Volkswagen New Beetle. Manual - part 1522

 

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Volkswagen New Beetle. Manual - part 1522

 

 

If the specification is obtained: 

z

Press --> button.  

z

Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.  

z

Switch off ignition.  

Continuation: 

If the specifications are not obtained: 

z

Press --> button.  

z

Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.  

z

Switch off ignition.  

Checking resistance of Knock Sensors (KS) 

z

Disconnect 2-pin harness connector to Knock Sensor (KS) 1 - G61- (item no. 1 ) and/or 2-pin harness 
connector to Knock Sensor (KS) 2 -G66- (item no. 7 ). 

Display zones
1

2

3

4

Display group 28: ignition, knock control
Display

xxxx RPM

xxx.x %

xxx.x °C

Test OFF/Test ON

Syst. OK.

Syst. n. OK.

Indicated

Engine 

speed 

(in steps of 

40)

Engine 

load

Engine 

Coolant 

Temperature

OBD condition

and

OBD result

Working 
range

0 to 6800 

RPM

0.0 to 

175.0%

-40.0 to 115.0 

° C

-

Specification

at least 

2200 RPM

> 40.0%

85.0 to 115.0 ° 

C

Syst. OK.

-

-

-

If the specifications are not achieved, see 

CHECKING WIRING , Continuation

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

Fig. 20: Disconnecting 2-Pin Knock Sensor Harness Connectors 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Measure resistance between the terminals 1 + 2 at connections to Knock Sensors (KS).  

Specification: ohm 

Fig. 21: Measuring Resistance Between Knock Sensor Terminals 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If the specification is not obtained: 

z

Replace Knock Sensors (KS) -G61- or -G66-, see item 12 or item 13 .  

z

Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC 
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND 
ERASING
 .  

z

Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or 
Engine Control Module was disconnected from battery positive, readiness code must be generated again, 
see READINESS CODE, GENERATING 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

If the specification is obtained: 

z

Check wiring, see CHECKING WIRING .  

Checking wiring 

z

Remove inner plenum chamber cover, left:  

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING . 

z

Connect V.A.G 1598/31 test box to control module wiring harness. Engine Control Module is not 
connected by this action. 

Fig. 22: Connecting V.A.G 1598/31 Test Box To Control Module Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Check wiring between test box and 2 -pin connector for open circuit using Electrical Wiring Diagrams. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

Fig. 23: Identifying Knock Sensor Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

Knock Sensor -G61-: -G66-: 

Contact 1 + socket 106 107 

Contact 2 + socket 99 99 

Wire resistance: Max. 1.5 ohm 

z

Additionally check wires at socket 99 for short to sockets 106 and 107.  

Specification: ohm 

If no malfunctions in wiring are detected: 

z

Loosen Knock Sensor (KS) and tighten again to 20 Nm.  

z

Perform a road test again and check knock control specifications on display. 

Observe the valid safety precautions when road testing, see SAFETY PRECAUTIONS . 

During the road test Engine Coolant Temperature must exceed 85 ° C 

When the temperature is reached, these operating conditions must be obtained several times: 

z

Idle  

z

Part throttle  

z

Full throttle  

z

Overrun  

z

At full throttle the engine speed must exceed 3500 RPM.  

z

Again check control module DTC memory.  

If the malfunction is still present: 

z

Replace Knock Sensors (KS) -G61- or -G66-, see item 12 or item 13 .  

z

Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC 
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND 
ERASING
 .  

z

Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or 
Engine Control Module was disconnected from battery positive, readiness code must be generated again, 
see READINESS CODE, GENERATING .  

Misfiring recognition, checking 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Ignition/Glow plug system, 1.8L AWP, AWV - New Beetle

  

 

 

 

 

 

 

 

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