2003 Volkswagen New Beetle GLS

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

1998-2004 ENGINE PERFORMANCE

Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

MULTIPORT FUEL INJECTION (MFI)

FUEL INJECTION SYSTEM, SERVICING

Component locations, overview

The following list pertains to Fig. 1 .

1. Heated Oxygen Sensor (HO2S) -G39-, 50Nm

z Location: before Three Way Catalytic Converter (TWC)

2. 6-pin connector
z Black

z Terminals gold plated

z For Heated Oxygen Sensor (HO2S) before Three Way Catalytic Converter (TWC) -G39- and
oxygen sensor heater -Z19-
z Right on underside of vehicle

3. Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) - G130-, 50Nm
z Location: behind Three Way Catalytic Converter (TWC)

4. 4-pin connector
z Black

z Terminals 3 and 4 gold-plated

z For Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) - G130- and oxygen sensor
heating - Z29-
z Right on underside of vehicle

5. Camshaft position (CMP) sensor - G40-

z See IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING , item 7

6. Secondary Air Injection (AIR) Solenoid Valve -N112-

z Secondary air system:

See SECONDARY AIR INJECTION (AIR) SYSTEM

7. Recirculating valve for turbocharger -N249-

z Checking charge pressure system

See TURBOCHARGER, G-CHARGER

8. Ignition coils with power output stage (-N70-, -N127-, -N291-, -N292-)

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

See IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING , item 2

z

9. Wastegate Bypass Regulator Valve - N75-

z Checking charge pressure system

See TURBOCHARGER, G-CHARGER

10. Protective housing

z For Secondary Air Injection (AIR) Pump Relay -J299-

z Secondary air system

See SECONDARY AIR INJECTION (AIR) SYSTEM

11. Motronic Engine Control Module (ECM) -J220-

(Motronic Motronic Engine Control Module (ECM) -J220- -J220-)

z Location: below inner cover of plenum chamber, left side in driver compartment
12. O-ring
z Replace if damaged

13. Engine Coolant Temperature (ECT) sensor -G62-

z For Motronic Engine Control Module (ECM) -J220-

z With Engine Coolant Temperature (ECT) gauge sensor -G2-

z If necessary release pressure in cooling system before removing

z Checking, see ENGINE COOLANT TEMPERATURE (ECT) SENSOR -G62-, CHECKING

14. Retaining clip

z Check for secure seating

15. Mass Air Flow (MAF) sensor -G70-

16. Valve 1 for camshaft adjustment - N205-
z Servicing valve train; checking camshaft adjustment

See ENGINE - CYLINDER HEAD, VALVETRAIN

17. Fuel pressure regulator

18. Injectors -N30- to -N33-
19. 10 Nm
20. Engine Speed (RPM) Sensor -G28-
z Checking, see ENGINE SPEED (RPM) SENSOR, CHECKING

21. O-ring
z Replace

22. 20 Nm

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Tightening torque influences the function of the knock sensor

23. Knock Sensor (KS) 2 -G66-
z Black

z See IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING , item 13

24. 2-pin connector

z Black

z For Knock Sensor (KS) 2 -G66-

z Identify before disconnecting

25. Secondary Air Injection (AIR) pump motor -V101-

z Secondary air system

See SECONDARY AIR INJECTION (AIR) SYSTEM

26. 20 Nm
z Tightening torque influences the function of the knock sensor

27. Knock Sensor (KS) 1 -G61-

z Black

z See IGNITION SYSTEM COMPONENTS, REMOVING AND INSTALLING , item 12

28. 2-pin connector

z Black

z For knock sensor 1 -G61-

z Identify before disconnecting

29. Charge pressure sensor -G31-

z Checking charge pressure system

See TURBOCHARGER, G-CHARGER

30. Throttle Valve Control Module -J338-

z No cable disc for accelerator cable as this is an Electronic Power Control (EPC)

z Checking, see THROTTLE VALVE CONTROL MODULE -J338-, CHECKING

z If replaced, adapt Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE -
J338-, ADAPTING
31. Intake Air Temperature (IAT) sensor - G42-
z Checking, see INTAKE AIR TEMPERATURE (IAT) SENSOR, CHECKING

32. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-

z Evaporative Emission (EVAP) system:

See EVAP CANISTER SYSTEM

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 1: Identifying Fuel Injection System Components

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Fuel injection, general information

Servicing ignition system, see IGNITION SYSTEM, SERVICING

NOTE: z The Motronic Engine Control Module (ECM) - J220- is equipped with On
Board Diagnostic (OBD). Before carrying out repairs and troubleshooting
the DTC memory of all control modules must be checked using the
automatic test sequence. This is necessary as various control modules
are connected to each other via a data bus. The vacuum hoses and
connections must also be checked (unmetered air).
z Fuel hoses in engine compartment must only be secured with spring type
clips. The use of clamp or screw type clips is not permissible.
z Disconnecting and connecting the battery must only be done with the
ignition switched off, otherwise the Motronic Engine Control Module (ECM)
-J220- could be damaged.
z Components marked with * are checked via the On Board Diagnostic
(OBD), see DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE
(ECM) -J220-, CHECKING AND ERASING .
z Components marked with **can be checked with the Output Diagnostic
Test Mode (DTM), see OUTPUT DIAGNOSTIC TEST MODE (DTM) .
z For trouble -free operation of the electrical components, a voltage of at
least 11.5 V is necessary.
z Do not use sealants containing silicone. Particles of silicone drawn into
the engine, will not be burned in the engine and damage the oxygen
sensor.
z Some checks can cause the control module to recognize and store a DTC.
Therefore after completing all checks and repairs the DTC memory must
be checked and if necessary erased, see DTC MEMORY OF MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND ERASING .
z Vehicles with an airbag are built with a crash/fuel shut -off. It reduces the
risk of a vehicle burning in the event of a crash and that the fuel pump is
switched off by the fuel pump relay. At the same time, this device
improves the starting of the engine because as soon as the door is
opened, the fuel pump is activated for 2 seconds to build up pressure in
the fuel system.

Safety precautions, see SAFETY PRECAUTIONS

Rules for cleanliness, see RULES OF CLEANLINESS

Technical data, see TECHNICAL DATA

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Checking engine operating mode, see ENGINE OPERATING MODE, CHECKING

Fuel injection system components, removing and installing

The following list pertains to Fig. 2 .

1. 10 Nm
2. Air cleaner
z Disassembling and assembling, see AIR CLEANER, DISASSEMBLING AND ASSEMBLING

3. 6 Nm
4. 40-pin connector
z Only disconnect or connect with ignition switched off

z Release to disconnect

5. 81-pin connector
z Only disconnect or connect with ignition switched off

z Release to disconnect

6. Motronic Engine Control Module (ECM) -J220-*

(Motronic Motronic Engine Control Module (ECM) -J220- -J220-)

zComponent location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment

overview
z Checking voltage supply, see MOTRONIC ENGINE CONTROL MODULE (ECM)

z Procedure after voltage supply open circuit, see PROCEDURE AFTER CORRECTING
VOLTAGE SUPPLY OPEN CIRCUIT
z Replace, see MOTRONIC ENGINE CONTROL MODULE (ECM) - J220-, REPLACING

z If replaced, carry out basic setting, see MOTRONIC ENGINE CONTROL MODULE (ECM) -
J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING
7. 4-pin connector
z Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment
overview
z Brown/Black

z For oxygen sensor 2 after Three Way Catalytic Converter (TWC) -G130- and Heated Oxygen
Sensor (HO2S) - Z29-
z Terminals 3 and 4 gold plated

8. Oxygen Sensor (O2S) 2 after Three Way Catalytic Converter (TWC) - G130-*, 50 Nm
z With 4-pin connector

z Component location, see MULTIPORT FUEL INJECTION (MFI)

z Grease only the threads with G 052 112 A3 hot bolt paste (anti-seize compound). Grease must not
get into slots on sensor body
z Remove and install with ring wrench 3337

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z If replaced, erase learned values and adapt Motronic Engine Control Module (ECM) -J220- to
Throttle Valve Control Module -J338-, see MOTRONIC ENGINE CONTROL MODULE
(ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING
z Sensor heating voltage supply via Fuel Pump (FP) Relay -J17-

z Checking Heated Oxygen Sensor (HO2S) for oxygen sensor after Three Way Catalytic Converter
(TWC), see HEATED OXYGEN SENSOR (HO2S) FOR OXYGEN SENSOR AFTER
THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
z Checking Oxygen Sensor (O2S) and oxygen sensor control after Three Way Catalytic Converter
(TWC), see OXYGEN SENSOR AND OXYGEN SENSOR CONTROL AFTER THREE
WAY CATALYTIC CONVERTER (TWC), CHECKING
9. 6-pin connector
z Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment
overview
z Black

z For Oxygen Sensor (O2S) 1 before Three Way Catalytic Converter (TWC) -G39- and Heated
Oxygen Sensor (HO2S) -Z19-
10. Oxygen Sensor (O2S) 1 before Three Way Catalytic Converter (TWC) -G39- *, 50Nm
z With 6-pin connector

z Component location, see MULTIPORT FUEL INJECTION (MFI)

z Grease only the threads with G 052 112 A3 hot bolt paste (anti-seize compound). Grease must not
get into slots on sensor body
z Remove and install with ring wrench 3337

z If replaced, erase learned values and adapt Motronic Engine Control Module (ECM) -J220- to
Throttle Valve Control Module -J338-, see MOTRONIC ENGINE CONTROL MODULE
(ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING
z Sensor heating voltage supply via Fuel Pump (FP) Relay -J17-

z Checking Heated Oxygen Sensor (HO2S) before Three Way Catalytic Converter (TWC), see
FUEL INJECTION SYSTEM COMPONENTS, CHECKING
z Checking Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter
(TWC), see OXYGEN SENSOR AND OXYGEN SENSOR CONTROL BEFORE THREE
WAY CATALYTIC CONVERTER (TWC), CHECKING
z Checking Oxygen Sensor (O2S) aging, see OXYGEN SENSOR AGING, OXYGEN SENSOR
BEFORE THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
z Terminals gold plated

11. Bracket
z For Engine Speed (RPM) Sensor - G28-

12. O-ring
z Replace

13. Engine Speed (RPM) Sensor -G28-*

z Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment
overview
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Checking, see ENGINE SPEED (RPM) SENSOR, CHECKING

14. 3-pin connector
z Gray

z For Engine Speed (RPM) Sensor - G28-

15. 20 Nm
16. 45 Nm
17. Support
z Between intake manifold and engine block

18. Intake manifold

19. Charge pressure sensor -G31-*
z Component location, see MULTIPORT FUEL INJECTION (MFI)

z 4 pin connector

z Removing and installing:

See TURBOCHARGER, G-CHARGER

20. Gasket
z Replace

21. From Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-
z Evaporative Emission (EVAP) system

See EVAP CANISTER SYSTEM

22. Throttle Valve Control Module -J338- *

z Checking, see THROTTLE VALVE CONTROL MODULE -J338-, CHECKING

z 6-pin connector

z No cable disc for accelerator cable as this is an Electronic Power Control (EPC)

z Connector terminals gold-plated

z If replaced adapt Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE -
J338-, ADAPTING
z If replaced adapt control module for automatic transmission:

See DIAGNOSIS - 01M

23. Return pipe

z Secure with spring-type clips

z Check securely seated

z To fuel delivery unit in fuel tank

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

See FUEL SUPPLY

24. Supply pipe/hose

z Secure with spring-type clips

z Make sure it is securely seated

z From fuel filter:

See FUEL SUPPLY

25. Fuel rail with fuel injectors

z Disassembling and assembling, see FUEL RAIL WITH FUEL INJECTORS,
DISASSEMBLING AND ASSEMBLING
26. Intake Air Temperature (IAT) sensor - G42-*
z Component location, see MULTIPORT FUEL INJECTION (MFI)

z 2-pin connector

z Checking, see INTAKE AIR TEMPERATURE (IAT) SENSOR, CHECKING

27. Retaining clip

z Make sure it is securely seated

28. Engine Coolant Temperature (ECT) sensor -G62-*

z Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment
overview
z For Motronic Engine Control Module (ECM) -J220-

z With Engine Coolant Temperature (ECT) sensor -G2-

z If necessary release pressure in cooling system before removing

z Checking, see ENGINE COOLANT TEMPERATURE (ECT) SENSOR -G62-, CHECKING

z Wiring chamber 3 and wiring chamber 4 for -G62-

z Terminals 3 and 4 gold plated

29. Connector
z Black, 4-pin

z For Engine Coolant Temperature (ECT) sensor -G62-

z Wiring chamber C and wiring chamber D for -G62-

z Terminals C and D gold plated

30. To pipe between turbo charger and charge air cooler

31. To pipe between turbo charger and charge air cooler
32. To intake hose at turbocharger

See TURBOCHARGER, G-CHARGER

33. From crankcase breather

z Oil filter bracket

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

34. From crankcase breather

z Valve cover

35. From intake hose

z See item 7

See TURBOCHARGER, G-CHARGER

36. To Recirculating valve for turbocharger -N249-

z See item 7

See TURBOCHARGER, G-CHARGER

37. To pressure unit on turbo charger

See TURBOCHARGER, G-CHARGER

38. Wastegate Bypass Regulator Valve - N75-*/**

z Component location, see MULTIPORT FUEL INJECTION (MFI) , engine compartment
overview
z Charge pressure system:

See TURBOCHARGER, G-CHARGER

39. Intake hose

z Note installation position

40. To vacuum booster

See TURBOCHARGER, G-CHARGER

41. Mass Air Flow (MAF) sensor -G70-*

z 5-pin connector

z Socket 1 not occupied

z Sensor and connector terminals are gold-plated

z Checking, see MASS AIR FLOW (MAF) SENSOR, CHECKING

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 2: Exploded View Of Fuel Injection System Components

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Air cleaner, disassembling and assembling

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

The following list pertains to Fig. 3 .

1. 10 Nm
2. Mass Air Flow (MAF) sensor -G70-
z Sensor and connector terminals are gold-plated

z Socket 1 not occupied

z Checking, see MASS AIR FLOW (MAF) SENSOR, CHECKING

3. Connector
z Black, 5-pin

z Sensor and connector terminals are gold-plated

z Socket 1 not occupied

4. Seal
z Replace if damaged

5. Air cleaner upper part

6. 6 Nm
7. Filter element
8. Air cleaner lower part
9. Air duct
10. O-ring
z Replace if damaged

11. Intake hose

z Ensure seated tightly

z Press together at front to release

z To Secondary air injection (AIR) pump motor -V101-:

See EXHAUST SYSTEM, EMISSION CONTROLS

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 3: Identifying MAF Sensor And Air Cleaner Components

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Fuel rail with fuel injectors, disassembling and assembling

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

The following list pertains to Fig. 4 .

1. Fuel rail
2. Retaining clip
z Check securely seated

3. O-ring
z Replace if damaged

z Before installing moisten with clean engine oil

4. Fuel pressure regulator

z Checking, see FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING

5. Vacuum hose

To intake manifold

6. 10 Nm
7. Return flow connection
8. Supply connection
9. Retaining clip
z Ensure seated correctly at injector and fuel rail

10. Fuel injectors (-N30- to -N33-)*

z Checking, see FUEL INJECTORS, CHECKING

z 2-pin connector

z Resistance 12 to 17

11. O-ring
z Replace

z Before installing moisten with clean engine oil

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 4: Disassembling Fuel Rail With Injectors

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Safety precautions

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

WARNING: Fuel system is under pressure! Before opening the system place a cloth
around the connection. Then release pressure by carefully loosening the
connection.

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
noted:

z For safety reasons the fuse No. 28 must be removed from the fuse holder before opening the fuel system,
otherwise the fuel pump can be activated by the door terminal switch.
z Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
z The ignition must be switched off before connecting or disconnecting injection or ignition system wiring
or tester cables.

Observe following if test and measuring instruments are required during a test drive:

z Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
z If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.

