Volkswagen New Beetle. Manual - part 1803

TEST DRIVE RELEARN PROCEDURE

1. If ECM was disconnected during diagnostic procedure or codes have been cleared, go to next step. If

ECM was not disconnected during diagnostic procedure and no codes are present. Perform a test drive.
Recheck for codes (no relearn procedure is necessary).

2. Turn ignition off. Remove test equipment. Reconnect ECM connector. Reconnect all remaining

(disconnected) electrical connectors/components. Go to next step.

Turn ignition on for a minimum of 10 seconds. Turn ignition off. Perform idle check. See IDLE
CHECK . Perform a long road test. Coolant temperature needs to be greater than 176°F (80°C). Idle,
partial throttle, full throttle and overdrive, all must be attained several times. During test drive, apply full
throttle until engine speed exceeds 3500 RPM. Read readiness code. Generate readiness code if
necessary. See READINESS CODE .

IDLE CHECK

Generic Scan Tool

1. Before checking idle. Throttle valve must not be obstructed or lose. Ensure no exhaust leaks in between

cylinder head and catalytic converter exist. Intake air temperature must be less than 140° F (60° C).
Coolant temperature needs to be greater than 176° F (80° C). Battery voltage needs to be greater than
11.5 volts. All electrical consumers and A/C need to be switched off. Cruise control system must be in
good working order. Vehicle in park or neutral, with parking brake set.

2. Connect scan tool to DLC. DLC is located at left side of steering column. See Fig. 1 . Start engine and

idle. Using scan tool check for DTCs in memory. See RETRIEVING DIAGNOSTIC TROUBLE
CODES . If any DTCs are present, repair as necessary and clear codes. See CLEARING
DIAGNOSTIC TROUBLE CODES . Continue running engine at idle speed.

3. Briefly increase engine RPM to 3500 and let idle for two minutes. Using scan tool, follow scan tool

manufacturer instructions to check idle speed. See IDLE SPECIFICATIONS table.

Scan Tool VAG 1551/1552 Or VAS 5051/5052

NOTE:

When voltage supply to ECM is interrupted or codes have been cleared, ECM
loses all "learned" and/or "basic" values. Serious driveability problems may
occur depending on vehicle mileage. A relearn procedure must be performed.

NOTE:

Throttle Valve Control Module (J338) adapts to ECM (J220) automatically if
ignition is switched on for 10 seconds or more without operating
accelerator pedal or starter and ECM recognizes a need for adaptation. No
notification that adaptation was successful will be given when this
happens.

NOTE:

When using Scan Tool VAG 1551/1552 or VAS 5051/5052, idle is tested in two
ways, one after the other. First in "Idling test" - "Basic Setting" Display Group 1,
then in "Basic Setting " - Display Group 56.

2003 Volkswagen New Beetle GLS

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

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1. Before checking idle. Throttle valve must not be obstructed or lose. There must be no exhaust leaks in

between cylinder head and catalytic converter. Intake air temperature must be less than 140° F (60° C).
Coolant temperature needs to be greater than 176° F (80° C). Battery voltage needs to be greater than
11.5 volts. All electrical consumers and A/C need to be switched off. Cruise control system must be in
good working order. Vehicle in park or neutral, with parking brake set.

2. Connect scan tool to DLC. DLC is located at left side of steering column. See Fig. 1 . Start engine and

3. Press keys "0" and "1" for "Engine Electronics", and enter by pressing "Q" key. Press keys "0" and "4"

for "Basic Setting", and enter by pressing "Q" key. Press keys "0", "0" and "1" for display group "1" and
enter by pressing "Q" key. Briefly increase engine RPM to 3500 and let idle for two minutes. If
"Specified value" window of display field 4 does not read 1x111111. Repair as necessary. Repeat Idle
Check. Go to step 1 .

4. Check idle speed. Press keys "0", "5" and "6" for display group 56 and enter by pressing "Q" key. Check

actual idle speed in "Specified value" window of display field "1", check specified idle speed in
"Specified value" window of display field "2". See IDLE SPECIFICATIONS . Press right arrow key.
Press keys "0", and "6" for function "End Output" and enter by pressing "Q" key. If "Specified value"
window of display field 1 is not okay. Repair as necessary. Repeat Idle Check. Go to step 1 .

