Volkswagen New Beetle. Manual - part 1297

 

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Volkswagen New Beetle. Manual - part 1297

 

 

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Press --> button.  

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Press 0 and 6 buttons to select Function 06: "End transfer"  

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Press Q button to enter input.  

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Switch ignition off.  

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Disconnect harness connector -1- from EGR valve -2-. 

Fig. 26: Locating Harness Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Measure resistance across valve. 

Specification: 14 to 20 ohms 

If specification not obtained: 

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Replace EGR Vacuum Regulator solenoid valve -N18-. 

If specification obtained: 

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Switch ignition on.  

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Measure supply voltage at valve connector terminal 1 and at engine Ground. 

NOTE:

At room temperature, resistance lies in the lower tolerance range and in 
the upper range at operating temperature.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 27: Identifying EGr Vacuum Regulator Solenoid Valve Connector Terminal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Specification: approx. battery voltage 

If specification not obtained: 

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Switch ignition off.  

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Connect Test Box VAG 1598/22 to ECM wiring harness. 

Fig. 28: Connecting Test Box VAG 1598/22 To ECM Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check wiring for open circuit between Test Box and harness connector using wiring diagram.  

Up to MY 1999 

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Socket 1 + terminals 2 + 28  

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Socket 2 + terminal 29  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

From MY 2000 

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Socket 1 + terminals 1 + 2  

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Socket 2 + terminal 61  

Wire resistance: 1.5 ohms maximum 

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Check wires for short to one another, to vehicle Ground and to battery Positive (+). 

Specification: "INFINITE" ohms 

If wiring OK: 

z

Replace Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248: 

See Engine Control Module (ECM), Replacing .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Exhaust System, Emission Controls - 1.9L 4-Cyl. - ALH, New Beetle

  

1998-2004 ENGINE

Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH 

GENERAL INFORMATION 

The Diesel direct injection system Engine Control Module (ECM) is equipped with a Diagnostic Trouble Code 
(DTC) memory. Before starting repairs, adjustments and troubleshooting, check DTC memory to see if there are 
any stored DTCs and make sure that Function 03: Output Diagnostic Test Mode (DTM) has been performed. 

SAFETY PRECAUTIONS 

To prevent injuries to persons and/or damage to the Diesel direct fuel injection and glow plug system, observe 
the following:  

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Switch OFF the ignition before connecting or disconnecting Diesel fuel injection or glow plug system 
wiring or test cables.  

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If the engine requires cranking at starter speed, without starting, e.g. when checking compression, 
disconnect the N109 Fuel cut-off valve harness connector from the Diesel injection pump.  

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Obtain the radio Anti-theft code from the customer BEFORE disconnecting the Battery Ground strap.  

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Always make sure that the ignition is switched OFF before disconnecting and connecting the battery. 
Otherwise, the Diesel direct injection system Engine Control Module could be damaged.  

Safety precautions during Test drives 

Always attach Test and measuring instruments to the rear seat and operate them using a second technician from 
this location. 

If test and measuring instruments are operated from the front passenger's seat and the vehicle is involved in an 
accident, there is a possibility that the person sitting in this seat could receive serious injuries if the airbag is 
triggered. 

RULES FOR CLEANLINESS 

When working on the fuel supply/injection system, pay careful attention to the following "6 rules":  

z

Thoroughly clean all unions and the adjacent areas before disconnecting. 

NOTE:

Some checking and adjustment procedures can cause DTCs to be stored in 
DTC memory. For this reason, always erase DTC memory after completing all 
checking and adjustment procedures to Set the Readiness code.

WARNING:

Secure Scan Tool to rear seat and operate from this position using a 
second technician. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Direct Fuel Injection System, Servicing - New Beetle, 1.9L 4-Cyl. ALH

  

 

 

 

 

 

 

 

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