Service

Self-Study Programme No. 211

The New Beetle

Design and Function

 The New Beetle

has caused a sensation and aroused instant
enthusiasm throughout the world.
The C o n c e p t 1 study in the mantle of the
N e w B e e t l e is now ready to enter volume
production.
The N e w B e e t l e is, in conceptual terms, an
entirely new vehicle, and yet it is still strongly
reminiscent of the classic Beetle. Except for its
unmistakeable body styling, however, it has
very little in common with the original Beetle.

This Self-Study Programme describes the The New Beetle is based on the A4 platform.
function as well as the design of the N e w
Beetle.

211/014

New. Important.
Note.

The Self-Study Programme is Please always refer to the relevant

not a Workshop Manual. Service Literature for all inspection,
adjustment and repair instructions.

2
Contents

The New Beetle........................................................... 4

News
The engineering of the New Beetle
Vehicle dimensions
The aerodynamics and body structure
Body............................................................................... 10
Occupant protection
Crash-optimised foot controls
Vehicle identification and mechanical anti-theft protection
Body repairs

Engines........................................................................... 16
General information
Assembly mounting
Gearbox versions
CAN databus
Engines
Motronic 5.9.2

Running gear................................................................. 26
Front axle/rear axle
Steering
Brake system

Elektrical system........................................................... 30
Electrical components
Sound system
Convenience system

Heating and air conditioning system......................... 40

Heating and air conditioning system
Dust and pollen filter

Service ........................................................................... 42
Body
New special tool

3
 The New Beetle

W S NEW
N E
N E WS
WS NEWS
S N E orn!
N E W a star i
sb
NEWS e t l e . . .
w Be
T he N e nal
ternatio
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t 1, th 94, is
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w N
Autosho e form of the le aroused
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is assure
success

IV.
e Golf
ame w ay as th
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as deve e Grou
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w Beetle w ur of th gine
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The de that a re
meant nd
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platform be used. The e e front.
could n
ot at th
located nsists of
ain are co
drive tr a r a ls o ven
h e ru n ning ge n ts w ith a pro
T m p o n e
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platform rd.
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track re

r system
Bum pe umper
ective b to
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N e w Beetle h odular system
The up m
the Gro g!
system bendin
ffe r: d re s is tant to
o an
strong
it is very

4
 N E W S
S N EWS
W S NEW
N E
NEWS

Safety
driver
cludes
e q u ip ment in irbag and
Standa
rd ra
ssenge
front pa
airbag, gs.
ba
side air
with all
omplies
N e w Beetle c onal crash
The rnati
ble inte crash-
applica s thanks to its
u la ti o n c tu re .
re g y str u
ed bod
optimis

. , amd
l Beetle ed instruments
o f th e origina ro u n d
ent iscent illar, the h
Equipm re remin the B-p eets hig
ic le in terior a b handles on e q u ip ment m
the ve h The ards.
, the gra . al stand design
atures in the glove box panels technic
Many fe a b ove in s id e ic s a n d ll
dle door Ergono
m us overa
The han e nets on the h a rmonio
a g mak e a
the stow ion.
impress

system
Sound
gnosis .
ith the self-dia
t
sy-En tr y s e a can be
tested w
The Ea The sou
nd system

new.
s to trols are
f acces The con
g re a te r ease o
gives
r seats.
the rea stable.
va ri a bly adju
ts are
The sea

5
211/042
 The New Beetle

The engineering of the New Beetle

(some features are optional)

Body and safety

Fully galvanised body

Safety steering column, adjustable
for rake and reach
Drivers, front passengers and side
airbags
Pyrotechnical belt tensioners
Crash-optimised pedal cluster

Engines

1.9-ltr. 66kW TDI engine

2.0-ltr. 85kW petrol engine
with crossflow cylinder head
5-speed manual gearbox and
4-speed automatic gearbox
Pendulum-type engine
suspension

6
 Electrics and equipment

Central locking with radio-wave

remote control
Anti-theft alarm system
Electronic immobiliser
Power windows
Air conditioning system
(optional)
Electrically adjustable glass
sliding sunroof (optional)

211/024

Running gear

McPherson strut front axle

Power steering
Torsion beam rear axle
ABS or ABS with ESP
Power steering
16 wheels

7
 The New Beetle

Vehicle dimensions
New Beetle Golf IV
Design Comparison: New Beetle vs Golf IV

The New Beetle and Golf IV are A-platform

vehicles.
For the New Beetle, however, model-specific fine
adjustments were made, e.g. in performance,
floorpan assembly design, gearbox and suspension
tuning.