IDLE SPECIFICATIONS

IDLE SPEED ADJUSTMENT

Test Requirements

Ensure throttle valve is not damaged or dirty. Throttle valve angle must be less than 10 degrees. Ensure all fuses
are okay, battery voltage is at least 11.5 volts and fuel pump relay is okay. Ensure all electrical accessories are
off and A/C is off. Ensure engine is mechanically sound. Ensure no intake or exhaust system leaks exist. Ensure
engine coolant temperature is at least 176°F (80°C). On vehicles with M/T, gear shifter must be in neutral with
parking brake set. On vehicles with A/T, selector lever must be in park or neutral with parking brake set. No

Model

Engine Code

RPM

Beetle A/T

AVH &AZG

730-890

Beetle M/T

AVH &AZG

780

Golf A/T

AVH & AZG

730-890

Golf M/T

AVH & AZG

780

Jetta A/T

AVH & AZG

730-890

Jetta M/T

AVH & AZG

780

NOTE:

In exceptional circumstances such as customer complaints concerning droning
noises and/or vibrations at idling speed, it is permitted to adjust idling speed
slightly. Ensure that idling speed is not outside the specified idling range. If the
speed is outside tolerance range it is possible that vehicle will fail the next
smog check.

2003 Volkswagen New Beetle GLS

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

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DTCs stored in ECM.

Generic Scan Tool (Test Procedure)

Turn ignition on, engine off. Follow scan tool manufacturer's instructions to adjust idle. See IDLE
SPECIFICATIONS table.

Scan Tool VAG 1551/1552 Or VAS 5051/5052 (Test Procedure)

1. Connect scan tool to DLC. DLC is located left side of steering column. See Fig. 1 .

2. Start engine and idle.

3. Press keys "0" and "1" for address word "Engine Electronics", press keys "1" and "0" for "Adaptation"

function 10 and enter by pressing "Q" key.

4. Press keys "0" and "1" for channel number "1" and enter by pressing "Q" key.

5. Change idle speed. When using scan tool VAG 1551 press keys "1" or "3" to move RPM up or down in

10 RPM increments. VAG 1552, VAS 5051 and VAS 5052 uses up and down arrows to move RPM up or
down in 10 RPM increments. See IDLE SPECIFICATIONS table.

6. After adjusting idle, press"Q" key to enter, "Store changed values?" should display, press "Q" key again

to enter. To end adaptation press right arrow key. Press keys "0" and "6" for function "End Output" and
enter by pressing "Q" key. If vehicle has A/T, A/T needs to be adapted to its basic setting. See A/T
BASIC SETTING .

ENGINE CONTROL MODULE (J220) - ME SFI CONTROL MODULE

Mixture Self-Adaptation

The Motronic ME-SFI engine control system regulates air/fuel mixture at a constant 14.7:1 under all engine
operating conditions. System automatically compensates for engine wear, injector wear, minor air leaks, and to
some degree inaccurate sensors. This automatic control has upper and lower compensating limits. When a lower
limit is not reached or an upper limit is exceeded, a DTC is set.

The amount of correction is constantly calculated and permanently stored. After a repair, Motronic ME-SFI
control module will automatically adapt again.

Engine Control Module Removal & Installation

1. Before disconnecting Engine Control Module (ECM) record code and identification number from ECM

that is to be replaced. See ECM CODING . Go to next step.

2. To remove ECM see specific model below:

Beetle
Turn ignition off. Move center dash panel forward and up. See Fig. 5 . Remove center dash panel.
Remove screw for left front dash cover. Lift cover at right side and pull to right to remove. Press
retaining tab to left and pull ECM out. Release lock tab for harness connector and disconnect
harness connector. Remove ECM. Install ECM.

2003 Volkswagen New Beetle GLS

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

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Golf & Jetta
Turn ignition off. Remove wiper arms and cowl panel. Release lock tab for harness connector and
disconnect harness connector. Remove ECM. Install ECM.

3. After installing ECM perform following procedures:

Use scan tool to check DTC memory, erase if necessary. See CLEARING DIAGNOSTIC
TROUBLE CODES .

Perform adaptation of throttle valve control module. See THROTTLE VALVE CONTROL
MODULE (J338) .

On vehicles equipped with cruise control, activate cruise control to ECM. See
ACTIVATING/DEACTIVATING CRUISE CONTROL .

On vehicles equipped with A/T, perform adaptation of A/T to its Basic Setting. See A/T BASIC
SETTING .

On vehicles equipped with A/T, perform adaptation of kickdown switch. See ADAPTING
KICKDOWN FUNCTION .

On vehicles equipped with factory alarm system, perform adaptation of immobilizer to ECM. See
IMMOBILIZER ADAPTATION TO ECM (J220) .

Perform idle check. See IDLE CHECK .

Generate ECM readiness code. See READINESS CODE .

2003 Volkswagen New Beetle GLS

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

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Wednesday, December 14, 2005 8:49:53 AM

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