Volkswagen New Beetle. Manual - part 1846

 

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Volkswagen New Beetle. Manual - part 1846

 

 

Fig. 3: Locating Malfunction Indicator Light & Electronic Power Control Warning Light (GTI, Jetta & 
Passat)
 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

MALFUNCTION INDICATOR LIGHT CHECK 

With key in the on position, if MIL does not illuminate. Check for codes, see RETRIEVING DIAGNOSTIC 
TROUBLE CODES 
, repair as necessary. If no DTCs are present, check wiring and instrument cluster MIL. 
See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.  

If MIL is illuminated with engine running, turn engine off. Check for codes, see RETRIEVING 
DIAGNOSTIC TROUBLE CODES 
, repair as necessary. If no DTCs are present, check wiring and 

NOTE:

Instrument Cluster Control Module (J285) and Can Data Bus OBD Interface 
(J533) are integral parts of the instrument cluster. If instrument cluster is 
replaced, Can Data Bus OBD Interface (J533) must be coded. See CAN DATA 
BUS OBD INTERFACE (J533) CODING . 

 

2003 Volkswagen New Beetle GLS 

2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

  

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instrument cluster MIL. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM 
WIRING DIAGRAMS.  

ELECTRONIC POWER CONTROL WARNING LIGHT (K132) 

Components that make up the EPC system are the ECM and EPC warning light. The Throttle Valve Drive 
(G186), Angle Sensor 1 for throttle valve drive (G187) and Angle Sensor 2 for throttle valve drive (G188) are 
an integral part of Throttle Valve Control Module (J338). Accelerator Position Sensor 1 (G79) and Accelerator 
Position Sensor 2 (G185) are together in 1 unit and are located in accelerator pedal assembly.  

MIL and EPC warning light both illuminate when a system failure has been detected in the EPC system. DTC is 
also stored in ECM memory. For location of EPC warning light, see Fig. 3 and Fig. 4 .  

Fig. 4: Locating Electronic Power Control Warning Light (Beetle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Electronic Power Control (EPC) is Volkswagen's name for their electronic 
throttle drive system. Also referred to as E-Gas System by Volkswagen. 

NOTE:

Instrument Cluster Control Module (J285) and Can Data Bus OBD Interface 
(J533) are integral parts of the instrument cluster. If instrument cluster is 
replaced, Can Data Bus OBD Interface (J533) must be coded. See CAN DATA 
BUS OBD INTERFACE (J533) CODING . 

 

2003 Volkswagen New Beetle GLS 

2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

  

Helpmelearn Repair Manuals 

 

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ELECTRONIC POWER CONTROL WARNING LIGHT CHECK 

With key in the on position, if EPC does not illuminate. Check for codes, see RETRIEVING DIAGNOSTIC 
TROUBLE CODES 
, repair as necessary. If no DTCs are present, check wiring and instrument cluster for 
EPC. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING 
DIAGRAMS.  

If EPC is illuminated with engine running, turn engine off. Check for codes, see RETRIEVING 
DIAGNOSTIC TROUBLE CODES 
, repair as necessary. If no DTCs are present, check wiring and 
instrument cluster for EPC. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in 
SYSTEM WIRING DIAGRAMS.  

TESTING PROCEDURES 

Diagnosis of engine control system should be performed in the following order:  

1. Perform a visual inspection, see VISUAL INSPECTION article. Ensure all engine systems not related to 

ECM are operating properly. Check for any Technical Service Bulletins (TSBs) that may apply. DO NOT 
proceed with testing unless all engine problems not related to ECM have been repaired.  

2.  

Start engine and check MIL. If MIL flashes, this indicates malfunctions that may cause catalytic 
converter damage (e.g. misfire). If MIL flashes or stays on, enter diagnostics and determine if DTCs are 
present. See RETRIEVING DIAGNOSTIC TROUBLE CODES . If DTCs were displayed, determine 
whether codes are hard or sporadic malfunctions (intermittent codes). Hard codes will cause MIL to 
illuminate continuously while engine is running. See ON-BOARD DIAGNOSTICS .  

