Volkswagen New Beetle. Manual - part 1389

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1387  1388  1389  1390   ..

 

 

Volkswagen New Beetle. Manual - part 1389

 

 

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

Up to MY 1999 

z

Terminal 5 + sockets 2 and 28  

z

Terminal 6 + sockets 59, 66 and 80  

From MY 2000 

z

Terminal 5 + sockets 1 and 2  

z

Terminal 6 + sockets 116 and 121  

z

Wire resistance: 1.5ohm maximum  

z

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

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 .  

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 

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

z

Measure resistance between sensor terminals. 

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

z

Specification: 80 to 120 ohm  

If specification not obtained: 

z

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

  

If specification obtained: 

z

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

Fig. 99: 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 harness connector using Wiring diagram. 

Fig. 100: Identifying Needle Lift Sensor Harness Connector Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Up to MY 1999 

z

Terminal 1 + socket 62  

z

Terminal 2 + socket 55  

From MY 2000 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Terminal 1 + socket 109  

z

Terminal 2 + socket 101  

z

Wire resistance: 1.5ohm maximum  

z

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

z

Specification: INFINITY ohm  

If wiring OK: 

z

Replace ECM -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 .  

Diesel injection timing control range, checking 

The EGR function occurs in Function 04 (basic setting). By using this procedure, the EGR valve is cycled every 
10 seconds, so that in the measurement block 003 the extreme values can be read for EGR (Mass Air Flow 
sensor) in channel 3. 

Special tools 

z

VAG1551/1552 Scan Tool using VAG1551/3 Adapter cable  

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

Connect VAG1551/1552 Scan Tool (See VAG1551/1552 SCAN TOOL, CONNECTING ) and start 
engine and let idle.  

z

Press -0- and -1- buttons to select Address word 01: "Engine electronics"  

Display will appear as shown (example only):

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1387  1388  1389  1390   ..