Volkswagen New Beetle. Manual - part 1317

z

VAG1598/31 Test Box (from MY 2000)  

z

Fluke 83 multimeter  

z

VW 1594 Adapter kit  

z

Wiring diagram  

Test requirements 

z

Battery Voltage OK.  

Test sequence 

z

Switch OFF ignition.  

z

Connect VAG1598/22 (or 1598/31) Test Box to ECM wiring harness. 

Fig. 31: Connecting VAG1598/22 Test Box To ECM Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Bridge sockets with jumper wires from VW 1594 kit.  

z

Up to MY 1999: sockets 33 + 1  

z

From 2000: sockets 18 + 4  

z

Measure Voltage between following sockets:  

z

Up to MY 1999: sockets 2 + 1, 28 + 1, 27 + 2 and 28 + 27  

z

From 2000: sockets 1 + 4, 2 + 4, 1 + 5, 2 + 5  

z

Specification: approx. battery Voltage  

If specification not obtained: 

z

Check power supply relay -J31-, terminal 30. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

z

-J317- located on fuse relay panel above the central electric.  

z

Check wiring for open circuit, short circuit and transfer resistance at terminals using Wiring diagram.  

If wiring and relay OK: 

z

Replace Engine Control Module -J248-. See Engine Control Module (ECM), replacing .  

Engine speed (RPM) sensor -G28-, checking 

Engine speed (RPM) sensor -G28- serves dual purpose of speed and reference mark sensor. An inoperative 
sensor will stop engine. 

Special tools 

z

VAG1598/22 Test Box (MY 1999)  

z

VAG1598/31 Test Box (from MY 2000)  

z

Fluke 83 multimeter  

z

VW 1594 Adapter kit  

z

Wiring diagram  

Test sequence 

z

Switch OFF ignition.  

z

Disconnect -G28- harness connector. See DIESEL INJECTION SYSTEM, COMPONENT 
LOCATIONS OVERVIEW .  

z

Measure resistance between connector terminals 1 + 2. 

z

Specification: 1000 to 1500 ohm  

Fig. 32: Identifying Engine RPM Sensor Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

If specification not obtained: 

z

Replace Engine Speed sensor -G28-.  

See ENGINE, DISASSEMBLING AND ASSEMBLING . 

z

Display the Readiness code. See READINESS CODE, DISPLAYING .  

If DTC memory was erased: 

z

Set the readiness code. See READINESS CODE, SETTING .  

If specification obtained: 

z

Connect VAG1598/22 (or 1598/31) Test Box to ECM wiring harness. 

Fig. 33: Connecting VAG1598/22 (Or 1598/31) Test Box To ECM Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Check wiring for open circuit between Test Box and 3-pin harness connector using Wiring diagram. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

Fig. 34: Identifying Engine RPM Sensor Harness Connector Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Up to MY 1999 

z

Terminal 1 + socket 69  

z

Terminal 2 + socket 67  

z

Terminal 3 + socket 71  

From MY 2000 

z

Terminal 1 + socket 102  

z

Terminal 2 + socket 110  

z

Terminal 3 + socket 86  

z

Wire resistance: 1.5ohm maximum  

z

Check wiring for short circuit to one another at 3-pin harness connector using Wiring diagram.  

z

Specification: INFINITY ohm  

If wiring OK: 

z

Replace Engine Control Module -J248-. See Engine Control Module (ECM), replacing .  

z

Display the Readiness code. See READINESS CODE, DISPLAYING .  

If DTC memory was erased: 

z

Set the readiness code. See READINESS CODE, SETTING .  

Manifold Absolute Pressure (MAP) Sensor -G71- and Barometric Pressure (BARO) Sensor -F96-, checking

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle