Volkswagen New Beetle. Manual - part 1912

 

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Volkswagen New Beetle. Manual - part 1912

 

 

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

off. Following scan tool manufacturer's instructions, check ABS system for DTCs. If no DTCs are 
present, go to next step. If DTC(s) are present, repair as necessary. After repairs, erase DTC memory. 
Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN 
PROCEDURE 
.  

2. Check wiring between ABS control module and ECM for open or short. See appropriate WIRING 

DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. See Fig. 61 , Fig. 62
and Fig. 63 . If wiring is okay, go to next step. If wiring is not okay, repair as necessary. After repairs, 
erase DTC memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE 
RELEARN PROCEDURE 
.  

3. Check centralized matching resistor in ECM. Turn ignition off. Connect ECM to test box, leave ECM 

harness connector disconnected from test box. Connect Test Box (VAG 1598/31). See CONNECTING 
VAG TEST BOX 
. Using DVOM, check resistance between test box sockets No. 58 and 60. Resistance 
should be 60-72 ohms. If resistance is not okay, replace faulty ECM. See ENGINE CONTROL 
MODULE REMOVAL & INSTALLATION 
. After repairs, erase DTC memory. Verify repair. Test is 
complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

DTC P1609/18017: CRASH SIGNAL FROM AIR BAG CONTROL MODULE (J234) 

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 

Check Air Bag Control Module (J234) for DTC(s). See DIAGNOSTICS in appropriate AIR BAG RESTRAINT 
SYSTEMS article, under RESTRAINTS. If DTC(s) are present, repair as necessary. After repairs, erase DTC 
memory. Verify repair. Test is complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN 
PROCEDURE 
.  

NOTE:

This code can be set while performing an emissions test where front wheels are 
rotated and rear wheels are stationary. Remove ABS control module fuse before 
performing this type of emissions test. 

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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DTC P1610/18018: 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. Ensure engine coolant temperature is at least 176°
F (80°C).  

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: 

z

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. 

z

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. 

z

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: 

z

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

z

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

z

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

z

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

z

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

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

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z

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

z

Perform idle check. See IDLE CHECK .  

z

Generate ECM readiness code. See READINESS CODE .  

DTC P1612/18020: ECM (J220) - INCORRECTLY CODED 

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. Ensure engine coolant temperature is at least 176°
F (80°C).  

ECM Coding 

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

DTC P1615/18023: OIL LEVEL SENSOR (G266) - IMPLAUSIBLE SIGNAL (PASSAT) 

Test Requirements 

Ensure oil level is correct. 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. Check wiring between Oil Level Sensor (G266) and Instrument Cluster Control Module (J285), for open 

or short circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM 
WIRING DIAGRAMS. If wiring is okay, go to next step. If wiring is 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 faulty Oil Level Sensor (G266). After repairs, erase DTC memory. Verify repair. Test is 

complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

DTC P1620/18028, DTC P1621/18029 & DTC P1622/18030 

Code Definition 

NOTE:

DTC P1615/18023 is for Passat only. 

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 

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

  

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z

DTC P1620/18028: ECT Sensor - Open Circuit/Short To B+  

z

DTC P1621/18029: ECT Sensor - Short To Ground  

z

DTC P1622/18030: ECT Sensor - Implausible Signal  

Test Requirements 

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 system and engine coolant system thermostat are in good working order.  

Test Procedure - (Beetle - Engine Code AWV) 

1. Disconnect ECT sensor harness connector. See Fig. 26 . Using DVOM, measure resistance of ECT sensor 

between ECT sensor terminals No. 1 and 3. See Fig. 27 . See ECT SENSOR (G62) RESISTANCE 
table. If ECT sensor resistance is okay, reconnect ECT sensor harness connector. Go to next step. If 
resistance is not okay, replace faulty ECT sensor. After repairs, erase DTC memory. Verify repair. Test is 
complete. Perform ECM relearn procedure. See TEST DRIVE RELEARN PROCEDURE .  

2. Connect Scan Tool. See RETRIEVING DIAGNOSTIC TROUBLE CODES . Turn ignition on. Using 

scan tool, check ECT sensor temperature value. If ECT sensor temperature value deviates greatly from 
ECT sensor ambient temperature, go to step 4 . If ECT sensor temperature value is approximately the 
same as ECT sensor ambient temperature, go to next step.  

3.  

Start engine and idle. Using scan tool, observe ECT sensor temperature value. Temperature value should 
steadily increase. If ECT sensor temperature value did not steadily increase, replace faulty ECT sensor. 
After repairs, erase DTC memory. Verify repair. Test is complete. Perform ECM relearn procedure. See 
TEST DRIVE RELEARN PROCEDURE 

WARNING:

To avoid injury, allow cooling system to cool and carefully release system 
pressure. 

NOTE:

Engine must be cold before performing test procedure. 

NOTE:

To bleed cooling system, fill cooling system. Warm engine to operating 
temperature, (run engine until coolant fan starts), do not allow engine to 
overheat, let engine cool and recheck coolant level. 

NOTE:

Next test step tests ECT sensor through its full range. 

NOTE:

Scan Tool (VAG 1551) and (VAG 1552) displays temperature in 1 to 1.5 
degree increments. If engine does not run smoothly in certain temperature 
ranges and temperature value does not increase without interruption, 
signal is intermittent. ECT sensor must be replaced. After repairs, erase 
DTC memory. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:44:56 AM

Page 273 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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