Volkswagen New Beetle. Manual - part 1750

 

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Volkswagen New Beetle. Manual - part 1750

 

 

Fig. 2: Locating Engine Code (2.0L - AVH, AZG, BDC, BEV & BGD) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

INTRODUCTION 

The following diagnostic steps will help prevent overlooking a simple problem. This is also where to begin 
diagnosis for a no-start condition.  

The first step in diagnosing any driveability problem is verifying the customer's complaint with a test drive 
under the conditions the problem reportedly occurred.  

Performing a thorough Visual Inspection and checking for DTCs, may pin point faulty circuit, (vacuum or 
electrical) and/or faulty component or adjustment. See VISUAL INSPECTION . After performing Visual 

NOTE:

Information that involve ECM sensors and components that generate DTCs are 
not covered in this article. See appropriate SELF-DIAGNOSTICS article, in 
ENGINE PERFORMANCE. 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

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Inspection, check for DTCs. See appropriate SELF-DIAGNOSTICS article. Most engine control problems 
result from mechanical breakdowns, poor electrical connections, or damaged/misrouted vacuum hoses.  

PRELIMINARY INSPECTION 

VISUAL INSPECTION 

Prior to retrieving DTCs, perform a thorough visual inspection of underhood components. Check ground 
connections located on intake manifold, ground cable between engine and vehicle body and that battery cables 
are clean and tight. See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in 
ELECTRICAL.  

Check vacuum hoses for breakage and blockage. Check electrical wiring and harness connectors for damage 
and corrosion. Repair as necessary.  

MECHANICAL INSPECTION 

Compression 

1. Engine oil temperature must be at least 86°F (30°C). Battery must be fully charged. All electrical 

consumers (lights and rear window defogger, etc.) must be switched off. If the vehicle is equipped with 
air conditioning, this must be switched off. On models with an automatic transmission selector lever in 
position "P" or "N".  

2. Remove engine cover. On 2.0L engines, disconnect 6-pin connector from ignition coil with final output 

stage. On 1.8L engines, pull connector(s) off ignition coils. Remove ignition coils.  

3. On all engines, turn off ignition. Remove fuse No. 32 (fuel injector power supply fuse) from fuse block at 

far left end of dash. See Fig. 3 .  

4. Remove spark plugs. Have a second technician fully depress accelerator pedal.  

5. Check engine mechanical condition with remote control starter switch and compression gauge. On 1.8L 

engines, install ignition coils and tighten mounting bolts to 89 INCH lbs. (10 N.m).  

COMPRESSION SPECIFICATIONS 

NOTE:

Perform all voltage tests using Digital Volt-Ohmmeter (DVOM) with a minimum 
10-megohm input impedance, unless stated otherwise in test procedure. 

WARNING:

DO NOT use ignition switch during compression tests on fuel injected 
vehicles. Use a remote starter to crank engine. Fuel injectors on many 
models are triggered by ignition switch during cranking mode, which can 
create a fire hazard or contaminate the engine's oiling system. 

Application 

(1)

Specification 

Normal Compression Pressure 

1.8L Turbo 

(2)

145-203 psi (10.0-14.0 bar) 

145-189 psi (10.0-13.0 bar) 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

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Exhaust System Backpressure 

A restricted exhaust system can be checked with a vacuum or pressure gauge. Remove heated oxygen sensor or 
air injection check valve (if equipped). Connect a 0-5 psi pressure gauge and operate engine at 2500 RPM. If 
exhaust system backpressure is greater than 3 psi, exhaust system or catalytic converter is plugged.  

If a vacuum gauge is used, connect vacuum gauge hose to intake manifold vacuum port and start engine. 
Observe vacuum gauge. Open throttle part way and hold steady. If vacuum gauge reading slowly drops after 
stabilizing, check exhaust system for restriction.  

FUEL SYSTEM 

FUEL PRESSURE 

Basic diagnosis of fuel system should begin with determining fuel system pressure.  

Fuel System Pressure Release 

Turn ignition off. Disconnect ignition coil output stage wiring harness to deactivate ignition. To disable fuel 
pump, remove fuse No. 28 from fuse panel at far left end of dash. See Fig. 3 . Place a clean shop rag around 
fuel line fitting and slowly loosen fitting. See Fig. 4 or Fig. 9 

2.0L 

(2)

Minimum Compression Pressure 

1.8L Turbo 

101 psi (7.0 bar) 

2.0L 

109 psi (7.5 bar) 

Maximum Variation Between Cylinders 

1.8 Turbo & 2.0L 

44 psi (3.0 bar) 

(1)

Operate starter until tester shows no further increase.

(2)

Remove fuel injector power fuse No. 32 in instrument panel fuse block (behind far 
left end of dash). See Fig. 3 .

WARNING:

ALWAYS relieve fuel pressure before disconnecting any fuel injection-
related component. See FUEL SYSTEM PRESSURE RELEASE . DO NOT 
allow fuel to contact engine or electrical components. 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

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© 2004 Mitchell Repair Information Company, LLC. 

Fig. 3: Identifying Dash Fuse Panel Fuses 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fuel Pressure Test (1.8L Turbo) 

1. Ensure ignition is off. Ensure battery voltage is at least 12 volts. Release fuel pressure, see FUEL 

SYSTEM PRESSURE RELEASE .  

2.  

Connect Pressure Gauge (VAG 1318) at fuel supply line/hose in engine compartment. See Fig. 4 and Fig. 
5
 . 

NOTE:

Fuel pressure tester must be installed with the shut-off valve between the 
fuel supply line and the gauge for proper evaluation of residual pressure 
tests. 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

Page 5 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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