If the engine is to be turned at starter speed, without starting:

z Disconnect all 4 -pin connectors -2- from power output stage for ignition coils -1-.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 5: Disconnecting All Pin Connectors From Power Output Stage For Ignition Coils
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Pull fuse No. 32 out of fuse holder.

NOTE: Removing fuse 32 interrupts the voltage supply to the fuel injectors. Fuse
holder is located behind access panel at far left end of dash.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 6: Removing Fuse 32 Interrupts Voltage Supply To Fuel Injectors

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Rules of cleanliness

When working on the fuel supply/injection system, pay careful attention to the following 5 rules:

z Thoroughly clean all unions and the adjacent areas before disconnecting.
z Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
z Carefully cover opened components or seal, if the repair cannot be carried out immediately.
z Only install clean components: Only unpack replacement parts immediately prior to installation. Do not
use parts that have been stored loose (e.g. in tool boxes etc.).

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z When the system is open: Do not work with compressed air if this can be avoided. Do not move vehicle
unless absolutely necessary.

Technical data

TECHNICAL DATA SPECIFICATION

Engine code AWP AWV
Idle check (at normal operating temperature)
Idle speed(1) RPM
Manual transmission 760 to 810 (1) 760 to 810(1)
Automatic transmission 700 to 750 (1) 700 to 750(1)
Motronic Engine Control Module (ECM) -J220-(2)
System Motronic ME7.5 Motronic ME7.5
Part number(3)
Manual transmission 1C0 906 032 06A 906 032 GA
Automatic transmission 06A 906 032 GB
Governed speed RPM from approx. 6800 from approx. 6800
(1) Not adjustable

(2) Replacing Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE
CONTROL MODULE (ECM)
(3) For latest part number for Engine Control Module: See Parts catalog.

FUEL INJECTION SYSTEM COMPONENTS, CHECKING

Heated Oxygen Sensor (HO2S) for oxygen sensor before Three Way Catalytic Converter (TWC), checking

NOTE: z Raise vehicle to reach oxygen sensor connector

z Only gold-plated terminals must be used to repair the terminals in the
oxygen sensors connectors.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash.
z The battery voltage must be at least 11.5 V
z Fuel pump relay must be OK

Fig. 7: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) - J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Indicated on display

Fig. 8: Identifying Scan Tool Display (1 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 9: Identifying Scan Tool Display (2 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -4- and -1- for "Display group number 41" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 10: Identifying Scan Tool Display (3 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Run engine for 2 minutes at idling speed.

z Check status of Heated Oxygen Sensor (HO2S) before catalytic converter in display field 2: Display:
Htg.bC.ON, Htg.bC.OFF (alternating)

DISPLAY GROUP 41: HEATED OXYGEN SENSOR (HO2S) BEFORE AND AFTER THREE WAY
CATALYTIC CONVERTER (TWC)
Display zones
1 2 3 4
Display group 41: Heated Oxygen Sensor (HO2S) before and after Three Way Catalytic Converter
(TWC)
Display - Htg.bC.ON / Htg.bC.OFF - Htg.aC.ON /
Htg.aC.OFF
Indicated - Heated Oxygen Sensor (HO2S) before Heated Oxygen Sensor
Three Way Catalytic Converter (HO2S) after Three Way
(TWC) ON Catalytic Converter (TWC)
or ON
Heated Oxygen Sensor (HO2S) before or
Three Way Catalytic Converter Heated Oxygen Sensor
(TWC) OFF (HO2S) after Three Way
Catalytic Converter (TWC)
OFF
Working - - - -
range
Specification - Htg.bC.ON - -
Htg.bC.OFF
(occasionally alternating)
- If the specification is not achieved, see - -
CONTINUATION

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

NOTE: The Heated Oxygen Sensor (HO2S) may be switched ON or OFF depending on
the operating conditions of the engine, therefore the display in display zone 2
may show "Htg.bC.ON" or alternating from "Htg.bC.ON" to "Htg.bC.OFF."

If the specification is obtained:

z Press button.
z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the specifications are not obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.
z Remove protective cover -arrows- and separate 6-pin connector (black) -1- to Heated Oxygen Sensor
(HO2S) before Three Way Catalytic Converter (TWC) -G39-.

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December-27-07 1:44:00 PM Page 23 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 11: Separating 6-Pin Connector (Black) -1- To HO2S -G39- Before TWC
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Set multimeter to measure resistance and connect it to terminals 3 + 4 of connector to oxygen sensor.
Check oxygen sensor heating for closed circuit.

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December-27-07 1:44:00 PM Page 24 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 12: Measuring Resistance Between Terminals 3 And 4 Of HO2S -G39- Before TWC Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification: 2.5...10 (at room temperature)

If it is determined that oxygen sensor heating has an open circuit:

z Replace Heated Oxygen Sensor (HO2S) -G39-.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
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December-27-07 1:44:00 PM Page 25 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If oxygen sensor heating has continuity:

Checking voltage supply

z Set multimeter to measure voltage and connect to terminal 3 (connector to Motronic Engine Control
Module (ECM) -J220-) and Ground (GND).

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December-27-07 1:44:00 PM Page 26 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 13: Measuring Voltage Between Terminal 3 And Ground On HO2S -G39- Harness Connector
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December-27-07 1:44:00 PM Page 27 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Start engine and run at idling speed.

z Measure voltage supply:

Specification: 11.0 to 14.5 V

If the specification is not obtained:

z Check wiring from terminal 3 to Fuel Pump (FP) Relay -J17- using Electrical Wiring Diagram.

If the specification is obtained:

z Connect multimeter using aux. cables from VAG 1594 to measure voltage at terminals 3 and 4 (connector
to Motronic Engine Control Module (ECM) -J220-).

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December-27-07 1:44:00 PM Page 28 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

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December-27-07 1:44:00 PM Page 29 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 14: Measuring Voltage Between Terminal 3 And 4 On HO2S -G39- Harness Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Measure voltage supply and note display group 41, display zone 2.

Display: Htg.bC.ON:

z Specification: 11.0 to 14.5 V

Display: Htg. bC.ON/Htg.bC.OFF (alternating):

z Specification: Between 0.0 to 12.0 V fluctuating

z Switch off ignition.

If no voltage is present:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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December-27-07 1:44:00 PM Page 30 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 15: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 6 -pin connector according to Electrical Wiring
Diagrams.

terminal 4 + socket 5

Wire resistance: Max. 1.5

If no wiring malfunction is found:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

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December-27-07 1:44:00 PM Page 31 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 16: Identifying HO2S -G39- Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Heated Oxygen Sensor (HO2S) for oxygen sensor after Three Way Catalytic Converter (TWC), checking

Special tools, test equipment and auxiliary items

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December-27-07 1:44:00 PM Page 32 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagrams

Test conditions

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash
z Battery voltage must be at least 11.5 V
z Fuel pump relay must be OK

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December-27-07 1:44:00 PM Page 33 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 17: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test sequence

z Connect VAG 1551 scan tool (or VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 18: Identifying Scan Tool Display - Checking HO2S After TWC (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

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December-27-07 1:44:00 PM Page 34 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 19: Identifying Scan Tool Display - Checking HO2S After TWC (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -4- and -1- for "Display group number 41" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

Fig. 20: Identifying Scan Tool Display - Checking HO2S After TWC (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check status of Heated Oxygen Sensor (HO2S) behind Three Way Catalytic Converter (TWC) in display
field 4: Display: Htg.aC.ON, Htg.aC.OFF (alternating)

DISPLAY GROUP 41: HEATED OXYGEN SENSOR (HO2S) BEFORE AND AFTER THREE WAY
CATALYTIC CONVERTER (TWC)
Display zones
1 2 3 4
Display group 41: Heated Oxygen Sensor (HO2S) before and after Three Way Catalytic Converter
(TWC)
Display - Htg.bC.ON / Htg.bC.OFF - Htg.aC.ON / Htg.aC.OFF
Indicated - Heated Oxygen Sensor (HO2S) before - Heated Oxygen Sensor (HO2S) after Three
Three Way Catalytic Converter (TWC) Way Catalytic Converter (TWC) ON
ON or
or Heated Oxygen Sensor (HO2S) after Three
Heated Oxygen Sensor (HO2S) before Way Catalytic Converter (TWC) OFF
Three Way Catalytic Converter (TWC)
OFF
Working - - - -
range
Specification - - - Htg.aC.ON
Htg.aC.OFF
(occasionally alternating)
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December-27-07 1:44:00 PM Page 35 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

- - - If the specification is not achieved, see

CHECKING VOLTAGE SUPPLY ,
Continuation

NOTE: The Heated Oxygen Sensor (HO2S) may be switched ON or OFF depending on
the operating conditions of the engine, therefore the display in display zone 4
may show "Htg.aC.ON" or alternating from "Htg.aC.ON" to "Htg.aC.OFF."

If the specification is obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the specifications are not obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.
z Remove protective cover -arrows- and separate 4-pin connector (brown/black) -1- to Oxygen sensor after
Three Way Catalytic Converter (TWC) -G130-.

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December-27-07 1:44:00 PM Page 36 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 21: Separating 4-Pin Connector (Brown/Black) -1- For HO2S -G130- After TWC
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Set multimeter to check resistance and connect it to terminals 1 + 2 of Oxygen Sensor connector. Check
Oxygen Sensor heating for continuity

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December-27-07 1:44:00 PM Page 37 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 22: Checking Resistance Between HO2S -G130- Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

If it is determined that Oxygen Sensor heating has an open circuit:

z Replace Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130-

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December-27-07 1:44:00 PM Page 38 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING

If oxygen sensor heating has continuity:

Checking voltage supply

z Set multimeter to measure voltage and connect to terminal 1 (connector to Motronic Engine Control
Module (ECM) -J220-) and Ground (GND).

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December-27-07 1:44:00 PM Page 39 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 23: Measuring Voltage Between HO2S -G130- Harness Connector Terminal 1 And Ground
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Start engine and run at idling speed.

z Check voltage supply:
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December-27-07 1:44:00 PM Page 40 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Specification: 11.0 to 14.5 V

If no voltage is present:

z Check wiring from terminal 1 to Fuel Pump (FP) Relay -J17- according to Electrical Wiring Diagram.

If the specification is obtained:

z Connect multimeter using auxiliary cables from VAG 1594 to measure voltage at terminals 1 + 2
(connector to Motronic Engine Control Module (ECM) -J220-).

Helpmelearn
December-27-07 1:44:00 PM Page 41 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 24: Measuring Voltage Between HO2S -G130- Harness Connector Terminal 1 And 2
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Measure voltage supply and observe display group 41, display zone 4.
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December-27-07 1:44:00 PM Page 42 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Display: Htg.aC.ON:

z Specification: 11.0 to 14.5 V

Display: Htg. aC.ON/Htg.aC.OFF (alternating):

z Specification: Between 0.0 to 12.0 V fluctuating

If no voltage is present:

z Switch off ignition.

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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December-27-07 1:44:00 PM Page 43 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 25: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 4 -pin connector according to Electrical Wiring
Diagram.

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December-27-07 1:44:00 PM Page 44 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 26: Identifying HO2S -G130- Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

terminal 2 + socket 63:

z Wire resistance: Max. 1.5

If no wiring malfunction is found:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Mass Air Flow (MAF) sensor, checking

NOTE: Only gold-plated terminals can be used to repair terminals in the connector for
the Mass Air Flow (MAF) sensor.

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December-27-07 1:44:00 PM Page 45 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK

z Battery voltage must be at least 11.5 V
z Fuel pump relay must be OK. Fuse holder is located behind access panel at far left end of dash.

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December-27-07 1:44:00 PM Page 46 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 27: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z All electrical accessories, e.g. lights and rear window defroster, must be switched off
z If the vehicle is equipped with air conditioning, it must be turned off
z On vehicles with automatic transmission: selector lever in "P" or "N" position
z Engine Coolant Temperature (ECT) must be at least 80 °C, see display group 04, display zone 3

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. (Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
Helpmelearn
December-27-07 1:44:00 PM Page 47 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- ).

Indicated on display

Fig. 28: Identifying Scan Tool Display - Checking MAF Sensor (1 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 29: Identifying Scan Tool Display - Checking MAF Sensor (2 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -0- and -2- for "Display group number 2" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

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December-27-07 1:44:00 PM Page 48 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 30: Identifying Scan Tool Display - Checking MAF Sensor (3 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check Mass Air Flow drawn in display zone 4: Specification: 2.0 to 4.5 g/s

DISPLAY GROUP 2: LOAD REGISTRATION

Display zones
1 2 3 4
Display group 2: Load registration
Display xxxx RPM xxx.x % xx.xx ms xxx.x g/s
Indicated Engine speed (in steps of Engine load Injection Mass Air Flow drawn
40) period in
Operating 0 to 6800/min. 12.0 to 0.0 to 2.0 ms 2.0 to 177.0 g/s
range 175.0%
Specification 760--810 RPM (1) 12.0 to 25.0% 1.5 to 4.0 ms 2.0 to 4.5 g/s
700-750 RPM (2)
(1) Engine idling at normal operating temperature for manual transmission

(2) Engine idling at normal operating temperature for automatic transmission

z If value is as specified but DTC memory has recorded a DTC relating to Mass Air Flow (MAF) sensor,
test power supply to Mass Air Flow (MAF) sensor, see TESTING POWER SUPPLY TO MASS AIR
FLOW (MAF) SENSOR -G70- .

If the specification is not obtained:

z Check signal and Ground (GND) wires for Mass Air Flow (MAF) sensor, see TESTING SIGNAL AND
GROUND (GND) WIRES FOR MASS AIR FLOW (MAF) SENSOR -G70- .

If the specification is obtained:

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December-27-07 1:44:00 PM Page 49 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Testing power supply to Mass Air Flow (MAF) sensor -G70-

z Disconnect 5-pin connector -1- from Mass Air Flow (MAF) sensor -G70- arrow.

Fig. 31: Disconnecting Pin Connector From Mass Air Flow (Maf) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect multimeter to measure voltage on connector terminal 2 and engine Ground (GND).

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December-27-07 1:44:00 PM Page 50 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 32: Measuring Voltage Between Terminal 2 And Ground On MAF Sensor Harness Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Start engine and run at idle speed.

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December-27-07 1:44:00 PM Page 51 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Specification: 11.0 to 15.0 V

If no voltage is present:

z Switch off ignition.

z Check wire between 5 -pin connector terminal 2 and Fuel Pump (FP) Relay -J17- for open circuit using
Electrical Wiring Diagram.

Wire resistance: max. 1.5

If the voltage supply and wiring is OK:

z Connect multimeter to measure voltage on connector terminal 4 and engine Ground (GND).

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December-27-07 1:44:00 PM Page 52 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 33: Measuring Voltage Between Terminal 4 And Ground On MAF Sensor Harness Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Switch on ignition.

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December-27-07 1:44:00 PM Page 53 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Specification: 4.5 to 5.5 V

If no voltage is present:

z Switch off ignition.

z Check signal and Ground (GND) wires, see TESTING SIGNAL AND GROUND (GND) WIRES FOR
MASS AIR FLOW (MAF) SENSOR -G70- .

Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor -G70-

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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December-27-07 1:44:00 PM Page 54 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 34: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 5 -pin connector using Electrical Wiring Diagram.
{ terminal 5 + socket 29

{ terminal 4 + socket 53

{ terminal 3 + socket 27

Wire resistance: Max. 1.5

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December-27-07 1:44:00 PM Page 55 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 35: Identifying MAF Sensor Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Additionally check wires all for short to one another.

Specification:

z Check wiring additionally for short circuit to battery positive/Ground (GND).

NOTE: Socket 1 in Mass Air Flow (MAF) sensor and connector is not occupied.

If no wiring malfunction is found:

z Replace Mass Air Flow (MAF) sensor -G70-, see item 2 .

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December-27-07 1:44:00 PM Page 56 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Throttle Valve Control Module -J338-, checking

Components of Throttle Valve Control Module - J338-: Throttle valve drive -G186-, Angle sensor 1 for throttle
valve drive -G187- and Angle sensor 2 for throttle valve drive -G188-.

