Volkswagen New Beetle. Manual - part 1773

 

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Volkswagen New Beetle. Manual - part 1773

 

 

Fig. 3: Locating MIL & Glow Plug Lights (Golf & Jetta) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

SERVICE PRECAUTIONS 

z

Thoroughly clean all unions and the adjacent areas before disconnecting any part of fuel supply/injection 
system.  

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

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

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When fuel supply/injection 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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Only install clean components.  

WARNING:

For safety during road test, it is advisable to have a helper operate tester 
from rear seat. If test and measuring instruments are operated from front 
passenger's seat and vehicle is involved in an accident, there is a 
possibility the person sitting in this seat may receive serious injuries 
when air bag is deployed. 

WARNING:

Steam can be released when removing the cap from coolant expansion 
tank. Cover cap with a cloth and open carefully. 

 

2003 Volkswagen New Beetle GLS 

2002-2004 ENGINE PERFORMANCE Self-Diagnostics - 1.9L Turbo Diesel - Beetle, Golf & Jetta (Engine Code ALH)

  

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Wednesday, December 14, 2005 8:48:20 AM

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z

Make sure that no diesel fuel contacts the coolant hoses. Clean or replace affected hoses immediately.  

z

Turn ignition off when connecting or disconnecting test equipment, unless specifically instructed not to 
do so in repair instructions.  

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Turn ignition off before connecting or disconnecting ECM (J248) connectors.  

z

Perform all resistance and voltage tests with a Digital Volt-ohmmeter (DVOM) with minimum 10-
megohm impedance, unless stated otherwise in test procedures.  

z

Ensure ignition switch is in OFF position when performing resistance tests.  

VISUAL INSPECTION 

Perform a comprehensive visual inspection of underhood components. Check ground connections located on 
intake manifold, ground cable between engine and vehicle body and that battery cables are clean and tight. See 
appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.  

Check electrical wiring and harness connectors for damage and corrosion. Repair as necessary. Ensure all 
engine systems not related to ECM are operating properly. Check for any Technical Service Bulletins (TSBs) 
that may apply. DO NOT proceed with testing unless all engine problems not related to ECM have been 
repaired. Connect scan tool. See Fig. 1 .  

Check ECM for DTCs, following scan tool manufacture's instructions. If DTC(s) are present, see 
DIAGNOSTIC TROUBLE CODE DEFINITIONS . If no DTC(s) are present check suspect component 
using Output Diagnostic Test Mode (if Output Diagnostic Test Mode is available for the suspect component). 
See OUTPUT DIAGNOSTIC TEST MODE .  

AUTOMATIC TEST SEQUENCE (FUNCTION 00) 

Generic Scan Tool 

Turn ignition off. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 1 . 
Follow scan tool manufacturer instructions for entering AUTOMATIC TEST SEQUENCE.  

Scan Tool VAG 1551/1552 or VAS 5051/5052 

1. Turn ignition off. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 

1 .  

2. To enter Automatic Test Sequence, press "0" key 2 times for address word "Automatic test sequence" and 

enter by pressing "Q" key. VAG 1551/1552 or VAS 5051/5052 communicates with all control modules in 
CAN Data Bus. Any DTCs that are stored will be displayed or "No DTC recognized" will display for 
each control module one after another. Automatic test sequence has ended when, "VAG On Board 

NOTE:

It is recommended that all control modules in the CAN Data Bus are checked for 
DTCs before starting and after performing DTC testing and repair work (during 
test and assembly work malfunctions can be recognized from other control 
modules like harness connector disconnected). Automatic Test Sequence is 
function 00 when using Scan Tool VAG 1551/1552 or VAS 5051/5052. 

 

2003 Volkswagen New Beetle GLS 

2002-2004 ENGINE PERFORMANCE Self-Diagnostics - 1.9L Turbo Diesel - Beetle, Golf & Jetta (Engine Code ALH)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:48:20 AM

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© 2004 Mitchell Repair Information Company, LLC. 

Diagnostic HELP 1 - Rapid data transfer 2 - Flash code output" is displayed. Erase DTCs. See 
CLEARING DIAGNOSTIC TROUBLE CODES (FUNCTION 05) . Perform test drive. See TEST 
DRIVE RELEARN PROCEDURE 
. Go to next step.  

3. If no DTCs are stored after test drive, press keys "0" and "6" for function "End Output" and enter by 

pressing "Q" key. If DTC(s) are stored in a control module in CAN Data Bus, see appropriate DTC table 
and diagnostic procedure, (e.g. ABS DTC IDENTIFICATION table, under appropriate BRAKES/ANTI-
LOCK/TRACTION CONTROL article, if ABS DTC is stored). Repair as necessary.  

4. After repairs, erase DTC memory. See CLEARING DIAGNOSTIC TROUBLE CODES 

(FUNCTION 05) under SELF DIAGNOSTIC SYSTEM. Verify repair. Test is complete. Perform test 
drive. See TEST DRIVE RELEARN PROCEDURE .  

