2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
2000-03 ENGINE PERFORMANCE
On-Vehicle Adjustments
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition
is okay.
VALVE CLEARANCE
NOTE: All models use hydraulic lifters. No adjustment is required.
IGNITION TIMING
NOTE: Ignition timing is not adjustable. Ignition timing can be checked on Cabrio (2.0L
ABA) & EuroVan (2.8L AES) models only. No ignition timing specifications are
available from manufacturer for all other models. To check ignition timing use
of Scan Tool (VAG 1551/1552) with adapter cable (VAG 1551/3) is recommended.
Ignition timing should be checked with engine at operating temperature.
IGNITION TIMING CHECKING
Cabrio (2.0L ABA)
Specification (0 to 5 degrees BTDC) in Display Field "3" on scan tool with engine at 800-880 RPM. Display
Field "4" should display a maximum of plus or minus 2 degrees from reading in Display Field "3" at 800-880
RPM. Specification for timing advance is not available from manufacturer.
EuroVan (2.8L AES)
Specification (11 to 13 degrees BTDC) in Display in Field "3" on scan tool with engine at 650-750 RPM.
Display Field "4" should display a maximum of plus or minus 2 degrees from reading in Display Field "3" at
650-750 RPM.
Checking ignition timing advance. Specification (0 to 50 degrees BTDC) in Display Field "3" with engine at
650-6000 RPM and (0 to 40) degrees in Display Field "4".
IDLE SPEED & MIXTURE
NOTE: Idle speed & mixture is computer controlled and is not adjustable. Ensure fuel
system pressure is correct. If idle speed and/or air mixture is incorrect, check
for vacuum leaks.
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2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
THROTTLE CABLE
THROTTLE CABLE ADJUSTMENT (A/T)
Beetle, Golf, GTI & Jetta (2.0L AEG), Cabrio & EuroVan (2.8L AES)
Remove retaining clip from throttle cable at throttle body support bracket. Depress accelerator pedal to pedal
stop. Adjust cable for wide open throttle at throttle body. Ensure that kickdown switch is activated .39-.59" (10-
15 mm) before accelerator pedal stop (audible click and zero ohms at kickdown switch). See Fig. 1 or Fig. 2 .
Reinstall retaining clip and check adjustment.
Fig. 1: Throttle Cable Kickdown Switch Test Points (Beetle, Golf, GTI & Jetta - 2.0L AEG)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
Fig. 2: Throttle Cable Kickdown Switch Test Points (Cabrio & EuroVan - 2.8L AES)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
THROTTLE CABLE ADJUSTMENT (M/T)
Beetle, Golf, GTI & Jetta (2.0L AEG), Cabrio & EuroVan (2.8L AES)
Remove retaining clip from throttle cable at throttle body support bracket. See Fig. 3 . Depress accelerator pedal
to pedal stop. Adjust cable for wide open throttle at throttle body, reinstall retaining clip and check adjustment.
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2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
Fig. 3: Adjusting Throttle Cable (Beetle, Golf, GTI & Jetta - 2.0L AEG, Cabrio & EuroVan - 2.8L AES)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
THROTTLE POSITION (TP) SENSOR
THROTTLE POSITION (TP) SENSOR ADJUSTMENT (1.9L TURBO DIESEL)
NOTE: Beetle, Golf and Jetta 1.9L turbo diesels are the only vehicles that have an
adjustable TP sensor. All other vehicles do not have an adjustable TP sensor.
1.9L Turbo Diesel
NOTE: TP sensor is located in accelerator pedal housing (inside vehicle).
1. To adjust cable cam, unplug and remove accelerator pedal sensor (TP sensor). Install cable disc as shown
in Fig. 5 . Install accelerator pedal sensor with preassembled cable cam. Reconnect TP sensor.
2. After adjusting TP sensor, check TP sensor function. With engine off, push accelerator pedal down by
hand to ensure that wide open throttle position is reached and kickdown switch is felt. If kickdown switch
is not felt or pedal does not reach the pedal stop, adjust sensor by turning in bracket slots. See Fig. 4 .
3. Connect Scan Tool (VAG 1551/1552) to Data Link Connector (DLC). DLC is located under dashboard,
left of steering column, or in center console. Turn ignition on with engine off. Press "0" and "1" buttons
to select Address Word "01" Engine Electronics, press arrow button on scan tool, display should read,
Rapid Data Transfer.
4. Press "0" and "8" buttons to select Function "08". Read Measuring Value Block will display. Press "Q"
button to enter input. Press "0", "0" and "2" buttons to select Display Field "2". Press "Q" button to enter
input. Observe value in Display Field "2" (Throttle Position). Specification should be zero percent (pedal
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2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
not depressed).
5. While observing Display Field "2", slowly open throttle to Wide Open Throttle (WOT). Display should
increase uniformly from zero percent at closed throttle to 100 percent at wide open throttle.
6. If display are correct, press right arrow button. Press "0" and "6" to select ENDING OUTPUT function.
Press "Q" button to enter input. If display is incorrect, readjust TP sensor. Retest TP sensor. If readings
are not corrected by adjustment, check TP sensor circuit, replace as necessary.
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2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
Fig. 4: Identifying TP Sensor Components (1.9L Turbo Diesel)
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2003 Volkswagen New Beetle GLS
2000-03 ENGINE PERFORMANCE On-Vehicle Adjustments
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig. 5: Adjusting Cable Cam (TP Sensor Adjustment - 1.9L Turbo Diesel)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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