Volkswagen New Beetle. Manual - part 1785

 

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Volkswagen New Beetle. Manual - part 1785

 

 

Misfire Recognized - Cylinder No. 3 

DTC P0304/16688 
Misfire Recognized - Cylinder No. 4  

Possible Effects 

Possible effect is reduced power. Engine runs rough. Increased emissions.  

Test Requirements 

Ensure battery voltage is at least 11.5 volts. Ensure all electrical accessories are off and A/C is off. Ensure 
engine coolant temperature is at least 176°F (80°C). On vehicles with M/T, gear shifter must be in neutral with 
parking brake set. On vehicles with A/T, selector lever must be in park or neutral with parking brake set.  

Test Procedure 

1. Remove engine cover. Disconnect 10-pin electrical connector, on diesel injection pump. See 

COMPONENT LOCATIONS .  

2. Disconnect connectors from glow plugs. Remove all glow plugs.  

3.  

Thread in VAG 1381/12 adaptor in place of glow plugs. Check compression using VAG 1763 
compression tester. Operate starter until tester displays no further increase in pressure. Record 
compression readings for each cylinder.  

4. Check compression readings against specifications. See COMPRESSION SPECIFICATIONS table. If 

any cylinder reading is not as specified, repair as necessary. Glow plug tightening torque is 11 ft. lbs. (15 
N.m).  

COMPRESSION SPECIFICATIONS 

DTC P0321/16705 & DTC P0322/16706 

NOTE:

Follow manufacturers operating instructions for correct use of 
compression tester. 

Application 

(1)

Specification 

Normal Compression Pressure (New Engine) 

Beetle, Golf & Jetta 

1.9L Turbo Diesel 

363-450 psi (25.0-31.0 bar) 

Minimum Compression Pressure 

1.9L Turbo Diesel 

276 psi (19.0 bar) 

Maximum Variation Between Cylinders 

1.9L Turbo Diesel 

73 psi (5.0 bar) 

(1)

Operate starter until tester shows no further increase.

 

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 8:48:22 AM

Page 52 

© 2004 Mitchell Repair Information Company, LLC. 

Code Definition 

DTC 0321/16705 
Engine Speed (RPM) Sensor (G28) - Implausible Signal 

DTC 0322/16706 
Engine Speed (RPM) Sensor (G28) - No Signal  

Possible Effects 

Possible effects are engine performance problem, engine stalls and/or glow plug indictor light blinks.  

Test Procedures 

1. Turn ignition off. Disconnect engine speed sensor harness connector, for location see Fig. 8 .  

2. Measure resistance between terminals No. 1 and 2 at engine speed sensor (component side), see Fig. 23 . 

Resistance should be 1100-1600 ohms. If resistance is as specified, go to next step. If resistance is not as 
specified, replace engine speed sensor. 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 
.  

3. Turn ignition off. Disconnect Engine Control Module (ECM) harness connector. Connect VAG 1598/31 

test box to ECM harness connector, leave ECM disconnected. See CONNECTING VAG TEST BOX .  

4.  

Measure resistance between terminal No. 1 at engine speed sensor harness connector and socket No. 102 
at test box. See Fig. 24 . Measure resistance between terminal No. 2 at engine speed sensor harness 
connector and socket No. 110 at test box. Measure resistance between terminal No. 3 at engine speed 
sensor harness connector and socket No. 86 at test box. Resistance should be less than 1.5 ohms for each 
reading.  

5. If resistances are as specified, go to next step. If any resistance is not as specified, repair open in wiring 

between engine speed sensor and 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 

NOTE:

For connector terminal wire colors, see appropriate WIRING DIAGRAM under 
ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. For component 
locations, see COMPONENT LOCATIONS . 

NOTE:

Before replacing any component, ensure all connectors at component and ECM 
are clean and tight. After making any repairs, disconnect ECM harness 
connector for 10 seconds, connect ECM harness connector and retest system. 
It is necessary to generate an ECM readiness code if ECM memory is cleared, 
battery voltage is disconnected or ECM is disconnected. 

NOTE:

Test box socket numbers correspond to ECM pin numbers. 

 

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 8:48:22 AM

Page 53 

© 2004 Mitchell Repair Information Company, LLC. 

PROCEDURE .  

6. Measure resistance between terminals No. 1, 2 and 3 at engine speed sensor harness connector. See Fig. 

24 . Resistance should be infinite for each reading. If resistances are as specified, go to next step. If any 
resistance is not as specified, repair circuits shorted to each other between engine speed sensor and 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 .  

7. Remove engine speed sensor and check sensor wheel for secure fit, damage and excessive run-out. If 

engine speed sensor is okay, go to next step. If engine speed sensor is not okay, replace engine speed 
sensor. 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 .  

8. If speed sensor is okay and resistances are as specified, replace 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 
.  

 

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 8:48:22 AM

Page 54 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 23: Identifying Engine Speed Sensor Terminals 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 24: Identifying Engine Speed Sensor Harness Connector Terminals 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DTC P0380/16764, DTC P1618/18026 & DTC P1619/18027 

Code Definition 

DTC P0380/16764 
Glow Plug Monitoring - No Display 

DTC P1618/18026 
Glow Plug Relay (J52) - Short To B+ 

DTC P1619/18027 
Glow Plug Relay (J52) - Open Circuit/Short To Ground  

 

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 8:48:22 AM

Page 55 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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