Volkswagen New Beetle. Manual - part 1592

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Tightening torque influences the function of the knock sensor  

23. Knock Sensor (KS) 2 -G66- 

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Black  

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See IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING , item 13  

24. 2-pin connector 

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Black  

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For Knock Sensor (KS) 2 -G66-  

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Identify before disconnecting  

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

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Secondary air system  

See SECONDARY AIR INJECTION (AIR) SYSTEM 

26. 20 Nm 

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Tightening torque influences the function of the knock sensor  

27. Knock Sensor (KS) 1 -G61- 

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Black  

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See IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING , item 12  

28. 2-pin connector 

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Black  

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For knock sensor 1 -G61-  

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Identify before disconnecting  

29. Charge pressure sensor -G31- 

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Checking charge pressure system  

See TURBOCHARGER, G-CHARGER 

30. Throttle Valve Control Module -J338- 

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No cable disc for accelerator cable as this is an Electronic Power Control (EPC)  

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Checking, see THROTTLE VALVE CONTROL MODULE -J338-, CHECKING  

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If replaced, adapt Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE 
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - 
J338-, ADAPTING  

31. Intake Air Temperature (IAT) sensor - G42- 

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Checking, see INTAKE AIR TEMPERATURE (IAT) SENSOR, CHECKING  

32. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- 

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Evaporative Emission (EVAP) system:  

See EVAP CANISTER SYSTEM 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

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

Fuel injection, general information 

Servicing ignition system, see IGNITION SYSTEM, SERVICING 

Safety precautions, see SAFETY PRECAUTIONS 

Rules for cleanliness, see RULES OF CLEANLINESS 

Technical data, see TECHNICAL DATA 

NOTE:

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The Motronic Engine Control Module (ECM) - J220- is equipped with On 
Board Diagnostic (OBD). Before carrying out repairs and troubleshooting 
the DTC memory of all control modules must be checked using the 
automatic test sequence. This is necessary as various control modules 
are connected to each other via a data bus. The vacuum hoses and 
connections must also be checked (unmetered air).  

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Fuel hoses in engine compartment must only be secured with spring type 
clips. The use of clamp or screw type clips is not permissible.  

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Disconnecting and connecting the battery must only be done with the 
ignition switched off, otherwise the Motronic Engine Control Module (ECM) 
-J220- could be damaged.  

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Components marked with * are checked via the On Board Diagnostic 
(OBD), see DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE 
(ECM) -J220-, CHECKING AND ERASING .  

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Components marked with **can be checked with the Output Diagnostic 
Test Mode (DTM), see OUTPUT DIAGNOSTIC TEST MODE (DTM) .  

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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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Do not use sealants containing silicone. Particles of silicone drawn into 
the engine, will not be burned in the engine and damage the oxygen 
sensor.  

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Some checks can cause the control module to recognize and store a DTC. 
Therefore after completing all checks and repairs the DTC memory must 
be checked and if necessary erased, see DTC MEMORY OF MOTRONIC 
ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND ERASING .  

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Vehicles with an airbag are built with a crash/fuel shut -off. It reduces the 
risk of a vehicle burning in the event of a crash and that the fuel pump is 
switched off by the fuel pump relay. At the same time, this device 
improves the starting of the engine because as soon as the door is 
opened, the fuel pump is activated for 2 seconds to build up pressure in 
the fuel system.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

Checking engine operating mode, see ENGINE OPERATING MODE, CHECKING 

Fuel injection system components, removing and installing 

The following list pertains to Fig. 2 . 

1. 10 Nm  

2. Air cleaner 

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Disassembling and assembling, see AIR CLEANER, DISASSEMBLING AND ASSEMBLING 

3. 6 Nm  

4. 40-pin connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

5. 81-pin connector 

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Only disconnect or connect with ignition switched off  

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Release to disconnect  

6. Motronic Engine Control Module (ECM) -J220-* 

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

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Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment 
overview  

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Checking voltage supply, see MOTRONIC ENGINE CONTROL MODULE (ECM)  

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Procedure after voltage supply open circuit, see PROCEDURE AFTER CORRECTING 
VOLTAGE SUPPLY OPEN CIRCUIT  

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Replace, see MOTRONIC ENGINE CONTROL MODULE (ECM) - J220-, REPLACING  

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If replaced, carry out basic setting, see MOTRONIC ENGINE CONTROL MODULE (ECM) - 
J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING  

7. 4-pin connector 

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Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment 
overview  

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Brown/Black  

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For oxygen sensor 2 after Three Way Catalytic Converter (TWC) -G130- and Heated Oxygen 
Sensor (HO2S) - Z29-  

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Terminals 3 and 4 gold plated  

8. Oxygen Sensor (O2S) 2 after Three Way Catalytic Converter (TWC) - G130-*, 50 Nm 

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With 4-pin connector  

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Component location, see MULTIPORT FUEL INJECTION (MFI)  

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Grease only the threads with G 052 112 A3 hot bolt paste (anti-seize compound). Grease must not 
get into slots on sensor body  

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Remove and install with ring wrench 3337 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle