Volkswagen New Beetle. Manual - part 1825

 

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Volkswagen New Beetle. Manual - part 1825

 

 

Fig. 36: Locating EVAP Canister Purge Valve (N80 - Golf & Jetta) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DTC P0442/16827, P0455/16839 & P0456/16840: EVAP LEAK 

Code Definition 

DTC P0442/16827 
EVAP - Small Leak Detected 

DTC P0455/16839 
EVAP - Very Large Leak Detected 

DTC P0456/16840 
EVAP - Very Small Leak Detected  

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 . 

 

2003 Volkswagen New Beetle GLS 

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:49:57 AM

Page 100 

© 2004 Mitchell Repair Information Company, LLC. 

Test Requirements 

Ensure intake air temperature is less than 140°F (60°C). Ensure engine coolant temperature is less than 176°F 
(80°C). Ensure all fuses are okay, battery voltage is at least 11.5 volts and fuel pump relay is okay. Ensure all 
electrical accessories are off and A/C is off. Ensure engine is mechanically sound. Ensure no intake or exhaust 
system leaks exist. 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. Check tubing and hoses from fuel tank to throttle body. If tubing and hoses are okay, go to next step. If 

tubing and/or hoses are not okay, repair as necessary. Erase DTC memory. Verify repair. Perform ECM 
relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

2.  

Connect scan tool. See RETRIEVING DIAGNOSTIC TROUBLE CODES . Turn ignition on. Using 
scan tool, follow scan tool manufacturer's instructions, check EVAP system for leaks. If leak(s) are 
detected, check fuel tank filler cap using a fuel tank filler cap tester, check fuel pump housing, EVAP 
canister, EVAP components, hoses and tubes for leaks. Repair as necessary. Erase DTC memory. Verify 
repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN 
PROCEDURE 
. If no leaks are detected. Erase DTC memory. Perform ECM relearn procedure. See 
TEST DRIVE RELEARN PROCEDURE . If DTC does not reset on test drive. Test is complete. If 
DTC returns on test drive, go to next step.  

3. Check EVAP Canister Purge Valve (N80). See DTC P0441/16825 .  

4. Check EVAP Leak Detection Pump (V144) using Output Diagnostic Test Mode. See OUTPUT 

DIAGNOSTIC TEST MODE . EVAP Leak Detection Pump (V144) should run in intervals (cycle on 
and off). If EVAP Leak Detection Pump (V144) does not run, go to next step.  

5. Disconnect EVAP Leak Detection Pump (V144) harness connector, install LED test light at EVAP leak 

detection pump harness connector terminal No. 2 and B+. See Fig. 37 . Turn ignition on. Using scan tool, 
activate EVAP Leak Detection Pump (V144). See OUTPUT DIAGNOSTIC TEST MODE . Turn 
ignition off. Install LED test light at EVAP leak detection pump harness connector terminal No. 3 and 
Ground. Turn ignition on. Using scan tool, activate EVAP Leak Detection Pump (V144). See OUTPUT 
DIAGNOSTIC TEST MODE 
. LED test light should flash during each test. If LED test light does not 
flash during each test, go to next step. If LED test light at EVAP Leak Detection Pump (V144) harness 
connector flashes during each test, replace faulty EVAP Leak Detection Pump (V144). Erase DTC 
memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE 
RELEARN PROCEDURE 
.  

NOTE:

Output Diagnostic Test Mode is used when using Scan Tools VAG 1551/1552 or 
VAS 5051/5052, always continue with output diagnostic test mode until last 
component in output diagnostic test mode test sequence has been checked. 
Follow scan tool manufacturer's instructions. 

NOTE:

When checking for leaks in EVAP system, pay particular attention to fuel 
tank filler cap, EVAP Canister Purge Valve (N80), EVAP Canister and EVAP 
canister hose connections. 

 

2003 Volkswagen New Beetle GLS 

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:49:57 AM

Page 101 

© 2004 Mitchell Repair Information Company, LLC. 

6. Turn ignition off. Disconnect ECM harness connector, leave ECM disconnected from test box. Connect 

Test Box (VAG 1598/31) to ECM harness connector. See CONNECTING VAG TEST BOX . Using 
DVOM, check resistance between the following EVAP Leak Detection Pump (V144) harness connector 
terminals and test box sockets. See Fig. 37 . 

z

EVAP Leak Detection Pump (V144) harness connector terminal No. 1 and test box socket No. 80.  

z

EVAP Leak Detection Pump (V144) harness connector terminal No. 2 and test box socket No. 25.  

z

EVAP Leak Detection Pump (V144) harness connector terminal No. 3 and Fuel Pump Relay (J17). 

Resistance should be a maximum of 1.5 ohms for each reading. Check harness connector wiring No. 1 
and 2 for short circuit to one another and all harness connector wiring for short circuit to ground and B+. 
Repair as necessary. Erase DTC memory. Verify repair. Test is complete. Perform ECM relearn 
procedure. See TEST DRIVE RELEARN PROCEDURE . If EVAP Leak Detection Pump (V144) 
wiring is okay, go to next step.  

7. Replace faulty ECM. See ENGINE CONTROL MODULE REMOVAL & INSTALLATION . Erase 

DTC memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE 
RELEARN PROCEDURE 
.  

Fig. 37: Identifying EVAP Leak Detection Pump (V144) Harness Connector Terminals 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DTC P0501/16885: VEHICLE SPEED SIGNAL - IMPLAUSIBLE SIGNAL

 

2003 Volkswagen New Beetle GLS 

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:49:57 AM

Page 102 

© 2004 Mitchell Repair Information Company, LLC. 

Test Requirements 

Ensure all fuses are okay, battery voltage is at least 11.5 volts, all electrical accessories are off, A/C is off. 
Engine is mechanically sound. Ensure engine coolant temperature is at least 176°F (80°C).  

Test Procedure 

1. Connect scan tool. See RETRIEVING DIAGNOSTIC TROUBLE CODES . Turn ignition on, engine 

off. Following scan tool manufacturer's instructions, check vehicle speed signal. Vehicle must be test 
driven to check speed signal. With help from a second person in the back seat to read scan tool, observe 
scan tool display. Scan tool display should be approximately driven speed. If no speed is displayed on 
scan tool, go to next step. If scan tool and speedometer displays approximately driven speed. Erase DTC 
memory. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE . If DTC 
P0501/16885 did not return on test drive, test is complete.  

2. Turn ignition off. Disconnect Engine Control Module (ECM) harness connector. Connect Test Box (VAG 

1598/31) to ECM harness connector, leave ECM disconnected. See CONNECTING VAG TEST BOX 
Raise one front wheel off the ground. Turn ignition on, engine off. Measure voltage between terminals 
No. 3 and 54 at test box while rotating front wheel. Voltage should fluctuate between zero and 4 volts. If 
voltage does not fluctuate, check Vehicle Speed sensor (G22) wiring for open and short circuits. See 
ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.  

3. If wiring is okay, replace faulty Vehicle Speed sensor (G22). With A/T see Fig. 38 . With M/T see Fig. 

39 . Erase DTC memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST 
DRIVE RELEARN PROCEDURE 
. If wiring is not okay, repair as necessary. Erase DTC memory. 
Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN 
PROCEDURE 
.  

 

2003 Volkswagen New Beetle GLS 

2001-2003 ENGINE PERFORMANCE Self-Diagnostics - 2.0L - Beetle, Golf & Jetta (Engine Codes AVH & AZG)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:49:57 AM

Page 103 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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