Volkswagen New Beetle. Manual - part 1569

 

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Volkswagen New Beetle. Manual - part 1569

 

 

Fig. 2: Identifying Injection System Component Locations (Engine Codes AVH And AZG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes BDC and BGD 

The components A, B and C are not shown on 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  

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. EVAP canister purge regulator valve -N80- 

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EVAP system. See EVAP SYSTEM COMPONENTS, SERVICING  

2. Return line 

Only engine with engine code BDC: 

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Secure with spring-type clips  

3. Supply line 

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Secure with spring-type clips  

4. Camshaft Position (CMP) sensor -G40- 

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Below upper toothed belt guard  

5. Intake manifold change-over valve -N156-  

6. Intake manifold upper part 

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

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Removing and installing. See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING
  

7. Intake manifold lower part 

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

8. Combination valve 

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Secondary air system. See SECONDARY AIR SYSTEM  

9. 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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Gold plated contacts  

10. 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. 11.5V  

11. 81-pin connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

12. 12 - 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: Under left side inner plenum chamber cover in passenger compartment  

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Replacing. See ENGINE CONTROL MODULE

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

13. 40-pin connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

14. 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 Location of 6-pin connector -1- for heated oxygen sensor  

15. 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  

16. Air cleaner 

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Disassembling and assembling. See AIR CLEANER, DISASSEMBLING AND ASSEMBLING 

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

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Gold plated contacts  

18. 3-pin connector 

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For Engine speed (RPM) sensor -G28-  

19. Ignition coils with final output stages -N70-, -N127-, -N291-, -N292- 

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

20. 10 N.m  

21. Engine speed (RPM) sensor -G28-  

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

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Secondary air system. See SECONDARY AIR SYSTEM  

23. Injector -N30-...-N33- 

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Checking quantity injected and for leaks. See COMPONENTS, CHECKING  

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Air shrouded  

24. Knock Sensor (KS) 2 -G66- 

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Gold plated contacts  

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Next to ignition transformer  

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See ENGINE CODES AVH, AZG, BDC, BEV, BGD , item - 7 -  

25. Knock Sensor (KS) 1 -G61- 

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Gold plated contacts  

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See ENGINE CODES AVH, AZG, BDC, BEV, BGD , item - 5 -  

26. Intake Manifold Tuning (IMT) valve -2- -N261-  

27. 4-pin connector 

 

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

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

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

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Location: in rear of catalyst  

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

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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  

29. 6-pin connector 

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Black: for HO2S -G39- and O2S heater -Z19-  

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

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

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

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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  

31. Fuel pressure regulator 

Only engine with engine code BDC: 

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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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