211/075

Overall height A: 1498mm

Track width B front/rear: 1508mm/1494mm
Overall width C: 1724mm
Wheelbase D: 2508mm
Overall length E: 4089mm
A
Turning circle: 10.9m
Luggage compartment: 209l/527l WOB-SP 60

211_003
B
211/076

D
E 211/077
8
The aerodynamics

of the New Beetle were optimised with painstaking attention to detail. The results of this work are
reflected in the Beettles outstanding drag coefficient of 0.33. The Old Beetle had a drag
coefficient of 0.48.

211/118

Body structure

The body structure meets the highest safety standards. The use of modern technology such as laser
welding, bonding or punch riveting provides the body of the New beetle with high structural rigidity.

211/119

9
 Body

Occupant protection Airbags

Standard equipment in the New Beetle includes:

Full-size airbags for driver and front
passenger
Side airbags for driver and front passenger
60
The airbags integrated in the steering wheel and
dash panel are triggered when a frontal impact
of a defined force occurs and if the collision
forces act within an angle of 60.

The side airbags are triggered individually by

crash sensors depending on the direction of
impact (from the left or right).
60 60
The crash sensors for the full-size airbag are
located in the airbag control unit (at the central
tunnel) and beneath the front seats for the side
airbags.

211/006

Front passenger's airbag

Driver's airbag

Side airbag (right)

Airbag control unit

(with crash sensor)
Side airbag (left)

Crash sensor (right)

Crash sensor (left)

211/053

10
Child safety seat fastening

All seat belts are prepared for the use

of child safety seats.

Under the rear seats retaining eyelets

are welded onto the vehicle body.

Child safety seats can be secured

easily and safely to these eyelets with
the new Isofix fastening system.

Crash concept of the steering system

During a head-on collision, the bulkhead can shift up to 150mm without causing damage to the steering
column.

In the event of a more severe crash, the steering column telescopes in three stages and does not intrude
into the passenger cabin any further.

If the bulkhead intrudes as far as the

Bulkhead
steering column during a crash, it can 50mm
telescope by up to 50mm.
If the collision forces act from below, the
steering column can telescope up to
38mm between the universal joints. 150mm
The steering column telescopes up to 50mm

50mm when the driver's torso collides with

the triggered airbag.
38mm

Universal joints

11
 Body

Crash-optimised foot controls

In the event of major head-on collisions involving severe structural deformation, the brake pedal swivels
away from the footwell area by means of an articulated support.

This function is defined by the deformation of the

engine bulkhead and does not depend on the
position of the brake pedal.

Central tube

Folding support

During a head-on collision, the foot controls shift

towards the central tube. This results in extension
of the folding support which subsequently leads
to the piston rod folding inwards.

Piston rod

The pedal plate swivels away by up to 170mm.

Angular movement of the braking foot is held in

check by the action of the piston rod bending
inwards and the resulting deformation work. This
reduces the load on the braking foot
considerably.

211/093

12
Vehicle identification

z


The vehicle identification number plate
is n o t attached to the plenum chamber
(NAR)
in the engine compartment as in other
Group vehicles. It is fixed below the
rear seats as in earlier Beetle models.

211/044

Example:
3VW N4B 1C 2WM000123
WVW 9C 211/117

Vehicle classes: 1C: New Beetle for USA, Mexico, North American Region
9C: New Beetle for Europe and rest of world (RoW)

Mechanical anti-theft protection

The slip coupling makes it impossible to turn the steering-

column lock by force.

