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Discussion Starter · #1 ·
So I’m going crazy here! I bought the wife a 2004 Beetle 2.0 Automatic and I’m trying to address a few issues. I replaced the fuse box, upgraded the wire from the alternator already and cleaned the ground below the box. The box was slightly melted and I read about the fix, so I already did that trying to address the a/c not working.

But I have a non working speedometer and dash lights I’m trying to remedy currently. I’ve replaced BOTH speed sensors on the transmission with no change. I’ve hooked up and OBD scan tool and I’m not getting a speed readout signal so I assumed it was a bad sensor. I pulled the cluster, checked the connection (which was fine), and when I plugged in the cluster the needle did a calibration movement. So I’m thinking the cluster is okay. But I’m looking for any help that might point me in the right direction. I’ve looked at wiring diagrams and they seem overwhelmingly confusing for this car. But I’m thinking this is an electrical issue that I’m going to be chasing and don’t know where to look.
 

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What scan tool; are you using? A VW specific factory level scan too; can be helpful, to diagnose the cluster and the live data, can confirm that the sensors are working.

Here is a example; of using VCDS, to test the gauges in the cluster, doing a self test procedure:

98 thru 2011 VW New Beetle Instrument Cluster Problem Information


If the speedometer stepper motor is bad; you can disassemble the cluster and replace the stepper motor with a used good one or brand new part.


If the whole speedo cluster is defective; you can try shipping it out for repair or get a used one. Programming, would be required or you could delete the immobilizer but the odometer reading would be off, programming or having a specialist transfer this from the eprom data, could be a option.
 

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Discussion Starter · #4 ·
I have an autel scanner (though it’s limited on a 2004) and OBD Link, neither are VW specific. The sensors are not OEM, the G68 one I got from FCP Euro and the G22 I replaced with a URO brand. I did test the G68 with a multimeter after removal and it appears to still be functional even though I replaced with the a new one.
 

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Ok, the URO brand, is the cheapest Chinese parts you can buy for a VW; so, it is possible, it could be defective out of the box.

Generic OBD II scan tools with live data capability; may or may not be able to read the sensors, that you need to read, to diagnose the problem (the auto vw transmissions by Aisin; have a number of different sensors); . You might consider, purchasing a VW factory level scan tool and that would help you diagnose things correctly (VCDS by Ross Tech $199, OBDeleven $65-$100+ or one lesser quality "VAG" scanners, on amazon $20-$150).
 

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Discussion Starter · #6 ·
I just had a recommendation for a similar post that is almost duplicate to my problem, I feel stupid I didn’t find it in my search prior to posting. Guess I need to check the tone ring for the VSS and then I’ll move on to the cluster.
 

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The vw specific scan tool investment; will save you time and money, by enabling you to do your own repairs and the info it provides, can help us, help you, diagnose and repair your own Volkswagen.
 

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Discussion Starter · #8 ·
Ok, the URO brand, is the cheapest Chinese parts you can buy for a VW; so, it is possible, it could be defective out of the box.

Generic OBD II scan tools with live data capability; may or may not be able to read the sensors, that you need to read, to diagnose the problem (the auto vw transmissions by Aisin; have a number of different sensors); . You might consider, purchasing a VW factory level scan tool and that would help you diagnose things correctly (VCDS by Ross Tech $199, OBDeleven $65-$100+ or one lesser quality "VAG" scanners, on amazon $20-$150).
I guess depending on what I find with the other issues I may have to invest in a VCDS scanner :-/. I have live data with the OBD Link software and I’m not getting anything, which was why I learned toward the sensors. Being that the speedometer needle bounced when I plugged the cluster back in, that makes me think the motor is good.
 

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Discussion Starter · #11 ·
What codes are still showing up? I’m thinking the uro Chinese sensor is a likely culprit.
I’ll have to wait until I get a chance to have the scan it again. I’ll see what codes I can pull because I know it had a fault for the speed sensor last time I checked. I’ll see if I’m still getting it, I’ll go from there and let you know. It’s going to take a few days before I can give out the time. I really appreciate all the guidance.
 

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Discussion Starter · #12 ·
I assume, you have a 01M 4 speed automatic trans; for the speedo sensor, you might check location for the G22 sensor, location shown here:

yes I have the four-speed and the G22 sensor is the one I just replaced today with the uro part. The other one was the G68 and I’ll have to double check the brand. I know the one I removed was VW OEM and according to my ohm meter, is functional.
 

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I think the 01M’s last year was 2003. The 2004’s had a different transmission slightly better than the 01M’s. Slightly better than the worst vw made isn’t saying much though.
 

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Discussion Starter · #14 · (Edited)
Okay so i has a chance to check some wiring. I really struggled to find great wiring diagrams for this car that makes sense. I have pretty good ones through an online source, but they don’t show the wiring specifically for the VSS sensor G22. But looking through other threads, I did come across what it supposed to be. Starting from the left side there should be 12 V, then reference, then finally ground. I have reference at 10.2 V and I have a solid ground. But where I should have 12V is actually shorted to ground. So now I need to figure out where it’s grounding out. Unfortunately chasing electrical nightmares is not my strong suit. Any suggestions of where to look, or should I just start taking apart the wiring harness. Where does the 12v signal come from? The ECU?
 

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Discussion Starter · #15 ·
So it's been a few days and I finally got a chance to dig into the car. I have torn the upper plenum apart on the dash searching for the possible wiring issue. When I look at the diagram the black/white wire for the G22 is supposed to intersect at a B163 Plus Connector 1-1 (15) and piggy back off a black/green wire that comes from the Multi-functional Transmission Range Switch. I found that switch and followed the wire and it too is shorted to ground. I then found where that black/green wire is under the left plenum and when I ohm it out with sound, i can put a lead in the 12V on the G22 connector and it will sound that there is contact, so both wires are grounded. I have started taking the tape of the harness in the engine compartment searching for where the short is, but I feel like I'm spinning my wheels. I DID find a ton of debris and mouse nest under the inner dash plenum, but no chewed wires I can see. Wiring is NOT my strong suit, so any advice is appreciated. Both of the wires from the G22 and the MTRS are in different looms and I cannot find the spot that they intersect.
 

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Wiring troubleshooting can be tough and fixing the short would be the first repair step; are you able to read live data with a vw specific scan tool?

There was a tech bulletin and repair harness vw sold, related to the various speed sensors and used at one point, i don't think it is available anymore, however.

Tech bulletin here: 1999 VW Beetle 2.0 Automatic Transmission Issue

Sent from my iPhone using Tapatalk
 

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Discussion Starter · #18 ·

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Viewing live data and being able to read vw factory trouble codes, is very helpful.

The advanced diagnostic features; can enable testing of sensors, the the speedo cluster, etc.

The wiring harness repairs; will need to be repaired, vw sells repair wires and new plug housings, if needed.

Pigtails, can typically found online like amazon or ebay; although, they tend to be cheaper quality Chinese parts and on the other extreme, the vw overlay harnesses can be expensive but effective if needed.
 
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