Volkswagen New Beetle. Manual - part 1881

Pump Relay (J299) for Beetle is located in relay/fuse box next to master cylinder. For GTI, Jetta and
Passat. See Fig. 54 and Fig. 55 . If Secondary Air Injection Pump Relay clicks, erase DTC memory.
Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE . If DTC does not reset
on test drive. Test is complete. If Secondary Air Injection Pump Relay does not click or DTC
P0418/16802 resets, go to next step.

2. Using DVOM check resistance of Secondary Air Injection Pump Relay wiring. See appropriate WIRING

DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Resistance should
be a maximum of 1.5 ohms for each reading. If resistance is okay, replace faulty Secondary Air Injection
Pump Relay (J299). Erase DTC memory. Test is complete. Perform ECM relearn procedure. See TEST
DRIVE RELEARN PROCEDURE . If resistance is not okay, repair as necessary. Erase DTC memory.
Test is complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .

Fig. 54: Locating Secondary Air Injection Pump Relay (J299 - GTI & Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2003 Volkswagen New Beetle GLS

2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

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Fig. 55: Locating Secondary Air Injection Pump Relay (J299 - Passat)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

DTC P0420/16804 & DTC P0422/16806

Code Definition

DTC P0420/16804: Catalyst System - Efficiency Below Threshold

DTC P0422/16806: Catalyst System - Efficiency Below Threshold

Test Requirements

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 exhaust system leaks exist.
Ensure engine coolant temperature is at least 176°F (80°C).

Test Procedure

1. Check air induction and secondary air injection system for leaks. If no air leaks are found, go to next step.

If air leaks are found. Repair as necessary. After repairs, erase DTC memory. Verify repair. Test is
complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .

2. Connect scan tool, see RETRIEVING DIAGNOSTIC TROUBLE CODES .

3. Check control of upstream TWC HO2S. See DTC P0131/16515 & DTC P0132/16516 . If control of

2003 Volkswagen New Beetle GLS

2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

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upstream TWC HO2S is okay, go to next step. If control of upstream TWC HO2S is not okay, repair
wiring or replace upstream TWC HO2S as necessary. After repairs, erase DTC memory. Verify repair.
Test is complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .

4. Check control of downstream TWC HO2S. See DTC P0136/16520, DTC P0137/16521 & DTC

P0138/16522 . If control of downstream TWC HO2S is okay, go to next step. If control of downstream
TWC HO2S is not okay, repair wiring or replace downstream TWC HO2S as necessary. After repairs,
erase DTC memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE
RELEARN PROCEDURE .

5. Check aging of upstream TWC HO2S, for engine codes AWV and AWM. See DTC P0133/16517 &

DTC P0134/16518 . If aging of upstream TWC HO2S is okay, go to next step. If aging of upstream TWC
HO2S is not okay, repair wiring or replace upstream TWC HO2S as necessary. After repairs, erase DTC
memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE
RELEARN PROCEDURE .

6. Check aging of upstream TWC HO2S, for engine code AWP. See DTC P0133/16517 & DTC

P0134/16518 . If aging of upstream TWC HO2S is okay, go to next step. If aging of upstream TWC
HO2S is not okay, repair wiring or replace upstream TWC HO2S as necessary. After repairs, erase DTC
memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE
RELEARN PROCEDURE .

Follow scan tool manufacturer's instructions, for checking catalytic converter. If catalytic converter is not
okay, replace faulty catalytic converter. After repairs, erase DTC memory. Verify repair. Test is
complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE . If catalytic
converter is okay, erase DTC memory. Perform ECM relearn procedure. See TEST DRIVE RELEARN
PROCEDURE . If DTC P0420/16804 or DTC P0422/16806 do not reset after test drive, test is complete.

DTC P0440/16824 & DTC P0441/16825

Code Definition

DTC P0440/16824: EVAP, Fuel Tank Ventilation System - Malfunction

DTC P0441/16825: EVAP, Fuel Tank Ventilation System - Flow Rate Malfunction

Test Requirements

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).

NOTE:

Catalytic converter must be 662° F (350° C) to 932° F (500° C) for scan tool
to check catalytic convertor.

NOTE:

If a test ends with ECM replacement. Before replacing ECM be certain that, all
wiring, power and ground supplies are okay. See ENGINE PERFORMANCE in
SYSTEM WIRING DIAGRAMS article in ELECTRICAL and ECM GROUND &
VOLTAGE SUPPLY .

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2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

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Test Procedure

1. Check tubing and hoses from fuel tank to throttle body. If tubing and hoses are okay, go to next step. If

tubing and/or hoses are not okay, repair as necessary. Erase DTC memory. Verify repair. Perform ECM
relearn procedure. See TEST DRIVE RELEARN PROCEDURE .

2. Turn ignition on. Using scan tool, check EVAP Canister Purge Valve (N80). See OUTPUT

DIAGNOSTIC TEST MODE . EVAP Canister Purge Valve (N80) should audibly click. EVAP Canister
Purge Valve (N80) for Beetle, GTI and Jetta are located in engine compartment, center of right side
fender, and for Passat by bottom of air cleaner. See Fig. 56 and Fig. 57 . If EVAP Canister Purge Valve
(N80) clicks, erase DTC memory. Perform ECM relearn procedure. See TEST DRIVE RELEARN
PROCEDURE . If DTC does not reset on test drive. Test is complete. If EVAP Canister Purge Valve
(N80) does not click or DTC P0440/16824 or P0441/16825 resets, go to next step.

3. Turn ignition off. Disconnect harness connector from EVAP Canister Purge Valve (N80). Connect LED

test light to EVAP canister purge valve harness connector. Turn ignition on. Using scan tool, check
EVAP Canister Purge Valve (N80). See OUTPUT DIAGNOSTIC TEST MODE . LED test light
should flash. If test light does not flash, go to next step. If test light flashes, replace faulty EVAP Canister
Purge Valve (N80). Erase DTC memory. Verify repair. Test is complete. Perform ECM relearn
procedure. See TEST DRIVE RELEARN PROCEDURE .

4. Turn ignition off. Using DVOM check resistance of EVAP Canister Purge Valve (N80) harness

connector wiring. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM
WIRING DIAGRAMS. Resistance should be a maximum of 1.5 ohms for each reading. Check wiring in
harness connector for short circuits to one another and to ground and B+. If resistance is okay and no shot
circuits are present, replace faulty ECM. See ENGINE CONTROL MODULE REMOVAL &
INSTALLATION . Erase DTC memory. Verify repair. Test is complete. Perform ECM relearn
procedure. See TEST DRIVE RELEARN PROCEDURE . If resistance is not okay, repair as
necessary. Erase DTC memory. Test is complete. Perform ECM relearn procedure. See TEST DRIVE
RELEARN PROCEDURE .

NOTE:

Output Diagnostic Test Mode is used when using Scan Tools VAG 1551/1552 or
VAS 5051/5052, always continue with output diagnostic test mode until last
component in output diagnostic test mode test sequence has been checked. If
you are not using Scan Tools VAG 1551/1552 or VAS 5051/5052 follow scan tool
manufacturer's instructions.

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2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

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