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Volkswagen New Beetle. Manual - part 855

Fig. 40: Identifying Special Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

WIRING DIAGRAMS

NOTE:

See CHARGING SYSTEM in appropriate SYSTEM WIRING DIAGRAMS article in
ELECTRICAL.

2003 Volkswagen New Beetle GLS

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

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2001-04 STARTING & CHARGING SYSTEMS

Starters - New Beetle

DESCRIPTION

Starter is a brush type, series-wound electric motor with an overrunning clutch. Field frame is enclosed by
commutator end frame and drive bushing, and carries pole shoes and field coils. A splined armature shaft drive
end carries drive assembly.

TROUBLE SHOOTING

PRELIMINARY INSPECTION

Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical
damage. Inspect for blown fuses and damaged relays. Inspect for loose or corroded connections, damaged
wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could
cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any
aftermarket electronic equipment is properly installed. If fault is found, repair as necessary.

ON-VEHICLE TESTING

STARTER DOES NOT CRANK ENGINE

NOTE:

See TROUBLE SHOOTING article in GENERAL INFORMATION.

NOTE:

Starter is actuated through immobilizer system. Ensure immobilizer system is
operating properly.

NOTE:

On vehicles with automatic transmission, ensure park/neutral switch is
operating properly.

2003 Volkswagen New Beetle GLS

2001-04 STARTING & CHARGING SYSTEMS Starters - New Beetle

2003 Volkswagen New Beetle GLS

2001-04 STARTING & CHARGING SYSTEMS Starters - New Beetle

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Fig. 1: Testing Starter Circuit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

STARTER CRANKS TOO SLOWLY TO START ENGINE

2003 Volkswagen New Beetle GLS

2001-04 STARTING & CHARGING SYSTEMS Starters - New Beetle

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Ensure battery is fully charged. Check for excessive voltage drop due to loose or corroded connections. Ensure
electrical and ground connections are clean and tight. If necessary, clean and tighten ground strap between
transmission and body. DO NOT loosen ground strap on body. If starter still turns slowly, repair or replace
starter.

REMOVAL & INSTALLATION

BATTERY DISCONNECT PRECAUTIONS

If the connector is disconnected from the ECM or the battery is disconnected, all adaptation values in the
control module are erased. DTC memory content will remain intact however. If the engine is started after this, a
rough, uneven idle can result. In this case, engine must be allowed to run at idle for a few minutes or a longer
road test must be performed until the adaptation procedure has been completed.

Once battery has been connected, check operation of radio, clock and convenience electronics. Completely open
and close all power windows.

STARTER

Removal & Installation

1. Disconnect negative battery cable. Raise and support vehicle. Remove noise insulation panel. See Fig. 2

or Fig. 3 . Remove insulation cover. See Fig. 4 .

2. Remove power steering line retaining bracket. See Fig. 5 . Remove battery, where applicable. Remove

bolts, and battery carrier. See Fig. 6 .

3. Separate electrical connections, and remove from retainer. Disconnect starter electrical connections.

WARNING:

Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG RESTRAINT SYSTEMS article.

CAUTION: Turn ignition off. Before disconnecting negative battery terminal, obtain

anti-theft radio security code. Disconnect negative battery terminal. After
reconnecting battery, re-code and check operation of anti-theft radio.

CAUTION: Turn ignition off. Before disconnecting negative battery terminal, obtain

anti-theft radio security code. Disconnect negative battery terminal. After
reconnecting battery, re-code and check operation of anti-theft radio.

NOTE:

Vehicles with On Board Diagnostics (OBD) II must have readiness code for
Electronic Control Module (ECM) re-generated after battery has been
disconnected. See appropriate SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE.

2003 Volkswagen New Beetle GLS

2001-04 STARTING & CHARGING SYSTEMS Starters - New Beetle

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