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The New Beetle
Service
Self-Study Programme No. 211
Design and Function
2
211/014
The New Beetle
has caused a sensation and aroused instant enthusiasm throughout the world.The
CCCCoooonnnncccceeeepppptttt 1111
study in the mantle of the
NNNNeeeewwww BBBBeeeeeeeetttt lllleeee
is now ready to enter volume production.
This Self-Study Programme describes the function as well as the design of the
NNNNeeeewwww BBBBeeeeeeeetttt lllleeee
.
The
NNNNeeeewwww BBBBeeeeeeeetttt lllleeee
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.
The New Beetle is based on the A4 platform.
The Self-Study Programme is not a Workshop Manual.
Please always refer to the relevantService Literature for all inspection, adjustment and repair instructions.
New. Important.Note.
3
10
16
Contents
NewsThe engineering of the New BeetleVehicle dimensionsThe aerodynamics and body structure
Occupant protectionCrash-optimised foot controlsVehicle identification and mechanical anti-theft protectionBody repairs
General informationAssembly mountingGearbox versionsCAN databusEnginesMotronic 5.9.2
Front axle/rear axleSteeringBrake system
Electrical componentsSound systemConvenience system
BodyNew special tool
Heating and air conditioning systemDust and pollen filter
4
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30
40
26
The New Beetle...........................................................
Body...............................................................................
Engines...........................................................................
Running gear.................................................................
Elektrical system...........................................................
Heating and air conditioning system.........................
Service ...........................................................................
4
NEWS NEWS NEWS NEWSNEWS NEW
NEWS
The New Beetle
The New Beetle ... a star is born!
Concept 1, the star of the International
Autoshow
in Detroit in 1994, is now a
reality in the form of the New Beetle.
Rarely has a concept vehicle aroused
so much interest as the Concept 1.
Impressive in every respect, massive
success is assured!
The decision in favour of the Group
platform meant that a rear engine
could not be used. The engine and
drive train are located at the front.
The running gear also consists of
platform components with a proven
track record.
The New Beetle has the most effective bumper
system the Group modular system currently has to
offer:
it is very strong and resistant to bending!
The New Beetle was developed on the basis of the A4 platform and is engineered much in the same way as the Golf IV.
Group platform
Bumper system
5
NEWS NEWS NEWS NEWS NEWS
211/042
The New Beetle complies with all
applicable international crash
regulations thanks to its crash-
optimised body structure.
Safety
Standard equipment includes driver
airbag, front passenger airbag and
side airbags.
Many features in the vehicle interior are reminiscent of the original Beetle.
The handle above the glove box, the grab handles on the B-pillar, the rounded instruments, amd
the stowage nets on the door inside panels.
Equipment
gives greater ease of access to
the rear seats.
The seats are variably adjustable.
The Easy-Entry seat
The sound system can be tested with the self-diagnosis.
The controls are new.
Sound system
The equipment meets high
technical standards.
Ergonomics and design
make a harmonious overall
impression.
6
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
•
Driver’s, front passenger’s 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
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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)
Running gear
•
McPherson strut front axle
•
Power steering
•
Torsion beam rear axle
•
ABS or ABS with ESP
•
Power steering
•
16“ wheels
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C
A
B
D
E
The New Beetle
Vehicle dimensions
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.
New Beetle Golf IV
Overall height A: 1498mmTrack width B front/rear: 1508mm/1494mmOverall width C: 1724mmWheelbase D: 2508mmOverall length E: 4089mmTurning circle: 10.9mLuggage compartment: 209l/527l
9
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The aerodynamics
of the New Beetle were optimised with painstaking attention to detail. The results of this work are reflected in the Beettle’s outstanding drag coefficient of 0.33. The „Old Beetle“ had a drag coefficient of 0.48.
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.
10
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60°
60°60°
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
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).
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.
Front passenger's airbag
Side airbag (right)
Crash sensor (right)
Airbag control unit(with crash sensor)
Driver's airbag
Side airbag (left)
Crash sensor (left)
11
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.
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.
• If the bulkhead intrudes as far as the
steering column during a crash, it can
telescope by up to 50mm.
• If the collision forces act from below, the
steering column can telescope up to
38mm between the universal joints.
• The steering column telescopes up to
50mm when the driver's torso collides with
the triggered airbag.