NOTE: z If the Throttle Valve Control Module -J338- is replaced, the new control
module must be adapted to the Motronic Engine Control Module (ECM) -
J220-, see MOTRONIC ENGINE CONTROL MODULE (ECM) - J220- TO
THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING .
z On vehicles with an automatic transmission, the transmission control
module must also be adapted:

See DIAGNOSIS - 01M

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z Engine not running, ignition switch on

z Throttle valve not damaged or dirty
z On vehicles with automatic transmission selector lever in "P" or "N" position
z Engine Coolant Temperature (ECT) must be at least 80 °C display group 04, display zone 3

NOTE: Only gold-plated terminals can be used to repair the terminals in the connector
for the Throttle Valve Control Module -J338-.

z Connect VAG 1551 scan tool (or VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

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Indicated on display

Fig. 36: Identifying Scan Tool Display - Checking Throttle Valve Control Module (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 37: Identifying Scan Tool Display - Checking Throttle Valve Control Module (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -6- and -2- for "Display group number 62" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

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Fig. 38: Identifying Scan Tool Display - Checking Throttle Valve Control Module (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check throttle valve angle at idling stop from Throttle valve angle sensor 1 -G187- in display zone 1:

Specification: 10 to 88%

z Check throttle valve at idling stop from Throttle valve angle sensor 2 -G188- in display zone 2:

Specification: 89 to 11%

DISPLAY GROUP 62: SPEED CONTROL, ELECTRONIC POWER CONTROL (EPC)

Display zones
1 2 3 4
Display group 62: Speed control, Electronic Power Control (EPC)
Display xxx % xxx % xxx % xxx %
Indicated Throttle valve angle Throttle valve angle Throttle Position Throttle Position
sensor 1 -G187- sensor 2 -G188- (TP) sensor 1 - (TP) sensor 2 -
G79- G185-
Working 0 to 100% 0 to 100% 0 to 100% 0 to 100%
range
Specification 10 to 88% 89 to 11% 10 to 18% 5 to 9%
If specifications are not achieved, see CHECKING - -
VOLTAGE SUPPLY AND WIRING TO
CONTROL MODULE , Continuation

z Depress accelerator slowly until full throttle position and observe angles displayed in display zones 1 and
2:

z Percent figure in display zone 1 must rise continuously and evenly. Full tolerance range 10 to 88% is not
always displayed.

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z Percent figure in display zone 2 must fall continuously and evenly. Full tolerance range 89 to 11% is not
always displayed.

NOTE: z The reason why the display in display zone 1 rises and the display in
display zone 2 falls is because the potentiometers (angle sensors) in the
angle sensors run in opposite directions.
z The voltage of angle sensor 1 moves toward 5 volts. (The more the throttle
valve is opened the higher the voltage; percentage increases).
z While the voltage of angle sensor 2 drops from 5 volts toward 0 volt. (The
more the throttle valve is opened the lower the voltage; percentage falls).

If the specifications are obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the displays do not indicate as described:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.
z Disconnect 6-pin connector from Throttle Valve Control Module - J338- -arrow-.

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Fig. 39: Disconnecting Pin Connector From Throttle Valve Control Module
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Measure resistance from throttle valve drive between terminals 3 and 5

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Fig. 40: Measuring Resistance From Throttle Valve Drive Between Terminals 3 And 5
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification: 1.0 to 5.0

If the specification is not obtained:

z Replace Throttle Valve Control Module -J338-, see item 22 .

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Adapt Motronic Engine Control Module (ECM) -J220- to Throttle Valve Control Module -J338-, see
MOTRONIC ENGINE CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE
CONTROL MODULE - J338-, ADAPTING .

z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .
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If the specification is obtained:

z Check voltage supply of Throttle Valve Control Module -J338- and wiring to control module, see
CHECKING VOLTAGE SUPPLY AND WIRING TO CONTROL MODULE .
z Check Throttle Position (TP) sensors (EPC).

See THROTTLE POSITION (TP) SENSOR, CHECKING

If the voltage supply and wiring is OK:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Checking voltage supply and wiring to control module

z Disconnect 6-pin connector from Throttle Valve Control Module - J338- -arrow-.

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Fig. 41: Disconnecting 6-Pin Connector From Throttle Valve Control Module
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect multimeter to measure voltage to terminals 2 + 6 of connector.

z Switch on ignition.

Specification: min. 4.5 V

z Switch off ignition.

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Fig. 42: Measuring Voltage Between Terminals 2 And 6 Of Throttle Valve Control Module Harness
Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect multimeter to measure voltage at connector terminal 2 and Ground (GND).

z Switch on ignition.

Specification: min. 4.5 V

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Fig. 43: Measuring Voltage Between Terminals 2 And Ground Of Throttle Valve Control Module
Harness Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Switch off ignition.

If the specifications are not obtained:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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Fig. 44: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring between test box and connector terminals for open circuit using Electrical Wiring Diagram:
z terminal 1 + Socket 92

z terminal 2 + Socket 83

z terminal 3 + Socket 117

z terminal 4 + Socket 84

z terminal 5 + Socket 118

z terminal 6 + Socket 91

Wire resistance: max. 1.5

{ Additionally check wires for short to one another.

Specification: INFINITY ohm

{ Check wiring additionally for short circuit to battery positive or Ground (GND).

Specification: INFINITY ohm

If no wiring malfunction is found:

z Check Motronic Engine Control Module (ECM) -J220- voltage supply, see MOTRONIC ENGINE
CONTROL MODULE (ECM) .

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Fig. 45: Identifying Throttle Valve Control Module Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Engine Coolant Temperature (ECT) sensor -G62-, checking

NOTE: The Motronic Engine Control Module (ECM) - J220- will use a replacement
temperature value for an engine start as soon as there is a DTC stored in the
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 2003 Volkswagen New Beetle GLS
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DTC memory which affects the Engine Coolant Temperature (ECT) sensor -
G62-. The temperature then rises according to a model stored in the ECM. When
the engine has reached normal working temperature a fixed replacement value
will be displayed after a certain period. This fixed value is also dependent on
intake air temperature.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z Engine must be cold

Test sequence

NOTE: Only gold-plated terminals must be used to repair the terminals 3 and 4 in the
connector for the Engine Coolant Temperature (ECT) sensor.

z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module with "Address word" 01. Connecting scan tool and selecting Motronic Engine Control Module
(ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC ENGINE
CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 46: Identifying Scan Tool Display - ECT Sensor, Checking (1 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.
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z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 47: Identifying Scan Tool Display - ECT Sensor, Checking (2 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -0- and -4- for "Display group number 4" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

Fig. 48: Identifying Scan Tool Display - ECT Sensor, Checking (3 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Read Engine Coolant Temperature (ECT) value in display zone 3. Specification: approx. Engine Coolant
Temperature (ECT)

DISPLAY GROUP 4: GENERAL ENGINE DATA

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Display zones
1 2 3 4
Display group 4: General engine data
Display xxxx RPM xx.xxx V xxx.x °C xxx.x °C
Indicated Engine Supply voltage for Engine Coolant Temperature (ECT) Intake air
speed (in Motronic Engine temperature
steps of Control Module
40) (ECM) -J220-
Working 0 to 6800 12.000 to 15.000 V -48.0 to 143.0 °C -48.0 to
range RPM 143.0 °C
Specification 760 to 810 12.000 to 15.000 V Approx. ambient air temperature (3) -
RPM (1)
700 to 750
RPM (2)
- - If the specifications are not obtained, see -
CONTINUATION OF CHECK WHEN
DISPLAY APPROX. - 48 °C: ,
Evaluating display group 4
(1) Engine idling at normal operating temperature for manual transmission

(2) Engine idling at normal operating temperature for automatic transmission

(3) If a temperature is displayed which deviates greatly from the ambient temperature of the sensor,
check sensor wiring for transfer resistances/open circuit.

If the specification is not obtained:

z Perform check according to following table:

Evaluating display group 4, display zone 3 - Engine Coolant Temperature (ECT)

EVALUATING DISPLAY GROUP 4, DISPLAY ZONE 3 - ENGINE COOLANT TEMPERATURE

(ECT)
Display
group: 4
Display zone:
3 Possible cause Corrective action
Approx. -48.0 z Wiring open circuit or z Continuation, see CONTINUATION OF CHECK
°C (1) short to positive WHEN DISPLAY APPROX. - 48 °C:
Approx. 143.0 z Short to Ground z Continuation, see CHECKING WIRING
°C (1) (GND)
(1) If a temperature is displayed which deviates greatly from the ambient temperature of the sensor,
check sensor wiring for transfer resistances. Note when doing this that sensor is heated from external
sources, e.g. radiated heat when engine is not running.
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If the specification is obtained:

z Start engine and run at idling speed.

Temperature value must increase uniformly

NOTE: z Temperature increases in steps of 1.0 C.

z If irregular engine running occurs in certain temperature ranges and
the temperature figure does not increase without interruption, the
temperature signal is temporarily interrupted and the sensor must be
replaced.

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.

Continuation of check when display approx. - 48 °C:

z Disconnect 4-pin connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant
Temperature (ECT) sensor -G2- -arrow-.

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Fig. 49: Disconnecting Pin Connector From Engine Coolant Temperature (ECT) Sensor With
Engine Coolant Temperature (ECT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Bridge connector terminals 3 + 4 using auxiliary cables from VAG 1594 and observe display.

If display jumps to approx. 143.0 °C:

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Fig. 50: Identifying ECT Sensor Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

z Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT)
sensor -G2 -, see item 28 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
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z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If display remains at approx. -48.0 C:

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.
z Check wiring using Electrical Wiring Diagram, see CHECKING WIRING .

Continuation of check when display approx. 143.0 °C:

z Disconnect 4-pin connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant
Temperature (ECT) sensor -G2- -arrow-.

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Fig. 51: Disconnecting Pin Connector From Engine Coolant Temperature (ECT) Sensor With
Engine Coolant Temperature (ECT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

If display jumps to approx. -48.0 C:

z Press -->button.
z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.
z Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT)
sensor -G2-, see item 28 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
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Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If display remains at approx. 143.0 °C:

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.
z Check wiring using Electrical Wiring Diagram, see CHECKING WIRING .

Checking wiring

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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Fig. 52: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Disconnect 4-pin connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant
Temperature (ECT) sensor -G2- -arrow-.

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Fig. 53: Disconnecting Pin Connector From Engine Coolant Temperature (ECT) Sensor With
Engine Coolant Temperature (ECT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wire for open circuit between test box and 4 -pin connector using Electrical Wiring Diagram.
z terminal 3 + Socket 93

z terminal 4 + Socket 108

Wire resistance: max. 1.5

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Fig. 54: Identifying ECT Sensor Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring between test box and 4 -pin connector terminal 3 for short circuit to wire terminal 4 and to
vehicle Ground (GND) using Electrical Wiring Diagram.

z terminal 3 + socket 108

z terminal 3 + vehicle Ground (GND)

Specification: INFINITY ohm

z Additionally check both wires for short to battery positive.

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Specification:

If no wiring malfunctions are detected:

z Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62- terminal C (signal)
and D (Ground).

Fig. 55: Identifying ECT Sensor Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Scale A shows resistance values for temperature range 0 to 50 °C and scale B the values for temperature range
50 to 100 °C.

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Fig. 56: ECT Sensor Resistance Versus Temperature Range Graph

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Examples:

z 30 °C is in range A and corresponds to a resistance of 1.5 to 2.0 kohm

z 80 °C is in range B and corresponds to a resistance of 275 to 375 ohm

If the specification is not obtained:

z Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT)
sensor -G2 -, see item 28 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
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Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If there is no malfunction in the wiring and the resistance measurement values are OK:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Intake Air Temperature (IAT) sensor, checking

NOTE: Only gold-plated terminals must be used to repair the terminals in the Intake Air
Temperature (IAT) sensor.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram
z VAG 1921 pliers for spring type clips
z Chilling spray (commercially available)

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

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Fig. 57: Identifying Scan Tool Display - Checking IAT Sensor (1 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 58: Identifying Scan Tool Display - Checking IAT Sensor (2 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -0- and -4- for "Display group number 4" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

Fig. 59: Identifying Scan Tool Display - Checking IAT Sensor (3 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Read off intake air temperature value in display zone 4.

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Specification: approx. ambient temperature

DISPLAY GROUP 4: GENERAL ENGINE DATA

Display zones
1 2 3 4
Display group 4: General engine data
Display xxxx RPM xx.xxx V xxx.x °C xxx.x °C
Indicated Engine Supply voltage for Engine Coolant Intake air temperature
speed (in Motronic Engine Temperature
steps of 40) Control Module (ECM) (ECT)
-J220-
Working 0 to 6800 12.000 to 15.000 V -48.0 to 143.0 °C -48.0 to 143.0 °C
range RPM
Specification 760 to 810 12.000 to 15.000 V - Approx. ambient temperature(3)
RPM (1)
700 to 750
RPM(2)
- - - If the specification is not
obtained, see CHECKING
WIRING , Evaluating display
group 4
(1) Engine idling at normal operating temperature for manual transmission
(2) Engine idling at normal operating temperature for automatic transmission
(3) If a temperature is displayed which is less than the ambient temperature of the sensor, check sensor
wiring for transfer resistances. When doing this be aware that when stationary the sensor can be
heated -up by radiated heat.

If the specification is not obtained:

z Perform check according to following table:

Evaluating display group 4, display zone 4 - Intake air temperature

EVALUATING DISPLAY GROUP 4, DISPLAY ZONE 4 - INTAKE AIR TEMPERATURE

Display group: 4
Display zone: 4 Possible cause Corrective action
Approx. -48.0 °C(1) z Wiring open circuit or z Continuation, see CHECKING WIRING
short to positive
Approx. 143.0 °C(1) z Short to Ground (GND) z Continuation, see CHECKING WIRING
Approx. ambient z Signal periodically z Check sensor, see CHECKING WIRING ,
temperature interrupted continuation for ambient temperature

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(1) If a temperature is displayed which is below the ambient air temperature of the sensor, check sensor
wiring for transfer resistances. Note when doing this that sensor is heated from external sources, e.g.
radiated heat when engine is not running.

If the specification is obtained:

Continuation of check when display = ambient temperature:

z Disconnect 2-pin connector -arrow- from Intake Air Temperature (IAT) sensor -G42-.

Fig. 60: Disconnecting Pin Connector From Intake Air Temperature (IAT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Remove Intake Air Temperature (IAT) sensor -arrow-.

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 2003 Volkswagen New Beetle GLS
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Fig. 61: Removing Intake Air Temperature (IAT) Sensor

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Re-connect 2-pin connector.

z Note intake air temperature value in display zone 4.

z Spray sensor -arrow- with commercial chilling agent while observing temperature value.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 62: Spray Sensor With Commercial Chilling Agent While Observing Temperature Value
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Temperature value must decrease.

If the specification is not obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation of check when display reads approx. -48.0 °C:

z Disconnect connector -1- from Intake Air Temperature (IAT) sensor -G42- -2-.

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 2003 Volkswagen New Beetle GLS
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Fig. 63: Disconnecting Connector From Intake Air Temperature (IAT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Bridge connector terminals using aux. cables from VAG 1594 and observe display.

If display jumps to approx. 143.0 °C:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.
z Replace Intake Air Temperature (IAT) sensor -G42-, see item 26 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .

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z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If display remains at approx. -48.0 °C:

z Press --> button.

z Press buttons 0 and 6 for function "End output" and confirm entry with Q button.
z Switch off ignition.
z Check wiring using Electrical Wiring Diagram, see CHECKING WIRING .

Continuation of check when display reads approx. 143 °C:

z Disconnect connector -1- from Intake Air Temperature (IAT) sensor -2-.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 64: Disconnecting Connector From Intake Air Temperature (IAT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

If display jumps to approx. -48.0 °C:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.
z Replace Intake Air Temperature (IAT) sensor -G42-, see item 26 .

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If display remains at approx. 143 °C:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.
z Check wiring using Electrical Wiring Diagram, see CHECKING WIRING .

