Volkswagen New Beetle. Manual - part 843

 

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Volkswagen New Beetle. Manual - part 843

 

 

Fig. 1: Drive Belt Routing (Except 1.9L - ALH & BEW) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 2 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 2: Drive Belt Routing (1.9L - ALH & BEW) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

TROUBLE SHOOTING 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 3 

© 2004 Mitchell Repair Information Company, LLC. 

PRELIMINARY INSPECTION 

Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical 
damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. 
Following manufacturers instructions for load tester, load test battery. See LOAD TEST under ON-VEHICLE 
TESTING. Inspect for blown fuses and damaged relays. For fuse and/or relay identification, see WIRING 
DIAGRAMS 
. Verify ground connection integrity between engine, body, battery and generator. Check for 
damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which 
could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure 
any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is 
found, check for conditions that might cause an intermittent situation.  

SYSTEM TESTS 

GENERATOR WARNING LIGHT DOES NOT GO OUT WITH SPEED INCREASE 

1. Turn ignition switch to OFF position. Disconnect D+ terminal at generator. Turn ignition switch to ON 

position. Observe GEN warning light. If warning light illuminates, go to next step. If warning light does 
not illuminate, go to GENERATOR .  

2. Turn ignition switch to OFF position. Disconnect Blue wire from instrument cluster terminal T32a/12. 

Turn ignition switch to ON position. Observe GEN warning light. If warning light illuminates, replace 
faulty instrument cluster. If warning light does not illuminate, repair short to ground in D+ circuit 
between generator, ignition switch and instrument cluster. See WIRING DIAGRAMS .  

GENERATOR WARNING LIGHT DOES NOT ILLUMINATE WITH IGNITION ON 

1. Ensure generator belt tension and battery voltage are okay. Verify ground connection integrity between 

engine, body, battery and generator. Repair as necessary.  

2. Turn ignition switch to OFF position. Disconnect D+ terminal at generator. Using a jumper wire, ground 

D+ terminal. Turn ignition switch to ON position. Observe GEN warning light. If warning light 
illuminates, go to next step. If warning light does not illuminate, check wiring using a wiring diagram. 
Verify GEN warning light operation in instrument panel. See WIRING DIAGRAMS .  

3. Turn ignition switch to OFF position. Remove voltage regulator. See VOLTAGE REGULATOR under 

REMOVAL & INSTALLATION. Check condition and length of brushes. See VOLTAGE 
REGULATOR BRUSH SPECIFICATIONS 
table under BENCH TESTING. If brushes are within 
specification, replace generator. See GENERATOR under REMOVAL & INSTALLATION. If brushes 
are out of specification, replace brushes or voltage regulator.  

ON-VEHICLE TESTING 

GENERATOR 

1. Ensure generator belt tension and mounting are okay. On vehicles equipped with 1.9L TDI, check 

function of generator pulley freewheeling clutch (if equipped). Check ground connection between engine, 
body, battery and generator. Repair as necessary. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 4 

© 2004 Mitchell Repair Information Company, LLC. 

2. Turn ignition switch to OFF position. Attach SUN VAT 40 Black lead to battery negative terminal. 

Attach SUN VAT 40 Red lead to battery positive terminal. Clamp SUN VAT 40 Green test lead to 
battery ground cable.  

3. Turn on all electrical components. Start engine, and maintain engine speed of 1500-2000 RPM. Observe 

SUN VAT 40 ammeter reading. If charging current is 75 amps or more, generator and voltage regulator 
are functioning properly.  

4. If charging current is less than 75 amps, check battery fluid specific gravity. If specific gravity is less than 

1.22, generator is malfunctioning. Repair or replace as necessary. If battery fluid specific gravity is 1.22 
or more, repair as necessary.  

LOAD TEST 

Connect tester cable clamps to battery terminal. Ensure clamps have a good contact with battery terminals. 
Connect battery tester according to tool manufacturer's instructions. Load test battery at approximately one-half 
cold-cranking amperage rating for 15 seconds while observing battery voltage. If voltage reading is 9.6 volts or 
more, battery is okay. If voltage reading is less than 9.6 volts, charge battery and retest. If loaded battery voltage 
is still less than 9.6 volts after charging battery, replace battery. See BATTERY under REMOVAL & 
INSTALLATION.  

NO LOAD TEST 

WARNING:

Dispose of electrolyte (sulfuric acid/water mixture) properly. Waste 
electrolyte must only be disposed of in appropriate waste disposal sites. 
Refer to local regulations pertaining to electrolyte disposal. 

WARNING:

DO NOT load test batteries which are gassing. There is a risk of 
explosion. 

NOTE:

Manufacturer recommends performing electrolyte specific gravity test, in order 
to determine battery overall condition. 

NOTE:

It is not necessary to remove battery from vehicle, or disconnect battery 
terminals. 

CAUTION: Battery cell caps must be bolted in tightly when charging, measuring 

voltage or performing load tests. 

NOTE:

If no load voltage is to be measured with battery installed in vehicle, first 
disconnect ground strap. 

NOTE:

Vehicle must not be started or driven with tested battery for at least 2 hours 
before taking measurements. During this time, DO NOT allow load or additional 
charge to be applied to battery. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 5 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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