Volkswagen New Beetle. Manual - part 1848

 

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Volkswagen New Beetle. Manual - part 1848

 

 

Generating Readiness Code (Generic Scan Tool) 

1. If possible it is best to warm-up vehicle by test driving. Connect scan tool to DLC. DLC is located at left 

side of steering column. See Fig. 1 .  

2. Follow scan tool manufacturer's instructions and generate Readiness Code. See Fig. 5 . Readiness code 

should display -0 0 0 0 0 0 0 0-. If readiness code does not display as specified, generate Readiness Code. 

Generating Readiness Code (Scan Tool VAG 1551/1552 Or VAS 5051/5052) 

1. If during a Work Step test result "OK" is indicated immediately after a display group was selected, test is 

finalized already. Proceed with next work step. When Generating Readiness Code and going from one 
Work Step to the next, DO NOT move ignition key into off position.  

2. If possible it is best to warm-up vehicle by test driving. Connect scan tool to DLC. DLC is located at left 

side of steering column. See Fig. 1 . Turn ignition on, engine off. Using scan tool, retrieve DTCs. See 
RETRIEVING DIAGNOSTIC TROUBLE CODES . If DTCs are stored. Repair as necessary. See 
DIAGNOSTIC TROUBLE CODE IDENTIFICATION . If no DTCs are stored, press right arrow key. 

3. Using scan tool, clear DTC memory. See CLEARING DIAGNOSTIC TROUBLE CODES . After 

clearing codes, press right arrow key.  

4. Adapt Throttle Valve Control Module (J338). See ADAPTING THROTTLE VALVE CONTROL 

MODULE (J338) TO ECM (J220) . Go to next step.  

5. Start engine and idle. DO NOT move ignition key into off position during remaining steps.  

6.  

EVAP Leak Detection - Allow engine to run at idle. Press keys "0", "7" and "0" for display group 70 and 
enter by pressing "Q" key. When diagnostic test for EVAP Leak Detection is initiated, display field 4 will 
change from "Test OFF" to "Test ON". Allow engine to run at idle until display field 4 changes to "TVV 

it is advisable to have a helper operate or observe scan tool from rear 
seat. If test and measuring instruments are operated from front 
passenger's seat and vehicle is involved in an accident, there is a 
possibility the person sitting in this seat may receive serious injuries 
when air bag is deployed. 

NOTE:

If ignition is turned off at any time while Generating Readiness Code, Readiness 
Code will not be generated. When DTC memory is erased or ECM looses power 
Readiness Code is also erased. 

NOTE:

During readiness code generating procedure, if test result is indicated as "OK" 
after selecting a display group, testing has already been carried out and it is 
okay to proceed to next work step. 

NOTE:

There must be no load on engine for EVAP Leak Detection diagnostic to 
function. If "TVV n.OK" and/or "Syst. n.OK" displays in "Specified value" 
window in display field 4, check for DTCs. See DIAGNOSTIC TROUBLE 
CODE IDENTIFICATION . Repair as necessary. 

 

2003 Volkswagen New Beetle GLS 

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

  

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OK". If "TVV OK" displays in "Specified value" window of display field 4, press "3" key (VAG 1551), 
up arrow (VAG 1552, VAS 5051 and VAS 5052) for Display group 071. Allow engine to run at idle for 
30 seconds, display field 4 should change from "Test OFF" to "Test ON". Allow engine to run at idle 
until "Specified value" in display field 4 changes to "Syst. OK". If "Syst. OK" is displayed, press right 
arrow key and check next component. If display field 4 changes from "Test ON" to "Test OFF"during 
EVAP Leak Detection and "Abort" displays in display field 2, open and retighten fuel filler cap and 
repeat EVAP Leak Detection diagnostic. DO NOT move ignition key into off position.  

7. HO2 Sensor Aging (Cycle Duration Monitor) - Allow engine to run at idle. Press keys "0" and "8" for 

"Read Measuring Value Block" and enter by pressing Q key. Press keys "0", "3" and "4" for display 
group 34 and enter by pressing "Q" key. Set engine speed to 1800-2500 RPM using pedal prop. Maintain 
1800-2500 RPM until display field 2 increases to above 665° F (352° C), (this may take a few minutes). 
Continue to maintain 2200-2800 RPM until "B1-S1 OK" appears in display field 4. If "B1-S1 OK" is 
displayed in display field 4, press "C" key and go to next step. If "B1-S1 OK" is not displayed in display 
field 4, check for DTCs. See DIAGNOSTIC TROUBLE CODE IDENTIFICATION . Repair as 
necessary.  

8. Secondary Air Injection - Allow engine to run at idle. Press keys "0" and "4" for "Basic Setting", and 

enter by pressing "Q" key. Press keys "0", "7" and "7" for display group 77 and enter by pressing "Q" 
key. When diagnostic test for Secondary Air Injection (AIR) System is initiated, display field 4 will 
change from "Test OFF" to "Test ON". Allow engine to run at idle until display field 4 changes to "Syst. 
OK". If "Syst. OK" displays in "Specified value" window of display field 4, AIR System is okay. Press 
"C" key and check next component. If "Syst. n.OK" is displayed, AIR System is not okay. Check for 
DTCs. See DIAGNOSTIC TROUBLE CODE IDENTIFICATION . Repair as necessary.  

