Volkswagen New Beetle. Manual - part 1887

 

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Volkswagen New Beetle. Manual - part 1887

 

 

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DTC P0606/16990: ECM (J220) - Malfunction  

Test Requirements 

Ensure battery is okay. 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.  

Test Procedure 

1. Check ECM ground and power supply. See ECM GROUND & VOLTAGE SUPPLY under ENGINE 

CONTROL MODULE (J220) ME SFI CONTROL MODULE. If ECM ground and voltage supply are 
okay, go to next step. If ECM ground and voltage supply 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 
.  

2. Replace ECM with known-good unit. Before disconnecting Engine Control Module (ECM - J220) record 

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

3. 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 and 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.  

4. After installing ECM perform following procedures: 

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Use scan tool to code new ECM. See ENGINE CONTROL MODULE (J220) CODING .  

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

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Perform adaptation of throttle valve control module. See THROTTLE VALVE CONTROL 
MODULE (J338) 
.  

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On vehicles equipped with cruise control, activate cruise control to ECM. See 
ACTIVATING/DEACTIVATING CRUISE CONTROL 

NOTE:

DTC P0601/16985, DTC P0602/16986, DTC P0604/16988 and DTC P0606/16990 
may set if battery voltage (ECM voltage supply) is to low when vehicle is being 
started. 

 

2003 Volkswagen New Beetle GLS 

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

  

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On vehicles equipped with A/T, perform adaptation of A/T to basic setting. See A/T BASIC 
SETTING 
.  

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On vehicles equipped with A/T, perform adaptation of kickdown switch. See ADAPTING 
KICKDOWN FUNCTION 
.  

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On vehicles equipped with factory alarm system, perform adaptation of immobilizer to ECM. See 
IMMOBILIZER .  

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Perform idle check. See IDLE CHECK .  

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Generate ECM readiness code. See READINESS CODE .  

P0638/17022: THROTTLE VALVE CONTROL MODULE (J338) - IMPLAUSIBLE SIGNAL 

Circuit/Component Description 

Throttle Valve Control Module (TVCM - J338) is located on throttle body. Throttle valve drive angle sensors 
and are located in TVCM (J338). ECM monitors throttle valve drive angle sensors for throttle valve position. 
ECM calculates throttle position based on percentage values sent by throttle valve drive angle sensors. Throttle 
valve drive angle sensors run in opposite directions of each other. Throttle Valve Drive Angle sensor No. 1 
(G187) displays throttle positions from 3-97 percent. Throttle Valve Drive Angle sensor No. 2 (G188) displays 
throttle positions from 97-3 percent. Throttle Valve Drive Angle sensor No. 1 (G187) ranges from 3-93 percent 
(0.15-4.65 volts), the larger the throttle opening the higher the percentage (voltage) reading. Throttle Valve 
Drive Angle sensor No. 2 (G188) ranges from 97-3 percent (4.90-0.15 volts), the larger the throttle opening the 
smaller the percentage (voltage) reading. When the engine is running (under load) the ECM can operate throttle 
valve independently of driver input.  

Test Requirements 

Ensure throttle valve is not damaged or dirty. 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. Ensure engine coolant temperature is at least 176°F (80°
C).  

Test Procedure 

1.  

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:

Test ranges for throttle valve drive angle sensors may not fully display on scan 
tool. No idle specifications for throttle valve drive angle sensors are given by 
manufacturer. 

NOTE:

If TVCM (J338) is replaced it must be adapted to the ECM and A/T control 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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

Page 171 

© 2004 Mitchell Repair Information Company, LLC. 

Turn ignition off. Disconnect TVCM (J338) 6-pin harness connector. Using DVOM check resistance 
between terminals No. 3 and 5 on TVCM. See Fig. 20 . Specification is one to 5 ohms. If resistance is 
okay, go to next step. If resistance is not okay, replace faulty TVCM. Erase DTC memory. Verify repair. 
Test is complete. Adapt TVCM (J338) to ECM (J220), see THROTTLE VALVE CONTROL 
MODULE (J338) 
. For vehicles with A/T, adapt TVCM (J338) to Transmission Control Module (J217), 
see A/T BASIC SETTING . On all models, perform ECM relearn procedure. See TEST DRIVE 
RELEARN PROCEDURE 
.  

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

off. Following scan tool manufacturer's instructions, observe percentage reading for Throttle Valve Drive 
Angle sensor No. 1 (G187) and Throttle Valve Drive Angle sensor No. 2 (G188).  

