Volkswagen New Beetle. Manual - part 1653

 

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Volkswagen New Beetle. Manual - part 1653

 

 

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 

z

Disassembling and assembling, see AIR CLEANER, DISASSEMBLING AND ASSEMBLING 

3. 6 Nm  

4. 40-pin connector 

z

Only disconnect or connect with ignition switched off  

z

Release to disconnect  

5. 81-pin connector 

z

Only disconnect or connect with ignition switched off  

z

Release to disconnect  

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

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

z

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

z

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

z

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

z

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

z

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

7. 4-pin connector 

z

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

z

Brown/Black  

z

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

z

Terminals 3 and 4 gold plated  

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

z

With 4-pin connector  

z

Component location, see MULTIPORT FUEL INJECTION (MFI)  

z

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

z

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

  

z

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
  

z

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

z

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
  

z

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 

z

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

z

Black  

z

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 

z

With 6-pin connector  

z

Component location, see MULTIPORT FUEL INJECTION (MFI)  

z

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

z

Remove and install with ring wrench 3337  

z

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
  

z

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

z

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

z

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
  

z

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

z

Terminals gold plated  

11. Bracket 

z

For Engine Speed (RPM) Sensor - G28-  

12. O-ring 

z

Replace  

13. Engine Speed (RPM) Sensor -G28-* 

z

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

  

z

Checking, see ENGINE SPEED (RPM) SENSOR, CHECKING  

14. 3-pin connector 

z

Gray  

z

For Engine Speed (RPM) Sensor - G28-  

15. 20 Nm  

16. 45 Nm  

17. Support 

z

Between intake manifold and engine block  

18. Intake manifold  

19. Charge pressure sensor -G31-* 

z

Component location, see MULTIPORT FUEL INJECTION (MFI)  

z

4 pin connector  

z

Removing and installing:  

See TURBOCHARGER, G-CHARGER 

20. Gasket 

z

Replace  

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

z

Evaporative Emission (EVAP) system  

See EVAP CANISTER SYSTEM 

22. Throttle Valve Control Module -J338- * 

z

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

z

6-pin connector  

z

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

z

Connector terminals gold-plated  

z

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

z

If replaced adapt control module for automatic transmission:  

See DIAGNOSIS - 01M 

23. Return pipe 

z

Secure with spring-type clips  

z

Check securely seated  

z

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 

z

Secure with spring-type clips  

z

Make sure it is securely seated  

z

From fuel filter:  

See FUEL SUPPLY 

25. Fuel rail with fuel injectors 

z

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

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

z

Component location, see MULTIPORT FUEL INJECTION (MFI)  

z

2-pin connector  

z

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

27. Retaining clip 

z

Make sure it is securely seated  

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

z

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

z

For Motronic Engine Control Module (ECM) -J220-  

z

With Engine Coolant Temperature (ECT) sensor -G2-  

z

If necessary release pressure in cooling system before removing  

z

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

z

Wiring chamber 3 and wiring chamber 4 for -G62-  

z

Terminals 3 and 4 gold plated  

29. Connector 

z

Black, 4-pin  

z

For Engine Coolant Temperature (ECT) sensor -G62-  

z

Wiring chamber C and wiring chamber D for -G62-  

z

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 

z

Oil filter bracket  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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