Volkswagen New Beetle. Manual - part 1856

 

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Volkswagen New Beetle. Manual - part 1856

 

 

Fig. 14: Locating Engine Control System Components (Passat - 1.8L Turbo) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

CONNECTOR IDENTIFICATION 

Connector location and pin test points are referenced in the individual DTC test procedures. Connector locations
are also referenced in component locating illustrations. See appropriate SYSTEM & COMPONENT TESTING 
article.  

NOTE:

Alpha-numeric identification in MANUFACTURER'S COMPONENT ALPHA-
NUMERIC IDENTIFICATION table is only a partial list. These are the components 

 

2003 Volkswagen New Beetle GLS 

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

  

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MANUFACTURER'S COMPONENT ALPHA-NUMERIC IDENTIFICATION 

pertaining to engine performance. 

Component 

Alpha-Numeric 

Identification 

ABS Control Module 

J104 

ABS Warning Light 

K47 

Accelerator Position Sensor 1 

G79 

Accelerator Position Sensor 2 

G185 

Air Bag Control Module 

J234 

Air Bag Warning Light 

K75 

AC Control Module 

J255 

Angle Sensor 1 For Throttle Valve Drive 

G187 

Angle Sensor 2 For Throttle Valve Drive 

G188 

Barometric Pressure Sensor (Inside ECM) 

G96 

Brake Booster Sensor 

G294 

Brake Light Switch 

Brake Pedal Switch 

F47 

Brake Vacuum Pump Motor 

V192 

CAN Data Bus Interface (Gateway) 

J533 

Camshaft Position Sensor 

G163 

Charge Air Pressure Sensor 

G31 

Clutch Pedal Switch 

F36 

Comfort Systems Central Control Module 

J393 

ECM 

J220 

ECM Power Supply Relay 

J271 

ECT Sensor 

G62 

Engine Coolant Level Sensor 

G32 

Engine Speed (RPM) Sensor 

G28 

EPC Warning Light 

K132 

EVAP Canister Purge Valve 

N80 

EVAP Leak Detection Pump 

V144 

Fuel Pump 

G6 

Fuel Pump Relay 

J17 

HO2S Upstream TWC 

G39 

HO2S Downstream TWC 

G130 

IAT Sensor 

G42 

Ignition Coil With Power Output Stage 

N70, N127, N129 & N292 

Immobilizer Induction Coil 

D2 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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DIAGNOSTIC TESTS 

TESTING PRECAUTIONS 

Immobilizer Warning Light 

K117 

Injectors 

N30-N33 

Instrument Cluster Control Module (Also Used By 
Immobilizer) 

J285 

Knock Sensor 1 

G61 

Knock Sensor 2 

G66 

MAF Sensor 

G70 

Malfunction Indicator Light 

K83 

Oil Level Sensor 

G266 

Oil Pressure Switch 

F1 

Oil Pressure Warning Light 

K3 

Power Steering Switch 

F88 

Recirculating Valve For Turbocharger 

N249 

Secondary Air Injection Valve 

N112 

Secondary Air Pump Motor 

V101 

Secondary Air Pump Relay 

J299 

Steering Control Module 

J453 

Steering Sensor 

G85 

Throttle Valve Control Module 

J338 

Throttle Valve Drive 

G186 

Transmission Control Module (Automatic Transmission) 

J217 

Valve For Camshaft Adjustment 

N205 

Vehicle Speed Sensor (Speedometer) 

G22 

Wastegate By-Pass Regulator Valve 

N75 

WARNING:

For safety during road test, it is advisable to have a helper operate tester 
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. 

WARNING:

Always use jack stands or hoist safeties when working on a raised 
vehicle. 

WARNING:

On some models fuel pump is activated by door contact switch. Always 
remove fuel pump fuse before opening fuel system. See appropriate 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING 
DIAGRAMS. 

WARNING:

Turbocharger and related components operate at a very high 
temperature. Always allow system to cool or use proper protective 
clothing to prevent severe burns. 

CAUTION: Perform all resistance and voltage tests with a Digital Volt-ohmmeter 

(DVOM) with minimum 10-megohm impedance, unless stated otherwise in 
test procedures. Ensure ignition switch is in OFF position when 
performing resistance tests. 

NOTE:

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

NOTE:

Before replacing any component, verify battery voltage is a minimum of 11.5 
volts and all fuses are okay. Ensure all wiring is okay and connectors at 
component and ECM are clean and tight. When codes have been cleared or 
voltage supply to ECM has been interrupted, ECM loses all "learned" and 
"basic" values. Serious driveability problems may occur depending on vehicle 
mileage. After reconnecting ECM, it is necessary to perform relearn procedure. 
See TEST DRIVE RELEARN PROCEDURE . 

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 . 

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 e.g. loose 
harness connector or an intermittently open circuit. If a sporadic malfunction 
does not occur again within 40 warm-up phases, sporadic DTC(s) 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). 

NOTE:

To properly diagnose vehicle, vehicle manufacturer recommends use of Scan 
Tool (VAG 1551/1552 or VAS 5051/5052) and Test Box (VAG 1598). Following 
test procedures are using Scan Tool (VAG 1551 or 1552) and Test Box (VAG 
1598). Test box terminal numbers and ECM terminal numbers are identical. To 
identify connector terminal wire colors, see appropriate WIRING DIAGRAM 
under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:44:32 AM

Page 49 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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