Checking wiring

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 65: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Disconnect connector -1- from Intake Air Temperature (IAT) sensor -2-.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 66: Disconnecting Connector From Intake Air Temperature (IAT) Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring between test box and 2 -pin connector -1- for open circuit according to Electrical Wiring
Diagram.
z Terminal 1 + Socket 85

z Terminal 2 + Socket 108

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 67: Identifying IAT Sensor Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Wire resistance: max. 1.5

z Additionally check both wires for short to battery positive.

Specification: INFINITY ohm

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 2003 Volkswagen New Beetle GLS
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If no wiring malfunctions are detected:

z Perform resistance measurement on Intake Air Temperature (IAT) sensor -G42- terminals 1 (signal) and 2
(ground).

Fig. 68: Performing Resistance Measurement On Intake Air Temperature (IAT) Sensor Terminal1
(Signal)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Scale A shows resistance values for temperature range 0 to 50 °C and scale B the values for temperature range
50 to 100 °C.

Examples:

z 30 °C is in range A and corresponds to a resistance of 1.5 to 2.0 kohm

z 80 °C is in range B and corresponds to a resistance of 275 to 375 ohm
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

If the specification is not obtained:

z Replace Intake Air Temperature (IAT) sensor -G42-, see item 26 .

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If there is no malfunction in the wiring and the resistance measurement values are OK:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Fig. 69: IAT Sensor Resistance Versus Temperature Range Graph

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1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Engine speed (RPM) sensor, checking

The Engine Speed (RPM) Sensor -G28- is a speed and reference mark sensor. The engine will not start if there
is no speed signal. If the speed signal fails when the engine is running, it will cause the engine to stall
immediately.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test sequence

z Separate gray 3 -pin connector -1- to Engine Speed (RPM) Sensor -G28-.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 70: Separating Pin Connector To Engine Speed (RPM) Sensor

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Measure sensor resistance between terminals 2 + 3 of connector to sensor.

Specification: 730 to 1000 ohm

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 71: Measuring Sensor Resistance Between Terminals Of Connector To Engine Speed (RPM)
Sensor
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check sensor for short between terminals 1 + 2 as well as 1 + 3.

Specification: INFINITY ohm

If the specifications are not obtained:

z Replace Engine Speed (RPM) Sensor -G28-, see item 13 .

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
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MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND

ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If no sensor malfunction is detected:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 72: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 3 -pin connector using Electrical Wiring Diagram.
z terminal 1 + socket 108

z terminal 2 + socket 90

z terminal 3 + socket 82

Wire resistance: Max. 1.5

Fig. 73: Identifying Engine Speed (RPM) Sensor Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Additionally check wires for short to one another.

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1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

If no wiring malfunction is found:

z Remove sensor and check sensor wheel for secure fit, damage and run -out.

NOTE: There is a larger gap on the sensor wheel. This gap is the reference mark
and does not mean that the sensor wheel is damaged.

If no malfunction is detected on sensor wheel:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Fuel injectors, checking

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1527 voltage tester
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash.

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Fig. 74: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Engine Speed (RPM) Sensor -G28- must be OK, checking, see ENGINE SPEED (RPM) SENSOR,
CHECKING
z Battery voltage must be at least 11.5 V
z Fuel pump relay must be OK

Test sequence

Checking resistance of fuel injectors

z Disconnect connectors from fuel injectors.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 75: Disconnecting Connectors From Fuel Injectors

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check resistance of fuel injectors between terminals.

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1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 76: Checking Resistance Of Fuel Injectors Between Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification: 12.0 to 17.0

NOTE: The resistance figures are valid for approx. 20°C. At higher temperature the
resistance figures will increase.

If the specification is not obtained:

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z Replace malfunctioning fuel injector, see item 10 .

Pay attention to the following when installing the fuel injector:

z Replace O -rings on all fuel injectors and lightly moisten with clean engine oil.
z Insert fuel injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
z Install fuel rail with secured fuel injectors onto intake manifold and press in evenly.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Checking voltage supply

z Disconnect connectors from fuel injectors.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 77: Disconnecting Connectors From Fuel Injectors

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect LED test light to terminal 1 and Ground (GND) of relevant fuel injector connector.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 78: Connecting LED Test Light To Terminal 1 And Ground Of Fuel Injector Harness
Connector
Courtesy of VOLKSWAGEN OF AMERICA, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Operate starter and check voltage supply for fuel injector.

LED must light up.

If the LED does not light up:

z Switch off ignition.

z Check wire between 2 pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit using
Electrical Wiring Diagram.

Wire resistance: max. 1.5

Checking activation and voltage supply

z Disconnect connectors from fuel injectors.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 79: Disconnecting Connectors From Fuel Injectors

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect VAG1527 voltage tester to connector terminals of fuel injector to be tested using cables from
VAG 1594.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 80: Connecting VAG1527 Voltage Tester To Fuel Injector Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Operate starter and check activation for fuel injector.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

LED must flicker

If the LED does not flicker:

z Switch off ignition.

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

Fig. 81: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

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 2003 Volkswagen New Beetle GLS
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z Check wiring between the test box and 2-pin connectors for open circuit, short circuit to Ground (GND)
or positive using Electrical Wiring Diagram:
z Fuel injector 1: terminal 2 + socket 96

z Fuel injector 2: terminal 2 + socket 89

z Fuel injector 3: terminal 2 + socket 97

z Fuel injector 4: terminal 2 + socket 88

z Wire resistance: Max.1.5

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 82: Identifying Fuel Injector Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Additionally check wires for short to one another.

Specification:

If there is no malfunction in the wiring and the resistance measurement values are OK.:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Fuel injectors, checking for leaks and quantity injected

Special tools, test equipment and auxiliary items

z VAG 1348/3 Remote control

z VAG 1348/3-2 Adapter
z VAG 1602 Calibration tester

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 83: Identifying Special Tools

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test conditions

z Check that the fuel pressure is in order, see FUEL PRESSURE REGULATOR AND HOLDING
PRESSURE, CHECKING
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

WARNING: Fuel system is under pressure! Before opening the system place a cloth
around the connection. Then release pressure by carefully loosening the
connection.

Test sequence

z Disconnect connectors from fuel injectors.

Fig. 84: Disconnecting Connectors From Fuel Injectors

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Remove fuel rail complete.

z Disconnect vacuum hose from fuel pressure regulator.
z Lift fuel rail with fuel injectors off intake manifold and support it.

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 2003 Volkswagen New Beetle GLS
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Checking for leaks

z Initiate output Diagnostic Test Mode (DTM), see OUTPUT DIAGNOSTIC TEST MODE (DTM)
(FUNCTION 03), INITIATING (fuel pump must run).

NOTE: This work sequence allows the fuel pump to run when the engine is not
running.

z Check fuel injector for leaks (visual check). Only 1 to 2 drops per minute must emit from each valve
when fuel pump is running.

If the fuel loss is greater:

z Switch off ignition.

z Replace malfunctioning fuel injector, see item 10 .

Pay attention to the following when installing the fuel injector:

z Replace O -rings on all fuel injectors and lightly moisten with clean engine oil.
z Insert fuel injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
z Install fuel rail with secured fuel injectors onto intake manifold and press in evenly.
z The connectors must audibly engage in the fuel injectors when pushed on.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Checking injected quantity

z Insert fuel injector to be checked in a measuring glass of VAG 1602 tester for injected quantity.
z Connect one terminal of fuel injector to be tested to engine Ground (GND) using auxiliary cables from
VAG 1594.
z Connect second fuel injector terminal with auxiliary cable to VAG 1348/3 remote control using VAG
1348/3 -2 adapter cable.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 85: Connecting One Terminal Of Fuel Injector To Engine Ground (Gnd) Using Auxiliary
Cables From VAG 1594
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect alligator clip to battery (+).

z Initiate output DTM, see OUTPUT DIAGNOSTIC TEST MODE (DTM) (FUNCTION 03),
INITIATING (fuel pump must run).

NOTE: This work sequence allows the fuel pump to run when the engine is not
running.

z Operate VAG 1348/3 remote control for 30 seconds.

z Repeat check on other fuel injectors. Use new measuring glasses.

z After all fuel injectors have been activated, place measuring glasses on a horizontal surface and compare
injected quantity.
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Specification: 133 to 157 ml per injector

If the measuring values of one or more fuel injectors are above or below the prescribed specifications:

z Switch off ignition.

z Replace malfunctioning fuel injector, see item 10 .

Pay attention to the following when installing the fuel injector:

z Replace O -rings on all fuel injectors and lightly moisten with clean engine oil.
z Insert fuel injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
z Install fuel rail with secured fuel injectors onto intake manifold and press in evenly.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Fuel pressure regulator and holding pressure, checking

The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure.

Special tools, test equipment and auxiliary items

z VAG 1318 Pressure gauge

z 1318/9 Adapter
z 1318/17 Adapter

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 86: Identifying Special Tools

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test sequence

z Remove fuse 28 (fuel pump) from fuse holder. Fuse holder is located behind access panel at far left end
of dash.
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

WARNING: Fuel system is under pressure! Before opening the system place a
cloth around the connection. Then release pressure by carefully
loosening the connection.

Fig. 87: Locating Fuse 28 (Fuel Pump)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Pull off supply line/hose -1- and collect leaking fuel with a cloth.

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 2003 Volkswagen New Beetle GLS
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Fig. 88: Pulling Off Supply Line/Hose -1-

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect VAG 1318 pressure gauge to fuel supply line/hose and to hose to fuel rail using adapters 1318/9
and 1318/17.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 89: Connecting VAG 1318 Pressure Gauge To Fuel Supply Line/Hose And To Hose To Fuel
Rail Using Adapters 1318/9 And 1318/17
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Open measured device cut -off tap. (Handle points in through-flow direction -arrow-).
z Refit fuse 28 (fuel pump) in fuse holder.
z Start engine and run at idle speed.
z Measure fuel pressure.

Specification: Approx. 2.5 bar

If the specification is obtained:

z Pull vacuum hose -1- off fuel pressure regulator -2-.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fuel pressure must increase to approx. 3.0 bar.

Fig. 90: Pulling Vacuum Hose Off Fuel Pressure Regulator

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Switch off ignition.

If the specification is not obtained:

z Check quantity supplied by fuel pump.

See FUEL SUPPLY

If the specification is obtained:

z Switch off ignition.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check for leaks and holding pressure by observing pressure drop on gauge.

After 10 minutes there must be a residual pressure of at least 2.0 bar.

If the holding pressure drops below 2 bar:

z Start engine and run at idle speed.

z Switch ignition off after pressure has built-up. At same time close pressure measured device cut-off tap
(handle cross through -flow direction -arrow-).

Fig. 91: Identifying Pressure Gauge

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Observe pressure drop on gauge.

If the pressure does not drop:

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check fuel pump non -return valve.

See CHECK FUEL PUMP

If the pressure drops again:

z Open VAG 1318 pressure gauge shut-off tap (handle in through - flow direction).

Fig. 92: Checking Pressure Gauge For Leaks

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Start engine and run at idle speed.

z Switch ignition off after pressure has built-up. At same time pinch/seal return hose together.

If the pressure does not drop:

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 2003 Volkswagen New Beetle GLS
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z Replace fuel pressure regulator, see item 4 .

If the pressure drops again:

z Check pipe connections, O -rings on fuel manifold and fuel injectors for leaks.
z Check pressure gauge for leaks.

NOTE: Before removing the pressure gauge, remove fuse 28 and place a cloth around
the connections to be loosened.

Intake air system (unmetered air), checking for leaks

Checking with engine leak detector spray G 001 800 A1

NOTE: z The vacuum in the intake system will cause the leak detector spray to be
drawn in with the unmetered air. The leak detector spray reduces the
combustibility of the mixture. This leads to a drop in engine speed and to a
change of oxygen sensor reading.
z The safety precautions listed on the container must be adhered to.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z Engine leak detector spray G 001 800 A1

Test conditions

z Engine Coolant Temperature (ECT) must be at least 80 °C, display group 04, display zone 3.

Test sequence

z Connect VAG 1551 scan tool (or VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 93: Identifying Scan Tool Display - Checking For Unmetered Air Leaks (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 94: Identifying Scan Tool Display - Checking For Unmetered Air Leaks (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -0- and -1- for "Display group number 1" and confirm entry with -Q- button.

Indicated on display (1 to 4 Display zones)

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 95: Identifying Scan Tool Display - Checking For Unmetered Air Leaks (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check whether Engine Coolant Temperature (ECT) is above 80 °C in display zone 2.

z Observe engine speed in display zone 1 and oxygen sensor control before Three Way Catalytic Converter
(TWC) in display zone 3.

DISPLAY GROUP 1: IDLING TEST

Display zones
1 2 3 4
Display group 1: Idling test
Display xxxx RPM xxx.x °C xx.x % xxxxxx
Indicated Engine speed Engine Coolant Oxygen sensor control Adjustment
(in steps of Temperature (ECT) before Three Way Catalytic conditions for basic
40) Converter (TWC) setting
Working 0 to 6800 -48.0 to 143.05C -10.0 to 10.0% -
range RPM
Specification 760 to 810 80.0 to 115.05C The value must fluctuate by -
RPM (1) at least 2% in the -10.0 to
700 to 750 10.0% range
RPM (2)
(1) Engine idling at normal operating temperature for manual transmission

(2) Engine idling at normal operating temperature for automatic transmission

z Systematically spray parts of intake system with engine leak detector spray.

If the engine speed drops or the oxygen sensor control changes:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Switch off ignition.

z Check sprayed areas of intake system for leaks and repair if necessary.

If the engine speed and the oxygen sensor control do not change:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

FUNCTIONS, CHECKING

Idle speed, checking

NOTE: z Idle speed, ignition timing and CO content not adjustable.

z The idle speed is regulated to specification by the throttle valve positioner
in conjunction with the DIS function.
z CO content regulated by oxygen sensor control. Malfunctions in oxygen
sensor control are detected in On Board Diagnostic (OBD) and stored in
DTC memory.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable

Test conditions

z Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks
z All electrical accessories, e.g. lights and rear window defroster must be switched off
z If the vehicle is equipped with air conditioning, it must be turned off
z On vehicles with automatic transmission selector lever in "P" or "N" position
z Engine Coolant Temperature (ECT) must be at least 80 °C display group 04, display zone 3
z Intake air temperature less than 60 °C, see display group 04, display zone 4

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .
z - Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .
z Leave VAG 1551 scan tool connected.
z Continue running engine at idle speed.

Indicated on display

Fig. 96: Identifying Scan Tool Display - Checking Idle Speed (1 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -4- for function "Basic Setting" and confirm entry with -Q- button.

Indicated on display

Fig. 97: Identifying Scan Tool Display - Checking Idle Speed (2 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.
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z Press buttons -0-, -0- and -1- for "Display group number 1" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 98: Identifying Scan Tool Display - Checking Idle Speed (3 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check adjustment conditions for basic setting in display zone 4.

Specification: 1x111111

Significance of the numbers, see CHECKING IDLE SPEED

NOTE: In the "System in basic setting" function the EVAP canister purge
regulator valve -N80- is closed and the air conditioner compressor
switched off.

DISPLAY GROUP 1: IDLING TEST

Display zones
1 2 3 4
Display group 1: Idling test
Display xxxx RPM xxx.x °C xx.x % xxxxxx
Indicated Engine speed Engine Coolant Oxygen sensor control Adjustment conditions
(in steps of Temperature (ECT) before Three Way Catalytic
40) Converter (TWC)
Working 0 to 6800 -48.0 to 143.0 C -10.0 to 10.0% -
range RPM
Specification 760 to 810 80.0 to 115.0 C Value must fluctuate by at 1x111111
RPM (1) least 2% in -10.0 to 10.0%
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

700 to 750 range

RPM (2)
- - - Significance, see
CHECKING IDLE
SPEED
(1) Engine idling at normal operating temperature for manual transmission
(2) Engine idling at normal operating temperature for automatic transmission

Significance of 8 digit number block

SIGNIFICANCE OF 8 DIGIT NUMBER BLOCK SPECIFICATION

Significance when display = 1
1 2 3 4 5 6 7 8 Significance
1 Engine Coolant Temperature (ECT) above 80 °C
1 Speed below 2000 RPM
1 Throttle valve closed
1 Oxygen sensor control OK.
1 Idling switch closed
1 Air conditioner compressor switched off
1 Three Way Catalytic Converter (TWC) temperature over 350 °C
1 No DTCs recognized by On Board Diagnostic (OBD)

If the specification is obtained:

z Briefly increase engine speed (RPM) (rev -up) and then allow engine to run at idle speed for 2 minutes.

