Volkswagen New Beetle. Manual - part 1546

 

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Volkswagen New Beetle. Manual - part 1546

 

 

1998-2004 ENGINE PERFORMANCE

Ignition-Glow Plug System, 1.8L APH - New Beetle 

IGNITION/GLOW PLUG SYSTEM 

IGNITION SYSTEM, SERVICING 

Ignition system, general information 

Safety precautions, see SAFETY PRECAUTIONS 

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

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:  

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

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 injection and ignition 
system, see MULTIPORT FUEL INJECTION (MFI) .  

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The engine control module is equipped with On Board Diagnostic (OBD).  

z

Components marked with * are checked via the On Board Diagnostic 
(OBD), see DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, 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 DIAGNOSTIC 
TROUBLE CODE (DTC) MEMORY, CHECKING AND ERASING .  

WARNING:

z

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.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L APH - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L APH - New Beetle

  

Ignition system components, removing and installing 

The following list pertains to Fig. 1 . 

1. Connector 

z

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  

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Tighten mounting bolts to 10 Nm  

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Spark plug connector can be pulled off  

3. Seal 

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Replace if damaged  

4. Spark plug, 30 Nm 

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Remove and install with spark plug spanner 3122B  

z

Type and electrode gap, see TEST DATA, SPARK PLUGS  

5. Connector 

z

Black, 3-pin  

z

For Camshaft Position (CMP) sensor-G40-  

6. 10 Nm  

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

z

Location, see COMPONENT LOCATIONS, OVERVIEW , engine compartment overview  

z

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

8. 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 in arrangement  

11. 20 Nm 

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Tightening torque influences the function of the knock sensor  

12. Knock sensor (KS) 1 -G61-* 

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Sensor and connector contacts are gold-plated 

z

During a road test in an airbag-equipped vehicle, test equipment 
must always be fastened to and operated from the rear seat by a 
second technician.  

NOTE:

Engine control module with connectors, see FUEL INJECTION SYSTEM 
COMPONENTS, REMOVING AND INSTALLING , item 6.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L APH - New Beetle

  

z

Checking, see KNOCK SENSORS, CHECKING  

13. Connector 

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Black, 2-pin  

z

For Knock sensor (KS) 1 -G61-  

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Sensor and connector contacts are gold-plated  

14. Ground wire 

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Only loosen or tighten with ignition switched off  

15. 10 Nm 

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Only loosen or tighten with ignition switched off  

16. Connector 

z

Black, 2-pin  

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For Knock sensor (KS) 2 -G66-  

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Sensor and connector contacts are gold-plated  

17. Knock sensor (KS) 2 -G66-* 

z

Sensor and connector contacts are gold-plated  

z

Checking, see KNOCK SENSORS, CHECKING

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L APH - New Beetle

  

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

z

Disconnect 4-pin connector -1- from power output stage for ignition coils (arrow). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Ignition-Glow Plug System, 1.8L APH - New Beetle

  

 

 

 

 

 

 

 

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