Volkswagen New Beetle. Manual - part 1791

 

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Volkswagen New Beetle. Manual - part 1791

 

 

Possible Effects 

Possible effects are black smoke, EGR system malfunction and/or lack of power.  

Test Procedures 

1. Check air induction and vacuum hoses for leaks. Check vacuum hoses for proper routing. See Fig. 31 . If 

vacuum hoses are routed properly and no air or vacuum leaks are found, go to next step. If vacuum hoses 
are not routed properly and/or air or vacuum leaks are found, repair as necessary. 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 
.  

2. Check EGR valve for proper operation and free movement using manual vacuum pump. If EGR operation 

is okay, go to next step. If EGR operation is not okay, replace EGR valve. 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. Check EGR Vacuum Regulator Solenoid Valve (N18). See DTC P401/16785, P402/16786, P1402/17810 

& P1441/17849 .  

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. 

 

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 8:48:23 AM

Page 76 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 31: Vacuum Hose Diagram 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DTC P1503/17911 & VAG DTC 01117 

Code Definition 

DTC P1503/17911 
Load Signal For Generator DF - Implausible Signal 

VAG DTC 01117 
 

Load Signal For Generator DF - Implausible Signal  

NOTE:

DTC 00668 is displayed in VW factory scan tool format only. 

NOTE:

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

 

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 8:48:23 AM

Page 77 

© 2004 Mitchell Repair Information Company, LLC. 

Possible Effects 

Engine warm-up (pre-heat inoperative).  

Test Procedures 

1. Check ground connection between engine, body, battery positive, ground and all electrical connections on 

generator. Check battery cables for corrosion. If no repair is needed, go to next step. If repairs are needed, 
repair as necessary. 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 .  

2. Ensure generator belt tension and mounting are okay. See Fig. 32 or Fig. 33 . 

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:

Testing procedure is for 2002-2004 generator w/serviceable voltage 
regulator/brushes only. 

 

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 8:48:23 AM

Page 78 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 32: Drive Belt Routing (With A/C) 
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 8:48:23 AM

Page 79 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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