Volkswagen New Beetle 2.0 Liter Fuel Injection and Ignition (Engine ...

Volkswagen New Beetle 2.0 Liter Fuel Injection and Ignition (Engine code: AEG) Additional signals, checking (Page 28-1)

Ignition system, general information Notes: Only components specifically related to the ignition system are contained in this Repair section. For other Fuel injection and Ignition system components Repair Group 24. Only disconnect and connect the Battery with the ignition switched OFF, otherwise the Engine Control Module (ECM) could be damaged. The ECM is equipped with an On Board Diagnostic II system. Components marked with an * are checked via On Board Diagnostic II Page 0113 . 11.5 Volts minimum is required for trouble-free electrical component operation. It is possible that the ECM will recognize and store a DTC during certain checking procedures. Therefore; check DTC memory after completing all checks and repairs, and erase if necessary Page 01-13 . Safety precautions Page 28-4 Test data, spark plugs Page 28-5

Volkswagen New Beetle 2.0 Liter Fuel Injection and Ignition (Engine code: AEG) Ignition system, servicing (Page 28-2)

Ignition system components, removing and installing

1 - Ignition wire With RF suppression type connector and spark plug connector - Check for continuity 2 - Spark plug 30 Nm (22 ft lb) - Remove and install with 3122B Type and electrode gap Page 28-5

3 - 20 Nm (15 ft lb) Tightening torque influences knock sensor function 4 - Knock sensor 1 G61* Sensor and connector terminals are gold - plated Checking Page 28-15 5 - 3 - pin harness connector Terminals gold plated Black for knock sensor 1 G61 Brown for knock sensor 2 G66


6 - Knock sensor 2 G66* Sensor and connector terminals are gold - plated Checking Page 28-15 7 - Camshaft Position sensor G40* Checking Page 28-6 8 - 3 - pin harness connector Black For Camshaft Position sensor G40 9 - 4 - pin harness connector

Black 10 - Ignition coils N, N128 Marked for ignition cables: A = Cylinder 1, B = Cylinder 2, C = Cylinder 3 and D = Cylinder 4 With Power output stage N122 Checking Page 28-9 11 - 10 Nm (7 ft lb)


Safety precautions To prevent injuries to persons and/or damage to the fuel injection and ignition system, note the following: Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed. Switch OFF the ignition before connecting or disconnecting injection or ignition system wiring or test cables. If engine must be turned at starter speed, without starting the engine.

- Disconnect 4 - pin harness connector - 1 - from ignition coil Power output stage - 2 .

- Remove fuse 28 (for fuel pump).

Observe following points if Test and measuring instruments are required during a test drive! Attach all Test and measuring instruments to the rear seat and operate them from that location using a 2nd technician.

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 if the airbag is triggered.


Test data, spark plugs

1)

Use tool 3277 for disconnecting and connecting the spark plug connector. Remove and install the spark plugs using tool 3122B


Camshaft Position sensor, checking Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1598/22 Test Box Fluke 83 multimeter VW 1594 Adaptor kit Wiring diagram

Test conditions Battery voltage must be 11.5 Volts minimum

Test sequence

- Disconnect 3 - pin harness connector - 1 - from Camshaft Position sensor - 2 - . - Switch Fluke 83 multimeter to Voltage range. - Connect multimeter between harness connector outer terminals using jumper wires from VW 1594 adaptor kit. - Switch ON ignition. Specification: 4.5 Volts minimum - Switch OFF ignition.


- Connect VAG 1598/22 Test Box to ECM harness connector.


- Check wiring for open circuit between Test Box and harness connector using wiring diagram. Terminal 1 + socket 62 Terminal 2 + socket 76 Terminal 3 + socket 67 Wire resistance: 1.5 maximum - Disconnect Throttle valve control module - J338 - harness connector. - Check wires for shorting to one another. Specification: If wiring OK and voltage present between terminals 1 + 3: - Replace Camshaft Position sensor G40. If wiring OK and no voltage is present between terminals 1 + 3: - Replace ECM Page 24-133 .