211/132

211/133
Encapsulated door locks and a
reinforcement plate behind the door
handle act as a deterrent to braking
open the door.

211/028

A lock cylinder freewheel is built into the door locks, Boot lock
and ignition lock.
If an attempt is made to force the lock cylinder, the locks stay
closed.
211/134

13
Body

Body repairs

Taillight

The taillight housing can be removed and

installed easily to replace bulbs:

In the luggage compartment: remove cover

from assembly opening
Undo plastic screw
Pull taillight out from wing

211/043

Headlights

The headlights can also be removed and

installed easily for replacing bulbs:

In the engine compartment: press the release

lever on the headlight housing
Pull release lever upwards
Pull headlight out from wing

When fitting the headlight, pay attention to the

guide rails.

Headlights can be adjusted by

means of two Torx screws.

211/045

14
High-mounted stop light

The high-level stop light is integrated in the boot.

If an LED fails, the complete unit must be
replaced.

When installing the stop light, take

care to ensure that the rubber seal is
properly seated, otherwise water
may enter the luggage
compartment.
211/047

Removing and installing of

the front bumper

The front bumper can only be

removed as a unit complete
with the two wings. These
components can then be fitted
individually.

211/078

Removing and installing the

rear bumper

The rear bumper also has to

be removed together with the
wings. The wings and bumper
can be separated after this.

211/023

15
 Engines

General information

The New Beetle, like the Golf 98, Audi A3 and Design features of the 1.9-ltr. and 2.0-ltr.
Skoda Oktavia, is based on the A-platform. The A4 platform engines:
engines of these vehicles are almost identical
from a technical viewpoint too. No intermediate shaft
The New Beetle is available with a 1.9-ltr. TDI Chain-driven oil pump
engine and a 2.0-ltr. petrol engine with crossflow New thermostat housing
cylinder head. Small engine block
Aluminium oil sump
Lightweight valve train
New coolant pump housing
Pendulum-type engine support

211/135 211/016

Assembly mounting

The assembly mounting comprises engine mount (hydraulic mount)

-1-, gearbox mount (bonded rubber bush) -2- and stabiliser link -3-.
The assembly layout is designed to increase flexibility about the
axis of rotation of the engine.

The stabiliser link absorbs the

engine movement which is
induced by engine torque.
Engine and transmission
vibrations are absorbed by
2
large-sized rubber mountings
which prevent these vibrations
being transmitted to the
bodyshell. 1

The hydraulic mount dampens

sympathetic vibration of the
engine.
3

Intrinsic engine weight 211/049

Engine torque

Lateral forces

16
Gearbox versions 5-speed manual gearbox 02J

A manual gearbox and an automatic

gearbox are used:

5-speed manual gearbox 02J

4-speed automatic gearbox 01M

The engine oil sump is attached to the

gearbox by bolts.
This engine-gearbox link-up increases the
rigidity of the complete engine-gearbox
211/136
unit. This serves to improve the transfer of
forces to the stabiliser link of the assembly 4-speed automatic gearbox 01M
mounting.

211/137

CAN databus

The engine control units, the control unit for the automatic gearbox and the ABS control unit are
interconnected via two CAN databus lines.
The control unit interchange information such as Throttle valve position, vehicle road speed or gearbox
shift point (also refer to SSP 186) via CAN databus.

211/050
17
 Engines

1.9-ltr. TDI engine (66 kW) - ALH

The special features of the A4 platform

1.9-ltr. TDI engine are:

Magnesium cylinder head cover with new

seal
Special fastening elements for the cylinder
head cover
Wet-filter oil separator integrated in the
cylinder head cover
Camshaft-driven vacuum pump
Stationary oil filter with filter cartridge

211/135

Power output Torque Specifications:

kW Nm

80 300

Code: ALH
70 275 Bore: 79.9mm
Stroke: 95.5mm
Displacement: 1896cm3
60 250 Compression ratio: 19.5 : 1
Power output: 66kW (90 bhp) at
50 225
3750 rpm
Torque: 210Nm at
1900 rpm
40 200 Exhaust emission standard: D-3 standard
Engine management: Bosch Electronic
Diesel Control
30 175
(EDC)

20 150

10 100

1000 3000 5000

Engine speed rpm
211/057

18
Gearbox versions

The 1.9-ltr. TDI engine is available in connection

with

5-speed manual gearbox 02J and

4-speed automatic gearbox 01M.

