Top 10 2002 Volkswagen Jetta TDI Questions & Answers

Try moving the fan blades by hand to see if the fan spins freely to see if the problem is frozen bearings in the fan motor. Replace the fan motor if it doesn't turn. If it spins freely disconnect the wires and hook the fan directly to the battery using a jumper. If it runs the problem is most likely the thermostatic switch. If it doesn't the fan motor is bad.

i recently had the problem with the immobilizer after mo 03 jetta battery had died after speaking with the dealer they said i would have to tow it to them. yeah a 160 miles after reading several blogs i put the battery charger back on put the key in the ignition and turned it to the on position and left it for @ 20 minutes when i returned the immobilizer light was out i then cycled the key off and back on the light came on then went out as it should then proceeded to crank the engine over and it fired without problems and seems to be fin now......curse greedy dealers

Despite what you may read from other comments....The glow plug light is simple a multi function warning light and IS among many othed things in fact used to warn of brake light and brake light switch failure. Therefore it can NOT be treated as glow plug problems only.
I have worked on V.W for many years and have encountered this problem many times. You should get the OBD codes read. This will reveal the exact problem...and there may be more than one
You can contact your V,W agents if you wish and check to see if I am correct.
Best of luck
John

None of the above solutions are correct. Here is the correct solution:

The problem is in the high beam switch assembly which also houses your turn signals and possibly cruise control. There are some electrical contacts in the assembly which dis-connect the low beams when you put the high beams on. Constant use of the high beam switch will create arcing on the low beam switch which makes the contacts not conduct electricity anymore.

The repair is to either replace the assembly, $300 at dealer, $100 or less do it yourself, or take the assembly apart and clean it for free. (2 hours or less)

Instructions on taking your steering wheel off here: http://forums.tdiclub.com/showthread.php?t=151557

Instructions for fixing the switch here: http://forums.tdiclub.com/showthread.php?t=167831&page=4

P.S. If you own a VW, especially around model years 1999 to 2004, there is a rare but devastating problem with engine coolant being literally pumped through all electrical parts of your car.... destroying it. Repair cost = $8,000. It is called coolant migration. Check your VW right now (takes two seconds, literally), and do a two-minute procedure to fix your car to prevent the problem here: http://www.myturbodiesel.com/1000q/multi/coolant_migration.htm

First thing you do is check fuses which are located driver side door side of the dash and 2nd fuse location is on top of battery
If fuses check ok next you turn on car allowing car to warm up and turn on the air condtioning full blast this should turn on both fans automaticly. Give time for car to warm up reach at half way mark on temperature gauge or air conditioning wont turn on fans automaticly if engine is to cold. If both fans turn on than your fans are not the problem. Next would be the cooling fan switch which is located on the radiator on the driver side lower bottom. It has 3 wires to it disconnect the switch and jump the wires that are parallel to each other and this should turn on your fans. Only if you give time for car to warm up reach at half way mark on temperature gauge. Its very important that the car is warmed up your guage should be reading half of the temperature gauge or none of theses tests which I explain will work. If the fans turn on when you jump the connectors than the problem is the cooling fan control thermal switch(costs $40)but if the fans dont turn on than I am sorry. Finally if all theses tests pass you have a real expensive problem or time consuming problem.
Glory To:
Christ My King

http://www.pdfoo.com/result-jetta-fuse-diagram.html

Follow this link and there is a fuse box diagram there

Fuse Locations & Functions
1. Washer nozzle heaters, glove compartment light (10A).
2. Turn signal lights (10A).
3. Fog light relay, instrument panel light dimmer switch (5A).
4. License plate light (5A).
5. Comfort system, cruise control, A/C, steering wheel module (7.5A).
6. Central locking system (5A).
7. Back-up lights, speedometer vehicle speed sensor (VSS) (10A).
8. Open
9. Anti-lock brake system (ABS) (5A).
10. Engine control module (ECM): gasoline engine (10A)
11. Instrument cluster, shift lock solenoid (5A).
12. Data Link Connector (DLC) power supply (7.5A).
13. Brake tail lights (10A).
14. Interior lights, central locking system (10A).
15. Instrument cluster, transmission control module (TCM) (5A).
16. A/C clutch, after-run coolant pump (10A).
17. Open.
18. Headlight high beam, right (10A).
19. Headlight high beam, left (10A).
20. Headlight low beam, right (15A).
21. Headlight low beam, left (15A).
22. Parking lights right, side marker right (5A).
23. Parking lights left, side marker left (5A).
24. Windshield washer pump, windshield wiper motor (20A).
25. Fresh air blower, A/C (25A).
26. Rear window defogger (25A).
27. Motor for rear windshield wiper (15A). (if equipped)
28. Fuel pump (FP) (15A).
29. Engine control module (ECM) gasoline engine (15A)
30. Power sunroof control module (20A).
31. Transmission control module (TCM) (20A).
32. Injectors: gasoline engine (10A)
33. Headlight washer system (20A).
34. Engine control elements (10A).
35. 12 V power outlet (in luggage compartment) (30A).
36. Fog lights (15A). (if equipped)
37. Terminal (86S) on radio, Instrument cluster (10A).
38. Central locking system (w/ power windows), Trunk light, fuel door, Trunk lid (15A).
39. Emergency flashers (15A).
40. Dual tone horn (20A).
41. Cigarette lighter (15A).
42. Radio (25A).
43. Engine control elements (10A).
44. Heated seats (15A). (if equipped)

Fuse arrangements in fuse bracket/battery:
S162. Glow plugs (coolant) (50A).
S163. Fuel pump (FP) relay/glow plug relay (50A).
S164. Coolant fan control (FC) control module/coolant fan (40A).
S176. Relays panel interior (110A).
S177. Generator (GEN) (90 Amp.) (110A). Generator (GEN) (120 Amp.) (150A).
S178. ABS (hydraulic pump) (30A).
S179. ABS (30A).
S180. Coolant fan (30A).

PLEASE DON'T FORGET TO RATE!!!



Drive belt routing—1.8L (AWD, AWW, AWP) engines without A/C



Drive belt routing—1.8L (AWD, AWW, AWP) engines with A/C

The outer door to the gas cap doesn't lock. You just press on the outer door and it clicks open. This is a problem, however, b/c there isn't a lockable gas cap available right now.

Dealership