Volkswagen New Beetle: Ignition system (Engine code AEG) (eng.)

Volkswagen New Beetle: Ignition system (Engine code AEG) (eng.)
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
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-3)
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)
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-4)
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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-5)
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
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-6)
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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-7)
- Connect VAG 1598/22 Test Box to ECM harness connector.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-8)
- 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 .
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-9)
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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-10)
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 .
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-11)
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
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-12)
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)
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-13)
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 .
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-14)
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).
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-15)
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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-16)
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).
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-17)
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 .
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-18)
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 .
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-19)
Display group 22/23, evaluating
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-20)
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:
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-21)
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 .
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-22)
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)
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-23)
- 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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-24)
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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-25)
- 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.
Volkswagen New Beetle
2.0 Liter Fuel Injection and Ignition (Engine code: AEG)
Ignition system, servicing (Page 28-26)
Display groups 14, 15 and 16, evaluating
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