RETRIEVING DIAGNOSTIC TROUBLE CODES (FUNCTION 02) 

When using Scan Tool VAG 1551/1552 or VAS 5051/5052, malfunctions which only occur sporadically 
(intermittently) will have the addendum sporadic (intermittent) malfunction on the print out and will be 
indicated on the display by the addendum /SP. Cause of sporadic malfunctions can be a loose harness connector 
or an intermittently open circuit. If a sporadic malfunction does not occur again within 40 warm-up phases, 
sporadic DTCs will be erased from ECM memory. A warm-up phase is engine started with coolant temperature 
below 122°F (50°C), and is switched off above 162°F (72°C).  

Generic Scan Tool 

Turn ignition off. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 1 . 
Follow scan tool manufacturer instructions for reading DTCs. To identify DTCs, see DIAGNOSTIC 
TROUBLE CODE DEFINITIONS 
. After performing DTC checks and repair work, malfunctions may be 
present in other control modules such as harness connector disconnected. DTC memories of all control modules 

NOTE:

Read and record DTCs before starting diagnostic work, some testing 
procedures will set DTCs. If no DTCs are stored, do not erase memory, erasing 
DTC memory will cause readiness code to be erased. If ignition is switched off 
between "Retrieving Diagnostic Trouble Codes" and "Clearing Diagnostic 
Trouble Codes" the DTC memory will not be erased, repeat "Retrieving 
Diagnostic Trouble Codes" procedure. 

NOTE:

It is recommended that all control modules in the CAN Data Bus are checked for 
DTCs before starting and after performing DTC testing and repair work (during 
test and assembly work malfunctions can be recognized from other control 
modules like a harness connector disconnected). See AUTOMATIC TEST 
SEQUENCE (FUNCTION 00) . 

NOTE:

Manufacturer recommends use of Scan Tool VAG 1551/1552 or VAS 5051/5052. 
Generic scan tool may not be able to perform all test functions. If engine does 
not start, (this test requires using Scan Tool VAG 1551/1552 or VAS 5051/5052) 
connect scan tool. Operate starter for approximately 6 seconds, do not switch 
ignition off. Turn on scan tool printer. Operate scan tool, according to scan tool 
display information. Check for DTCs. 

 

2003 Volkswagen New Beetle GLS 

2002-2004 ENGINE PERFORMANCE Self-Diagnostics - 1.9L Turbo Diesel - Beetle, Golf & Jetta (Engine Code ALH)

  

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must be checked and erased. See AUTOMATIC TEST SEQUENCE (FUNCTION 00) .  

Scan Tool VAG 1551/1552 Or VAS 5051/5052 

1. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 1 . Start engine 

and idle.  

2. Using Scan Tool VAG 1551/1552 or VAS 5051/5052 start engine and press keys "0" and "1" for address 

word "Engine Electronics", press keys "0" and "2" for "Check DTC memory" and enter by pressing "Q" 
key.  

3. If DTCs are present, record or print DTCs. Press keys "0" and "5" for function "Erase DTC memory" and 

enter by pressing "Q" key. Press right arrow key, press keys "0" and "6" for function "End Output" and 
enter by pressing "Q" key. To identify DTCs, see DIAGNOSTIC TROUBLE CODE DEFINITIONS 
Repair as necessary. If no DTCs are present "No DTC recognized" will display. Press right arrow key, 
press keys "0" and "6" for function "End Output" and enter by pressing "Q" key.  

4. After performing DTC checks and repair work, malfunctions may be present in other control modules 

such as harness connector disconnected.  

5. DTC memories of all control modules must be checked and erased. This sequence when using Scan Tool 

VAG 1551/1552 or VAS 5051/5052. See AUTOMATIC TEST SEQUENCE (FUNCTION 00) .  

6. If no DTCs are present or after clearing diagnostic trouble codes from all control modules, perform a long 

road test. Coolant temperature needs to be greater than 176°F (80°C). Idle, partial throttle, full throttle 
and overdrive, must all be attained several times. During test drive, apply full throttle until engine speed 
exceeds 3500 RPM. After road test recheck all control modules for DTCs. If DTCs are present, repair as 
necessary. Clear codes. See CLEARING DIAGNOSTIC TROUBLE CODES (FUNCTION 05) 
Verify repairs. Test is complete.  

CLEARING DIAGNOSTIC TROUBLE CODES (FUNCTION 05) 

Generic Scan Tool 

Turn ignition off. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 1 . 
Follow scan tool manufacturer instructions for clearing DTCs.  

Scan Tool VAG 1551/1552 Or VAS 5051/5052 

Turn ignition off. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 1 

NOTE:

It is recommended that all control modules in the CAN Data Bus are checked for 
DTCs before starting and after performing DTC testing and repair work (during 
test and assembly work malfunctions can be recognized from other control 
modules like e.g. harness connector disconnected). See AUTOMATIC TEST 
SEQUENCE (FUNCTION 00) . 

NOTE:

If ignition is switched off between "Retrieving Diagnostic Trouble Codes" and 
"Clearing Diagnostic Trouble Codes" the DTC memory will not be erased, repeat 
"Retrieving Diagnostic Trouble Codes" procedure. 

 

2003 Volkswagen New Beetle GLS 

2002-2004 ENGINE PERFORMANCE Self-Diagnostics - 1.9L Turbo Diesel - Beetle, Golf & Jetta (Engine Code ALH)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:48:20 AM

Page 7 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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