Volkswagen New Beetle. Manual - part 1778

 

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Volkswagen New Beetle. Manual - part 1778

 

 

Fig. 10: Identifying Injection Pump Sprocket Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

NOTE:

Fuel Temperature Sensor (G81), Injection Pump Quantity Adjuster (N146) and 
Modulating Piston Displacement Sensor (G149) are integral parts of fuel 
injection pump and can not be replaced separately. 

 

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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© 2004 Mitchell Repair Information Company, LLC. 

Fig. 11: Identifying Fuel Injection Pump Components 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

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 25 

© 2004 Mitchell Repair Information Company, LLC. 

Relay panel is located under driver's side of dash, behind trim panel. Fuel pump relay is not used until model 
year 2004 with engine code BEW. Control number for Load Reduction Relay is (Control Number 100), for 
Glow Plug Relay (Control Number 180) and for Power Supply Relay (Control Number 109).  

Fig. 12: Identifying Relay Panel Components (1.9L Turbo Diesel) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DIAGNOSTIC TESTS 

z

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

z

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

z

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

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. 

CAUTION: Perform all resistance and voltage tests with a Digital Volt-ohmmeter 

(DVOM) with minimum 10-megohm impedance, unless stated otherwise in 
test procedures. Ensure ignition switch is in OFF position when 
performing resistance tests. 

 

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 26 

© 2004 Mitchell Repair Information Company, LLC. 

z

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.  

z

Only install clean components.  

z

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

DTC P0101/16485, DTC P0102/16486, DTC P0103/16487, DTC P1144/17552, DTC P1145/17553 & DTC 
P1146/17554 

Code Definition 

DTC P0101/16485 
MAF Sensor Signal (G70) - Open Circuit/Short To B + 

NOTE:

Read and record DTCs before starting diagnostic work, (some testing 
procedures will set DTCs). 

NOTE:

Before replacing any component, verify battery voltage is a minimum of 11.5 
volts and all fuses are okay. Ensure all wiring is okay and connectors at 
component and ECM are clean and tight. When codes have been cleared or 
voltage supply to ECM has been interrupted, ECM loses all "learned" and 
"basic" values. Serious driveability problems may occur depending on vehicle 
mileage. After reconnecting ECM, it is necessary to perform relearn procedure. 
See TEST DRIVE RELEARN PROCEDURE . 

NOTE:

If a test ends with ECM replacement. Before replacing ECM be certain that, all 
wiring, power and ground supplies are okay. See ENGINE PERFORMANCE in 
SYSTEM WIRING DIAGRAMS article in ELECTRICAL and ECM GROUND & 
VOLTAGE SUPPLY . 

NOTE:

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 loose contact or 
a brief open circuit. If a sporadic malfunction does not occur again within 40 
warm-up phases, sporadic DTC(s) will be erased from ECM memory. A warm-up 
phase is engine started with coolant temperature below 122°F (50°C), and 
switched off at above 162°F (72°C). 

NOTE:

To properly diagnose vehicle, vehicle manufacturer recommends use of Scan 
Tool (VAG 1551/1552 or VAS 5051/5052) and Test Box (VAG 1598). Test box 
terminal numbers and ECM terminal numbers are identical. To identify 
connector terminal wire colors, see ENGINE PERFORMANCE in SYSTEM 
WIRING DIAGRAMS article in ELECTRICAL. 

 

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 8:48:21 AM

Page 27 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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