Volkswagen New Beetle. Manual - part 1568

 

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Volkswagen New Beetle. Manual - part 1568

 

 

Fig. 1: Identifying Injection System Component Locations (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes AVH, AZG 

Components A, B and C are not shown in the illustration. 

A. Brake pedal switch -F47- or Brake light switch -F- 

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Together in one housing, in footwell  

B. Throttle Position (TP) sensor -G79- and Sender -2- for accelerator pedal position -G185- 

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In footwell on accelerator pedal:  

C. Clutch vacuum vent valve switch -F36- 

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In footwell  

1. EVAP canister purge regulator valve -N80- 

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EVAP system. See EVAP SYSTEM COMPONENTS, SERVICING  

NOTE:

The following list refers to items in Fig. 2 .

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

2. Camshaft Position (CMP) sensor -G40- 

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Below upper toothed belt guard  

3. Intake manifold 

Upper part: 

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Disassembling and assembling. See INTAKE MANIFOLD UPPER PART, DISASSEMBLING 
AND ASSEMBLING
 

Lower part: 

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Disassembling and assembling. See INTAKE MANIFOLD LOWER PART, 
DISASSEMBLING AND ASSEMBLING
  

4. Throttle valve control module -J338- 

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When replacing, adapt (match) engine control module to throttle valve control module. See 
COMPONENTS AND FUNCTIONS, ADAPTING  

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No cable disc for accelerator cable as this is an electronic accelerator system  

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6-pin connector  

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Gold plated contacts  

5. Heated Oxygen Sensor (HO2S) -G39-, 50 N.m 

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Location: In exhaust manifold  

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Grease only threads with hot bolt paste G 052 112 A3. Grease must not get into slots on sensor 
body  

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Remove and install with 3337  

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When replacing erase fault memory. See ENGINE CONTROL MODULE FAULT MEMORY, 
INTERROGATING AND ERASING
 .  

6. 6-pin connector 

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Black: for Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater -Z19-  

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Contacts gold plated  

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Location: On right underside of vehicle. See Location of 6-pin connector -1- for heated oxygen 
sensor
 .  

7. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC)-G130-, 50 N.m 

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Location: in rear of catalytic converter  

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Grease only threads with hot bolt paste G 052 112 A3. Grease must not get into slots on sensor 
body  

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Remove and install with 3337  

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When replacing erase fault memory. See ENGINE CONTROL MODULE FAULT MEMORY, 
INTERROGATING AND ERASING
 .  

8. 4-pin connector 

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Brown: for O2S Behind TWC -G130- and O2S heater 1 -Z29-

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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Connector contacts 3 and 4 are gold-plated  

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Location: On right underside of vehicle. See Location of 4-pin connector -1- for oxygen sensor 
behind catalytic converter
 .  

9. 81-pin harness connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

10. 40-pin harness connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

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

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On replacement, control module must be matched to electronic immobilizer. See COMPONENTS 
AND FUNCTIONS, ADAPTING
 .  

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Location: below inner cover of plenum chamber, left side in passenger compartment  

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Engine Control Module (ECM), replacing. See ENGINE CONTROL MODULE .  

12. Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- 

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Gold plated contacts  

13. Protective housing for relays 

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Secondary Air Injection (AIR) pump relay -J299-  

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Motronic ECM power supply relay -J271-  

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Relay locations in protective housing. See Location of 6-pin connector -1- for heated oxygen 
sensor
 .  

14. Air cleaner 

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Disassembling and assembling. See AIR CLEANER, DISASSEMBLING AND 
ASSEMBLING
 .  

15. Main fuses 

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For additional protection  

16. Positive Crankcase Ventilation (PCV) heating element -N79- 

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For crankcase breather  

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Check heating element voltage supply between contacts 1 and 2 with engine running, Specification: 
min. 11.5 V  

17. Engine Coolant Temperature (ECT) sensor -G62- 

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Green  

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Gold plated contacts  

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For engine control module  

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With ECT sensor -G2-  

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Release pressure in cooling system if necessary before removing components  

18. Ignition coils with power output stage -N70-, -N127-, -N291-, -N292- 

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See ENGINE CODES AVH, AZG, BDC, BEV, BGD , item. - 2 -

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

19. Injectors -N30-...-N33- 

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Air shrouded  

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Checking quantity injected and for leaks. See COMPONENTS, CHECKING  

20. 10 N.m  

21. Engine speed (RPM) sensor -G28-  

22. O-Ring 

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Replace if damaged  

23. 20 N.m 

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Tightening torque influences function of knock sensor  

24. Knock Sensor (KS) 2 -G66- 

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Black: 2-pin  

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Gold plated contacts  

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Next to ignition transformer  

25. 2-pin connector 

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For Knock Sensor (KS)2 -G66-  

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Black  

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Mark connector before disconnecting  

26. Secondary Air Injection (AIR) pump motor -V101- 

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Secondary air system. See SECONDARY AIR SYSTEM  

27. Knock Sensor (KS) 1 -G61- 

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Black: 2-pin  

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Gold plated contacts  

28. 2-pin connector 

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For Knock Sensor (KS) 1 -G61-  

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Black  

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Mark connector before disconnecting  

29. Fuel pressure regulator 

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Checking. See FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, 
CHECKING
 .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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