Volkswagen New Beetle. Manual - part 1572

 

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Volkswagen New Beetle. Manual - part 1572

 

 

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

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Replacing. See ENGINE CONTROL MODULE  

3. 28-pin harness connector 

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Only disconnect or connect with ignition switched OFF  

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Release to disconnect  

4. 52-pin connector 

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Only disconnect or connect with ignition switched OFF  

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Release to disconnect  

5. 2-pin harness connector 

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For Secondary Air Injection (AIR) solenoid valve -N112-  

6. Air filter 

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Disassembling and assembling. See AIR CLEANER, DISASSEMBLING AND ASSEMBLING 

7. 10 N.m  

8. To Secondary Air Injection (AIR) pump -V101-  

9. Mass Air Flow (MAF) sensor -G70-  

10. Air duct 

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In wheelhousing  

11. 4-pin harness connector 

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Blue  

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for Engine Coolant Temperature (ECT) sensor -G62-  

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

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Blue  

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For Engine Control Module  

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With Engine Coolant Temperature sensor -G2-  

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If necessary, release pressure in cooling system before removing  

13. Retaining clip 

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Ensure it is securely seated  

14. pin harness connector 

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Gray  

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For Engine Speed sensor  

15. Engine Speed (RPM) sensor -G28- 

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In transmission housing above starter ring gear  

16. O-ring 

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Replace if damaged  

17. Spacer  

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

 

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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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
  

19. 4-pin harness connector 

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Brown  

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ForO2S Behind TWC -G130- and O2S heater 1 -Z29-, cylinder bank 1  

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Right underside of vehicle  

20. Heated Oxygen Sensor (HO2S) -G39- 

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50 N.m  

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In front exhaust pipe  

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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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Sensor heater Voltage supply via Fuel pump (FP) relay -J17-  

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

21. 4-pin harness connector 

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Black  

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For HO2S -G39- and O2S heater -Z19-, cylinder bank 2  

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Right underside of vehicle  

22. Intake rail, lower section 

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

23. Fuel rail with injectors 

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

24. Return line 

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Blue  

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Secure with spring clips  

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Ensure it is securely seated  

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To fuel delivery unit in fuel tank  

25. Supply line/hose 

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Black  

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From fuel filter  

26. 2-pin harness connector 

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Black  

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For injectors -N30- to -N33-  

27. Gasket 

 

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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Replace if damaged  

28. 20 N.m (15 ft lb)  

29. To Positive Crankcase Ventilation valve  

30. Intake hose  

Fig. 7: Exploded View Of Fuel Injection System Components (Engine Code AEG) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

INTAKE MANIFOLD UPPER PART, DISASSEMBLING AND ASSEMBLING 

Engine codes AVH, AZG, BEV 

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Engine code AEG. See FUEL INJECTION SYSTEM COMPONENTS, REMOVING AND 
INSTALLING
 .  

 

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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Engine codes BDC, BGD. See ENGINE CODES BDC, BGD  

1. Intake manifold upper part 

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

2. 6 N.m  

3. Rubber bushing 

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For engine cover  

4. To fuel pressure regulator 

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Only engine codes AVH, AZG  

5. From Leak Detection Pump (LDP) -V144- 

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EVAP system. See EVAP SYSTEM COMPONENTS, SERVICING .  

6. From EVAP canister purge regulator valve -N80- 

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Assembly overview of EVAP system. See EVAPORATIVE EMISSIONS (EVAP) SYSTEM, 
ASSEMBLY
 .  

7. 10 N.m  

8. Connecting pipe  

9. To brake servo vacuum line  

10. Seal 

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Replace  

11. To intake hose  

12. Unions for coolant hoses  

13. 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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6-pin connector  

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Gold plated contacts  

14. Seal 

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Replace  

15. Connecting union 

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From Model Year 2002  

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To shaped hose for cylinder head cover or intake hose 

NOTE:

The following list refers to items in Fig. 8 .

 

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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