150mm
50mm
50mm
38mm
Universal joints
Bulkhead
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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.
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.
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.
Central tube
Folding support
Piston rod
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2WM000123N4B 1C9C
3VWWVW
�z
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Vehicle identification
The vehicle identification number plate is
nnnnooootttt
attached to the plenum chamber in the engine compartment as in other Group vehicles. It is fixed below the rear seats as in earlier Beetle models.
Encapsulated door locks and a reinforcement plate behind the door handle act as a deterrent to braking open the door.
Mechanical anti-theft protection
The slip coupling makes it impossible to turn the steering-column lock by force.
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.
Example:
1C: New Beetle for USA, Mexico, North American Region
(NAR)
9C: New Beetle for Europe and rest of world (RoW)
Vehicle classes:
14
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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
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.
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Removing and installing of the front bumper
Removing and installing the rear bumper
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.
The front bumper can only be removed as a unit complete with the two wings. These components can then be fitted individually.
The rear bumper also has to be removed together with the wings. The wings and bumper can be separated after this.
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Engines
General information
The New Beetle, like the Golf ´98, Audi A3 and Skoda Oktavia, is based on the A-platform. The engines of these vehicles are almost identical from a technical viewpoint too.The New Beetle is available with a 1.9-ltr. TDI engine and a 2.0-ltr. petrol engine with crossflow cylinder head.
Design features of the 1.9-ltr. and 2.0-ltr.A4 platform engines:
•
No intermediate shaft
•
Chain-driven oil pump
•
New thermostat housing
•
Small engine block
•
Aluminium oil sump
•
Lightweight valve train
•
New coolant pump housing
•
Pendulum-type engine support
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 large-sized rubber mountings which prevent these vibrations being transmitted to the bodyshell.The hydraulic mount dampens sympathetic vibration of the engine.
Intrinsic engine weight
Engine torque
Lateral forces
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Gearbox versions
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 unit. This serves to improve the transfer of forces to the stabiliser link of the assembly mounting.
4444----ssssppppeeeeeeeedddd aaaauuuuttttoooommmmaaaattttiiiicccc ggggeeeeaaaarrrrbbbbooooxxxx 00001111MMMM
5555----ssssppppeeeeeeeedddd mmmmaaaannnnuuuuaaaallll ggggeeeeaaaarrrrbbbbooooxxxx 00002222JJJJ
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.
18
1000 3000 5000
40 200
22550
60
30
20
10
70
250
175
150
100
80
275
300
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Engines
1.9-ltr. TDI engine (66 kW) - ALH
The special features of the A4 platform1.9-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
EEEEnnnnggggiiiinnnneeee ssssppppeeeeeeeedddd rrrrppppmmmm
PPPPoooowwwweeeerrrr oooouuuuttttppppuuuuttttkkkkWWWW
TTTToooorrrrqqqquuuueeeeNNNNmmmm
Specifications:
Code: ALHBore: 79.9mmStroke: 95.5mmDisplacement: 1896cm
3
Compression ratio: 19.5 : 1Power output: 66kW (90 bhp) at
3750 rpmTorque: 210Nm at
1900 rpmExhaust emission standard: D-3 standardEngine management: Bosch Electronic
Diesel Control (EDC)
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Gearbox versions
The 1.9-ltr. TDI engine is available in connection with
•
5-speed manual gearbox 02J and
•
4-speed automatic gearbox 01M.
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
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.
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180
155
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101
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96
85
72
59
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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
Engines
2.0-ltr. engine (85 kW) - AQY
Deviations from US version:
•
Code AEG
•
Compression ratio 10.0 : 1
•
Max. output is at 5400rpm and max.
torque is 165Nm at 2600rpm
PPPPoooowwwweeeerrrr oooouuuuttttppppuuuuttttkkkkWWWW
TTTToooorrrrqqqquuuueeeeNNNNmmmm
EEEEnnnnggggiiiinnnneeee ssssppppeeeeeeeedddd rrrrppppmmmm
Specifications
Code: AQYBore: 82.5mmStroke: 92.8mmDisplacement: 1984cm
3
Compression ratio: 10.5 : 1Power output: 85kW (115 bhp) at
5200 rpmTorque: 170Nm at
2400rpmExhaust emission standard: D-4 standardEngine management: Motronic 5.9.2
21
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.
