Volkswagen New Beetle. Manual - part 1333

 

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Volkswagen New Beetle. Manual - part 1333

 

 

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Switch OFF ignition.  

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Disconnect 10-pin Fuel Temperature sensor harness connector (connection to Diesel injection pump 
metering control). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 95: Identifying 10-Pin Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Measure resistance between connector terminals 5 + 6.  

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Specification: 0.5 to 2.5 ohm  

If specification not obtained: 

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Replace Diesel injection pump. See DIESEL INJECTION PUMP, REMOVING AND 
INSTALLING
 .  

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Display the Readiness code. See READINESS CODE, DISPLAYING .  

If DTC memory was erased: 

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Set the readiness code. See READINESS CODE, SETTING .  

If specification obtained: 

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

Fig. 96: Connecting VAG1598/22 (Or 1598/31) Test Box 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. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 97: Identifying 10-Pin Harness Connector Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Up to MY 1999 

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Terminal 5 + sockets 2 and 28  

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Terminal 6 + sockets 59, 66 and 80  

From MY 2000 

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Terminal 5 + sockets 1 and 2  

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Terminal 6 + sockets 116 and 121  

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Wire resistance: 1.5ohm maximum  

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Check wires for shorting to: one another, Ground and Battery +.  

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Specification: INFINITY ohm  

If wiring OK: 

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

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Display the Readiness code. See READINESS CODE, DISPLAYING .  

If DTC memory was erased: 

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Set the readiness code. See READINESS CODE, SETTING .  

Needle Lift Sensor -G80-, checking 

The Needle Lift Sensor -G80- signal determines the start of injection. If -G80- fails, start of injection switches 
to open-loop control (based on engine speed and load). During normal operation, start of injection is controlled 

 

2003 Volkswagen New Beetle GLS 

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

  

via closed-loop function (based on engine speed, load and temperature).

Special tools 

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VAG1598/22 Test Box (MY 1999)  

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VAG1598/31 Test Box (from MY 2000)  

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Fluke 83 multimeter  

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VW 1594 Adapter kit  

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Wiring diagram  

Test sequence 

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Switch OFF ignition.  

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Disconnect Needle Lift Sensor -G80- harness connector. See DIESEL INJECTION SYSTEM, 
COMPONENT LOCATIONS OVERVIEW
 .  

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Measure resistance between sensor terminals. 

Fig. 98: Identifying Needle Lift Sensor Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Specification: 80 to 120 ohm  

If specification not obtained: 

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Replace cyl. 3 fuel injector complete with -G80-. See item 13 .  

z

Display the Readiness code. See READINESS CODE, DISPLAYING .  

If DTC memory was erased: 

z

Set the readiness code. See READINESS CODE, SETTING 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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