Volkswagen New Beetle. Manual - part 2030

 

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Volkswagen New Beetle. Manual - part 2030

 

 

Gasoline Engines 

Check compression with fuel pump fuse removed. Disconnect ignition coil electrical harness connector(s). 
Engine at operating temperature and fully charged battery. See COMPRESSION SPECIFICATIONS table.  

Diesel Engines 

Check compression with 10-pin fuel cut-off valve electrical harness connector disconnected (located on diesel 
injection pump). Using a compression gauge capable of reading up to 600 psi (41 bar). Engine at operating 
temperature and a fully charged battery. See COMPRESSION SPECIFICATIONS table.  

COMPRESSION SPECIFICATIONS 

WARNING:

Fuel pump fuse must be removed and ignition coil electrical harness 
connector(s) disconnected before performing compression check. 

WARNING:

Disconnect 10-pin fuel cut-off valve electrical connector (located on 
diesel injection pump) before performing compression check. 

Application 

(1)

Specification 

Normal Compression Pressure 

Beetle 

1.8L Turbo 

(2)

145-203 psi (10-14 bar) 

1.9L Turbo Diesel 

363-450 psi (25.0-31.0 bar) 

2.0L 

(2)

145-189 psi (10-13 bar) 

Cabrio 2.0L 

(3)

145-189 psi (10.0-13.0 bar) 

EuroVan 2.8L 

(3)

145-189 psi (10.0-13.0 bar) 

Golf 

1.8L Turbo 

(2)

145-203 psi (10.0-14.0 bar) 

1.9L Turbo Diesel 

363-450 psi (25.0-31.0 bar) 

2.0L 

(2)

145-189 psi (10.0-13.0 bar) 

GTI 

1.8L 

(2)

145-203 psi (10.0-14.0 bar) 

2.0L & 2.8L 

(2)

145-189 psi (10.0-13.0 bar) 

Jetta 

1.8L Turbo 

(2)

145-203 psi (10.0-14.0 bar) 

1.9L Turbo Diesel 

363-450 psi (25.0-31.0 bar) 

2.0L & 2.8L 

(2)

145-189 psi (10.0-13.0 bar) 

Passat 

1.8L Turbo (ATW) 

(2)

145-189 psi (10.0-13.0 bar) 

 

2003 Volkswagen New Beetle GLS 

2000-03 ENGINE PERFORMANCE Service & Adjustment Specifications

  

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VALVE CLEARANCE 

1.8L Turbo (AUG & AWM) 

(2)

145-203 psi (10.0-14.0 bar) 

2.8L 

(4)

131-203 psi (9.0-14.0 bar) 

Minimum Compression Pressure 

Beetle 

1.8L 

101 psi (7.0 bar) 

1.9L Turbo Diesel 

276 psi (19.0 bar) 

2.0L 

109 psi (7.5 bar) 

Cabrio 2.0L 

109 psi (7.5 bar) 

EuroVan 2.8L 

109 psi (7.5 bar) 

Golf 

1.8L Turbo 

101 psi (7.0 bar) 

1.9L Turbo Diesel 

276 psi (19.0 bar) 

2.0L 

109 psi (7.5 bar) 

GTI 

1.8L Turbo 

101 psi (7.0 bar) 

2.0L & 2.8L 

109 psi (7.5 bar) 

Jetta 

1.8L Turbo 

101 psi (7.0 bar) 

1.9L Turbo Diesel 

276 psi (19.0 bar) 

2.0L & 2.8L 

109 psi (7.5 bar) 

Passat 

1.8L Turbo 

101 psi (7.0 bar) 

2.8L Turbo 

109 psi (7.5 bar) 

Maximum Variation Between Cylinders 

1.8 Turbo, 2.0L, 2.8L VR6 & 2.8L V6 

44 psi (3.0 bar) 

1.9L Turbo Diesel 

73 psi (5.0 bar) 

(1)

Operate starter until tester shows no further increase.