Ignition coil and Power output stage, checking Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1598/22 Test Box Fluke 83 multimeter VW 1594 Adaptor kit VAG 1527B Voltage tester Wiring diagram

Check conditions Battery voltage must be 11.5 Volts minimum. Camshaft Position sensor OK checking Page 28-6 . Engine Speed sensor OK checking Page 24-76 . Notes: Ignition coils and Power output stages are a combined unit. Ignition coil primary resistance cannot be measured. Secondary resistance can be measured (with ignition cables connected) by connecting the multimeter between the spark plug connectors of the ignition coil to be tested. Ignition cable RF suppression resistance is also measured.


Ignition coils and ignition cables, checking

- Disconnect 4 - pin harness connector - 1 - from ignition coil Power output stage - 2 . - Disconnect spark plug connector. - Disconnect ignition cables from ignition coils. - Measure resistance of ignition wires and coils - Resistance of ignition wires Specified value: 4 to 6 k - Secondary resistance of ignition coils Specified value: 8 to 14 k If specifications not obtained - Replace ignition coils and Power output stage Page 28-3 (item 10) If specifications obtained - Check Power output stage triggering Page 28-12 .


Voltage supply, checking

- Disconnect 4 - pin harness connector - 1 - from ignition coil Power output stage - 2 . - Switch Fluke 83 multimeter to Voltage range - Connect multimeter between terminals 2 + 4 of harness connector using jumper wires from VW 1594 adaptor kit - Switch ON ignition Specification: 11.5 Volts minimum - Switch OFF ignition. If no voltage present - Check wiring for open circuit between 4 - pin harness connector terminal 2 and fuse/relay panel using wiring diagram. Wire resistance: 1.5 maximum - Check wiring for open circuit between 4 - pin harness connector terminal 4 and Ground using wiring diagram. Wire resistance: 1.5 maximum


Activation, checking

- Remove fuse 32 Notes: Removing fuse 32 interrupts the voltage supply to the fuel injectors.

- Connect VAG 1527B Voltage tester between terminals 1 + 4 (ignition output 1), and terminals 3 + 4 (ignition output 2) of harness connector using jumper wires from VW 1594. - Operate starter and check ignition signal from ECM. LED must flicker - Switch OFF ignition. If LED flickers and there is voltage between terminals 2 + 4: - Replace ignition coils N, N128 Page 28-3 (item 10)


If LED does not flicker - Check wiring Page 28-13

Wiring, checking

- Connect VAG 1598/22 Test Box to ECM harness connector.

- Check wiring for open circuit between Test Box and 4 - pin harness connector using wiring diagram. Terminal 1 + socket 71 Terminal 3 + socket 78 - Wire resistance: 1.5 maximum - Check wires for short to one another. - Terminal 3 + socket 71 specification: If wiring OK and voltage present between terminals 2 + 4: - Replace ECM Page 24-133 .


Secondary winding, checking

- Check secondary winding on terminal 4 between cylinder 1 + cylinder 4, and cylinder 2 + cylinder 3. Specification: 4.0 to 6.0 k (at 20 C) If specification not obtained: - Replace ignition coils N, N128 Page 28-3 (item 10).


Knock sensors, checking Notes: Intake manifold must be removed to remove and install the knock sensors. Knock sensor tightening torque of 20 Nm (15 ft lb) must be maintained to ensure the knock sensors perform perfectly. Only gold - plated terminals may be used when servicing the knock sensor connector terminals.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551/1552 Scan Tool using VAG 1551/3 adaptor cable VAG 1598/22 Test Box Fluke 83 multimeter VW 1594 Adaptor kit Wiring diagram

Test conditions On Board Diagnostic must store a malfunction for one or both knock sensors.


