Volkswagen New Beetle. Manual - part 33

 

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Volkswagen New Beetle. Manual - part 33

 

 

BASIC HOT START SYMPTOMS TROUBLE SHOOTING CHART 

BASIC COLD ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART 

BASIC WARM ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART 

Hot fast idle RPM too low 

Reset fast idle RPM, see TUNE-UP 

CONDITION & POSSIBLE CAUSE 

CORRECTION 

Engine Won't Start 

Engine flooded 

Allow fuel to evaporate 

CONDITION & POSSIBLE 
CAUSE 

CORRECTION 

Engine Stalls in Gear 

Choke vacuum kick setting 
incorrect 

Reset choke vacuum kick, see FUEL SYSTEMS 

Fast idle RPM incorrect 

Reset fast idle RPM, see TUNE-UP 

Fast idle cam index incorrect 

Reset fast idle cam see FUEL SYSTEMS 

Acceleration Sag or Stall 

Defective choke control switch 

Replace choke control switch 

Choke vacuum kick setting 
incorrect 

Reset choke vacuum kick see, FUEL SYSTEMS 

Float level incorrect (too low) 

Adjust float level, FUEL SYSTEMS 

Accelerator pump defective 

Repair or replace pump see FUEL SYSTEMS 

Secondary throttles not closed 

Inspect lockout adjustment, see FUEL SYSTEMS 

Sag or Stall After Warmup 

Defective choke control switch 

Replace choke control switch, see FUEL 

SYSTEMS 

Defective accelerator pump 

Replace pump, see FUEL SYSTEMS 

Float level incorrect (too low) 

Adjust float level, see FUEL SYSTEMS 

Backfiring & Black Smoke 

Plugged heat crossover system 

Remove restriction 

CONDITION & POSSIBLE CAUSE 

CORRECTION 

Hesitation With Small Amount of Gas Pedal Movement 

Vacuum leak 

Inspect vacuum lines 

Accelerator pump weak or inoperable 

Replace pump, see FUEL SYSTEMS 

Float level setting too low 

Reset float level, see,FUEL SYSTEMS 

Metering rods sticking or binding 

Inspect and/or replace rods, see FUEL 

SYSTEMS 

Carburetor idle or transfer system 
plugged 

Inspect system and remove restriction 

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Trouble Shooting - Basic Procedures

  

DIESEL ENGINE TROUBLE SHOOTING 

BASIC DIESEL ENGINE TROUBLE SHOOTING CHART 

Frozen or binding heated air inlet 

Inspect heated air door for binding 

Hesitation With Heavy Gas Pedal Movement 

Defective accelerator pump 

Replace pump, see FUEL SYSTEMS 

Metering rod carrier sticking or 
binding 

Remove restriction 

Large vacuum leak 

Inspect vacuum system and repair leak 

Float level setting too low 

Reset float level, see FUEL SYSTEMS 

Defective fuel pump, lines or filter 

Inspect pump, lines and filter 

Air door setting incorrect 

Adjust air door setting, see FUEL 

NOTE:

This is GENERAL information. This article is not intended to be specific to any 
unique situation or individual vehicle configuration. The purpose of this Trouble 
Shooting information is to provide a list of common causes to problem 
symptoms. For model-specific Trouble Shooting, refer to SUBJECT, 
DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing. 

NOTE:

Diesel engines mechanical diagnosis is the same as gasoline engines for items 
such as noisy valves, bearings, pistons, etc. The following trouble shooting 
covers only items pertaining to diesel engines. 

CONDITION & POSSIBLE CAUSE 

CORRECTION 

Engine Won't Crank 

Bad battery connections or dead batteries 

Check connections and/or replace 

batteries 

Bad starter connections or bad starter 

Check connections and/or replace 

starter 

Engine Cranks Slowly, Won't Start 

Bad battery connections or dead batteries 

Check connections and/or replace 

batteries 

Engine oil too heavy 

Replace engine oil 

Engine Cranks Normally, But Will Not Start 

Glow plugs not functioning 

Check glow plug system, see FUEL 

SYSTEMS 

Glow plug control not functioning 

Check controller, see FUEL SYSTEMS 

Fuel not injected into cylinders 

Check fuel injectors, see FUEL 

SYSTEMS 

No fuel to injection pump 

Check fuel delivery system 

Fuel filter blocked 

Replace fuel filter 

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Trouble Shooting - Basic Procedures

  

