Volkswagen New Beetle. Manual - part 1793

 

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Volkswagen New Beetle. Manual - part 1793

 

 

Fig. 35: Identifying Nuts & Bolts For Voltage Regulator & Generator Brushes 
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)

  

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Wednesday, December 14, 2005 8:48:23 AM

Page 84 

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Fig. 36: Identifying Voltage Regulator & Generator Brushes 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

9. Replace faulty generator. 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 .  

DTC P1537/17945 & DTC P1538/17946 

Code Definition 

DTC P1537/17945 
Fuel Cut-Off Valve (N109) - Incorrect Function 

DTC P1538/17946 
Fuel Cut-Off Valve (N109) - Open Circuit/Short to Ground  

NOTE:

For connector terminal wire colors, see appropriate WIRING DIAGRAM under 

 

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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Possible Effects 

Possible effects are engine stalls, engine will not start and/or lack of power.  

Test Procedures 

1. Test Fuel Cut-Off Valve (N109) using DTM. See OUTPUT DIAGNOSTIC TEST MODE . Engine 

should stall. If engine stalled using DTM, continue using DTM with ignition on and engine off until DTM 
has tested all components. See OUTPUT DIAGNOSTIC TEST MODE .  

2. 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 DTC resets.  

3. If engine did not stall when using DTM, remove, clean metal chips/dirt from Fuel Cut-Off Valve (N109) 

and reinstall Fuel Cut-Off Valve (N109). Repeat DTM, if engine does not stall, go to next step.  

4. Turn ignition off. Disconnect ECM harness connector. Connect VAG 1598/31 test box to ECM harness 

connector, see CONNECTING VAG TEST BOX (leave ECM disconnected).  

5.  

Measure resistance between terminal No. 8 at 10 pin harness connector and socket No. 120 at test box. 
See Fig. 20 . Resistance should be less than 1.5 ohms. If resistance is as specified, go to next step. If 
resistance is not as specified, repair open in wiring between 10 pin Fuel Cut-Off Valve (N109) harness 
connector 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 .  

6. Check wire at terminal No. 8 at 10 pin harness connector and socket No. 120 at test box for short circuit 

to B+ and ground. If wire is okay, go to next step. If wire has a short circuit, 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 .  

7. Replace Fuel Cut-Off Valve (N109). After repairs, erase DTC memory. See CLEARING 

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:

It may be difficult to test Fuel Cut-Off Valve (N109) using Output Diagnostic Test 
Mode (DTM) since stalling is a symptom of both DTC P1537/17945 and 
P1538/17946. 

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)

  

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

DTC P1550/17958: CHARGE PRESSURE - CONTROL DIFFERENCE 

Possible Effects 

Possible effect is a lack of power.  

Test Procedures 

1. Verify battery voltage is a minimum of 11.5 volts and all fuses are okay. Repair as necessary. Connect 

Scan Tool VAG 1551/1552 or 5051/5052. See Fig. 1 .  

2. Start engine and idle. Using scan tool access "Display group 11". With a helper to operate scan tool from 

rear seat, accelerate vehicle in 3rd gear from about 1500 RPM to wide open throttle. Press VAG 1551 
PRINT button at approximately 3000 RPM. Boost value should be 24.5-32.0 psi (1.7-2.2 bar).  

3. If specified boost pressure is not attained, check turbo charger hoses/fittings and vacuum hoses for correct 

fit and routing. See Fig. 31 , Fig. 37 and Fig. 38 . If hoses and fittings are okay, go to next step. If hoses 
or fittings are not okay, repair as necessary. After repairs, erase DTC memory. Verify repair. Test is 
complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

4. If specified boost pressure is not attained, check Wastegate by-pass regulator valve. See DTC 

P0245/16629, P0246/16630, P1546/17954 & P1549/17957 . Repeat turbocharger test. 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:

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. 

 

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 87 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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