Checking idle speed

z Continue running engine at idle speed.

z Change to display group 56 as follows:
z Press -C- button.

NOTE: z Idling speed cannot be adjusted.

z Idling speed is tested during the basic setting of the engine.
z In the "System in basic setting" function the EVAP canister purge
regulator valve -N80- is closed and the air conditioner compressor
switched off.

WARNING: The electric coolant fan must not be running.

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 2003 Volkswagen New Beetle GLS
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z Press buttons -0-, -5- and -6- for "Display group number 56" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 99: Identifying Scan Tool Display - System In Basic Setting 56

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check operating mode in display zone 4.

Specification: 0x000 (Significance, see OXYGEN SENSOR AND OXYGEN SENSOR CONTROL
BEFORE THREE WAY CATALYTIC CONVERTER (TWC), CHECKING )

z Check specified idle speed in display zone 2.

Specification:

Manual transmission 760 RPM

Automatic transmission 700 RPM

z Check actual idle speed in display zone 1.

Specification:

Manual transmission 760 to 810 RPM 1 )

Automatic transmission 700 to 750 RPM 1 )

1 ) Engine idling at normal operating temperature

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

NOTE: During idling check the EVAP canister purge regulator valve and the air
conditioner are switched off and the oxygen sensor control learning
procedure is initiated.

DISPLAY GROUP 56: IDLING TEST - ENGINE IDLING AT NORMAL OPERATING

TEMPERATURE
Display zones
1 2 3 4
Display group 56: Idling test - Engine idling at normal operating temperature
Display xxxx RPM xxxx RPM xxx.x % xxxxx
Indicated Actual engine speed Specified engine speed Idling Operating conditions
(in steps of 10) (in steps of 10) regulator
Working 0 to 6800 RPM - -5.0 to -
range 12.0%
Specification 760 to 810 RPM (1) 760 RPM (1) -5.0 to 0x000
700 to 750 RPM (2) 700 RPM (2) 12.0%
If the specifications are not obtained, - Significance, see OXYGEN
see OXYGEN SENSOR AND SENSOR AND OXYGEN
OXYGEN SENSOR CONTROL SENSOR CONTROL BEFORE
BEFORE THREE WAY THREE WAY CATALYTIC
CATALYTIC CONVERTER CONVERTER (TWC),
(TWC), CHECKING , Continuation CHECKING
(1) For manual transmission

(2) For automatic transmission

NOTE: z The value shown in display zone 1 is the actual engine speed.
z The value shown in display zone 2 (specified engine speed) is a
theoretical value calculated by the Motronic Engine Control Module
(ECM) -J220-.
z When the engine is idling the Motronic Engine Control Module (ECM)
-J220- tries constantly to adjust the actual engine speed so that it
adapts the specified value.
z This means that the actual engine speed when idling should be
approximately the same as the specified engine speed.

Significance of 5 digit number block

SIGNIFICANCE OF 5 DIGIT NUMBER BLOCK SPECIFICATION

Significance when display = 1
1 2 3 4 5 Significance
1 Air conditioner compressor switched on

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 2003 Volkswagen New Beetle GLS
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1 Driving range (gear) selected

1 Air conditioning system switched on
1 Rear mirror defogger on
1 Power assisted steering pressure switch on

If the specification is obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the idle speed is not obtained:

z Adapt ECM to Throttle Valve Control Module - J338-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-, ADAPTING .
z Road test vehicle.

Observe the valid safety precautions when road testing, see SAFETY PRECAUTIONS .

z Again check control module DTC memory.

z Repeat idle check.

If the specifications are not obtained again:

z Check Throttle Valve Control Module -J338-, see THROTTLE VALVE CONTROL MODULE -
J338-, CHECKING .
z Check operating condition of engine, see ENGINE OPERATING MODE, CHECKING .
z Check intake air system for unmetered air, see INTAKE AIR SYSTEM (UNMETERED AIR),
CHECKING FOR LEAKS
z Check signals from/to air conditioner, see SIGNAL FROM/TO AIR CONDITIONING,
CHECKING .

Oxygen Sensor and oxygen sensor control before Three Way Catalytic Converter (TWC), checking

NOTE: z Raise vehicle to reach oxygen sensor connector.

z The Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC)
has constant regulation and can be distinguished by a 6 -pin connector
from the Oxygen Sensor (O2S) behind the Three Way Catalytic Converter
(TWC).
z Only gold terminals may be used for servicing the terminals in the
connector for the oxygen sensor.
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 2003 Volkswagen New Beetle GLS
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Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holder located behind access panel at far left end of dash.

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Fig. 100: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks
z Engine Coolant Temperature (ECT) must be at least 80 °C display group 04, display zone 3

Functional check

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 101: Identifying Scan Tool Display - Checking HO2S Before TWC (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

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Fig. 102: Identifying Scan Tool Display - Checking HO2S Before TWC (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -3- and -0- for "Display group number 30" and confirm entry with -Q- button.

Indicated on display (1 to 2 - Display zones)

Fig. 103: Identifying Scan Tool Display - Checking HO2S Before TWC(3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check status of the oxygen sensor control before Three Way Catalytic Converter (TWC) (display zone 1):

Specification: 1 1 1

DISPLAY GROUP 30: OXYGEN SENSOR CONTROL

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Display zones
1 2 3 4
Display group 30: oxygen sensor control
Display xxx xxx - -
Indicated Status of oxygen sensor control before Three Way Status of oxygen sensor - -
Catalytic Converter (TWC) control after Three Way
Catalytic Converter (TWC)
Working - - - -
range
Specification 111 110 - -
Significance, see CHECKING OXYGEN SENSOR - - -
WIRING FOR OXYGEN SENSOR 1
If the specification is not obtained, see Heated Oxygen - - -
Sensor (HO2S) for oxygen sensor before Three Way
Catalytic Converter (TWC), checking

NOTE: For display zone 1:

z The first figure in the 3 figure number block periodically changes between
0 and 1 (Heated Oxygen Sensor (HO2S) on and off).
z The numbers in the 3 figure number block can alternate from 0 and 1 in the
display depending on the status of the oxygen sensor control.

Significance of 3 digit number block in display zone 1

SIGNIFICANCE OF 3 DIGIT NUMBER BLOCK IN DISPLAY ZONE 1 SPECIFICATION

Significance if display = 1
1 2 3 Significance
1 Oxygen sensor control active
1 Oxygen sensor operationally ready
1 Heated Oxygen Sensor (HO2S) on

If the specification is obtained:

z Change to display group 32 as follows:

z Press -C- button.
z Press buttons -0-, -3- and -2- for "Display group number 32" and confirm entry with -Q- button.

Indicated on display (1 to 2 -- Display zones)

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Fig. 104: Identifying Scan Tool Display - Read Measuring Value Block 32
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check oxygen sensor control learned values at idling speed (additive) in display zone 1.

Specification: -3.0...3.0%

z Check oxygen sensor control learned values at part load (multiplicative) in display zone 2.

Specification: -10.0...10.0%

DISPLAY GROUP 32: OXYGEN SENSOR CONTROL LEARNED VALUES BEFORE THREE
WAY CATALYTIC CONVERTER (TWC)
Display zones
1 2 3 4
Display group 32: oxygen sensor control learned values before Three Way Catalytic Converter
(TWC)
Display xx.x % xx.x % - -
Indicated Oxygen sensor control learned Oxygen sensor control learned value at part load - -
value at idling (additive) (multiplicative)
Working -25.0 to 25.0% -25.0 to 25.0% - -
range
Specification -3.0 to 3.0% -10.0 to 10.0% - -
can fluctuate slightly can fluctuate slightly
If the specifications are not See CHECKING OXYGEN SENSOR WIRING
achieved FOR OXYGEN SENSOR 1 , Evaluating display - -
group 32

NOTE: In display zones 1 and 2:

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z Oxygen Sensor control learned values are fuel dependent!

z Low values indicate that the engine is running too rich and therefore
the oxygen sensor control is leaning the mixture.
z High values indicate that the engine is running too lean and therefore
the oxygen sensor control enriches the mixture.
z If there is no voltage supply to the control module all the values
learned will be cancelled.
z add = additive - The effects of the malfunction (e.g. unmetered air)
will reduce as the engine speed increases. The injection period will
be modified by a fixed amount for additive learned values. This
amount is not dependent upon the basic injection period.
z mul = multiplicative - The effects of the malfunction (e.g.
malfunctioning fuel injector) will increase as the engine speed
increases. A multiplicative learned value is a proportional change to
the injection period. This change is dependent on the basic injection
period.

Initiating learning process: Control module in mode 04, Basic

settings

z Learning prerequisites for idle speed: idle speed, Engine Coolant

Temperature (ECT) min. 75 C, intake air temperature max. 90 °C.
z Learning prerequisites for part load: Engine Coolant Temperature
(ECT) min. 75 °C, intake air temperature max. 90 °C
z EVAP canister purge regulator valve must be closed and the A/C
compressor must be off.

If the specification is obtained:

z Change to display group 33 as follows:

VAG 1551: Press button -3-

VAG 1552: Press button

Indicated on display (1 to 2 Display zones)

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Fig. 105: Identifying Scan Tool Display - Read Measuring Value Block 33
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Observe oxygen sensor control in display zone 1. Display must fluctuate at least 2% in the range -10.0 to
10.0%

DISPLAY GROUP 33: OXYGEN SENSOR CONTROL BEFORE THREE WAY CATALYTIC
CONVERTER (TWC)
Display zones
1 2 3 4
Display group 33: oxygen sensor control before Three Way Catalytic Converter (TWC)
Display xx.x % x.xxx V - -
Indicated Oxygen sensor control before Three Way Catalytic Oxygen sensor voltage before - -
Converter (TWC) Three Way Catalytic
Converter (TWC)
Working -25.0 to 25.0% - - -
range
Specification The value must fluctuate at least 2% in -10.0 to 10.0% - - -
range
If the specification is not obtained, see CHECKING - - -
OXYGEN SENSOR WIRING FOR OXYGEN
SENSOR 1 , Continuation

NOTE: In display zone 1: the display must fluctuate around 0.0%. If 0.0% is displayed
constantly, the oxygen sensor control has switched from regulation to control,
because there is a malfunction in the oxygen sensor control. Check DTC
Memory, see DTC MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM)
-J220-, CHECKING AND ERASING .

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If the specification is obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the oxygen sensor control in display zone 1 does not fluctuate as stated:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Test drive vehicle to remove possible residue on oxygen sensor and repeat check.

Observe the valid safety precautions when carrying out a road test, see SAFETY PRECAUTIONS .

If the specifications in display zone 1 are not obtained even after a test drive, or the value does not
fluctuate by at least 2%:

z Check oxygen sensor before Three Way Catalytic Converter (TWC) for aging, see OXYGEN SENSOR
AGING, OXYGEN SENSOR BEFORE THREE WAY CATALYTIC CONVERTER (TWC),
CHECKING .

Evaluating display zone 33, display zones 1 - oxygen sensor control learned values before Three Way
Catalytic Converter (TWC)

EVALUATING DISPLAY ZONE 33, DISPLAY ZONES 1 - OXYGEN SENSOR CONTROL LEARNED
VALUES BEFORE THREE WAY CATALYTIC CONVERTER (TWC) - 1 OF 2
Appears on
display Possible cause Corrective action
Low oxygen z Low learned values at idling but z Check if it disappears after highway
sensor control with normal learned values at part drive or oil change
learned values throttle: possible oil dilution (high z Check fuel injector, see FUEL
level of fuel in oil) INJECTORS, CHECKING
z Fuel injector leaking
z Check fuel pressure regulator and
z Fuel pressure too high holding pressure, see FUEL
z EVAP solenoid valve 1
PRESSURE REGULATOR AND
permanently open HOLDING PRESSURE, CHECKING
z Check EVAP solenoid valve 1, see
z Mass Air Flow (MAF) sensor
malfunctioning OUTPUT DIAGNOSTIC TEST
MODE (DTM)
z Heated Oxygen Sensor (HO2S)
z Check Mass Air Flow (MAF) sensor,
malfunctioning or oxygen sensor
soiled see MASS AIR FLOW (MAF)
SENSOR, CHECKING
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 2003 Volkswagen New Beetle GLS
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z Check Heated Oxygen Sensor (HO2S),

see FUEL INJECTION SYSTEM
COMPONENTS, CHECKING

EVALUATING DISPLAY ZONE 33, DISPLAY ZONES 1 - OXYGEN SENSOR CONTROL LEARNED
VALUES BEFORE THREE WAY CATALYTIC CONVERTER (TWC) - 2 OF 2
Appears on
display Possible cause Corrective action
High oxygen z High learned values at idle speed, z Check intake air system for leaks, see
sensor control not so high learned values at part INTAKE AIR SYSTEM
learned values throttle: possible unmetered air in (UNMETERED AIR), CHECKING
area of intake manifold FOR LEAKS
z Unmetered air between Mass Air z Repair cause
Flow (MAF) sensor and throttle z Check quantity injected, see FUEL
valve INJECTORS, CHECKING
z Fuel injector blocked
z Check Mass Air Flow (MAF) sensor,
z Mass Air Flow (MAF) sensor see MASS AIR FLOW (MAF)
malfunctioning SENSOR, CHECKING
z Fuel pressure too low z Check fuel pressure regulator and

z Heated Oxygen Sensor (HO2S)

holding pressure, see FUEL
malfunctioning or oxygen sensor PRESSURE REGULATOR AND
soiled HOLDING PRESSURE,
CHECKING
z Unmetered air at exhaust manifold
z Check Heated Oxygen Sensor (HO2S),
gasket
see FUEL INJECTION SYSTEM
COMPONENTS, CHECKING

Possible causes of malfunction if sensor control frequency is too slow:

z Slots or holes in sensor body are blocked

z Sensor vent hole in area of connecting wire is blocked
z Sensor has been overheated (glazed)
z Sensor has been damaged by leaded fuel

Checking Oxygen Sensor wiring for oxygen sensor 1

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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Fig. 106: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Remove protective cover -arrows- and separate 6-pin connector (black) -1- to Heated Oxygen Sensor
(HO2S) before Three Way Catalytic Converter (TWC) -G39-.

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Fig. 107: Separating 6-Pin Connector To HO2S -G39- Before TWC

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 6 -pin connector (to control module) according to
Electrical Wiring Diagram.
z terminal 1 + socket 70

z terminal 2 + socket 71

z terminal 5 + socket 51

z terminal 6 + socket 52

Wire resistance: Max. 1.5

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Fig. 108: Identifying HO2S -G39- Before TWC Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Additionally check wires all for short to one another.

Specification: INFINITY ohm

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If no wiring malfunction is found:

z Replace Heated Oxygen Sensor (HO2S) before Three Way Catalytic Converter (TWC) -G39-, see item
10 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Oxygen sensor and oxygen sensor control after Three Way Catalytic Converter (TWC), checking

NOTE: z Raise vehicle to reach oxygen sensor connector.

z Only gold terminals may be used for servicing terminals 3 and 4 in
connector for oxygen sensor.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holde is located behind access panel at far left end of dash.

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Fig. 109: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V.

z Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks
z Engine Coolant Temperature (ECT) must be at least 80 °C display group 04, display zone 3

Functional check

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of ECM. Engine
must be running at idle speed. Connecting scan tool and selecting Engine Control Module, see VAG
1551, CONNECTING AND SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -
J220- .
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Indicated on display

Fig. 110: Identifying Scan Tool Display - Checking HO2S After TWC (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measured value block" and confirm entry with -Q- button.

