOR WIRING TEST, 
CONNECTING
 .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 2.0L Generic Scan Tool - New Beetle

  

z

Check for open circuits in wires between test box and connector according to wiring diagram. 

Terminal 1 + socket 62 

Terminal 2 + socket 76 

Terminal 3 + socket 67 

Wire resistance: max. 1.5 ohm 

Fig. 9: Identifying ECT Sensor Harness Connector Terminals (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Also check wires for short circuit to each other. Specified value: INFINITY ohm 

If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: 

z

Replace Camshaft Position (CMP) Sensor -G40-. See item 9 .  

z

Erase DTC memory of Engine Control Module (ECM). See DIAGNOSTIC MODE 4: RESET/ERASE 
DIAGNOSTIC DATA
 .  

z

Generate readiness code. See READINESS CODE, GENERATING .  

If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: 

z

Replace Motronic Engine Control Module (ECM) -J220-. See REPLACING ENGINE CONTROL 
MODULE (ECM)
 .  

Test sequence (Vehicles with engine code AVH, AZG, BDC) 

z

Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor (arrow). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 2.0L Generic Scan Tool - New Beetle

  

 

 

 

 

 

 

 

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