Volkswagen New Beetle. Manual - part 745

 

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Volkswagen New Beetle. Manual - part 745

 

 

1998-2004 BRAKES

On Board Diagnostic (OBD) - New Beetle 

ITT MARK 20 IE ON BOARD DIAGNOSTIC (OBD), GENERAL INFORMATION 

FUNCTION 

Since the control modules are interconnected with a Controller Area Network bus (CAN-bus), always start 
troubleshooting by pressing buttons -0- and -0- to insert "Automatic Test Sequence" address word 00. This 
checks DTC memory for all control modules in the vehicle, including those that may influence the ABS system 
in case of malfunction. 

On Board Diagnostic (OBD) relates to the electrical and electronic components of the ABS; in other words, 
only malfunctions pertaining to the electrical connections to the control module are recognized (e.g. wheel 
speed sensor, open circuit). 

The 25-pin ABS Control Module (w/EDL) -J104- and the ABS hydraulic unit together form a compact module. 
The control module is equipped with DTC memory, and is located on the left side of the engine compartment. 
The Data Link Connector (DLC) is located left of the steering column under the instrument panel. Only early 
production cars DLC is in the center console below the heating and air conditioning controls. 

The control module recognizes malfunctions during vehicle operation and stores them as Diagnostic Trouble 
Codes (DTC) in permanent memory. The DTCs remain in memory if the voltage from the battery is interrupted.

Sporadic malfunctions will also be recognized and stored. If these do not occur again within the next 50 vehicle 
starts and driving cycles DTC memory will be erased (with the exception of "Control Module Malfunctioning").

Sporadic malfunctions are identified as such by "/SP" appearing on the VAG1551 Scan Tool (ST) display. 

After switching the ignition on and/or starting the engine, ABS warning light -K47- and brake system warning 
lamp -K118- (red) lights up for approx. 2 seconds. During this period a test sequence (self-test) is run in the 
control module, checking the following: 

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Voltage supply (at least 10.0 volts)  

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Control module, including valve windings  

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Wheel speed sensor; electrical check fully completed at 20 km/h (approx. 13 mph)  

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Control module coding  

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If after driving off and exceeding a speed of approx. 20 km/h (approx. 13 MPH) the speed signal is not 
OK. The ABS warning light -K47- will light up again.  

VAG1551 Scan Tool (ST) or tester VAS 5051 

The On Board Diagnostic (OBD) program must be initiated at the start of troubleshooting. Electrical 
malfunctions which influence braking characteristics will be stored, and can only be checked with the 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

VAG1551 Scan Tool (ST) or with the tester VAS 5051.

The following procedures refer only to the VAG1551 scan tool. 

The malfunction information displayed is used in conjunction with a DTC table, which has information on the 
possible cause of malfunctions and specific corrective actions. 

IDENTIFICATION 

Left-hand drive 

The brake booster boost is produced by vacuum pressure. 

Distinguishing features: 

1. 10" brake booster  

2. Hydraulic unit  

3. Control module, 25-pin (bolted to hydraulic unit)  

Fig. 1: Identifying ABS Left-Hand Drive Distinguishing Features (ITT Mark 20 IE) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Right-hand drive 

The brake booster boost is produced by vacuum pressure. 

Distinguishing features: 

1. 7"/8" brake booster  

2. Hydraulic unit  

3. Control module, 25-pin (bolted to hydraulic unit) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

Fig. 2: Identifying ABS Right-Hand Drive Distinguishing Features (ITT Mark 20 IE) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Distinguishing features of ABS & ABS/EDL (ITT Mark 20 IE hydraulic unit), left and right-hand drive 

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Dimension -A-: 100 mm (vehicles with ABS)  

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Dimension -A-: 130 mm (vehicles with ABS/EDL)  

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Dimension -A: -130 mm vehicles with ABS/EDL/ASR 

Fig. 3: Distinguishing Features Of ABS & ABS/EDL (ITT Mark 20 IE hydraulic unit) - Left And 
Right-Hand Drive
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

TECHNICAL DATA 

ABS Control Module (w/EDL) -J104- 

When checking DTC memory, the control module identification will be displayed on the VAG1551 scan tool. 

1J0 907 379D: ABS 

1J0 907 379 E: ABS/EDL 

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

1 J0 907 379 R / J - ABS/EDL/ASR 

Diagnostic Trouble Code (DTC) memory 

Permanent memory (DTC memory) contents remain even without a supply voltage. 

Data output 

Data output is achieved using "Rapid data transfer" operating mode 1. 

SAFETY PRECAUTIONS AND GENERAL TROUBLESHOOTING INFORMATION 

Necessary technical information 

See SYSTEM WIRING DIAGRAMS in ELECTRICAL.  

See DISC and ANTI-LOCK BRAKE SYSTEM . 

Road test 

CAUTION:

z

ABS is a vehicle safety system; the appropriate knowledge is 
necessary to work on the system.  

z

In order to check complaints and to be able to carry out specific 
troubleshooting, DTC memory must be checked before beginning 
work on the ABS system.  

z

Only disconnect harness connectors when the ignition is switched 
off.  

z

Observe the appropriate instructions regarding the handling of brake 
fluid, see SAFETY PRECAUTIONS . 

See . 

z

ABS malfunctions are indicated by the ABS warning lamp lighting 
up; certain malfunctions will only be recognized at speeds above 20 
km/h (approx. 13 mph) (road test).  

z

If the ABS Warning Light -K47- and the warning light for brake 
system -K118- warning lamps do not light up, but the brake system is 
not functioning correctly, check the conventional braking system.  

WARNING:

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If you drive the vehicle after a malfunction has been detected by 
OBD, bear in mind that the function of the brake system is limited, 
and there is a risk of accident. The brake pressure at the rear wheels 
is no longer controlled by the Electronic Brake Distribution (EBD) 
function. This can result in excessive braking at the rear, and the 
vehicle may skid unexpectedly under braking.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

 

 

 

 

 

 

 

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