Volkswagen New Beetle. Manual - part 1570

 

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Volkswagen New Beetle. Manual - part 1570

 

 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 3: Identifying Injection System Component Locations (Engine Codes BDC And BGD)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

Engine code BEV 

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  

D. Fuel pressure regulator 

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Together with fuel filter  

1. EVAP canister purge regulator valve -N80- 

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EVAP system. See EVAP SYSTEM COMPONENTS, SERVICING  

2. Supply line 

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Secure with spring-type clips  

3. Camshaft Position (CMP) sensor -G40- 

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Below upper toothed belt guard  

4. 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
  

5. 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  

6. Combination valve 

NOTE:

The following list refers to items in Fig. 4 .

NOTE:

The following list refers to items in Fig. 4 .

 

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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Secondary air system. See SECONDARY AIR SYSTEM  

7. 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  

8. 81-pin connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

9. Motronic Engine Control Module -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  

10. 40-pin connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

11. 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  

12. 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  

13. Air cleaner 

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Disassembling and assembling. See AIR CLEANER, DISASSEMBLING AND ASSEMBLING 

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

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Gold plated contacts  

15. Main fuses 

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For additional protection  

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

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

17. 10 N.m  

18. Engine speed (RPM) sensor -G28-  

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

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Secondary air system. See SECONDARY AIR SYSTEM

 

2003 Volkswagen New Beetle GLS 

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

  

20. Injector -N30-...- N33- 

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Checking quantity injected and for leaks. See COMPONENTS, CHECKING  

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Air shrouded  

21. 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 -  

22. 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 -  

23. 4-pin connector 

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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
  

24. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC)-G130-, 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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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  

25. 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
  

26. 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  

27. 3-pin connector 

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For Engine speed (RPM) sensor -G28-

 

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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