Volkswagen New Beetle. Manual - part 1532

 

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Volkswagen New Beetle. Manual - part 1532

 

 

Fig. 32: Identifying Ignition Coil 6-Pin Harness Connector Terminals (Engine Code AVH, AZG, 
BDC)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Operate starter and test ignition signal from Engine Control Module (ECM). LED should flicker.  

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Switch ignition off. 

If LED flickers and voltage supply is OK: 

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Replace ignition coil with power output stage (-N70-, -N127-, -N291-, -N292-). See item 2 .  

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

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Generate readiness code. See READINESS CODE, GENERATING . 

If LED does not flicker: 

 

2003 Volkswagen New Beetle GLS 

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

  

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Check wires. See CHECKING WIRING .  

Checking wiring 

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

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Check wires between test box and 6-pin connector for open circuit according to wiring diagram. 

Cylinder 1 terminal 2 + socket 102 

Cylinder 2 terminal 3 + socket 95 

Cylinder 3 terminal 4 + socket 103 

Cylinder 4 terminal 5 + socket 94 

Wire resistance: max. 1.5ohm 

Fig. 33: Identifying Ignition Coil 6-Pin Harness Connector Terminals (Engine Code AVH, AZG, 
BDC)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

If there is no malfunction in wire connections: 

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Replace Motronic Engine Control Module (ECM) -J220-. 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

  

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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