Fuel tank filter blocked 

Replace fuel tank filter 

Fuel pump not operating 

Check pump operation and/or replace 

pump 

Fuel return system blocked 

Inspect system and remove restriction 

No voltage to fuel solenoid 

Check solenoid and connections 

Incorrect or contaminated fuel 

Replace fuel 

Incorrect injection pump timing 

Re-adjust pump timing, see FUEL 

SYSTEMS 

Low compression 

Check valves, pistons, rings, see 

ENGINES 

Injection pump malfunction 

Inspect and/or replace injection pump 

Engine Starts, Won't Idle 

Incorrect slow idle adjustment 

Reset idle adjustment, see TUNE-UP 

Fast idle solenoid malfunctioning 

Check solenoid and connections 

Fuel return system blocked 

Check system and remove restrictions 

Glow plugs go off too soon 

See glow plug diagnosis in FUEL 

SYSTEMS 

Injection pump timing incorrect 

Reset pump timing, see FUEL 

SYSTEMS 

No fuel to injection pump 

Check fuel delivery system 

Incorrect or contaminated fuel 

Replace fuel 

Low compression 

Check valves, piston, rings, see 

ENGINES 

Injection pump malfunction 

Replace injection pump, see FUEL 

SYSTEMS 

Fuel solenoid closes in RUN position 

Check solenoid and connections 

Engines Starts/Idles Rough W/out Smoke or Noise 

Incorrect slow idle adjustment 

Reset slow idle, see TUNE-UP 

Injection line fuel leaks 

Check lines and connections 

Fuel return system blocked 

Check lines and connections 

Air in fuel system 

Bleed air from system 

Incorrect or contaminated fuel 

Replace fuel 

Injector nozzle malfunction 

Check nozzles, see FUEL SYSTEMS 

Engines Starts and Idles Rough W/out Smoke or Noise, But Clears After Warm-Up 

Injection pump timing incorrect 

Reset pump timing, see FUEL 

SYSTEMS 

Engine not fully broken in 

Put more miles on engine 

Air in system 

Bleed air from system 

Injector nozzle malfunction 

Check nozzles, see FUEL SYSTEMS 

Engine Idles Correctly, Misfires Above Idle 

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Trouble Shooting - Basic Procedures

  

Blocked fuel filter 

Replace fuel filter 

Injection pump timing incorrect 

Reset pump timing, see FUEL 

SYSTEMS 

Incorrect or contaminated fuel 

Replace fuel 

Engine Won't Return To Idle 

Fast idle adjustment incorrect 

Reset fast idle, see TUNE-UP 

Internal injection pump malfunction 

Replace injection pump, see FUEL 

SYSTEMS 

External linkage binding 

Check linkage and remove binding 

Fuel Leaks On Ground 

Loose or broken fuel line 

Check lines and connections 

Internal injection pump seal leak 

Replace injection pump, see FUEL 

SYSTEMS 

Cylinder Knocking Noise 

Injector nozzles sticking open 

Test injectors, see FUEL SYSTEMS 

Very low nozzle opening pressure 

Test injectors and/or replace 

Loss of Engine Power 

Restricted air intake 

Remove restriction 

EGR valve malfunction 

Replace EGR valve 

Blocked or damaged exhaust system 

Remove restriction and/or replace 

components 

Blocked fuel tank filter 

Replace filter 

Restricted fuel filter 

Remove restriction and/or replace filter 

Block vent in gas cap 

Remove restriction and/or replace cap 

Tank-to-injection pump fuel supply blocked 

Check fuel lines and connections 

Blocked fuel return system 

Remove restriction 

Incorrect or contaminated fuel 

Replace fuel 

Blocked injector nozzles 

Check nozzle for blockage, see FUEL 

SYSTEMS 

Low compression 

Check valves, rings, pistons, see 

ENGINES 

Loud Engine Noise With Black Smoke 

Basic timing incorrect 

Reset timing, see FUEL SYSTEMS 

EGR valve malfunction 

Replace EGR valve 

Internal injection pump malfunction 

Replace injection pump, see FUEL 

SYSTEMS 

Incorrect injector pump housing pressure 

Check pressure, see FUEL SYSTEMS 

Engine Overheating 

Cooling system leaks 

Check cooling system and repair leaks 

Belt slipping or damaged 

Check tension and/or replace belt 

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Trouble Shooting - Basic Procedures

  

 

 

 

 

 

 

 

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