(2)

On all models (except 2.0L Cabrio), with 1.8L turbo engine and 2.0L engine, 
remove fuel pump fuse No. 32. On GTI and Jetta with 2.8L engine, remove fuel 
pump fuse No. 32.

(3)

On Cabrio and EuroVan, remove fuel pump fuse No. 18.

(4)

On Passat with 2.8L engine, remove fuel pump fuse No. 28.

NOTE:

All engines are equipped with hydraulic valve lifters. No adjustments are 
required. 

 

2003 Volkswagen New Beetle GLS 

2000-03 ENGINE PERFORMANCE Service & Adjustment Specifications

  

Helpmelearn Repair Manuals 

 

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IGNITION SYSTEM 

IGNITION COIL 

IGNITION COIL RESISTANCE-Ohms 

Application 

Primary 

Secondary 

Beetle 

1.8L Turbo 

(1)

(2)

2.0L (AEG) 

(1)

(3)

 4000-6000 

2.0L (AVH & AZG) 

(1)

(2)

Cabrio 2.0L 

.5-1.5 

2500-4000 

EuroVan 

2.8L (AES) 

(1)

3600-4400 

2.8L (AXK) 

(1)

(2)

Golf 

1.8L Turbo 

(1)

(2)

2.0L 

(1)

(3)

 4000-6000 

GTI 

1.8L Turbo 

(1)

(2)

2.0L 

(1)

(3)

 4000-6000 

2.8L 

(1)

(4)

 3600-4400 

Jetta 

1.8L Turbo 

(1)

(2)

2.0L (AEG) 

(1)

(3)

 4000-6000 

2.0L (AVH & AZG) 

(1)

(2)

2.8L 

(1)

(4)

 3600-4400 

Passat 

1.8L Turbo 

(1)

(2)

2.8L (ATQ) 

(1)

8000-14,000 

2.8L (ATQ) 

(1)

(5)

 18,000-25,000 

(1)

Primary ignition coil resistance cannot be measured.

(2)

Ignition coil specifications not available from manufacturer.

(3)

Check resistance at number 4 terminal (at rounded end of electrical receptacle) and 
coil outlets for cylinders 1-4 and 2-3.

(4)

Check resistance at coil outlets for cylinders 1-6, 3-4 and 2-5. See Fig. 5 .

 

2003 Volkswagen New Beetle GLS 

2000-03 ENGINE PERFORMANCE Service & Adjustment Specifications

  

Helpmelearn Repair Manuals 

 

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© 2004 Mitchell Repair Information Company, LLC. 

HIGH TENSION WIRE RESISTANCE 

HIGH TENSION WIRE RESISTANCE 

SPARK PLUGS 

SPARK PLUG TYPE 

(5)

Manufacturer recommends measuring resistance between two spark plug wires, still 
connected to ignition coil. See Fig. 4 .

Application 

Ohms 

Beetle 

1.8L Turbo 

(1)

2.0L 

(2)

 4000-8000 

Cabrio 2.0L 

(2)

 4800-7200 

EuroVan 

2.8L (AES) 

(2)

 4600-7200 

2.8L (AXK) 

(1)

Golf 

1.8L Turbo 

(1)

2.0L 

(2)

 4000-8000 

GTI & Jetta 

1.8L Turbo 

(1)

2.0L 

(2)

 4000-8000 

2.8L 

(2)

 4000-6000 

Passat 

1.8L Turbo 

(1)

2.8L 

(2)

 3000-7000 

2.8L 

(3)

 18,000-25,000 

(1)

No high tension wires are used as ignition coil on spark plug type ignition system is 
used.

(2)

Resistance listed with spark plug connector installed on end of high tension wire and 
suppressor installed on ignition coil end of high tension wire.

(3)

Manufacturer recommends measuring resistance between two spark plug wires, still 
connected to ignition coil. See Fig. 4 .

Application 

NGK No. 

Beetle 

1.8L Turbo 

PFR6Q 

 

2003 Volkswagen New Beetle GLS 

2000-03 ENGINE PERFORMANCE Service & Adjustment Specifications

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:53:44 AM

Page 17 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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