The 1.9-ltr. TDI engine with manual or

automatic transmission delivers power by way
of triple roller joint drive shafts.

Triple roller joint drive shafts dampen the

vibrations which occur in the drive train.

211/048

211/088

Vacuum pump

The vacuum pump is located on the cylinder

head and is driven directly by the camshaft.

The vacuum pump produces additional

vacuum to safely operate the following
vacuum-controlled components reliably under
all operating conditions:

Vacuum brake servo

Intake manifold flap changeover valve
Exhaust gas recirculation valve, and
Charge-pressure limiting valve

211/051

19
 Engines

2.0-ltr. engine (85 kW) - AQY

The engine driving the New Beetle is being used

here for the first time on the A4 platform vehicle.
The special features of the 2.0-ltr. engine are as
follows:

Crossflow cylinder head

Two-piece intake manifold
Exhaust manifold of stainless steel
Air-swept injectors
2nd lambda probe downstream of catalytic
converter
Secondary air pump

211/016

Specifications
Power output Torque
kW Nm

223
96
Code: AQY
Bore: 82.5mm
85 203 Stroke: 92.8mm
Displacement: 1984cm3
Compression ratio: 10.5 : 1
72 180 Power output: 85kW (115 bhp) at
5200 rpm
155
Torque: 170Nm at
59
2400rpm
Exhaust emission standard: D-4 standard
47 128 Engine management: Motronic 5.9.2

36 101

24 74
Deviations from US version:

12 47
Code AEG
Compression ratio 10.0 : 1
2000 4000 6000 Max. output is at 5400rpm and max.
Engine speed rpm
211/055 torque is 165Nm at 2600rpm

20
Gearbox versions

The 2.0-ltr. crossflow engine is available with:

5-speed manual gearbox 02J and

4-speed automatic gearbox 01M.

The engine block of the 2.0-ltr. engine is

identical to the A4 platform 1.8-ltr. engine block.

The crossflow cylinder head used previously in

the US version of the Golf 3 is a tried and tested
design.
Advantages:
The intake manifold at the front end of the
engine enhances crash performance, as
there is more space between the intake tube
and engine bulkhead.
The optimised gas flow characteristics
improve handling performance and exhaust
emission.

21
 Engines

Motronic 5.9.2

The Motronic 5.9.2 has a string of features which Air mass meter with reverse flow recognition and
facilitate engine starting, improve fuel economy integrated intake air temperature sensor
and reduce exhaust emission. yActivation of cruise control system via the
These include:
throttle valve control unit.
Hall sender configured as a quick-start
sender
Distributorless electronic ignition

Air mass meter G70 with

intake manifold
perature sensor sender
G72 Fuel pump relay Fuel pump G6
J17 (pre-supply pump)

Engine speed sender G28

Control unit for Injector cylinders 1-4

Motronic J220 N30, N31, N32, N33
Hall sender G40

Ignition transformer
N152
Lambda probe G39

Solenoid valve 1 for

Lambda probe 2 G108 activated charcoal
canister-system N80

Idling speed switch F60

and Heater for lambda
Throttle valve potentio- probe Z19
meter G69
Throttle valve positioner
potentiometer Heater for lambda
probe 2 Z28
Coolant Diagnosis plug
temperature sender G62 connection

Knock sensors 1 and 2 Throttle valve positioner

G61 and G66 V60

clutch pedal switch F36

Brake light switch F and

Brake pedal switch F36

22
Air-swept injectors

The vacuum in the intake manifold draws in air

from the intake air duct and conveys the air to
the individual injectors along a line.
The fuel is atomised completely by this.
Combustion is improved and exhaust emissions
are reduced.

211/138

Secondary air system

A condition for low contaminant emissions during the warm-up phase is that the catalytic converter
reaches a high operating temperature quickly.
Secondary air injection accelerates the rate of catalytic converter temperature rise considerably.