3. For diagnosing hard codes, proceed to appropriate DTC test. See DIAGNOSTIC TROUBLE CODE 

IDENTIFICATION . When diagnosing sporadic malfunctions (intermittent codes), using Scan Tool 
VAG 1551/1552 or VAS 5051/5052 most sporadic malfunctions (intermittent codes) will display 
with /SP (sporadic malfunction) after code. If there is a driveability problem and MIL comes on and than 
goes off, but no code is stored, proceed to INTERMITTENTS in appropriate TROUBLE SHOOTING - 
NO CODES article.  

4. If MIL stays on, and no DTCs are present, or if MIL does not come on, check MIL. See 

MALFUNCTION INDICATOR LIGHT CHECK .  

5. If no DTCs are present and a driveability problem exists, refer to INTERMITTENTS in appropriate 

TROUBLE SHOOTING - NO CODES article. Doing so will help identify proper system or component 
to check. See appropriate SYSTEM & COMPONENT TESTING article for diagnosis of faulty 
component.  

6. After necessary repairs are made, perform ECM test drive relearn procedure. See TEST DRIVE 

RELEARN PROCEDURE .  

VISUAL INSPECTION 

NOTE:

Read and record DTCs before starting diagnostic work, (some testing 
procedures will set DTCs). 

 

2003 Volkswagen New Beetle GLS 

2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

  

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Prior to retrieving DTCs, perform a comprehensive visual inspection of underhood components. Check ground 
connections located on intake manifold, ground cable between engine and vehicle body and that battery cables 
are clean and tight. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM 
WIRING DIAGRAMS.  

Check vacuum hoses for breakage and blockage. Check electrical wiring and harness connectors for damage 
and corrosion. Repair as necessary. Ensure all engine systems not related to ECM are operating properly. Check 
for any Technical Service Bulletins (TSBs) that may apply. DO NOT proceed with testing unless all engine 
problems not related to ECM have been repaired. Go to step 2 under TESTING PROCEDURES.  

RETRIEVING DIAGNOSTIC TROUBLE CODES 

Generic Scan Tool 

1. Turn ignition off. Connect scan tool to diagnostic connector located under left side of dashboard. See Fig. 

1 . Follow scan tool manufacturer instructions for reading DTCs. To identify DTCs, see DIAGNOSTIC 
TROUBLE CODE IDENTIFICATION 
. If no DTCs are present and driveability problem exists, refer 

NOTE:

Read and record DTCs before starting diagnostic work, some testing 
procedures will set DTCs. If no DTCs are stored, do not erase memory, erasing 
DTC memory will cause readiness code to be erased. If ignition is switched off 
between "Retrieving Diagnostic Trouble Codes" and "Clearing Diagnostic 
Trouble Codes" the DTC memory will not be erased, repeat "Retrieving 
Diagnostic Trouble Codes" procedure. 

NOTE:

It is recommended that all control modules in the CAN Data Bus are checked for 
DTCs before starting and after performing DTC testing and repair work (during 
test and assembly work malfunctions can be recognized from other control 
modules like e.g. harness connector disconnected). See AUTOMATIC TEST 
SEQUENCE . 

NOTE:

Manufacturer recommends use of Scan Tool VAG 1551/1552 or VAS 5051/5052. 
Generic scan tool may not be able to perform all test functions. If engine does 
not start, (this test requires using Scan Tool VAG 1551/1552 or VAS 5051/5052). 
Connect scan tool. Operate starter for approximately 6 seconds, do not switch 
ignition off. Turn on scan tool printer. Operate scan tool, according to scan tool 
display information. Check for DTCs. 

NOTE:

When using Scan Tool VAG 1551/1552 or VAS 5051/5052, malfunctions which 
only occur sporadically (intermittently) will have the addendum sporadic 
(intermittent) malfunction on the print out and will be indicated on the display 
by the addendum /SP. Cause of sporadic malfunctions can be a loose harness 
connector or an intermittently open circuit. If a sporadic malfunction does not 
occur again within 40 warm-up phases, sporadic DTCs will be erased from ECM 
memory. A warm-up phase is, engine started with coolant temperature below 
122°F (50°C) - switched off at above 162°F (72°C). 

 

2003 Volkswagen New Beetle GLS 

2002-2003 ENGINE PERFORMANCE Self-Diagnostics - 1.8L Turbo

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:44:27 AM

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© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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