Indicated on display

Fig. 111: Identifying Scan Tool Display - Checking HO2S After TWC (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -3- and -0- for "Display group number 30" and confirm entry with -Q- button.

Indicated on display (1 to 2 - Display zones)

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Fig. 112: Identifying Scan Tool Display - Checking HO2S After TWC (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check status of oxygen sensor control after Three Way Catalytic Converter (TWC) (display zone 2).

Specification: 1 1 0

DISPLAY GROUP 30: OXYGEN SENSOR CONTROL

Display zones
1 2 3 4
Display group 30: Oxygen sensor control
Display xxx xxx - -
Indicated Status of oxygen sensor Status of oxygen sensor control after Three Way Catalytic - -
control before Three Way Converter (TWC)
Catalytic Converter
(TWC)
Working - - - -
range
Specification 111 110 - -
- Significance, see POSSIBLE CAUSES OF - -
MALFUNCTION IF SENSOR CONTROL
FREQUENCY IS TOO SLOW:
- If the specification is not obtained, see HEATED - -
OXYGEN SENSOR (HO2S) FOR OXYGEN SENSOR
AFTER THREE WAY CATALYTIC CONVERTER
(TWC), CHECKING

Notes on display zone 2:

z The first figure in the 3 figure number block periodically changes between 0 and 1 (Heated Oxygen
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Sensor (HO2S) on and off).

z The numbers in the 3 figure number block can alternate from 0 and 1 in the display depending on the
status of the oxygen sensor control.
z The third position of the 3 digit number block will be set to 1 only at increased exhaust temperature and
part load.

Significance of 3 digit number block in display zone 2

Significance of 3 digit number block in display zone 2 SPECIFICATION

Significance if display = 1
1 2 3 Significance
1 Oxygen sensor control active
1 Oxygen sensor operationally ready
1 Heated Oxygen Sensor (HO2S) on

If the specification is obtained:

z Change to display group 36 as follows:

z Press --> button.
z Press buttons -0- and -4- for "Basic Setting" function and confirm entry with -Q- button.

Indicated on display

Fig. 113: Identifying Scan Tool Display - Basic Setting

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -3- and -6- for "Display group number 36" and confirm entry with -Q- button.

Indicated on display (1 to 2 - Display zones)

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Fig. 114: Identifying Scan Tool Display - System In Basic Setting 36

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check oxygen sensor voltage after Three Way Catalytic Converter (TWC) in display zone 1.

Specification: 0.100...0.900 V (can fluctuate slightly)

z Maintain engine speed at 1800 -2200 RPM.

If the diagnostic is initiated from Engine Control Module the display in display zone 4 jumps from "Test
OFF" to "Test ON."

Specification: "B1-S2 OK." appears in display zone 2.

NOTE: It can take a few minutes until display jumps from "Test ON" to "B1 -S2
OK".

DISPLAY GROUP 36: OXYGEN SENSOR CONTROL, OPERATIONAL READINESS AFTER

THREE WAY CATALYTIC CONVERTER (TWC)
Display zones
1 2 3 4
Display group 36: Oxygen sensor control, operational readiness after Three Way Catalytic
Converter (TWC)
Display x.xxx V Test OFF/Test ON -
Indicated Oxygen sensor voltage for oxygen sensor B1-S2 OK.
after Three Way Catalytic Converter B1-S2 n. OK.
(TWC) Diagnostic condition and Diagnostic
result
Working - - -
range 0.100 to 0.900 V (must fluctuate slightly) B1-S2 OK.
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Specification If specifications are not achieved, see If specifications are not achieved, see
POSSIBLE CAUSES OF POSSIBLE CAUSES OF
MALFUNCTION IF SENSOR MALFUNCTION IF SENSOR
CONTROL FREQUENCY IS TOO CONTROL FREQUENCY IS TOO
SLOW: , Evaluating display group 36 SLOW: , Continuation

If the specification is obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the specification is not obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Perform a road test to remove possible contaminates on oxygen sensor and repeat check.

Observe the valid safety precautions when carrying out a road test, see SAFETY PRECAUTIONS .

If the specifications are again not obtained:

z Replace Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130-, see item 8 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Evaluating display group 36, display zone 1 - oxygen sensor voltage oxygen sensor after Three Way
Catalytic Converter (TWC)

EVALUATING DISPLAY GROUP 36, DISPLAY ZONE 1 - OXYGEN SENSOR VOLTAGE OXYGEN
SENSOR AFTER THREE WAY CATALYTIC CONVERTER (TWC)
Appears on
display Possible cause Corrective action
Constant 1.105 z Short to positive via: oxygen sensor, z Check oxygen sensor basic voltage,
V sensor wiring, Ground (GND) wiring, see CHECKING BASIC
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Motronic Engine Control Module VOLTAGE FOR OXYGEN

(ECM) -J220- SENSOR 2
Constant z Open circuit via: oxygen sensor, z Check oxygen sensor wiring, see
between 0.400 sensor wiring, Ground (GND) wiring, CHECKING OXYGEN SENSOR
to 0.500 V Motronic Engine Control Module WIRING, OXYGEN SENSOR 2
(ECM) -J220-
Constant 0.000 z Short to Ground (GND) via: oxygen
V sensor, sensor wiring, Ground (GND)
wiring, Motronic Engine Control
Module (ECM) -J220-

Possible causes of malfunction if sensor control frequency is too slow:

z Slots or holes in sensor body are blocked

z Sensor vent hole in area of connecting wire is blocked
z Sensor has been overheated (glazed)
z Sensor has been damaged by leaded fuel

Checking basic voltage for oxygen sensor 2

z Remove protective cover -arrows- and separate 4-pin connector (black/brown) -1- to Oxygen Sensor
(O2S) after Three Way Catalytic Converter (TWC) -G130-.

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Fig. 115: Separating 4-Pin Connector (Black/Brown) -1- To HO2S -G130- After TWC
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect multimeter with auxiliary cables from VAG 1594 to measure voltage at terminals 3 + 4
(connector to Motronic control module).

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 2003 Volkswagen New Beetle GLS
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Fig. 116: Measuring Voltage At Terminals 3 And 4 On HO2S -G130- Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

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z Start engine and measure basic voltage.

Specification: 0.400 to 0.500 V

z Switch off ignition.

If the specification is not obtained:

z Check oxygen sensor wiring, see CHECKING OXYGEN SENSOR WIRING, OXYGEN SENSOR
2.

If the specification is obtained:

z Replace Oxygen Sensor after Three Way Catalytic Converter (TWC) -G130-, see item 8 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Checking Oxygen Sensor wiring, oxygen sensor 2

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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Fig. 117: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 4 -pin connector to Motronic control module using
Electrical Wiring Diagram.
z terminal 3 + socket 68

z terminal 4 + socket 69

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Fig. 118: Identifying HO2S -G130- Harness Connector Terminals

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Wire resistance: Max. 1.5 ohm

z Check wiring at connector terminals 3 + 4 for short circuit to terminals 1 + 2 using Electrical Wiring
Diagram.
z terminal 4 and socket 68

Specification: INFINITY ohm

If no wiring malfunction is found:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Oxygen sensor aging, oxygen sensor before Three Way Catalytic Converter (TWC), checking
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Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1788/10 RPM adjuster

Fig. 119: Identifying Special Tool

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test conditions

z Engine Coolant Temperature (ECT) must be at least 80 °C, see display group 04, display zone 3

Functional check

z Connect VAG 1551 scan tool (or VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) - J220-, see VAG 1551, CONNECTING AND
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SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 120: Identifying Scan Tool Display - Checking Aging, HO2S Before TWC (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -4- for function "Basic Setting" and confirm entry with -Q- button.

Indicated on display

Fig. 121: Identifying Scan Tool Display - Checking Aging, HO2S Before TWC (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -3- and -4- for "Display group number 34" and confirm entry with -Q- button.

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Indicated on display (1 to 4 - Display zones)

Fig. 122: Identifying Scan Tool Display - Checking Aging, HO2S Before TWC (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Adjust RPMs with VAG1788/10 RPM adjuster to 1800 to 2200RPM.

z Check specifications in display zones 1 to 4.
z Maintain engine speed at 1800...2200 rpm until display in display zone 4 jumps from "Test OFF" to "Test
ON". Three Way Catalytic Converter (TWC) temperature in display zone 2 must be 350 to 500 °C
z Continue to maintain speed at 1800...2200 rpm until specification "B1-S1 OK" appears in display zone 4.

OXYGEN SENSOR CONTROL SPECIFICATION

Display zones
1 2 3 4
Display group 34: Oxygen sensor aging diagnostic Bank 1 (sensor dynamics)
Display xxxx xxx.x °C xx.xx Test OFF/Test ON B1-S1
RPM OK/B1-S1 n.OK
Indicated Engine Three Way Sensor dynamics Bank 1 Diagnostic condition and
speed (in Catalytic oxygen sensor 1 diagnostic result
steps of Converter (TWC)
40) temperature
Working 0 to 6800 - 0.00 to 1.99 -
range RPM
Specifications 1800 to 350 to 500 °C > 0.50 B1-S1 OK.
2200
RPM
- - If the specifications are not obtained, see
OXYGEN SENSOR AGING, OXYGEN
SENSOR AFTER THREE WAY
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CATALYTIC CONVERTER (TWC),

CHECKING , continuation

If the specifications are obtained:

z Press --> button.

z Remove engine speed adjuster VAG 1788/10 from accelerator pedal.
z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the specifications are not obtained:

z Remove engine speed adjuster VAG 1788/10 from accelerator pedal.

z Road test vehicle to free oxygen sensor of possible contaminates and repeat test.

Observe the valid safety precautions when carrying out a road test, see SAFETY PRECAUTIONS .

If the specifications are again not obtained:

z Replace oxygen sensor before Three Way Catalytic Converter (TWC) -G39-, see item 10 .
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Oxygen sensor aging, oxygen sensor after Three Way Catalytic Converter (TWC), checking

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool (or VAG 1552 mobile scan tool) with VAG 1551/3B cable
z VAG 1788/10 RPM adjuster

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Fig. 123: Identifying Special Tool

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Test conditions

z Engine Coolant Temperature (ECT) must be at least 80 °C, see display group 04, display zone 3

Functional check

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

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Fig. 124: Identifying Scan Tool Display - Checking Aging, HO2S After TWC (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -4- for function "Basic Setting" and confirm entry with -Q- button.

Indicated on display

Fig. 125: Identifying Scan Tool Display - Checking Aging, HO2S After TWC (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -4- and -3- for "Display group number 43" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

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Fig. 126: Identifying Scan Tool Display - Checking Aging, HO2S After TWC (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Adjust RPMs with VAG 1788/10 RPM adjuster to 1800 to 2200 RPM.
z Check specifications in display zones 1 to 4.
z Maintain engine speed at 1800...2200 rpm until display in display zone 4 jumps from "Test OFF" to "Test
ON". Three Way Catalytic Converter (TWC) temperature in display zone 2 must be at least 300 °C
z Continue to maintain speed at 1800...2200 rpm until specification "B1-S2 OK" appears in display zone 4.

DISPLAY GROUP 43: OXYGEN SENSOR DIAGNOSTIC AFTER THREE WAY CATALYTIC
CONVERTER (TWC) (AGING CHECK)
Display zones
1 2 3 4
Display group 43: oxygen sensor diagnostic after Three Way Catalytic Converter (TWC) (aging
check)
Display xxxx RPM xxx.x °C x.xxx V Test OFF/Test ON
B1-S2 OK/B1-S2 n.OK
Indicated Engine speed Three Way Catalytic Diagnostic condition and diagnostic result
(in steps of Converter (TWC)
40) temperature
Working 0 to 6800 - - -
range RPM
Specifications 1800 to 2200 >300 °C 0.100 to 0.900 B1-S2 OK.
RPM
- - If the specifications are not
obtained, see Functional check ,
Continuation

If the specifications are obtained:

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z Press --> button.

z Remove engine speed adjuster VAG 1788/10 from accelerator pedal.
z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Continuation

If the specifications are not obtained:

z Remove engine speed adjuster VAG 1788/10 from accelerator pedal.

z Road test vehicle to free oxygen sensor of possible contaminates and repeat test.

Observe the valid safety precautions when road testing, see SAFETY PRECAUTIONS .

If the specifications are again not obtained:

z Replace oxygen sensor after Three Way Catalytic Converter (TWC) -G130-.
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Operational readiness of oxygen sensor after Three Way Catalytic Converter (TWC), checking

Function

To test the operational readiness of the oxygen sensor after Three Way Catalytic Converter (TWC), the fuel/air
mixture is enriched while the oxygen sensor voltage is observed. The oxygen sensor voltage must rise.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool (or VAG 1552 mobile scan tool) with VAG 1551/3B cable

Test conditions

z Engine Coolant Temperature (ECT) must be at least 80 C, display group 04, display zone 3.

Functional check

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

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Indicated on display:

Fig. 127: Identifying Scan Tool Display - Checking Operational Readiness, HO2S After TWC (1 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -4- for function "Introduction of basic setting" and confirm entry with -Q- button.

Indicated on display:

Fig. 128: Identifying Scan Tool Display - Checking Operational Readiness, HO2S After TWC (2 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -3- and -6- for "Display group number 36" and confirm entry with -Q- button.

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Indicated on display: (1...2 - Display zones)

Fig. 129: Identifying Scan Tool Display - Checking Operational Readiness, HO2S After TWC (3 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Allow engine to run at idle until readout in display zone 2 jumps from "Test OFF" to "Test ON".
z Observe oxygen sensor voltage in display zone 1. Value must rise.
z Allow engine to continue to run at idle until specified value "B1 -S2 OK" appears in display zone.

If the specifications are obtained:

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

If the specifications are not obtained:

z Road test vehicle to free oxygen sensor of possible contaminates and repeat test.

Observe the valid safety precautions when road testing, see SAFETY PRECAUTIONS .

If the specifications are again not obtained:

z Check basic voltage, see CHECKING BASIC VOLTAGE FOR OXYGEN SENSOR 2

Engine operating mode, checking

NOTE: Checks whether Motronic Engine Control Module (ECM) -J220- recognizes the

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engine operating modes idling, overrun, part throttle, enrichment, full throttle.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool (or VAG 1552 mobile scan tool) with VAG 1551/3B cable

Test conditions

z Engine Coolant Temperature (ECT) must be at least 80 °C display group 04, display zone 3

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 130: Identifying Scan Tool Display - Engine Operating Mode, Checking (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

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Fig. 131: Identifying Scan Tool Display - Engine Operating Mode, Checking (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -0- and -5- for "Display group number 5" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 132: Identifying Scan Tool Display - Engine Operating Mode, Checking (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check whether control module recognizes operating mode (display zone 4):

Idling:

As long as the engine is running at idle speed "idling" must be displayed

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z Display: Idling

Overrun mode:

z Increase engine speed to above 3000 RPM.

z Close throttle abruptly.
z As long as the engine speed is above 1400 RPM "overrun" must be displayed

z Display: Overrun

NOTE: z A test drive may have to be performed to show "Overrun" in display.

z Below 1400 RPM idling speed will be recognized.

Observe the valid safety precautions when carrying out a road test, see SAFETY PRECAUTIONS .

Part throttle:

z Rev up evenly.

As long as the engine is being revved up evenly, "part throttle" must be displayed

z Display: Part throttle

Enrichment:

z Floor accelerator pedal (onto throttle valve stop).

Acceleration "enrichment" must be displayed briefly

z Display: Enrichment

Full throttle:

z Floor accelerator pedal (onto throttle valve stop).

"Full throttle" must be displayed briefly

z Display: Full throttle

NOTE: A test drive may have to be performed to show "Full throttle" in the
display.

Observe the valid safety precautions when carrying out a road test, see SAFETY PRECAUTIONS .

z Press --> button.

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z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.

If the specifications are not obtained:

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Check accelerator mechanism for ease of operation.
z Check throttle valve potentiometer, see THROTTLE VALVE CONTROL MODULE -J338-,
CHECKING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

MOTRONIC ENGINE CONTROL MODULE (ECM)

Motronic Engine Control Module (ECM) - J220- voltage supply, checking

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash.