The secondary air pump

blows air behind the exhaust 1 2 3
valve. The air surplus oxidises
(burns) the hydrocarbons and
the carbon monoxide, and the
catalytic converter reaches its
operating temperature. 4
5

Legend:
1 Control unit 6
2 Relay for secondary air pump
3 Secondary air injection valve 8 7
4 Secondary air pump
5 Combi valve
6 Coolant temperature sender
7 Lambda probe
8 Catalytic converter

211/139

23
 Engines

2nd lambda probe

A 2nd lambda probe is integrated in the exhaust

system downstream of the catalytic converter.
It checks the degree of conversion (a measure of
the cleaning efficiency of the catalytic converter).

The engine control unit compares the probe

voltage of the probes located upstream and
downstream of the catalytic converter. If the ratio
parameter deviates from the setpoint, the engine
management system assumes that a malfunction
has occurred in the catalytic converter.

The engine control unit then saves a fault

message to the fault memory.
211/071

Fuel tank purging system

The activated charcoal canister is not located in the Front right wheel housing, as in other VW models,
but behind the wheel housing liner under the rear right wing. The activated charcoal system is
technically the same as the system fitted to the Golf 4.

211/085

24
 Fuel evaporation system for
USA

The US version of the New Beetle has a fuel
evaporation system which complies with the
stringent US laws.
The evaporation system can be checked for
leaks and throughflow characteristics with the
aid of the leak detector pump.
Since the fuel evaporation control system is
mechanical, no additional on-board diagnostic
capabilities are required to check the system
and clear problems.
The operation evaporation container holds the
fuel vapours which are given off during normal
vehicle operation. The filling evaporation
container retains these fuel vapours as well as
the large volumes of air displaced from the fuel
tank (during refuelling operation).

Filling evarpoation Constant Gravity float value Evaporation circuit

container pressure valve

Air bleed valve

211/087

Solenoid valve for activated Operating evaporation Evaporation tank

charcoal canister N80 container

25
 Running gear

General information

Thanks to the large wheels

and long wheelbase, the
New Beetle offers an
excellent ride.

The tried and tested axle

construction also provides
effective anti-interference. As
a result, the vehicle has large
safety reserves and holds the
road safely.

Basis (platform)

New part

Adaptable part

The front axle ...

is based on a proven principle: McPherson strut axle with wishbones.

Details:

The anti-roll bar is connected

to the track control arms by
means of coupling rods.
The suspension strut is
inserted in the wheel bearing
housing and clamped by a
bolt.
Wheel bearing housing is
made of cast iron with a high
graphite content. As a result,
no lubricant is required to
install a wheel bearing.

26
The rear axle ...
is a torsion beam axle with anti-roll bar and separate spring-damper layout.
The springs are fitted compactly in between the trailing arms and frame side members. The shock
absorbers are mounted behind the springs.

Rear axle bearing

The large-sized rear axle bearings are 25

attached at an angle of 25 relative to
the vehicle's transverse axis.
Lateral forces act on the suspension
while cornering and change the toe. This
produces a self-steering effect.
The diagonally installed bearings
reduce the self-steering effect and
enhance driving stability when exiting a
corner.

Self-steering cannot be
effectively corrected if the
rubber mountings are not fitted
properly.

211/059

44mm adjustment for height

Steering 40mm adjustment fore and aft

The New Beetle has power steering as standard.

The steering column can be adjusted 44mm for

height.
The steering column can be adjusted 40mm fore
and aft.

Both settings can can be changed simultaneously

after operating a lever on the lower part of the
steering column.

211/018

Lever for locking steering column

27
 Running gear

Brakes

The New Beetle has disc

Front axle 280x22mm Rear axle 232x9mm
brakes at the front and rear as
standard.

The front disc brakes are

ventilated.

At the rear wheels, brake

calipers made of aluminium
reduce the unsprung masses.

