Volkswagen New Beetle. Manual - part 1593

 

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Volkswagen New Beetle. Manual - part 1593

 

 

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If replaced, erase learned values and adapt Motronic Engine Control Module (ECM) -J220- to 
Throttle Valve Control Module -J338-, see MOTRONIC ENGINE CONTROL MODULE 
(ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING
  

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Sensor heating voltage supply via Fuel Pump (FP) Relay -J17-  

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Checking Heated Oxygen Sensor (HO2S) for oxygen sensor after Three Way Catalytic Converter 
(TWC), see HEATED OXYGEN SENSOR (HO2S) FOR OXYGEN SENSOR AFTER 
THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
  

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Checking Oxygen Sensor (O2S) and oxygen sensor control after Three Way Catalytic Converter 
(TWC), see OXYGEN SENSOR AND OXYGEN SENSOR CONTROL AFTER THREE 
WAY CATALYTIC CONVERTER (TWC), CHECKING
  

9. 6-pin connector 

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

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Black  

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For Oxygen Sensor (O2S) 1 before Three Way Catalytic Converter (TWC) -G39- and Heated 
Oxygen Sensor (HO2S) -Z19-  

10. Oxygen Sensor (O2S) 1 before Three Way Catalytic Converter (TWC) -G39- *, 50Nm 

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With 6-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  

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If replaced, erase learned values and adapt Motronic Engine Control Module (ECM) -J220- to 
Throttle Valve Control Module -J338-, see MOTRONIC ENGINE CONTROL MODULE 
(ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING
  

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Sensor heating voltage supply via Fuel Pump (FP) Relay -J17-  

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Checking Heated Oxygen Sensor (HO2S) before Three Way Catalytic Converter (TWC), see 
FUEL INJECTION SYSTEM COMPONENTS, CHECKING  

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Checking Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter 
(TWC), see OXYGEN SENSOR AND OXYGEN SENSOR CONTROL BEFORE THREE 
WAY CATALYTIC CONVERTER (TWC), CHECKING
  

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Checking Oxygen Sensor (O2S) aging, see OXYGEN SENSOR AGING, OXYGEN SENSOR 
BEFORE THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
  

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Terminals gold plated  

11. Bracket 

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For Engine Speed (RPM) Sensor - G28-  

12. O-ring 

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Replace  

13. Engine Speed (RPM) Sensor -G28-* 

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

 

2003 Volkswagen New Beetle GLS 

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

  

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Checking, see ENGINE SPEED (RPM) SENSOR, CHECKING  

14. 3-pin connector 

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Gray  

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For Engine Speed (RPM) Sensor - G28-  

15. 20 Nm  

16. 45 Nm  

17. Support 

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Between intake manifold and engine block  

18. Intake manifold  

19. Charge pressure sensor -G31-* 

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Component location, see MULTIPORT FUEL INJECTION (MFI)  

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4 pin connector  

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Removing and installing:  

See TURBOCHARGER, G-CHARGER 

20. Gasket 

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Replace  

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

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Evaporative Emission (EVAP) system  

See EVAP CANISTER SYSTEM 

22. Throttle Valve Control Module -J338- * 

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

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6-pin connector  

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

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Connector terminals gold-plated  

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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
  

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If replaced adapt control module for automatic transmission:  

See DIAGNOSIS - 01M 

23. Return pipe 

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Secure with spring-type clips  

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Check securely seated  

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To fuel delivery unit in fuel tank 

 

2003 Volkswagen New Beetle GLS 

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

  

See FUEL SUPPLY 

24. Supply pipe/hose 

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Secure with spring-type clips  

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Make sure it is securely seated  

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From fuel filter:  

See FUEL SUPPLY 

25. Fuel rail with fuel injectors 

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Disassembling and assembling, see FUEL RAIL WITH FUEL INJECTORS, 
DISASSEMBLING AND ASSEMBLING
  

26. Intake Air Temperature (IAT) sensor - G42-* 

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Component location, see MULTIPORT FUEL INJECTION (MFI)  

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2-pin connector  

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

27. Retaining clip 

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Make sure it is securely seated  

28. Engine Coolant Temperature (ECT) sensor -G62-* 

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

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For Motronic Engine Control Module (ECM) -J220-  

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With Engine Coolant Temperature (ECT) sensor -G2-  

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If necessary release pressure in cooling system before removing  

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Checking, see ENGINE COOLANT TEMPERATURE (ECT) SENSOR -G62-, CHECKING  

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Wiring chamber 3 and wiring chamber 4 for -G62-  

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Terminals 3 and 4 gold plated  

29. Connector 

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Black, 4-pin  

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For Engine Coolant Temperature (ECT) sensor -G62-  

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Wiring chamber C and wiring chamber D for -G62-  

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Terminals C and D gold plated  

30. To pipe between turbo charger and charge air cooler  

31. To pipe between turbo charger and charge air cooler  

32. To intake hose at turbocharger 

See TURBOCHARGER, G-CHARGER 

33. From crankcase breather 

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Oil filter bracket  

 

2003 Volkswagen New Beetle GLS 

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

  

34. From crankcase breather 

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Valve cover  

35. From intake hose 

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See item 7  

See TURBOCHARGER, G-CHARGER 

36. To Recirculating valve for turbocharger -N249- 

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See item 7  

See TURBOCHARGER, G-CHARGER 

37. To pressure unit on turbo charger 

See TURBOCHARGER, G-CHARGER 

38. Wastegate Bypass Regulator Valve - N75-*/** 

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

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Charge pressure system:  

See TURBOCHARGER, G-CHARGER 

39. Intake hose 

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Note installation position  

40. To vacuum booster 

See TURBOCHARGER, G-CHARGER 

41. Mass Air Flow (MAF) sensor -G70-* 

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5-pin connector  

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Socket 1 not occupied  

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Sensor and connector terminals are gold-plated  

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Checking, see MASS AIR FLOW (MAF) SENSOR, CHECKING  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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