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Fig. 133: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z All electrical accessories, e.g. lights and rear window defroster must be switched off
z If the vehicle is equipped with air conditioning, it must be turned off
z Selector lever must be in position "P" or "N" on vehicles with an automatic transmission
z Alternator OK.

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic

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Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 134: Identifying Scan Tool Display - ECM Voltage Supply, Checking (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 135: Identifying Scan Tool Display - ECM Voltage Supply, Checking (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

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z Press buttons -0-, -0- and -4- for "Display group number 4" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 136: Identifying Scan Tool Display - ECM Voltage Supply, Checking (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Read supply voltage for Motronic Engine Control Module (ECM) - J220- in display zone 2:

Specification: At least 11.5 V

DISPLAY GROUP 4: GENERAL ENGINE DATA

Display zones
1 2 3 4
Display group 4: General engine data
Display xxxx RPM xx.xxx V xxx.x °C xxx.x °C
Indicated Engine Supply voltage for Motronic Engine Engine Coolant Intake air
speed (in Control Module (ECM) -J220- Temperature temperature
steps of 40) (ECT)
Working 0 to 6800 0.000 to 16.500 V -48.0 to 143.0 °C -48.0 to 143.0
range RPM °C
Specification 760 to 810 >11.5 V 80.0 to 115.0 °C -
RPM (1)
700 to 750
RPM(2)
- If the specification is not obtained, see - -
CHECKING VOLTAGE SUPPLY
TERMINAL 30 , Evaluating display
group 4
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(1) Engine idling at normal operating temperature for manual transmission

(2) Engine idling at normal operating temperature for automatic transmission

z Press --> button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Evaluating display group 4, display zone 2 - Control module voltage supply

EVALUATING DISPLAY GROUP 4, DISPLAY ZONE 2 - CONTROL MODULE VOLTAGE

SUPPLY
Appears
on display Possible cause Corrective action
Less than z Alternator malfunctioning, battery z Check alternator and battery voltage,
12.0 V heavily discharged charge battery
z Battery heavily loaded shortly after z Increase revs (RPM) slightly for a few
starting due to high charging current minutes and switch off current
and current consumers consumers
z Transfer resistance in the current z Check voltage supply terminal 30, see
supply or the Motronic Engine CHECKING VOLTAGE SUPPLY
Control Module (ECM) -J220- TERMINAL 30
Ground (GND) connection z - Check voltage supply terminal 15, see
z Current draw when ignition is off CHECKING VOLTAGE SUPPLY
TERMINAL 15
z Eliminate current draw

More than z Voltage regulator on alternator z Check voltage regulator, replace if

14.5 V malfunctioning necessary
z Excess voltage due to jump starting z Check DTC Memory, see DTC
or quick charging unit MEMORY OF MOTRONIC ENGINE
CONTROL MODULE (ECM) -J220-,
CHECKING AND ERASING

If the specification is not obtained:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z ConnectVAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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Fig. 137: Connecting VAGXS 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Checking voltage supply terminal 30

z Measure supply voltage between test box sockets 1 + 62 using multimeter and adapter cables from VAG
1594:

Specification: at least 11.5 V

If the specification is not obtained:

z Check wiring connections to relay plate according to Electrical Wiring Diagram.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
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ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Checking voltage supply terminal 15

z Measure supply voltage between test box sockets 2 + 3 using multimeter and cables from VAG 1594.
z Switch on ignition.

Specification: min. 11.5 V

If the specification is not obtained:

z Check wiring connections to relay plate according to Electrical Wiring Diagram.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Procedure after correcting voltage supply open circuit

All values learned by the Motronic Engine Control Module (ECM) -J220- and the basic setting values as well as
the readiness code will be erased if the voltage supply is interrupted. Therefore, depending upon the vehicle
mileage it can lead to serious engine running problems.

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable

Work sequence

Perform the following operations after voltage supply open circuit:

z Switch ignition on for at least 10 seconds.

z Switch off ignition.
z Adapt Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module -J338-, see
MOTRONIC ENGINE CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE
CONTROL MODULE - J338-, ADAPTING .
z Perform idle check, see FUNCTIONS, CHECKING .
z Generate readiness code, see READINESS CODE, GENERATING .

NOTE: During idling check the EVAP canister purge regulator valve and the air
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conditioner are switched off and the oxygen sensor control learning procedure
is initiated.

z Perform a longer test drive until poor driving characteristics are eliminated.

Observe the valid safety precautions when road testing, see SAFETY PRECAUTIONS .

z During the road test the following operating conditions must be fulfilled:

z Engine Coolant Temperature (ECT) must exceed 80 °C

When the temperature is reached, the operating conditions:

z Idling
z Part throttle
z Full throttle
z Overrun

Must be obtained several times.

z At full throttle the speed must exceed 3500 RPM

Motronic Engine Control Module (ECM) - J220-, replacing

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool with VAG 1551/3B cable

Removing

z First print out control module identification and thereby previous control module coding as follows:
z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

The control module identification and coding are indicated on the display, e.g.:

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Fig. 138: Identifying Scan Tool Display - ECM, Replacing (1 Of 2)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Print out control module identification by pressing scan tool print button.
z Press --> button.
z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.

Indicated on display:

Fig. 139: Identifying Scan Tool Display - ECM, Replacing (2 Of 2)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Switch off ignition.

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

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z Press retaining tab -arrow- to left and pull control module out.

Fig. 140: Removing Engine Control Module

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Release connector from control module and disconnect it.

z Remove control module.

Installing

z Install control module connector and lock.

z Place new control module into retaining frame.
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Adapt new control module to immobilizer Repair Manual, Electrical Equipment On Board Diagnostic
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(OBD), Repair Group 01.

z Adapt new control module to Throttle Valve Control Module - J338-, see MOTRONIC ENGINE
CONTROL MODULE (ECM) - J220- TO THROTTLE VALVE CONTROL MODULE - J338-,
ADAPTING .

z On vehicles with cruise control system: Check whether this function has been enabled (activated), see
VAG 1551, CONNECTING AND SELECTING MOTRONIC ENGINE CONTROL MODULE
(ECM) -J220- . If "G" is not evident in control module identification, activate cruise control system.

Vehicles with automatic transmissions:

z Learning kick-down point, see KICK-DOWN POSITION, LEARNING

z Adapt control module for automatic transmission:

See DIAGNOSIS - 01M

Continued for all vehicles

z Perform idle check, see FUNCTIONS, CHECKING .

z Generate readiness code, see READINESS CODE, GENERATING

Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module - J338-, adapting

The adaptation teaches the Motronic Engine Control Module (ECM) -J220- the various positions of the throttle
unit when the ignition is switched on and the engine is not running. These positions are stored in the control
module. The feedback of the throttle valve position is via both angle sensors for throttle valve drive.

Adapting sequence must be performed if:

z Voltage supply is interrupted

z Throttle Valve Control Module -J338- is removed and installed
z Throttle Valve Control Module -J338- is replaced
z If when installing another engine another Throttle Valve Control Module -J338- is installed
z Motronic Engine Control Module (ECM) -J220- is replaced.

NOTE: On vehicles with an automatic transmission, the transmission control module

must also be adapted:

See DIAGNOSIS - 01M

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool (or VAG 1552 mobile scan tool) with VAG 1551/3B cable

Test conditions
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z No DTCs must be stored in DTC memory, see DTC MEMORY OF MOTRONIC ENGINE
CONTROL MODULE (ECM) -J220-, CHECKING AND ERASING
z Battery voltage must be at least 11.5 V
z All electrical accessories, e.g. lights and rear window defroster, must be switched off
z The throttle valve must be at idling speed position (The accelerator must not be operated during the test).
z Throttle valve must not be dirty (carbonization).
z Engine Coolant Temperature (ECT) must be 5 to 95 °C display group 04, display zone 3.
z The cruise control system must be functioning correctly if installed.

Work sequence

z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 141: Identifying Scan Tool Display - Adapting ECM To Throttle Valve Control Module (1 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -4- for function "Basic Setting" and confirm entry with -Q- button.

Indicated on display

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Fig. 142: Identifying Scan Tool Display - Adapting ECM To Throttle Valve Control Module (2 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -6- and -0- for "Display group number 60" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 143: Identifying Scan Tool Display - Adapting ECM To Throttle Valve Control Module (3 Of
3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

After pressing the -Q- button the throttle valve positioner is switched so that it is not supplied with
voltage at start of test.

In this condition the throttle valve is pulled into an emergency running position by a mechanical spring in
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the Throttle Valve Control Module -J338-. The values from both angle sensors in the emergency running
position are stored by the ECM.

Thereafter the throttle valve is opened a predetermined value. If this value is achieved, the throttle valve
is again switched so that it is not supplied with voltage. Now the mechanical spring must pull the throttle
valve to the previously learned emergency running position within a predetermined time (spring test).

Then the throttle valve is closed by the throttle valve positioner and the values, which are supplied by the
angle sensors in the Throttle Valve Control Module -J338- are stored by the Motronic Engine Control
Module (ECM) -J220-.

If the Motronic Engine Control Module (ECM) - J220- switches the throttle valve positioner so that it is
without voltage during normal operation, this is indicated by the increased and hunting idle speed. The
engine reacts slowly to accelerator changes.

{ Check specifications (display zones 1 to 4):

DISPLAY GROUP 60: ADAPTING THROTTLE VALVE CONTROL MODULE -J338-

Display zones
1 2 3 4
Display group 60: Adapting Throttle Valve Control Module -J338-
Display xxx % xxx % x ADP. runs
ADP. OK.
ERROR
Indicated Throttle Throttle Learn step counter Adaptation condition
valve angle valve angle
sensor 1 - sensor 2 -
G187- G188-
Working range 0 to 100% 0 to 100% 0 to 8 -
Specification 10 to 88% 89 to 11% Counter counts up to 8 ADP. runs
during adaptation
- - 8 ADP. OK. (ERROR Appears
after unsuccessful adaptation)
If the specification is not obtained, see DTC MEMORY OF MOTRONIC ENGINE CONTROL
MODULE (ECM) -J220-, CHECKING AND ERASING or, see THROTTLE VALVE CONTROL
MODULE -J338-, CHECKING .

z Terminate engine basic setting at earliest after 30 seconds by pressing button.

Adapting has been performed successfully.

To store the values:

z Switch off ignition.

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NOTE: If the basic setting of the control module is interrupted, the cause could be
one of the following:

z The test conditions were not fulfilled.

z Throttle valve cannot reach the mechanical idle speed stop because
of contamination e.g. oil deposits.
z Throttle Valve Control Module is malfunctioning or there is a
malfunction in the wiring, checking, see THROTTLE VALVE
CONTROL MODULE -J338-, CHECKING .

After an interruption a DTC is stored in DTC memory. When next switching on ignition the basic setting
is automatically performed again.

z End engine basic setting by pressing button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Switch off ignition.

Kick-down position, learning

Following replacement of the Motronic Engine Control Module (ECM) -J220- or the accelerator pedal, vehicles
with automatic transmission must relearn the kick -down point.

Test conditions

z Ignition on, engine not running

Test sequence

z Connect scan tool VAG 1551 ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. (Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- ).

Indicated on display:

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Fig. 144: Identifying Scan Tool Display - Kick-Down Position, Learning (1 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -4- for function "Introduction of basic setting" and confirm entry with -Q- button.

Indicated on display:

Fig. 145: Identifying Scan Tool Display - Kick-Down Position, Learning (2 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -6- and -3- for "Display group number 63" and confirm with -Q- button.

Indicated on display:

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Fig. 146: Identifying Scan Tool Display - Kick-Down Position, Learning (3 Of 3)

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Observe display in display zones 3 and 4:

Display: Operate kick down

z Press accelerator pedal beyond kick -down pressure point to floor.

z Hold pedal at this point for at least 2 seconds.
z Observe display in display zones 3 and 4:

Specification: Kick Down ADP. runs then

Specification: Kick Down ADP. OK

z Observe display in display zones 3 and 4:

Display: Kick Down ERROR

z End engine basic setting by pressing the button.

z Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
z Check Throttle Position (TP) sensor:

See THROTTLE POSITION (TP) SENSOR, CHECKING

ADDITIONAL SIGNALS, CHECKING

Engine speed signal (RPM), checking

Special tools, test equipment and auxiliary items

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z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash.

Fig. 147: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Battery voltage must be at least 11.5 V

z Speedometer must be OK., checking speedometer:

See INSTRUMENTS

z Selector lever must be in position "P" or "N" on vehicles with an automatic transmission

Test sequence

NOTE: To check the speed signal the vehicle must be driven and a second person is
necessary.

WARNING: During a road test in an airbag-equipped vehicle, test equipment must

always be fastened to and operated from the rear seat by a second
technician.

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 148: Identifying Scan Tool Display - Engine Speed Signal (RPM), Checking (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 149: Identifying Scan Tool Display - Engine Speed Signal (RPM), Checking (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -0- and -5- for "Display group number 5" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 150: Identifying Scan Tool Display - Engine Speed Signal (RPM), Checking (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Test drive vehicle with a 2nd person to observe display.

Observe the valid safety precautions when carrying out a road test, see SAFETY PRECAUTIONS .

z Observe figure displayed in display zone 3:

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Specification: approx. driven speed

DISPLAY GROUP 5: GENERAL ENGINE DATA

Display zones
1 2 3 4
Display group 5: General engine data
Display xxxx RPM xxx % xxx km/h Idling part load full
load overrun
enrichment
Indicated Engine Engine Vehicle speed Operating mode
speed (in load
steps of 40)
Working 0 to 6800 0 to 0 to 260 km/h -
range RPM 175%
Specification - - Approx. vehicle speed -
- - If no driving speed is displayed, see
SIGNAL FROM/TO AIR
CONDITIONING, CHECKING ,
Continued

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

Continuation

If no speed is displayed:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 151: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Connect multimeter to measure voltage between test box sockets 3 (terminal 15) + 54 (speed signal).
z Switch on ignition.
z Lift vehicle at front left.
z Rotate front wheel and observe voltage display.

Specification: between 0 and at least 4 Volt fluctuating

NOTE: If necessary, hold the front right wheel to prevent it from turning.

If the display does not fluctuate:

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check wiring to speedometer/speedometer sensor.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Signal from/to air conditioning, checking

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse block is located behind access panel at far left end of dash.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 152: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z Air conditioner functioning OK
z Air conditioner must be switched off
z All electrical accessories, e.g. lights and rear window defroster must be switched off
z No DTCs must be stored in DTC memory, see DTC MEMORY OF MOTRONIC ENGINE
CONTROL MODULE (ECM) -J220-, CHECKING AND ERASING
z Vehicle at room temperature (warmer than + 15 °C)

Test sequence

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Connect VAG 1551 scan tool ((VAG 1552). Start engine and select "Address word" 01 of Motronic
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 153: Identifying Scan Tool Display - Signal From/To Air Conditioning, Checking (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 154: Identifying Scan Tool Display - Signal From/To Air Conditioning, Checking (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Press buttons -0-, -5- and -0- for "Display group number 50" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 155: Identifying Scan Tool Display - Signal From/To Air Conditioning, Checking (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check specifications for air conditioner (display zones 3 and 4)

DISPLAY GROUP 50: SIGNALS TO MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-
Display zones
1 2 3 4
Display group 50: Signals to Motronic Engine Control Module (ECM) -J220-
Display xxxx RPM xxxx RPM A/C-LOW Compr. ON
A/C-HIGH Compr. OFF
Indicated Actual Specified Air conditioner status Air conditioner compressor status
engine engine speed
speed (in (in steps of 10)
steps of 10)
Working 0 to 6800 - - -
range RPM
Specification 760 to 810 760 RPM (1) A/C -LOW Compressor on:
(1) Compr. ON
RPM 700 RPM (2)
700 to 750 Compressor off:
RPM (2) Compr. OFF
- - If specification is not obtained, see SIGNAL
FROM CLUTCH VACUUM VENT
VALVE SWITCH -F36-, CHECKING,
VEHICLES FROM MY 2001 ,
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Continuation
(1) Engine idling at normal operating temperature for manual transmission

(2) Engine idling at normal operating temperature for automatic transmission

z Observe display in display zone 4. It must show: Compr. OFF.

z Switch on air conditioning system.
z Select lowest temperature and highest blower speed.