211/089 211/038

ABS with Electronic Stability Programme (ESP)

The New Beetle is fitted with the Electronic Stability Programme (ESP) as standard.
This additional safety package made by ITT Automotive is based on the conventional ABS/EDL 20 IE
system and ensures maximum stability in any driving situation.

ABS/ESP control unit

211/060

28
Components of the ESP

Angle of turn Yaw rate

sender sender

Active
brake
servo Lateral acceleration
sender

Hydraulic unit with Wheel speed

ABS/ESP control sensor
unit

211/061

Design Function examples

The ESP control unit and the hydraulic assembly When ESP detects from the input signals that the
form a single unit. vehicle is beginning to understeer, it brakes the
The ESP hydraulic unit is an extended version of rear wheel on the inside of the corner.
the ABS/EDL hydraulic unit. It can develop,
maintain and again reduce brake pressure at In case of oversteer, ESP brakes the front wheel
each wheel individually without the driver having on the outside of the corner.
to operate the brake pedal. This prevents the rear end breaking away,
allowing the vehicle to stabilise itself.
The following components belong to ESP:
If braking an individual wheel is not enough, ESP
Hydraulic unit and ESP control unit reduces input torque by decreasing engine
Active brake servo with pressure sensor output and/or by activating the individual wheel
Wheel speed sensor brakes.
Lateral acceleration sender
Yaw rate sender
Angle of turn sender
TCS/ESP warning lamp
CAN databus network to engine and
gearbox control units
Button for TCS/ESP

29
 Electrical system

Wiring harnesses

The distribution of the wiring harnesses in the The engine wiring harness connects all engine-
New Beetle matches the decentralised electrics specific components to the vehicle electrical
concept of the A4 platform. system via connector T10a; it also connects these
components directly to the engine control unit.
The wiring harness of the engine compartment
connects, for example, the engine and the
gearbox electronics with the ABS/ESP, as well as
the other parts of the electrical system.

The wiring harness of the headlights supplies

power to the front-end components included in
the standard specification, such as the headlights
and windscreen wipers.

Engine control unit

Automatic
gearbox control
unit

MOTO
R
T.A.
211_009
Connector
station in the
plenum
chamber

211/009

Wiring harness, engine compartment

Wiring harness, engine

Wiring harness, headlights

30
Control units in the plenum chamber

The plenum chamber in the New The units housed in the inner plenum chamber
Beetle is only accessible from the include:
vehicle interior on account of the the engine control unit and
bodyshell stying. the automatic gearbox control unit.

The plenum chamber is locked by two locking

units.
A three-section cover is located above the
locking units. The mid-section can be
detached by sliding it towards the
windscreen.

Automatic
gearbox control
Engine control unit
unit

G
A
B
R
I
A

211/062

31
 Electrical system

Control units Immobiliser control unit J362

in the dash panel insert
Due to the fact that the electrical system is
decentralised, the control units are located directly
adjacent to the individual systems.

Advantages:
Weight savings through short wiring
harnesses.
Fewer connections mean fewer fault sources.
211/111

Automatic gearbox control unit J217

211/056

Radiator fan control unit J293

211/115

Important. ABS control unit

Note. (at the hydraulic unit)
The above-mentioned items
are contained in the
chapter on "Fitting
locations" in the current
flow diagram folder

211/110

32
Control unit for sliding sunroof adjustment J245 Central control unit for convenience
electrics J393
(under the dash panel to the left)

211/116

211/140

Airbag control unit J234

(centre tunnel below dash panel)

211/114

Door control units J386 /J387

at window lifter motor
211/102

Motronic control unit J220

211/112
211/109

33
 Electrical system

The dash panel insert

is a round instrument cluster with blue The dash panel insert can be
illumination. removed without having to dismantle
The red dial is illuminated from the dial hub. the steering wheel.
The indicator and warning lamps are arranged
in a circular pattern on the exterior of the dash
panel insert.

For vehicles with automatic gearbox, the selector

lever position is displayed on the LCD display.

