Volkswagen New Beetle. Manual - part 1792

 

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Volkswagen New Beetle. Manual - part 1792

 

 

Fig. 33: Drive Belt Routing (Without A/C) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3.  

 

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 80 

© 2004 Mitchell Repair Information Company, LLC. 

Check function of generator pulley freewheeling clutch (if equipped). To check freewheeling clutch, 
multi-tooth socket 3400 and 17mm wrench are needed. Turn generator input shaft counterclockwise using 
multi-tooth socket 3400 and 17mm wrench. See Fig. 34 . If input shaft and outside of pulley turns no 
repair is necessary, go to next step. If only input shaft turns and outside of pulley does not turn, replace 
faulty freewheeling clutch w/pulley. See GENERATORS & REGULATORS - FROM LATE 1999 
PRODUCTION
 or GENERATORS & REGULATORS - NEW BEETLE . 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 

NOTE:

Generator freewheeling pulley clutch is identified by protective cap in 
center of generator pulley. Freewheeling pulley clutch momentarily 
freewheels when variable load is applied to drive belt, A/C or switching on 
high current electrical consumers. Freewheeling pulley clutch ensures 
that belt driving force to generator is applied in clockwise rotation only. 
When checking freewheeling clutch, 6 mm allen socket is not used, 6 mm 
allen socket is used for removal and installation 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 81 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 34: Checking Or Removing Freewheeling Clutch W/Pulley 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

4. Turn ignition off. Attach SUN VAT 40 ammeter, or equivalent, black lead to battery negative terminal. 

 

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 82 

© 2004 Mitchell Repair Information Company, LLC. 

Attach SUN VAT 40 Red lead to battery positive terminal. Clamp SUN VAT 40 Green test lead to 
battery ground cable.  

5. Turn on all electrical components. Start engine and maintain engine speed of 1500-2000 RPM. Observe 

SUN VAT 40 ammeter reading. If charging current is less than 75 amps, go to next step. If charging 
current is 75 amps or more, generator and voltage regulator are functioning properly, erase DTC memory. 
See CLEARING DIAGNOSTIC TROUBLE CODES (FUNCTION 05) under SELF DIAGNOSTIC 
SYSTEM. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE . Test is 
complete, if no DTCs reset.  

6. Load test battery. If load test is okay, go to next step. If load test is not okay, replace battery. 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. Recheck charging current. Turn ignition off. Attach SUN VAT 40 ammeter black lead to battery negative 

terminal. Attach SUN VAT 40 Red lead to battery positive terminal. Clamp SUN VAT 40 Green test lead 
to battery ground cable. Turn off all electrical components. Start engine and maintain engine speed of 
1500-2000 RPM. Observe SUN VAT 40 ammeter reading. If charging current is less than 75 amps, go to 
next step.  

8.  

Disconnect battery. Remove voltage regulator w/generator brushes. See Fig. 35 . Check generator 
brushes, see Fig. 36 . Brushes should protrude minimum 0.200" (5 mm) from brush holder. If brushes are 
okay, go to next step. If brushes are not okay, replace faulty brushes. 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 

NOTE:

This 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 83 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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