Volkswagen New Beetle. Manual - part 774

 

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Volkswagen New Beetle. Manual - part 774

 

 

FUNCTIONAL CHECK: WARNING LIGHT FOR BRAKE SYSTEM K118 

sensor -G251- 

wiring

z

Disconnect connector for 

longitudinal acceleration sensor -

G251-  

 

 

 

z

Disconnect multi-pin connector 

T25 from control module 

(w/EDL) -J104-  

 

 

 

 

 

z

Connect test box V.A.G 1598/21  

 

 

 

 

 

z

Check wiring between multi-pin 

connector for longitudinal 

acceleration sensor -G251- and 

multi-pin connector for control 

module (w/EDL) -J104- for open 

circuit  

max. 1.5 

ohm

z

Check 

wiring 

using 

wiring 

diagram 

 

 

 

z

Set to measuring range 20 M ohm 

 

 

 

 

 

z

Remove fuse S9  

 

 

 

 

 

z

Check wiring for short circuit to 

positive or Ground  

ohm

 

 

 

 

 

 

z

Check 

wiring 

using 

wiring 

diagram 

Functional check: Warning light for brake system -K118

Test 
step

V.A.G 

1598 

sockets

Item tested

z

Test conditions 

z

Additional 

operations  

Specified value

Corrective action

21

-

Function of 

warning light 

for brake 

system -K118-

z

Brake fluid level 

is OK.  

z

Switch ignition 

on  

Warning light for 

brake system -K118- 

lights up for approx. 

2 seconds and goes 

out again

z

Check brake fluid 

level warning 

switch -F34- in 

sealing cap 

 

 

 

z

Pull connectors 

off both front 

speed sensors  

z

Start engine and 

run at more than 

2000 RPM  

Warning light for 

brake system -K118- 

lights up and 3 

warnings are 

sounded

z

Check wiring 

using wiring 

diagram 

 

 

 

 

 

z

Malfunction in 

 

2003 Volkswagen New Beetle GLS 

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

  

FUNCTIONAL CHECK: ESP CONTROL LAMP -K155 

BRAKE LIGHT SWITCH, ADJUSTING 

Vehicle up to m.y. 02.00 

See BRAKE LIGHT SWITCH . 

z

Remove driver's side storage compartment.  

z

Pull harness connector off brake light switch.  

z

Remove brake light switch by turning 90° clockwise.  

z

Pull brake light switch plunger fully out.  

z

Press brake pedal down as far as possible by hand.  

z

Guide brake light switch through assembly opening and reinstall by turning 90° to left.  

z

Release brake pedal.  

instrument cluster 

 

 

 

z

Reconnect 

connectors to 

both front speed 

sensors again  

z

Check DTC 

memory and 

erase  

 

 

Functional check: ESP Control lamp -K155

Test 
step

V.A.G 

1598 

sockets

Item tested

z

Test 

conditions  

z

Additional 

operations  

Specified value

Corrective action

22

-

Function of 

ASR/ESP 

control lamp -

K155-

z

Switch 

ignition on  

ASR/ESP control lamp 

-K155- lights up for 2 

seconds and goes out 

again

 

 

 

 

 

 

z

Check wiring 

using wiring 

diagram 

 

 

 

 

 

z

Malfunction in 

instrument 

cluster 

NOTE:

Remove brake light switch to adjust.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Install brake light switch harness connector.  

z

Reinstall driver's side storage tray.  

z

Operate brake pedal. 

Both brake lights light up. 

z

Take foot off brake pedal. 

Both brake lights must not light up. 

Vehicle from m.y. 03.00 

z

Pull out brake light switch plunger to full extension.  

z

Keep brake pedal in up position (IMPORTANT! hold pedal up if necessary while installing switch).  

z

Guide switch through mounting hole (only fits in one position).  

z

Seat switch fully into opening (pressing plunger against pedal to adjust.  

z

Seat switch by turning it 45° clockwise. This action also turns the plunger shoe into the correct 
orientation to make electrical contracts in switch operate as well as locks in plunger adjustment.  

z

Connect brake light switch connector.  

z

Operate brake pedal to verify proper function.  

z

Reinstall lower cover panel.  

ABS MARK 60 VEHICLES FROM M.Y. 10.00, ON BOARD DIAGNOSTIC 
(OBD) 

The ABS system Mark 60 is available in three different versions. 

z

ABS  

z

ABS/EDL/ASR  

z

ABS/EDL/ASR/ESP with front wheel drive  

Each version has its own control module. The control modules can be coded accordingly through coding 
bridges via tester VAS 5051 or V.A.G 1551. 

The ESP (Electronic Stabilization Program) is an electronic dynamics Program (EDP). It stabilizes the vehicle 
when over steering or under steering. The ESP works over the whole speed range. If the ESP is regulating the 
system the ESP warning lamp will flash 3 times per second. 

The ESP is a further extension of the familiar vehicle safety systems . 

ESP increases control over the vehicle in critical situations. It reduces the danger of skidding and increases the 
steering control when compared with familiar vehicle safety systems.

 

2003 Volkswagen New Beetle GLS 

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

  

FUNCTION 

As the control modules are interconnected with a data bus wire, always start troubleshooting by checking 
Diagnostic Trouble Code (DTC) memories of all the control modules in the vehicle. 

This occurs in "Automatic test sequence" and is activated with key function 00. 

When doing this, check to see if there are DTCs stored which may influence the ABS. 

The OBD relates to the electrical/electronic part of the ABS, i.e. only malfunctions via the electrical connection 
to the control module are recognized (e.g. speed sensor open circuit). 

The 47-pin ABS Control Module (w/EDL) -J104- forms a compact assembly with the hydraulic unit. The unit is 
located on the left in the engine compartment. The control module is equipped with a DTC memory. 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 in a permanent memory, 
the contents of which remain even during periods of no battery voltage. 

Sporadic (irregular) malfunctions will also be recognized and stored. But if faults affecting the data bus system 
do not occur again within the next 15 vehicle start and driving off sequences, or other malfunctions within the 
next 50 vehicle start and driving off sequences, they will be erased from DTC memory except for the 
malfunction "Control module faulty" (forget-malfunction counter). 

After the ignition is switched on and/or the engine is started, the ABS warning light -K47- and the ASR/ESP 
control lamp -K155- will light up for approx. 2 seconds. 

During this period a test sequence (self-check) is run in the control module for the following functions: 

z

To check if the supply voltage is at least 10.0 Volt,  

z

To check control module including the valve windings,  

z

To check the coding of the control module,  

z

A static check of the speed sensor (no speed signal),  

z

If the wheel speed signal is not OK after the car has been driven and a speed of approx. 20 km/h (approx. 
13 mph) has been exceeded, the ABS warning light -K47- will light up again.  

Special detail for bleeding brake systems with ABS/EDL 

If a chamber in the brake fluid reservoir has run empty, basic setting must be performed for bleeding the brakes, 
see Initiating basic setting . 

V.A.G 1551 scan tool or tester VAS 5051 

The On Board Diagnostic must be initiated at the commencement of troubleshooting. Electrical malfunctions 
which influence the braking characteristics will be stored.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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