22
Engines
Motronic 5.9.2
The Motronic 5.9.2 has a string of features which facilitate engine starting, improve fuel economy and reduce exhaust emission.These include:
•
Hall sender configured as a quick-start
sender
•
Distributorless electronic ignition
•
Air mass meter with reverse flow recognition and
integrated intake air temperature sensor
•
yActivation of cruise control system via the
throttle valve control unit.
Engine speed sender G28
Hall sender G40
Lambda probe G39
Lambda probe 2 G108
Idling speed switch F60 andThrottle valve potentio-meter G69
Coolanttemperature sender G62
Knock sensors 1 and 2G61 and G66
clutch pedal switch F36
Fuel pump G6(pre-supply pump)
Injector cylinders 1-4N30, N31, N32, N33
Ignition transformer N152
Solenoid valve 1 for activated charcoal canister-system N80
Heater for lambda probe Z19
Throttle valve positioner V60
Heater for lambda probe 2 Z28
Control unit forMotronic J220
Diagnosis plug connection
Fuel pump relay J17
Air mass meter G70 withintake manifoldperature sensor sender G72
Throttle valve positioner potentiometer
Brake light switch F and Brake pedal switch F36
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4
7
6
8
5
The secondary air pump blows air behind the exhaust valve. The air surplus oxidises (burns) the hydrocarbons and the carbon monoxide, and the catalytic converter reaches its operating temperature.
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.
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.
1 Control unit
2 Relay for secondary air pump
3 Secondary air injection valve
4 Secondary air pump
5 Combi valve
6 Coolant temperature sender
7 Lambda probe
8 Catalytic converter
Legend:
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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.
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.
25
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).
211/087
Operating evaporation container
Air bleed valve
Evaporation circuitFilling evarpoation container
Gravity float valueConstant pressure valve
Solenoid valve for activated charcoal canister N80
Evaporation tank
26
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.
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.
Basis (platform)
New part
Adaptable part
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25
°
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.
Steering
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.
Rear axle bearing
The large-sized rear axle bearings are 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.
44mm adjustment for height
40mm adjustment fore and aft
Lever for locking steering column
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Front axle Ø 280x22mm Rear axle Ø 232x9mm
Running gear
Brakes
The New Beetle has disc 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.
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
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Components of the ESP
Design
The ESP control unit and the hydraulic assembly form a single unit.The ESP hydraulic unit is an extended version of the ABS/EDL hydraulic unit. It can develop, maintain and again reduce brake pressure at each wheel individually without the driver having to operate the brake pedal.
The following components belong to ESP:
•
Hydraulic unit and ESP control unit
•
Active brake servo with pressure sensor
•
Wheel speed sensor
•
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
Function examples
When ESP detects from the input signals that the vehicle is beginning to understeer, it brakes the rear wheel on the inside of the corner.
In case of oversteer, ESP brakes the front wheel on the outside of the corner.This prevents the rear end breaking away, allowing the vehicle to stabilise itself.
If braking an individual wheel is not enough, ESP reduces input torque by decreasing engine output and/or by activating the individual wheel brakes.
Angle of turn sender
Active brake servo
Yaw rate sender
Wheel speed sensor
Hydraulic unit with ABS/ESP control unit
Lateral acceleration sender
30
211/009
MOTORT.A.
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Electrical system
Wiring harnesses
The distribution of the wiring harnesses in the New Beetle matches the decentralised electrics concept of the A4 platform.
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.
Wiring harness, engine compartment
Wiring harness, engine
Wiring harness, headlights
The engine wiring harness connects all engine-specific components to the vehicle electrical system via connector T10a; it also connects these components directly to the engine control unit.
Connector station in the plenum chamber
Engine control unit
Automatic gearbox control unit
31
A I R
B A
G
211/062
Control units in the plenum chamber
The units housed in the inner plenum chamber include:
•
the engine control unit and
•
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.
The plenum chamber in the New Beetle is only accessible from the vehicle interior on account of the bodyshell stying.
Engine control unit
Automatic gearbox control unit
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Radiator fan control unit J293
Electrical system
Control units
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.
Immobiliser control unit J362in the dash panel insert
ABS control unit(at the hydraulic unit)
Automatic gearbox control unit J217
Important.Note.