211/037a

The dash panel insert has the following self- The dash panel insert can be encoded for
diagnosis functions, which can be activated different country spec versions and engine
via address word 1 7 : variants.
01 Interrogate control unit version The A d a p t i o n function can be used to enter
02 Interrogate fault memory the mileage in a new dash panel insert and
03 Actuator diagnosis calibrate the fuel gauge.
05 Erase fault memory
06 End of output
07 Encode control unit
08 Read measured value block
10 Adaption

34
Immobiliser

An electronic immobiliser of the 2nd generation
is used in the New Beetle.
This system differs from its predecessor by the
following features:
The immobiliser control unit is located
in the dash panel insert.
In addition to the fixed code, a
variable code is cross-checked
between the car key and immobiliser
control unit.

EPC

211/064

This process for cross-checking the fixed code or variable code between the transponder and
immobiliser control unit means that the vehicle can only be started with the correct car key.
Replacement keys are only available in the form of original spare parts.

35
 Electrical system

Radio/Sound system

The New Beetle has a new sound system with 6 loudspeakers; this system offers a wider range of
adjustments and better sound quality.
The volume adjustment button can also be used for tone control.

If the power supply to the radio is disconnected, the anti-theft device code must be re-entered using
the arrow keys of the search function.

211/023A

Additional features:

The radio has a special front panel which is

only fitted in the New Beetle.
Special tools are required to remove the
radio.
The lighting for the switches, buttons and
displays is identical to the dash panel
lighting.
A CD-changer which is fitted in the luggage
compartment is optional.

211/131

36
Variable intermittent wipe

The New Beetle also features four intermittent

wipe settings.
The intermittent wipe cycle length decreases
automatically as road speed increases.

Intermittent wipe cycle length = wiping time +

pause time

200/093

Windscreen washer jets for the

windscreen

The windscreen washer jets are secured to the

bonnet from below.
They can be adjusted by rotating an eccentric.

The windscreen washer jets in the optional

winter package are heated.

211/065

37
 Electrical system

The convenience system ...

assumes the functions illustrated. On vehicles equipped with power windows,

The central control unit and the door control unit the central control unit and the door control
are responsible for the control functions. units communicate over the CAN databus.

Functions of the central control unit

Central locking Anti-theft alarm system

Rear lid

Interior lighting control Self-diagnosis

Radio-wave remote control Interface to vehicle electrical

system

Tilting/sliding sunroof
- Convenience locking
- Enable

Functions of the door control units

Door central locking with Safe Electrically adjustable and

function heated door mirrors

Electrical windows with roll- Self-diagnosis via the central

back function control unit

38
Design of the convenience system
The convenience system has
self-diagnostic capability.
The central control unit is installed close to the
The address word is 4 6 .
steering column behind the dash panel.

For vehicles without power

The door control units are located on the window
windows, the address word
lifter motors.
is 3 5 .

4 17
6 7
2
5 9
8
1
14
11 10
15
12
16
13

211/067

1 Connector station, right-hand A-pillar

2 Window lifter switch, front passenger's door E107
3 Aerial for central locking and anti-theft alarm system R47
4 Interior locking switch, front passenger's side E198
5 Door control unit, front passenger's side J387
6 Locking unit for central locking, front passenger's side F221
7 Mirror adjustment switches E43 and E48
8 Interior locking switch, driver's side E150
9 Rear lid remote control motor V151
10 Locking unit for central locking, driver's side F220
11 Door control unit, driver's side J386
12 Rear lid remote control switch E188/tank flap switch E204
13 Connector station, left-hand A-pillar
14 Window lifter switch, front left E40/front right E81(driver)
15 Central control unit for convenience system J393
16 Contact switch for anti-theft alarm system/anti-rodent system F120
17 Tank flap lock motor V155

39
 Electrical system
Opening the boot
The boot of the New Beetle can be opened
mechanically with the key or electrically by the
radio-wave remote control or boot switch.
Opening the boot electrically
The boot switch is located on the driver's door
interior trim.
When this switch is Activated, the central control
unit for the convenience system activates a relay
on the auxiliary relay carrier.
The relay activates an electric motor which opens
the boot.
Boot switch
40
The boot can also be opened electrically with the
car key.
When the car key is turned in the boot lock, the
boot lock is opened by means of a microswitch.
Mechanical emergency boot opening
If the convenience system fails, the boot must be
opened mechanically.
To activate the emergency boot opening
function, t u r n the car key in the boot lock
b e y o n d the point at which the electric motor
normally opens.
211/068
Locking the tank flap

