Volkswagen New Beetle. Manual - part 1366

 

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Volkswagen New Beetle. Manual - part 1366

 

 

Fig. 20: Identifying VAS 5051 Vehicle Diagnosis, Testing And Information System 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Select "guided fault finding" in the VAS 5051 tester. 

After all control modules have been interrogated: 

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Press "Go to" button  

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Select "Function/component selection"  

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Select "drivetrain"  

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Select "engine code"  

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"01 Select "01-Systems capable of self-diagnosis"  

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Select "engine management system"  

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Select "Functions"  

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Select "Function or component"  

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE PERFORMANCE

Diesel Fuel Injection, 1.9L ALH - New Beetle 

DIESEL FUEL INJECTION 

DIESEL DIRECT FUEL INJECTION SYSTEM, SERVICING 

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. See DTC MEMORY, CHECKING . Make sure that Function 03: Output Diagnostic Test 
Mode (DTM) has been performed. See FUNCTION 03: OUTPUT DIAGNOSTIC TEST MODE, 
PERFORMING
 . 

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 

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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 

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. See DTC MEMORY, ERASING . See 
READINESS CODE, SETTING 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 PERFORMANCE Diesel Fuel Injection, 1.9L ALH - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

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

  

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

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Thoroughly clean all unions and the adjacent areas before disconnecting.  

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Place removed parts on a clean surface and cover over but do NOT use fluffy cloths (lint contamination)! 

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Carefully cover opened components or seal over, if the repair cannot be carried out immediately.  

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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. 

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When the system is open: 

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

Do not move the vehicle unless absolutely necessary. 

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Make sure that no Diesel fuel runs onto the coolant hoses. Clean contaminated hoses immediately. 
Always replace affected hoses.  

Diesel injection system, component locations overview 

Components A, B and C are not shown on the illustration. 

A. Brake vacuum vent valve switch for cruise control/diesel fuel injection -F47- and Brake light switch 

-F63- 

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Together in one housing in footwell on brake pedal  

B. Throttle Position (TP) Sensor - G79- 

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in footwell on throttle pedal  

See THROTTLE POSITION SENSOR, CHECKING . 

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In case of malfunction it is displayed as Throttle Position sensor -G69-  

C. Clutch vacuum vent valve switch -F36- 

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in footwell on clutch pedal  

1. EGR valve  

2. Change-over valve for intake manifold flap -N239-  

3. Needle Lift Sensor -G80-  

4. EGR vacuum regulator solenoid valve -N18-  

5. Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- 

NOTE:

The following list refers to Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

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with Barometric Pressure (BARO) sensor -F96-  

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tighten nut for ground wire (located forward of ECM) to 9 +/- 1 Nm (80 +/- 9 in. lb)  

6. Wastegate bypass regulator valve -N75-  

7. Mass Air Flow (MAF) Sensor -G70-  

8. Engine Coolant Temperature (ECT) Sensor -G62-  

9. Engine speed (RPM) sensor -G28-  

10. Harness connector 

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for Needle lift sensor -G80-  

11. Harness connector 

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for Engine Speed sensor -G28-  

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for Cold Start injector -N108-  

12. Harness connector 

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for Fuel temperature sensor -G81-  

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for Quantity adjuster -N146-  

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for Modulating piston displacement sensor -G149-  

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for Fuel shut-off valve -N109-  

13. Cold start injector -N108-  

14. Fuel shut-off valve -N109-  

15. Injection pump Quantity adjuster -N146- 

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with Fuel temperature sensor  

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with Quantity adjuster -N146-  

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with Modulating piston displacement sensor -G149-  

16. Manifold Absolute Pressure (MAP) sensor -G71- and Intake Air Temperature (IAT) sensor -G72-  

Fig. 1: Identifying Diesel Injection System Component Locations (1.9L ALH) 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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