2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
1998-2004 ENGINE
Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
IGNITION SYSTEM, SERVICING
GENERAL NOTES ON IGNITION SYSTEM
z Only the components which specifically relate to the ignition system are covered here. For the other
components of the injection and ignition system, see MULTIPORT FUEL INJECTION (MFI) - 2.0L -
AEG, AVH, AZG, BDC, BEV & BGD) .
z For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary.
z Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
engine control module could be damaged.
z During some checks it is possible that the control module will detect and store a fault. Therefore, after
completing all checks and repairs the fault memory must be interrogated and, if necessary, erased. See
ENGINE CONTROL MODULE FAULT MEMORY, INTERROGATING AND ERASING .
z If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests,
then the fault may lie with the immobilizer which is blocking the engine control unit. In such cases the
control unit must be adapted. See COMPONENTS AND FUNCTIONS, ADAPTING .
Safety precautions. See SAFETY PRECAUTIONS .
Test data, spark plugs. See TEST DATA, SPARK PLUGS .
IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING
Engine code AEG
z Engine codes AVH, AZG, BDC, BEV, BGD. See ENGINE CODES AVH, AZG, BDC, BEV, BGD .
NOTE: The following list refers to items in Fig. 1 .
1. 10 N.m
2. Ignition wire
z With RF suppression type connector and spark plug connector
z Pull spark plug connector off with T10112
z Check for continuity
3. Spark plug
z 30 N.m
z Remove and install with 3122B
z Type and electrode gap. See TEST DATA, SPARK PLUGS
4. 20 N.m
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2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
z Tightening torque influences knock sensor function
5. Knock Sensor (KS) 2 -G66-
z Sensor and connector terminals are gold-plated
6. 3-pin harness connector
z Terminals gold plated
z Brown for KS 2 -G66-
7. Knock Sensor (KS) 1 -G61-
z Sensor and connector terminals are gold-plated
8. 3-pin harness connector
z Terminals gold plated
z Black for KS 1 -G61-
9. Camshaft Position (CMP) sensor -G40-
z Location. See item - 17 - on ENGINE CODE AEG
10. 3-pin harness connector
z Black
z For CMP sensor -G40-
11. 4-pin harness connector
z Black
12. Ignition coils - N-, -N128-
z Marked for ignition cables: A = Cylinder 1, B = Cylinder 2, C = Cylinder 3 and D = Cylinder 4
z With Power output stage -N122-
z Location. See item - 12 - on ENGINE CODE AEG .
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2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
Fig. 1: Exploded View Of Ignition System Components (Engine Code AEG)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Engine codes AVH, AZG, BDC, BEV, BGD
NOTE: The following list refers to items in Fig. 2 .
1. H.T. cable
z 4...8 kohm
z With suppression connector and spark plug connector
z Check for continuity
z Pull spark plug connector off with T10112.
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2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
2. Ignition coils with final output stages -N70-, -N127-, -N291-, -N292-
z With marks for H.T. cables: HV1 = Cylinder 1, HV2 = Cylinder 2, HV3 = Cylinder 3, HV4 =
Cylinder 4
3. 10 N.m
4. 6-pin connector
5. Knock Sensor (KS) 1 -G61-
z Gold plated contacts
z Location: Cylinder block intake side
6. 2-pin connector
z For KS 1 -G61-
z Gold plated contacts
z Do not interchange
7. Knock Sensor (KS) 2 -G66-
z Gold plated contacts
z Next to ignition transformer
8. 2-pin connector
z For KS2 -G66-
z Gold plated contacts
z Do not interchange
9. 20 N.m
z Torque setting influences the function of knock sensor
10. Spark plug, 25 N.m
z Type and electrode gap. See TEST DATA, SPARK PLUGS
z To remove and install pull off connectors for outer injectors
z Remove and install with 3122 B
11. Connector
z Gold plated contacts
z 3-pin
12. 10 N.m
13. 100 N.m
z Use counter support tool 3415 to loosen and tighten
14. Camshaft pulley
z With rotor for camshaft position sensor
z Removing and installing. See VALVE GEAR, SERVICING
15. Camshaft Position (CMP) sensor -G40-
16. Retainer
z For camshaft position sensor
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December-27-07 12:30:37 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
Fig. 2: Exploded View Of Ignition System Components (Engine Code AVH, AZG, BDC, BEV AND BGD)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
SAFETY PRECAUTIONS
To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
observed:
WARNING: When performing repair work, especially due to the confined conditions
in the engine compartment, pay attention to the following:
z Route all types of lines (e.g. for fuel, hydraulics, EVAP system,
coolant, refrigerant, brake fluid and vacuum) as well as electrical
wiring so that the original positions are restored.
z Ensure sufficient clearance to all moving or hot components.
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December-27-07 12:30:37 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
z Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
z The ignition must be switched off before connecting or disconnecting injection or ignition system wiring
or tester cables.
z If the engine is to be turned at starter speed, without starting:
Engine code AEG
z Disconnect 4-pin harness connector -1- from ignition coil power output stage -2-.
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2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
Fig. 3: Disconnecting Pin Harness Connector From Ignition Coil Power Output Stage (Engine Code
AEG)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
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December-27-07 12:30:37 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
Engine codes AVH, AZG, BDC, BEV, BGD
z Disconnect 6-pin connector from ignition coil with final output stage (arrow).
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2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
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December-27-07 12:30:37 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
Fig. 4: Disconnecting Pin Connector From Ignition Coil With Final Output Stage (Engine codes
AVH, AZG, BDC, BEV, BGD)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Continuation for all engines
z Pull fuse No. 32 out of fuse holder. Fuse holder is located under access panel at far left end of dash.
Fig. 5: Identifying Fuse No. 32
Courtesy of VOLKSWAGEN OF AMERICA, INC.
NOTE: Removing fuse 32 interrupts the voltage supply to the injectors.
Observe following if test and measuring instruments are required during a road test:
z Test and measuring instruments must be secured to rear seat and operated by an assistant from this
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2003 Volkswagen New Beetle GLS
1998-2004 ENGINE Ignition Glow Plug System - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)
location.
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
z Erase engine control module fault memory because pulling connectors off injector will have caused a
fault to be recorded. See ENGINE CONTROL MODULE FAULT MEMORY, INTERROGATING
AND ERASING .
z Generate readiness code if fault memory has been erased. See COMPONENTS AND FUNCTIONS,
ADAPTING .
TEST DATA, SPARK PLUGS
SPARK PLUGS TEST DATA
Engine code AEG AVH, AZG, BEV BDC, BGD
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Spark Plugs (1) , (2)
VW 101 000 033 AA 101 000 062 101 000 062
AB AB
Manufacturer's BKR6ET-10 PZFR5D-11 PZFR 5D-11
designation
Electrode gap 0.9 to 1.1 mm (0.035 to 1.0 to 1.1 mm 1.0 to 1.1 mm
0.043 in.)
Torque setting 30 N.m (22 ft lb) 25 N.m 25 N.m
(1) For spark plug change intervals, see maintenance schedule in owners manual.
(2) Use tool T10112 for disconnecting and connecting spark plug connector. Remove and install spark
plugs using tool 3122B.
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