Volkswagen New Beetle. Manual - part 1774

 

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Volkswagen New Beetle. Manual - part 1774

 

 

DTCs must be read before being erased. See RETRIEVING DIAGNOSTIC TROUBLE CODES 
(FUNCTION 02) 
. If using Scan Tool VAG 1551/1552 or VAS 5051/5052, start engine. Press keys "0" and "1" 
for address word "Engine Electronics". Press keys "0" and "5" for function "Erase DTC memory," and enter by 
pressing "Q" key. Press keys "0" and "6" for function "End Output", and enter by pressing "Q" key.  

TEST DRIVE RELEARN PROCEDURE 

1. If ECM was disconnected during diagnostic procedure or diagnostic trouble codes have been cleared, go 

to next step. If ECM was not disconnected during diagnostic procedure and no codes are present. Perform 
a test drive. Recheck for codes (no relearn procedure is necessary).  

2. Turn ignition off. Remove test equipment. Reconnect ECM connector. Reconnect all remaining 

(disconnected) electrical connectors/components. Go to next step.  

3.  

Turn ignition on for a minimum of 10 seconds. Turn ignition off. Perform a long road test. Coolant 
temperature needs to be greater than 176°F (80°C). Idle, partial throttle, full throttle and overdrive, all 
must be attained several times. During test drive, apply full throttle until engine speed exceeds 3500 
RPM. Read readiness code. Generate readiness code if necessary. See READINESS CODE .  

READINESS CODE 

Reading Readiness Code 

Read readiness code in display zone 2. Specified value X000XXXX. Read readiness code in display zone 4. 
Specified value 0XXXXXXX. Press (arrow right) button. Press keys "0" and "6" to end data transfer function. 
Press "Q" button to enter input. If readiness code specifications are not attained in display zones 2 and 4. Repeat 
generating readiness code procedure. See GENERATING READINESS CODE .  

Generating Readiness Code 

1. After reconnecting ECM, it is necessary to perform relearn procedure, see TEST DRIVE RELEARN 

PROCEDURE . No DTCs stored. Engine coolant 50°F (10°C) minimum.  

2.  

NOTE:

When voltage supply to ECM is interrupted or diagnostic trouble codes have 
been cleared, ECM loses all "learned" and/or "basic" values. Serious 
driveability problems may occur depending on vehicle mileage. A relearn 
procedure must be performed. 

NOTE:

Throttle Valve Control Module (J338) adapts to ECM (J220) automatically if 
ignition is switched on for 10 seconds or more without operating 
accelerator pedal or starter and ECM recognizes a need for adaptation. No 
notification that adaptation was successful will be given when this 
happens. 

NOTE:

If test sequence is interrupted or not adhered to, readiness code will not 

 

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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Let engine idle for a minimum of 35 seconds.  

3. Road test vehicle and maintain 2000 RPM in 3rd gear for a minimum of 5 seconds.  

4. Accelerate from engine speed of 2200 RPM to wide open throttle in 2nd or 3rd gear for 8 seconds. Switch 

off engine and wait a minimum of 10 seconds. Repeat steps 2, 3 and 4.  

5. Read readiness code. Start engine and let idle. Press keys "0" and "1". Press "Q" button to enter input. 

Rapid data transfer. Input display group number "XX" will appear. Press keys "0" and "8". Press "Q" 
button to enter input. Read measuring value block. Input display group number "XXX" will appear. Press 
"0", "1" and "7" buttons to select display group "17". Press "Q" button to enter input. Read measuring 
value block "17" will appear. Read readiness code in display zone 2. Specified value X000XXXX. Read 
readiness code in display zone 4. Specified value 0XXXXXXX. Press (arrow right) button.  

6. Press keys "0" and "6" to end data transfer function. Press "Q" button to enter input. If readiness code 

specifications are not attained in display zones 2 and 4. Repeat readiness code procedure, go to step 1 .  