The fuel filler flap may be unlocked electrically

or mechanically. Mechanical emergency tank flap unlocking

Unlocking the tank flap electrically
The tank flap switch is located on the inner trim
of the driver's door.
This switch activates a final control element
which is mounted on the C-pillar in the vehicle
interior.
The final control unlocks the tank flap lock by
cable pull.
If the electrical opening function is defective, the
tank flap can be unlocked mechanically.
For this purpose, a small cover on the right-hand
side of the luggage compartment must be
removed.
The rear lid is activated and the tank flap
unlocked by drawing a cable pull.

Tank flap switch

Cable
pul

211/069

41
 Heating, air conditioning system

There is a choice of two equipment versions for

the heating and air conditioning system in the
New Beetle:

a heater, and Only a manually operated air

conditioning system is available
a manually operated heater and air
for the New Beetle.
conditioner

A plate-type evaporator is used for the air

conditioning system.
The evaporator requires 40% less space but it
has the same capacity and cooling surface area.

Heating Fresh air/air recirculation flap Servomotor Air recirculation mode

211/142

The fresh air/air recirculation flap is

activated by servomotor.
All other flaps are moved by means of
Bowden cables.
In defrost mode, the air recirculation
mode is switched off mechanically.
211/141

Manual air conditioning system Fresh air/air recirculation flap Air conditioning system

211/144

When a manual air conditioning

system is installed, the cabin climate is
driver-controlled.
211/143
The fresh air/air recirculation flap is
electric motor driven.
All other flaps are adjusted via
Bowden cables.

42
Dust and pollen filter with activated charcoal
The dust and pollen filter consists of a
combination of a fleece material and an
activated charcoal granulate.
Dust and pollen are filtered by the fleece. The
activated charcoal reduces odour and noxious
gases.
The gases are bound or chemically changed on
the surface of the activated charcoal.
Consider ozone, for example. It is almost fully
converted into oxygen.
Activated charcoal granulate
The dust and pollen filter is located in the plenum
chamber which can only be accessed through
the vehicle interior.
Removing the dust and pollen filter:
Remove the upper, three-section cover
located in between the dash panel and
defrost duct.
Remove the locking unit on the right.
Located on the air distributor housing below
this is the dust and pollen filter.
Fleece material
211/145
43
 Service

Service

Removing seat
Before removing a front seat, you
must remove any static charge you
may be carrying by touching the
door locking pin or the bodyshell,
since the side airbag can be
triggered during repair work by the
static charge a person normally
carries.

211/130

After disconnecting the plug and socket

connection under the seat, plug in the adapter
for the side airbag VAS 5061 so that the airbag
system is connected to earth.

VAS 5061

211/001

Repairing high-strength sheet-metal

panels
For spot painting, do not heat up the
panel too quickly or to an
excessively high temperature
(approx. 200C), since the panel will
otherwise become misshapen.

During panel beating, the high-strength panel

exhibits higher buckling strength. The panel is
springier.

211_073
211/073

44
Here are the new special tools for the New Beetle

Tool number and designa- Usage

tion

10-222A/8

Adapter

for removing the engine

211/145 211/146

3344A
Releasing tool

for removing the radio

211/147 211/148

3423

Gripper

for removing the front wheel

bearing
211/149 211/150

3450/2A, 3450/3 3450/2A 3450/3

Guide pins

for installing the cylinder head

211/151/152 211/153

3411

Guide rods

For moving the lock carrier

with attachments to servicing
position 211/154
211/155

45
 notes

46
47
 211

For internal use only VOLKSWAGEN AG, Wolfsburg

All rights reserved. Technical specifications subject to change without notice.
840.2810.30.20 Technical status: 10/98

Printed on chlorine-free
bleached cellulose paper.