9.  

TWC Diagnostic - Allow engine to run at idle. Press keys "0", "4" and "6" for display group 46 and enter 
by pressing "Q" key. Set engine speed to 1800-2500 RPM using pedal prop. Maintain 1800-2500 RPM 
until TWC temperature in display field 2 increases to above 665° F (352° C) and "Test OFF" changes to 
"Test ON" in display field 4. Continue to maintain 1800-2500 RPM until "Cat B1 OK" appears in display 
field 4. Press right arrow key. Press keys "0", and "6" for function "End Output" and enter by pressing 
"Q" key. If "Cat B1 OK" is not displayed in display field 4, check for DTCs. See DIAGNOSTIC 
TROUBLE CODE IDENTIFICATION 
. Repair as necessary. If "Cat B1 OK" is displayed in display 
field 4. Turn ignition off.  

10. Read Readiness Code - See READING READINESS CODE 

NOTE:

Diagnostic of TWC takes approximately 100 seconds. If there is still no 
result in the display after 150 seconds, change engine speed within 1800-
2500 RPM range. 

 

2003 Volkswagen New Beetle GLS 

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

  

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Fig. 5: Identifying Readiness Code 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

IDLE CHECK 

1. Before checking idle. There must be no exhaust leaks in between cylinder head and catalytic converter. 

Coolant temperature needs to be greater than 176°F (80°C). Battery voltage needs to be greater than 11.5 
volts. All electrical consumers and A/C need to be switched off. Vehicle in park or neutral, with parking 
brake on.  

2. Connect scan tool to DLC. DLC is located at left side of steering column. See Fig. 1 . Start engine and 

idle. Using scan tool check for DTCs in memory. See RETRIEVING DIAGNOSTIC TROUBLE 
CODES 
. If any DTCs are present, repair as necessary and clear codes, see CLEARING DIAGNOSTIC 
TROUBLE CODES 
.  

3. Briefly increase engine RPM to 3500 and let idle for two minutes. Using scan tool, follow scan tool 

manufacturer instructions to check idle speed. See IDLE SPECIFICATIONS table.  

IDLE SPECIFICATIONS 

IDLE SPEED ADJUSTMENT 

Model 

Engine Code 

RPM 

Beetle 

AWV 

640-820 

Beetle A/T 

APW 

640-760 

Beetle M/T 

APW 

700-840 

GTI A/T 

APW 

640-760 

GTI M/T 

APW 

700-840 

Jetta A/T 

APW 

640-760 

Jetta M/T 

APW 

700-840 

Passat 

AWM 

740-920 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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Using scan tool, follow scan tool manufacturer's instructions to adjust idle speed. Using scan tools VAG 
1551/1552 or VAS5051/5052 this is done in Adaption/Channel 1 VAG 1551 keys 1 and 3 moves RPM up or 
down in 10 RPM increments. VAG 1552, VAS 5051 or VAS 5052 uses up and down arrows to move RPM up 
or down in 10 RPM increments. See IDLE SPECIFICATIONS table. Initiate A/T basic setting, see A/T 
BASIC SETTING 
.  

ENGINE CONTROL MODULE (J220) - ME SFI CONTROL MODULE 

Mixture Self-Adaptation 

The Motronic ME-SFI engine control system regulates air/fuel mixture at a constant 14.7:1 under all engine 
operating conditions. System automatically compensates for engine wear, injector wear, minor air leaks, and to 
some degree inaccurate sensors. This automatic control has upper and lower compensating limits. When a lower 
limit is not reached or an upper limit is exceeded a DTC is set.  

The amount of correction is constantly calculated and permanently stored. After a repair, Motronic ME-SFI 
control module will automatically adapt again.  

Removal & Installation 

1. Replace ECM with known-good unit. Before disconnecting Engine Control Module (ECM) record code 

and identification number from ECM that is to be replaced. See ECM CODING . Go to next step.  

2. To remove ECM see specific model below: 

Beetle 
Turn ignition off. Move center dash panel forward and up. See Fig. 6 . Remove center dash panel. 
Remove screw for left front dash cover. Lift cover at right side and pull to right to remove. Press 
retaining tab to left and pull ECM out. Release lock tab for harness connector and disconnect 
harness connector. Remove ECM. Install ECM. 

GTI & Jetta 
Turn ignition off. Remove wiper arms and cowl panel. Release lock tab for harness connector and 
disconnect harness connector. Remove ECM. Install ECM. 

Passat 
Turn ignition off. ECM is located at left rear of engine compartment. Remove ECM protective 
cover and retaining bracket, see Fig. 7 . Release lock tab for harness connector and disconnect 
harness connector. Remove ECM. Install ECM.  

3. After installing ECM perform following procedures: 

z

Use scan tool to check DTC memory, erase if necessary. See CLEARING DIAGNOSTIC 

NOTE:

In exceptional circumstances (e.g. customer complaints concerning droning 
noises and/or vibrations at idling speed), it is permitted to adjust idling speed 
slightly. Ensure that idling speed is not outside the specified idling range. (If the 
speed is outside tolerance range it is possible that vehicle will fail the next 
exhaust emissions test). 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:44:28 AM

Page 17 

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