Display in display zone 4 must change to Compr. ON.

z Floor accelerator pedal quickly and then release (brief burst of throttle).

Display in display zone 4 must change from Compr.ON to Compr. OFF for a few seconds (compressor
switch-off when vehicle is accelerating).

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

Continuation

If the display does not change:

z Remove inner plenum chamber cover at left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 156: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box sockets 40 + 41 and air conditioner system using
Electrical Wiring Diagram.

Wire resistance: max. 1.5 ohm

If no wiring malfunctions can be found:

z Check function of air conditioner control module.

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

Signal from Clutch Vacuum Vent Valve Switch -F36-, checking, vehicles from MY 2001

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 157: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z All electrical accessories, e.g. lights and rear window defroster must be switched off

Test sequence

z Connect VAG 1551 scan tool (or VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Indicated on display

Fig. 158: Identifying Scan Tool Display - Checking Clutch Vacuum Vent Valve Switch Signal,
Vehicles From MY 2001 (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 159: Identifying Scan Tool Display - Checking Clutch Vacuum Vent Valve Switch Signal,
Vehicles From MY 2001 (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -6- and -6- for "display group 66" and confirm with -Q- button.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Indicated on display (1 to 4 - Display zones)

Fig. 160: Identifying Scan Tool Display - Checking Clutch Vacuum Vent Valve Switch Signal,
Vehicles From MY 2001 (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Observe display in display zone 2 (3rd digit from right).

Specification: x x x x x 0 x x

z Depress clutch pedal fully and observe display in display zone 2.

Specification: x x x x x 1 x x

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

If the display does not change:

z Remove driver's side footwell cover:

See STORAGE, COVERS AND TRIMS

z Disconnect connector from Clutch Vacuum Vent Valve Switch -F36-.

z Measure resistance between switch terminals.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 161: Measuring Resistance Between Clutch Vacuum Vent Valve Switch Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification:

z Clutch not depressed: max. 1.5

z Clutch depressed: INFINITY ohm(no continuity)

If the specifications are not obtained:

z Replace Clutch Vacuum Vent Valve Switch -F36-.

NOTE: Observe installation position of Clutch Vacuum Vent Valve Switch - F36- in
bearing bracket upper assembly hole.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If the specifications are obtained:

z Connect multimeter using auxiliary cables from VAG 1594 to measure voltage between terminal 2 and
Ground (GND).

Fig. 162: Identifying Clutch Vacuum Vent Valve Switch Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Switch on ignition.

Specification: min. 11.5 V

If the specification is not obtained:

z Check wiring for open circuit between connector terminal 2 and central electric using Electrical Wiring
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Diagram.

If the specification is obtained:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

Fig. 163: Connecting Vag 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and connector using Electrical Wiring Diagram.
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 164: Identifying Clutch Vacuum Vent Valve Switch Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

terminal 3 + socket 39

Wire resistance: Max. 1.5 ohm

If the specification is obtained:

z Additionally check wires for short to one another.

z Additionally check wiring for short to battery positive or Ground GND).

If no wiring malfunction is found:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

Signal from Clutch Vacuum Vent Valve Switch -F36-, checking, vehicles through MY 2000

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z VAG 1598/31 test box

z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK. Fuse holder is located behind access panel at far left end of dash.

Fig. 165: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Battery voltage must be at least 11.5 V

z All electrical accessories, e.g. lights and rear window defroster must be switched off

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 166: Identifying Scan Tool Display - Checking Signal From Clutch Vacuum Vent Valve
Switch, Vehicles Through MY 2000 (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 167: Identifying Scan Tool Display - Checking Signal From Clutch Vacuum Vent Valve
Switch, Vehicles Through MY 2000 (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -6- and -6- for "display group 66" and confirm with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 168: Identifying Scan Tool Display - Checking Signal From Clutch Vacuum Vent Valve
Switch, Vehicles Through MY 2000 (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Observe values displayed in display zone 2 (2nd digit from left).

Clutch pedal not depressed.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Specification: x 0 x x

z Depress clutch pedal fully and observe display in display zone 2.

Specification: x 1 x x

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

If the display does not change:

z Remove driver's side footwell cover.

See STORAGE, COVERS AND TRIMS

z Disconnect 2-pin connector from Clutch Vacuum Vent Valve Switch -F36-.
z Measure resistance between switch terminals 1 and 2.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 169: Measuring Resistance Between Clutch Vacuum Vent Valve Switch Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification:

z Clutch not depressed: max. 1.5

z Clutch depressed: (no continuity)

If the specifications are not obtained:

z Replace Clutch Vacuum Vent Valve Switch -F36-.

NOTE: Observe installation position of Clutch Vacuum Vent Valve Switch - F36- in
bearing bracket upper assembly hole.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If the specifications are obtained:

z Connect multimeter using auxiliary cables from VAG 1594 to measure voltage between terminal 1 and
Ground (GND).

Fig. 170: Identifying Clutch Vacuum Vent Valve Switch Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Switch on ignition.

Specification: min. 11.5 V

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

If the specification is not obtained:

z Check wiring for open circuit between 2 -pin connector terminal 1 and central electric using Electrical
Wiring Diagram.

If the specification is obtained:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

Fig. 171: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 2 -pin connector using Electrical Wiring Diagram.

Fig. 172: Identifying Clutch Vacuum Vent Valve Switch Harness Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

terminal 2 + socket 39

Wire resistance: Max. 1.5

If the specification is obtained:

z Additionally check wires for short to one another.

z Additionally check wiring for short to battery positive or Ground (GND).

If no wiring malfunction is found:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Signal from Brake Light Switch -F- and Brake Vacuum Vent Valve Switch -F47-, checking

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 173: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z Brake lights functioning OK
z All electrical accessories, e.g. lights and rear window defroster must be switched off
z Selector lever must be in position "P" or "N" on vehicles with an automatic transmission

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 174: Identifying Scan Tool Display - Checking Signal From Brake Light Switch And Brake
Vacuum Vent Valve Switch (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 175: Identifying Scan Tool Display - Checking Signal From Brake Light Switch And Brake
Vacuum Vent Valve Switch (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Press buttons -0-, -6- and -6- for "display group 66" and confirm with -Q- button.

Indicated on display (1 to 4 - Display zones)

Fig. 176: Identifying Scan Tool Display - Checking Signal From Brake Light Switch And Brake
Vacuum Vent Valve Switch (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Observe display in display zone 2: (1st and 2nd positions from right)

Brake pedal not depressed:

Specification: x x x x x x 0 0

z Depress brake pedal fully and observe display in display zone 2.

Specification: x x x x x x 1 1

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

If the display does not change:

z Remove driver's side footwell cover:

See STORAGE, COVERS AND TRIMS

z Disconnect 4-pin connector from Brake Light Switch -F- and Brake Vacuum Vent Valve Switch -F47-.
z Measure resistance between terminals 1 + 4 of switch.
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Specification:

z Brake pedal not depressed: (no continuity)

z Brake pedal depressed: Max. 1.5

z Measure resistance between terminals 2 + 3 of the switch.

Fig. 177: Identifying Brake Light Switch And Brake Vacuum Vent Valve Switch Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Specification: 0 ohm
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z Brake pedal not depressed: Max. 1.5

z Brake pedal depressed: (no continuity)

If the specifications are not obtained:

z Replace Brake Light Switch -F- and Brake Vacuum Vent Valve Switch -F47-.
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

If the specifications are obtained:

z Connect multimeter to measure voltage between terminal 1 and Ground (GND).

Specification: at least 11.5 V

z Connect multimeter to measure voltage between terminal 2 and Ground (GND).

z Switch on ignition.

Specification: min. 11.5 V

If the specifications are not obtained:

z Check wiring between 4 -pin connector terminals 1 and 2 to central electric using Electrical Wiring
Diagram.

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 2003 Volkswagen New Beetle GLS
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Fig. 178: Identifying Brake Light Switch And Brake Vacuum Vent Valve Switch Harness
Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

If the specifications are obtained:

z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 179: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring for open circuit between test box and 4 -pin connector using Electrical Wiring Diagram.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 180: Identifying Brake Light Switch And Brake Vacuum Vent Valve Switch Harness
Connector Terminals
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z terminal 3 + socket 55
z terminal 4 + socket 56

Wire resistance: Max. 1.5 ohm

z Also check wires for short to one another.

z Also check wiring for short to battery positive or Ground (GND).

If no wiring malfunction is found:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

MODULE (ECM) - J220-, REPLACING .

Driving range signal, checking

Vehicles with automatic transmission only

Motronic Engine Control Module (ECM) -J220- receives the following information from transmission control
module:

z Driving range selected (selector lever in 1/2/3/R/D) or

z No driving range selected (selector lever in P or N)

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool (or VAG 1552 mobile scan tool) with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z Selector lever of the automatic transmission must be in "P" or "N" position

z Air conditioning must be turned off
z All electrical accessories, e.g. lights and rear window defroster must be switched off

Test sequence

z Connect VAG 1551 scan tool (or VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 181: Identifying Scan Tool Display - Driving Range Signal, Checking (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 182: Identifying Scan Tool Display - Driving Range Signal, Checking (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -5- and -1- for "Display group number 51" and confirm entry with -Q- button.

Indicated on display (1 to 4 - Display zones)

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 183: Identifying Scan Tool Display - Driving Range Signal, Checking (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check specifications in display zone 3:

DISPLAY GROUP 51: DRIVING RANGE SIGNAL

Display zones
1 2 3 4
Display group 51: Driving range signal
Display xxxx RPM xxxx RPM x xx.xxx V
Indicated Engine Engine Driving range signal Motronic Engine
Speed (in speed (in Control Module
steps of 10) steps of 10) (ECM) -J220- supply
voltage
Working 0 to 6800 - - 0.000 to 16.500 V
range RPM
Specification 0 RPM 840 RPM Selector lever in position P or N: 0 12.000 to 15.000 V
Selector lever in position 1/2/3 or D: 1
Selector lever in position R: 7
- - If the specifications are not achieved, -
see CRUISE CONTROL SYSTEM
(CCS), CHECKING , Continuation

If the specifications are obtained:

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.

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Continuation

If the specifications are not obtained:

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.
z Check CAN-bus, see CAN-BUS, CHECKING .

Cruise Control System (CCS), checking

Special tools, test equipment and auxiliary items

z VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable
z VAG 1598/31 test box
z VAG 1526 A or Fluke 83 multimeter
z VAG 1594 adapter set
z Electrical Wiring Diagram

Test conditions

z All fuses must be OK

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1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 184: Locating Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z All electrical accessories, e.g. lights and rear window defroster must be switched off
z Air conditioning must be turned off
z Selector lever of the automatic transmission must be in "P" or "N" position

Test sequence

z Connect VAG 1551 scan tool ((VAG 1552). Switch ignition on and select Motronic Engine Control
Module (ECM) -J220- with "Address word" 01. Connecting scan tool and selecting Motronic Engine
Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND SELECTING MOTRONIC
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ENGINE CONTROL MODULE (ECM) -J220- .

Indicated on display

Fig. 185: Identifying Scan Tool Display - Cruise Control System, Checking (1 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button.

Indicated on display

Fig. 186: Identifying Scan Tool Display - Cruise Control System, Checking (2 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Press buttons -0-, -6- and -6- for "display group 66" and confirm with -Q- button.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Indicated on display (1 to 4 - Display zones)

Fig. 187: Identifying Scan Tool Display - Cruise Control System, Checking (3 Of 3)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE: Vehicles with automatic transmission only:

z Perform a test drive and exceed a speed of 30 km/h (approx. 19 MPH)

once. Afterward switch off engine and leave selector lever in position
2, 3 or D.

Observe the valid safety measures during a test drive, see SAFETY PRECAUTIONS .

z Engage parking brake.

NOTE: On vehicles with an automatic transmission, the CCS switch will not be
supplied with voltage until the vehicle speed exceeds 30 km/h and the
selector lever is in position 2, 3 or D. Once the switch has been supplied
with voltage it will also remain live at idle speed provided a driving range
(except 1 or R) is selected.

z Check in display zone 2 if the CCS is activated:

Specification: x x x x 1x x x

If the specification is not obtained:

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Activate Cruise Control System.
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 2003 Volkswagen New Beetle GLS
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See CRUISE CONTROL

If the specification is obtained:

z Check specification for switch position from CCS operating switch in display zone 4 (last 4-digit
numbers).

Fig. 188: Checking Switch Position From CCS Operating Switch In Display Zone 4
Courtesy of VOLKSWAGEN OF AMERICA, INC.

SWITCH IN DISPLAY ZONE 4 SPECIFICATION

Check prerequisites Display zone 4
Switch B in detent at "OFF" 0001
Switch B not in detent at "OFF" 0000
Switch B at "ON" 0011
Switch B at "RES" 1011
Switch A pressed 0111
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(Switch B at "ON")

If the specifications are not obtained:

z Press --> button.

z Press buttons -0- and -6- for "End output" function and confirm input with -Q- button.
z Switch off ignition.
z Remove inner plenum chamber cover, left:

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING

z Connect VAG 1598/31 test box to control module wiring harness. Motronic Engine Control Module
(ECM) -J220- is not connected by this action.

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

Fig. 189: Connecting VAG 1598/31 Test Box To Control Module Wiring Harness
Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Check wiring from Motronic Engine Control Module (ECM) -J220- to CCS operating switch for
open/short circuits:
z Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND
ERASING .
z Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code
must be generated again, see READINESS CODE, GENERATING .

CAN-bus, checking

Function

The Motronic Engine Control Module (ECM) - J220- communicates with all data -bus capable control modules
via a CAN -bus.

The data-bus capable control modules are connected and exchange information (messages) via two data -bus
wires (CAN -High and CAN-Low) that are twisted to each other. Missing information on the data-bus is
recognized as a malfunction by the Motronic Engine Control Module (ECM) -J220- as well as by other CAN-
bus control modules.

The data-bus requires an adapting resistor to function fault-free. This central adapting resistor is located in the
Motronic Engine Control Module (ECM) -J220-.

Diagnosis via the CAN-bus wire is undertaken via the diagnostic interface for data -bus -J533- in the
"Gateway".

See DATA BUS ON BOARD DIAGNOSTIC INTERFACE -J533- "GATEWAY"

NOTE: Control modules which are actively connected via data bus to the Motronic
Engine Control Module (ECM) -J220- can be read in measured value blocks 125
and 126.

Further information:

See Self Study Program "The CAN data bus".

Special tools and equipment

z VAG 1598/31 test box

z Multimeter (Fluke 83 or equivalent)
z VW 1594 adapter set

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Electrical Wiring Diagram

Test conditions

z Malfunction has been recognized by Data Bus On Board Diagnostic (OBD)

z All fuses must be OK

Fig. 190: Identifying Fuses

Courtesy of VOLKSWAGEN OF AMERICA, INC.

z Battery voltage must be at least 11.5 V

z All electrical accessories, e.g. lights and rear window defroster must be switched off

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 2003 Volkswagen New Beetle GLS
1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

z Air conditioner must be switched off

z Selector lever of the automatic transmission must be in "P" or "N" position

Test sequence

z Switch off ignition.

z Unlock Motronic Engine Control Module (ECM) - J220- connector and disconnect it.
z Connect VAG 1598/31 test box to Motronic Engine Control Module (ECM) -J220-. Control module
wiring harness is not connected by this action.
z Check centralized adapting resistor in Motronic Engine Control Module (ECM) -J220- by performing a
resistance measurement between test box

Sockets 58 + 60

Specification: 60 to 72

If the resistance value is outside the specified range:

z Replace Motronic Engine Control Module (ECM) -J220-, see MOTRONIC ENGINE CONTROL
MODULE (ECM) - J220-, REPLACING .

If the resistance value is within the specified range:

z Check CAN-Bus wiring using Electrical Wiring Diagram.

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