Volkswagen New Beetle. Manual - part 1638

(OBD), Repair Group 01.

Adapt new control module to Throttle Valve Control Module - J338-, see MOTRONIC ENGINE
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-,
ADAPTING .

On vehicles with cruise control system: Check whether this function has been enabled (activated), see
VAG 1551, CONNECTING AND SELECTING MOTRONIC ENGINE CONTROL MODULE
(ECM) -J220- . If "G" is not evident in control module identification, activate cruise control system.

Vehicles with automatic transmissions:

Learning kick-down point, see KICK-DOWN POSITION, LEARNING

Adapt control module for automatic transmission:

See DIAGNOSIS - 01M

Continued for all vehicles

Perform idle check, see FUNCTIONS, CHECKING .

Generate readiness code, see READINESS CODE, GENERATING

Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module - J338-, adapting

The adaptation teaches the Motronic Engine Control Module (ECM) -J220- the various positions of the throttle
unit when the ignition is switched on and the engine is not running. These positions are stored in the control
module. The feedback of the throttle valve position is via both angle sensors for throttle valve drive.

Adapting sequence must be performed if:

Voltage supply is interrupted

Throttle Valve Control Module -J338- is removed and installed

Throttle Valve Control Module -J338- is replaced

If when installing another engine another Throttle Valve Control Module -J338- is installed

Motronic Engine Control Module (ECM) -J220- is replaced.

See DIAGNOSIS - 01M

Special tools, test equipment and auxiliary items

VAG 1551 scan tool (or VAG 1552 mobile scan tool) with VAG 1551/3B cable

Test conditions

NOTE:

On vehicles with an automatic transmission, the transmission control module
must also be adapted:

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

No DTCs must be stored in DTC memory, see DTC MEMORY OF MOTRONIC ENGINE
CONTROL MODULE (ECM) -J220-, CHECKING AND ERASING

Battery voltage must be at least 11.5 V

All electrical accessories, e.g. lights and rear window defroster, must be switched off

The throttle valve must be at idling speed position (The accelerator must not be operated during the test).

Throttle valve must not be dirty (carbonization).

Engine Coolant Temperature (ECT) must be 5 to 95 °C display group 04, display zone 3.

The cruise control system must be functioning correctly if installed.

Work sequence

Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 141: Identifying Scan Tool Display - Adapting ECM To Throttle Valve Control Module (1 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Press buttons -0- and -4- for function "Basic Setting" and confirm entry with -Q- button.

Indicated on display

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 142: Identifying Scan Tool Display - Adapting ECM To Throttle Valve Control Module (2 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Press buttons -0-, -6- and -0- for "Display group number 60" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 143: Identifying Scan Tool Display - Adapting ECM To Throttle Valve Control Module (3 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

After pressing the -Q- button the throttle valve positioner is switched so that it is not supplied with
voltage at start of test.

In this condition the throttle valve is pulled into an emergency running position by a mechanical spring in

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

the Throttle Valve Control Module -J338-. The values from both angle sensors in the emergency running
position are stored by the ECM.

Thereafter the throttle valve is opened a predetermined value. If this value is achieved, the throttle valve
is again switched so that it is not supplied with voltage. Now the mechanical spring must pull the throttle
valve to the previously learned emergency running position within a predetermined time (spring test).

Then the throttle valve is closed by the throttle valve positioner and the values, which are supplied by the
angle sensors in the Throttle Valve Control Module -J338- are stored by the Motronic Engine Control
Module (ECM) -J220-.

If the Motronic Engine Control Module (ECM) - J220- switches the throttle valve positioner so that it is
without voltage during normal operation, this is indicated by the increased and hunting idle speed. The
engine reacts slowly to accelerator changes.

{

Check specifications (display zones 1 to 4):

DISPLAY GROUP 60: ADAPTING THROTTLE VALVE CONTROL MODULE -J338-

Terminate engine basic setting at earliest after 30 seconds by pressing button.

Adapting has been performed successfully.

To store the values:

Switch off ignition.

Display zones

Display group 60: Adapting Throttle Valve Control Module -J338-
Display

xxx %

ADP. runs

ADP. OK.

ERROR

Indicated

Throttle

valve angle

sensor 1 -

G187-

Throttle

valve angle

sensor 2 -

G188-

Learn step counter

Adaptation condition

Working range 0 to 100%

0 to 100%

0 to 8

Specification

10 to 88%

89 to 11%

Counter counts up to 8

during adaptation

ADP. runs

ADP. OK. (ERROR Appears

after unsuccessful adaptation)

If the specification is not obtained, see DTC MEMORY OF MOTRONIC ENGINE CONTROL
MODULE (ECM) -J220-, CHECKING AND ERASING or, see THROTTLE VALVE CONTROL
MODULE -J338-, CHECKING .

2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

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