Function, checking - Connect VAG 1551/1552 Scan Tool Page 01-9 . - Start engine and let idle. - Press 0 and 1 buttons to select "Address word" 01: "Engine electronics"

Display will appear as shown (example only) - Press button.

Display will appear as shown - Press 0 and 8 buttons to select Function 08: "Read measuring value block" - Press Q button to enter input.

Display will appear as shown - Press 0, 2 and 2 buttons to select "Display group 22" (cylinders 1 and 2), and/or - Press 0, 2 and 3 buttons to select "Display group 23" (cylinders 3 and 4). - Press Q button to enter input.

Display will appear as shown (1 to 4 = Display zones) - Take a test drive and check specified values for knock control on Scan Tool display (display fields 3 and 4).


Notes: Knock sensor checking must be conducted during a test drive since the knock sensor diagnostic is active at an engine speed greater than 3000 RPM and an engine load greater than 3 ms. Observe the appropriate safety precautions during test drive Page 28-4 .


If specifications obtained - Press button.

Display will appear as shown - Press 0 and 6 buttons to select Function 06: "End output." - Press Q button to enter input. - Switch OFF ignition. - Display Readiness code Page 01-52 If DTC memory has been erased or ECM was disconnected from Battery +: - Set Readiness code Page 01-55 .


Display group 22/23, evaluating


Wiring resistance, checking

- Disconnect 2 - pin harness connector to knock sensor - 1 - G61 and/or 2 - pin harness connector to knock sensor - 2 - G66. - Measure resistance between terminals 1 + 2 at knock sensor connections. Specification

- Connect VAG 1598/22 Test Box to ECM harness connector. - Check wiring for open circuit between Test Box and 2 - pin harness connector using wiring diagram. G61: Terminal 1 + socket 68, Terminal 2 + socket 67 G66: Terminal 1 + socket 60, Terminal 2 + socket 67 Wire resistance: 1.5 maximum - Check wiring at socket 67 for short to sockets 60 and 68.

Specification:


If wiring OK - Loosen knock sensor and re - torque to 20 Nm (15 ft lb). - Take test drive and check VAG 1551/1552 Scan Tool display for knock control specified values using a second technician. Notes: Perform knock sensor checks during a test drive since knock sensor diagnosis is active at an engine speed greater than 2600 RPM and an engine load greater than 3 ms. - Observe appropriate safety precautions during test drive Page 28-4 . - Check DTC memory. If malfunction still present: - Replace knock sensors Page 28-2 (items 4 or 6). - Display Readiness code If DTC memory has been erased or ECM was disconnected from Battery +: - Set Readiness code Page 01-55 .


Misfire recognition, checking Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551/1552 Scan Tool using VAG 1551/3 adaptor cable

Test sequence - Connect VAG 1551/1552 Scan Tool Page 01-9 . - Start engine and let idle. - Press 0 and 1 buttons to select "Address word" 01: "Engine electronics"

Display will appear as shown (example only) - Press button.

Display will appear as shown - Press 0 and 8 buttons to select Function 08: "Read measuring value block" - Press Q button to enter input.

Display will appear as shown - Press 0, 1 and 4 buttons to select "Display group 14" - Press Q button to enter input.

Display will appear as shown (1 to 4 = Display zones)


- Check spec. for misfire recognition in display zones 3 and 4:

If specifications obtained - Press button.

- Press 0 and 6 buttons to select Function 06: "End output" - Press Q button to enter input. - Switch OFF ignition.


If specifications not obtained - Change to Display group 15 as follows: VAG 1551, Press 3 button, and VAG 1552, press ↑button.

- Check spec. for misfire recognition in display zones 1-4:

If specifications obtained - Change to Display group 16 as follows: VAG 1551, Press 3 button, and VAG 1552, press ↑ button.


- Check spec. for misfire recognition in display zones 1 to 4:

- Press

button.

- Press 0 and 6 buttons to select Function 06: "End output." - Press Q button to enter input. - Switch OFF ignition.


Display groups 14, 15 and 16, evaluating