OUTPUT DIAGNOSTIC TEST MODE 

Output Diagnostic Test Mode (Generic Scan Tool) 

Turn ignition off. Connect scan tool to DLC. See Fig. 1 . Follow scan tool manufacturer instructions for 
entering OUTPUT DIAGNOSTIC TEST MODE.  

Output Diagnostic Test Mode (Scan Tool VAG 1551/1552 or VAS 5051/5052) 

1. Connect scan tool to DLC. See Fig. 1 .  

2. Turn ignition on, engine off. Press keys "0" and "1" for address word "Engine Electronics", press keys "0" 

and "3" for DTM and enter by pressing "Q" key. During DTM sequence individual components will be 
activated until advancing to the next component by pressing arrow key. It is possible to skip a component 
by pressing right arrow key more than once. When finished, press keys "0" and "6" for function "End 
Output" and enter by pressing "Q" key.  

3. Activation sequence of components may vary, depending on current ECM version. Vehicle need to be at 

a room temperature higher than 59°F (15°C). A/C needs to be switched on, with highest blower speed and 
coolest temperature settings selected. A/C test step is displayed on vehicles without A/C; when this 
occurs go to next component. Output Diagnostic Test Mode activates each component for 30 seconds or 
right arrow button can be pushed to activate next component. 

be set. 

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. Output 
Diagnostic Test Mode (DTM) can be aborted by pressing "C" key. DTM will be 
aborted after 60 seconds, if right arrow key is not pressed again. 

NOTE:

When using scan tool in DTM to activate engine components, some 
components may be barely audible. Check component by touch or use 
mechanics stethoscope if necessary. 

 

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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Output Diagnostic Test Mode for 1.9L Turbo Diesel activates the following components in given sequence:  

z

Cold Start Injector (N108) - Engine running at idle, activation should make a change in combustion that 
can be heard.  

z

EGR Vacuum Regulator Valve (N18) - Engine running at idle, activation should make a change in 
combustion that can be heard.  

z

A/C Compressor Interruption - Engine running at idle, activation should cycle A/C clutch at 
approximately 5 second intervals.  

z

Fuel Cut-off Valve (N109) - Engine running at idle, activation should stall the engine.  

z

Wastegate Bypass Regulator Valve (N75)  

z

Glow Plug Relay (J52)  

z

Glow Plug Indicator Light (K29) - Glow Plug Indicator Light (K29) should flash.  

z

Low Heat Output Relay (J359) - For coolant preheating, M/T only, (relay should click).  

z

High Heat Output Relay (J360) - For coolant preheating, M/T only, only (relay should click).  

z

MIL (K83) - MIL should flash.  

FUNCTION 08 - READ MEASURING VALUE BLOCK 

Different control modules can transmit a variety of test data. Test data provides information on the operating 
condition of the system and/or its sensors. Diagnostic function "08 - READ MEASURING VALUE BLOCK" 
allows scan tool to display test data using display group numbers. Test data can provide support in diagnosing 
and correcting malfunctions.  

Before entering diagnostic function "08 - READ MEASURING VALUE BLOCK" run engine until coolant 
temperature is 176°F (80°C) or more. A/C is switch off. Transaxle is in Park or Neutral. Turn steering wheel 
until front wheels are in straight line. Connect VAS 5051 or equivalent scan tool to DLC. DLC is located 
behind cover under left side of steering column.  

Turn ignition on or start engine as necessary for testing procedure. Using scan tool, select vehicle system "01 - 
ENGINE ELECTRONICS". Select diagnostic function "08 - READ MEASURED VALUE BLOCK". Press 
"Q" button to confirm input, and enter appropriate 3-digit group number in button field 2. Follow scan tool 
instructions to display desired test data.  