3. Operate accelerator pedal slowly to Wide Open Throttle and observe percentage (voltage) readings for 

Throttle Valve Drive Angle sensor No. 1 (G187) and Throttle Valve Drive Angle sensor No. 2 (G188). 
Specification for Throttle Valve Drive Angle sensor No. 1 (G187) is 3 to 93 percent (0.15 to 4.65 volts). 
Specification for Throttle Valve Drive Angle sensor No. 2 (G188) is 97 to 3 percent (4.90 to 0.15 volts). 
If throttle valve drive angle sensor tests are not okay, go to step 6 . If throttle valve drive angle sensor 
tests are okay, go to next step.  

4. Check APP sensors. See DTC P0226/16610: ACCELERATOR PEDAL POSITION SENSOR 1 

(G79) ACCELERATOR PEDAL POSITION SENSOR 2 (G185), IMPLAUSIBLE SIGNAL . If 
APP sensors are not okay, go to next step. If APP sensors are okay. Erase DTC memory. Perform ECM 
relearn procedure. See TEST DRIVE RELEARN PROCEDURE . If code did not return on test drive, 
test is complete.  

5. Replace APP sensors. Erase DTC memory. Verify repair. Test is complete. For vehicles with A/T, adapt 

APP sensors to Transmission Control Module (J217). See A/T BASIC SETTING . On all models, 
perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

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 TVCM (J338) 6-pin harness connector and test box sockets, see 
TVCM (J338) 6-PIN HARNESS CONNECTOR/VAG TEST BOX SOCKET IDENTIFICATION 
table. Record resistance readings. Resistance should be a maximum of 1.5 ohms for each reading. Check 
wiring in TVCM (J338) 6-pin harness connector for short circuits to one another, and for short circuits to 
B+ and ground. If resistance measurements are okay and no short circuits exist, go to next step. If any 
resistance measurement is not okay, or a short circuit exists, repair circuit(s) as necessary. After repairs, 
erase DTC memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE 
RELEARN PROCEDURE 

TVCM (J338) 6-PIN HARNESS CONNECTOR/VAG TEST BOX SOCKET IDENTIFICATION 

module (if equipped). 

TVCM 6-Pin Harness Connector Terminal 

VAG Test Box Socket 

92 

83 

117 

84 

118 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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7. Turn ignition on. Using DVOM, measure voltage between TVCM (J338) 6-pin harness connector 

specified terminals. See TVCM (J338) VOLTAGE SPECIFICATIONS table. See Fig. 33 . Record 
voltage readings. If voltage readings are not okay, go to next step. If voltage readings are okay, resistance 
measurements are okay and no short circuits exist, replace faulty TVCM. After repairs, erase DTC 
memory. Verify repair. Test is complete. Adapt TVCM (J338) to ECM (J220). See THROTTLE 
VALVE CONTROL MODULE (J338) 
. For vehicles with A/T, adapt TVCM (J338) to Transmission 
Control Module (J217), see A/T BASIC SETTING . On all models, perform ECM relearn procedure. 
See TEST DRIVE RELEARN PROCEDURE 

TVCM (J338) VOLTAGE SPECIFICATIONS 

8. Check ECM voltage supply. See ECM GROUND & VOLTAGE SUPPLY under ECM (J220) ME SFI 

CONTROL MODULE. If ECM ground circuits and ECM voltage supply are okay, go to next step. If 
ECM ground circuits and/or ECM voltage supply 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 
.  

9. 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 
.  

P0642/17026: KNOCK SENSOR - ECM MALFUNCTION (PASSAT) 

Test Requirements 

Ensure battery is okay. 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.  

Test Procedure 

1. Check ECM ground and power supply. See ECM GROUND & VOLTAGE SUPPLY under ENGINE 

CONTROL MODULE (J220) ME SFI CONTROL MODULE. If ECM ground and voltage supply are 
okay, go to next step. If ECM ground and voltage supply 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 
.  

91 

TVCM 6-Pin Harness Connector Terminals 

Voltage 

2 & Ground 

Minimum 4.5 

2 & 6 

Minimum 4.5 

NOTE:

DTC P0642/17026 is for Passat only. 

NOTE:

DTC P0601/16985, DTC P0602/16986, DTC P0604/16988, DTC P0606/16990 and 
DTC P0642/17026 may set if battery voltage (ECM voltage supply) is to low when 
vehicle is being started. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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

Page 173 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  1885  1886  1887  1888   ..