The above-mentioned items are contained in the chapter on "Fitting locations" in the current flow diagram folder
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Door control units J386 /J387at window lifter motor
Central control unit for convenience electrics J393(under the dash panel to the left)
Motronic control unit J220
Airbag control unit J234(centre tunnel below dash panel)
Control unit for sliding sunroof adjustment J245
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211/037a
Electrical system
The dash panel insert
is a round instrument cluster with blue illumination.The red dial is illuminated from the dial hub.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.
The dash panel insert can be removed without having to dismantle the steering wheel.
The dash panel insert has the following self-diagnosis functions, which can be activated via address word
11117777
:01 Interrogate control unit version02 Interrogate fault memory03 Actuator diagnosis05 Erase fault memory06 End of output07 Encode control unit08 Read measured value block10 Adaption
The dash panel insert can be encoded for different country spec versions and engine variants.The
AAAAddddaaaapppptttt iiiioooonnnn
function can be used to enter the mileage in a new dash panel insert and calibrate the fuel gauge.
35
EPC
211/064
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.
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.
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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.
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.
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211/065
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
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.
38
Electrical system
The convenience system ...
assumes the functions illustrated.
The central control unit and the door control unit
are responsible for the control functions.
Functions of the central control unit
Functions of the door control units
On vehicles equipped with power windows,
the central control unit and the door control
units communicate over the CAN databus.
Central locking
Rear lid
Interior lighting control
Radio-wave remote control
Tilting/sliding sunroof
- Convenience locking
- Enable
Anti-theft alarm system
Self-diagnosis
Interface to vehicle electrical
system
Door central locking with Safe
function
Electrical windows with roll-
back function
Electrically adjustable and
heated door mirrors
Self-diagnosis via the central
control unit
39
1
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98
7
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1 Connector station, right-hand A-pillar2 Window lifter switch, front passenger's door E1073 Aerial for central locking and anti-theft alarm system R474 Interior locking switch, front passenger's side E1985 Door control unit, front passenger's side J3876 Locking unit for central locking, front passenger's side F2217 Mirror adjustment switches E43 and E488 Interior locking switch, driver's side E1509 Rear lid remote control motor V15110 Locking unit for central locking, driver's side F22011 Door control unit, driver's side J38612 Rear lid remote control switch E188/tank flap switch E20413 Connector station, left-hand A-pillar14 Window lifter switch, front left E40/front right E81(driver)15 Central control unit for convenience system J39316 Contact switch for anti-theft alarm system/anti-rodent system F12017 Tank flap lock motor V155
The convenience system has self-diagnostic capability.The address word is
44446666
.
For vehicles without power windows, the address word is
33335555
.
Design of the convenience system
The central control unit is installed close to the steering column behind the dash panel.
The door control units are located on the window lifter motors.
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Boot switch
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.
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,
ttttuuuurrrrnnnn
the car key in the boot lock
bbbbeeeeyyyyoooonnnndddd
the point at which the electric motor normally opens.
Electrical system
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Locking the tank flap
The fuel filler flap may be unlocked electrically or mechanically.
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.
Mechanical emergency tank flap unlocking
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
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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
• a manually operated heater and air
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.
Only a manually operated air conditioning system is available for the New Beetle.
Manual air conditioning system
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.
Fresh air/air recirculation flap Servomotor Air recirculation modeHeating
Fresh air/air recirculation flap Air conditioning system
When a manual air conditioning system is installed, the cabin climate is driver-controlled.The fresh air/air recirculation flap is electric motor driven.All other flaps are adjusted via Bowden cables.
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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.
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
Activated charcoal granulate
Dust and pollen filter with activated charcoal
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Service
Service
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.
Repairing high-strength sheet-metal panels
For spot painting, do not heat up the panel too quickly or to an excessively high temperature (approx. 200°C), since the panel will otherwise become misshapen.
During panel beating, the high-strength panel exhibits higher buckling strength. The panel is springier.
VAS 5061
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.
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3450/2A 3450/3
Here are the new special tools for the New Beetle
10-222A/8
Adapter
for removing the engine
3344AReleasing tool
for removing the radio
Tool number and designa-tion
Usage
3423
Gripper
for removing the front wheel bearing
3450/2A, 3450/3
Guide pins
for installing the cylinder head
3411
Guide rods
For moving the lock carrier with attachments to servicing position
46
notes
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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.
