Volkswagen New Beetle. Manual - part 1361

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1359  1360  1361  1362   ..

 

 

Volkswagen New Beetle. Manual - part 1361

 

 

Fig. 196: Identifying CAN-Bus Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Function 

The Engine Control Module (ECM) (item -1-) communicates with the ABS control module (item -2-), the 
Transmission Control Module (item -3-), the airbag control module (item -4-) and the instrument cluster (item -
5-) via a CAN-Bus (item -6-). 

Function, continued 

At least two control modules capable of CAN - Bus are connected by two wires (CAN-High and CAN-Low, 
twisted together) and exchange information (messages). Missing information on the CAN-Bus will be 
recognized as a malfunction by the ECM as well as by other CAN-Bus control modules. 

All control modules have 120 W terminal resistors which make sure that the CAN-Bus can function without 
fault. 

Special tools and equipment 

z

Multimeter (Fluke 83 or equivalent)  

z

VW 1594 adapter set  

z

Wiring diagram  

z

VAG1598/21 Test box  

Test conditions 

z

Malfunction has been recognized by CAN-Bus OBD  

z

ABS control module coded to CAN-Bus operation  

Test sequence 

z

Connect VAG1598/21 test box -1- to ABS control module wiring harness -2-. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 197: Connecting VAG1598/21 Test Box To ABS Control Module Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Check terminal resistor in Engine Control Module (ECM) by performing resistance measurement 
between test box sockets 10 + 11.  

z

Specified value: 115 to 135 W  

If the resistance value is outside the specified range: 

z

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

If the resistance value is within the specified range: 

z

Check CAN-Bus wiring using wiring diagram. 

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW 

DIESEL DIRECT INJECTION SYSTEM, SERVICING 

The diesel direct injection system control module is equipped with a fault memory. Check the fault memory 
before/after performing repairs or adjustments, See ENGINE CONTROL MODULE (DTC) MEMORY, 
READING AND ERASING
 . 

Safety precautions, See SAFETY PRECAUTIONS . 

Rules for cleanliness, See RULES FOR CLEANLINESS . 

SAFETY PRECAUTIONS 

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

z

The ignition must be switched off before connecting or disconnecting the glow plug system or injection 
system wiring or tester cables.  

z

If the engine is to be turned over at starter speed without starting, e.g. for compression pressure test, 
separate connection for injector unit at cylinder head.  

z

Before disconnecting the battery Ground (GND) strap obtain the code for radios with anti-theft coding.  

z

Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the 
diesel direct injection system control module could be damaged.  

Observe the following if test and measuring instruments are required during a road test: 

z

Test and measuring instruments must be secured to rear seat and operated by an assistant from this 
location.  

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

RULES FOR CLEANLINESS 

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

z

Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

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

z

Thoroughly clean all unions and adjacent areas before disconnecting.  

z

Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

z

Carefully cover opened components or seal if repairs cannot be carried out immediately.  

z

Only install clean components: 

Only unpack replacement parts immediately prior to installation. 

Do not use parts that have been stored loose (e.g. in tool boxes etc.). 

z

When system is open: 

Do not work with compressed air if this can be avoided. 

Do not move vehicle unless absolutely necessary. 

z

Make sure that no diesel fuel runs onto the coolant hoses. Immediately clean any accidental hose 
contamination. Affected hoses must be replaced.  

DIESEL DIRECT INJECTION SYSTEM, COMPONENT LOCATIONS OVERVIEW 

A. Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection) -F47- 

z

In footwell on brake pedal  

B. Brake light switch -F- 

z

In footwell on brake pedal  

C. Throttle Position (TP) sensor -G79- 

z

In footwell on accelerator pedal  

1. Engine Coolant Temperature (ECT) sensor -G62- 

z

For engine control module.  

z

With Engine Coolant Temperature (ECT) Sensor -G2-  

z

If necessary, release pressure in cooling system before removing.  

2. Intake manifold flap 

z

With Motor for intake flap -V157-  

3. EGR Vacuum Regulator Solenoid Valve -N18-  

4. Positive Crankcase Ventilation (PCV) Heating Element -N79-

NOTE:

The following list refers to items in Fig. 1 . The components A to C are not 
shown on the illustration.

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Diesel Fuel Injection - New Beetle, 1.9L 4-Cyl. - BEW

  

 

 

 

 

 

 

 

Content   ..  1359  1360  1361  1362   ..