ECM GROUND & VOLTAGE SUPPLY 

1. Verify battery voltage is a minimum of 11.5 volts and all fuses are okay. Ensure battery and engine to 

body grounds are okay. Repair as necessary. Turn off all electrical consumers and A/C. Shift lever in park 
(A/T) or neutral (M/T). Set parking brake. Battery voltage must a minimum of 11.5 volts. Start engine 
and idle.  

2. Check battery, alternator, parasitic load and ECM grounds. See ENGINE PERFORMANCE in SYSTEM 

WIRING DIAGRAMS article in ELECTRICAL. Repair as necessary. If repairs where performed, repeat 
step 1 . If battery, alternator, parasitic load and ECM grounds are okay, go to step, go to next step. If 
battery, alternator, parasitic load and ECM grounds are okay, go to step 4 .  

3. Possible cause is alternator and/or voltage regulator failure. Repair as necessary. If repairs were 

 

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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performed, repeat step 1 . If alternator and voltage regulator are okay, go to next step.  

4. Turn ignition off. Connect Test Box (VAG 1598/31) to ECM harness connector, leave ECM disconnected 

from test box. See CONNECTING VAG TEST BOX and go to next step. 

5. Turn ignition on. Using adapter cables from Test Kit (VAG 1594), connect jumper wire to terminals No. 

4 and 18 of test box. Using DVOM, measure voltage supply at test box sockets No. 1 and 4, (+15 and 
ground). Measure voltage supply at test box sockets No. 2 and 4, (+15 and ground). Measure voltage 
supply at test box sockets No. 1 and 5, (+15 and ground). Measure voltage supply at test box sockets No. 
2 and 5, (+15 and ground). Battery voltage should be present. If battery voltage is present, ECM ground 
and voltage supply are okay. Test is complete. If ECM ground and voltage supplies are not okay, go to 
next step.  

6. Check terminal 30 (B+) at voltage supply relay, see ENGINE PERFORMANCE in SYSTEM WIRING 

DIAGRAMS article in ELECTRICAL and Fig. 12 . If wiring to voltage supply relay is not okay, repair 
wiring. If voltage supply relay is still not functional, check each individual wire going to voltage relay for 
open circuit and short circuit and check voltage supply relay, repair or replace as necessary.  

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

(FUNCTION 05) under SELF DIAGNOSTIC SYSTEM. Verify repair. Test is complete. Perform ECM 
relearn procedure. See TEST DRIVE RELEARN PROCEDURE . If voltage supply is still not okay 
and all voltage supply wiring and voltage supply relay is okay, go to next step.  

8. Replace faulty ECM. After repairs, erase DTC memory. See CLEARING DIAGNOSTIC TROUBLE 

CODES (FUNCTION 05) under SELF DIAGNOSTIC SYSTEM. Verify repair. Test is complete. 
Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

ECM (248) REMOVAL & INSTALLATION 

1. Before disconnecting Engine Control Module (ECM) record code and identification number from ECM 

that is to be replaced. See ENGINE CONTROL MODULE (J248) CODING . For Beetle go to next 
step. For Golf and Jetta, go to step 3 .  

2. Turn ignition off. Remove cowl panel. Release lock tab for ECM harness connector and disconnect 

harness connectors.  

3. Turn ignition off. Remove wiper arms and cowl panel. Release lock tab for ECM harness connector and 

disconnect harness connectors. Installation is in reverse order. 

NOTE:

If test box is not available, use wiring diagram and DVOM to check ECM 
grounds and voltage supply. See ENGINE PERFORMANCE in SYSTEM 
WIRING DIAGRAMS article in ELECTRICAL. 

CAUTION: When replacing ECM (J248). It is necessary to adapt ECM to immobilizer. 

No information is available for VW. 

CAUTION: Manufacturers states that scan tools VAS 5051 and VAS 5052 MUST be 

programmed with correct Importer/Dealer number as well as correct time 
when adapt ECM to immobilizer from model year 2002 on (Generation III 
immobilizer). 

 

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 11 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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