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Electrical system

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


21,21 €7% VAT incl.

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Language: English

Digital PDF file

5.340 KB

264 Sites

Detailed technical data

Immediately readable

This repair manual contains: Battery A, Disconnecting and connecting battery A, Cruise control system (CCS), Dash panel insert, Headlight washer system, Fog lights, Side turn signals, Steering column switch, Ignition/starter switch D and lock cylinder, Parking aid, Anti-theft alarm (ATA) and interior monitoring, Horn, Vehicle diagnosis tester and Cleaning contact surfaces with contact surface cleaning set VAS 6410. Show more
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Repair manual New Beetle Cabrio / New Beetle Electrical system PDF download has the following content:

Chapter overview

  • Starter, current supply, CCS
    1
  • 1 Battery A
    1
  • 1.1 Fundamentals for batteries A
    1
  • 1.2 Types of battery
    1
  • 1.3 Warning notices and safety regulations
    2
  • 1.4 Battery terminal connection
    4
  • 2 Checking battery A
    5
  • 2.1 Visual check
    5
  • 2.2 Test of colour display of magic eye
    6
  • 2.3 Checking low maintenance battery A
    8
  • 2.4 Checking no-load voltage of battery A (stock and stored vehicles)
    11
  • 2.5 Battery test using battery tester with printer VAS 5097 A
    12
  • 2.6 Battery tester with printer VAS 6161
    17
  • 2.7 Current draw test
    23
  • 3 Charging battery A
    25
  • 3.1 Battery charger VAS 5095 A
    25
  • 3.2 Battery charger VAS 5900
    31
  • 3.3 Battery charger VAS 5903
    42
  • 3.4 Battery charger VAS 5906
    52
  • 3.5 Solar panel VAS 6102 A
    55
  • 3.6 Totally discharged batteries A
    56
  • 4 Disconnecting and connecting battery A
    58
  • 4.1 Disconnecting battery A
    58
  • 4.2 Connecting battery A
    59
  • 5 Removing and installing battery A
    61
  • 5.1 Vehicles with 4-cylinder engine (petrol/diesel)
    61
  • 5.2 Vehicles with 5-cyl. 2.5l petrol engine
    63
  • 6 Starter B
    66
  • 6.1 Removing and installing starter B , 4-cylinder engines (petrol/diesel)
    66
  • 6.2 Removing and installing starter B , 5-cylinder petrol engine
    69
  • 6.3 Specified torques: starter B
    71
  • 7 Alternator C
    72
  • 7.1 Assembly overview - 4-cyl. 1.6l/1.8l/2.0l petrol engine
    72
  • 7.3 4-cylinder diesel engine with power steering - Assembly overview
    74
  • 7.5 Removing and installing alternator C
    76
  • 7.7 Securing battery positive wire on alternator C
    81
  • 7.8 Checking poly V-belt
    82
  • 7.9 Removing and installing voltage regulator C1
    82
  • 7.10 Checking carbon brushes
    84
  • 7.11 Removing and installing poly-V belt pulley on alternator C
    84
  • 8 Cruise control system (CCS)
    88
  • 8.1 Activating/deactivating cruise control system (CCS)
    88
  • 8.2 CCS switch E45
    88
  • Gauges, instruments
    89
  • 1 Dash panel insert
    89
  • 1.1 Renewing dash panel insert
    89
  • 1.2 Removing and installing dash panel insert
    90
  • 1.3 Installing adapter cable
    90
  • 1.4 Warning lamp symbols in dash panel insert
    93
  • 1.5 Multi-pin connector on dash panel insert up to 04.99
    95
  • 1.6 Multi-pin connector on dash panel insert from 05.99
    98
  • 2 Service interval display
    101
  • 2.1 Service table
    101
  • 2.2 Service interval display: resetting, up to 04.99
    101
  • 2.3 Service interval display, from 05.99
    102
  • 2.4 Service interval display: resetting, from 05.99
    103
  • Windscreen wash/wipe system
    105
  • 1 Windscreen wiper system
    105
  • 1.1 Assembly overview - windscreen wiper system
    105
  • 1.2 Removing and installing windscreen wiper system
    105
  • 1.3 Adjusting wiper blade park position
    108
  • 1.4 Removing and installing wiper rubber
    109
  • 2 Window washer system
    111
  • 2.1 Assembly overview - windscreen washer system
    111
  • 2.2 Adjusting spray fields for window spray jets
    111
  • 2.3 Removing and installing window washer system spray jet
    112
  • 3 Headlight washer system
    113
  • 3.1 Assembly overview - headlight washer system
    113
  • 3.2 Removing and installing spray jet carrier with spray jets
    113
  • 3.3 Removing and installing headlight washer system supplementary reservoir
    114
  • Lights, bulbs, switches - exterior
    115
  • 1 Headlight with halogen bulbs
    115
  • 1.1 Assembly overview up to 06.05
    115
  • 1.2 Assembly overview from 07.05
    116
  • 1.3 Adjusting headlights
    116
  • 1.4 Converting headlights from driving on the right to driving on the left and visa versa
    117
  • 1.5 Removing and installing headlight, up to 06.05
    119
  • 1.6 Removing and installing headlight, from 07.05
    120
  • 1.7 Removing and installing headlight mounting plate, from 07.05
    122
  • 1.8 Replacing bulbs up to 06.05
    123
  • 1.9 Replacing bulbs from 07.05
    126
  • 1.10 Removing and installing headlight range control motor, up to 06.05
    129
  • 1.11 Removing and installing headlight range control motor, from 07.05
    130
  • 2 Headlights with gas discharge bulbs
    132
  • 2.1 Operation and safety notes for gas discharge bulbs
    132
  • 2.2 Assembly overview
    134
  • 2.3 Renewing bulbs
    136
  • 2.4 Removing and installing headlight
    139
  • 2.5 Adjusting headlights
    139
  • 2.6 Removing and installing gas discharge bulb control unit
    140
  • 2.7 Removing and installing front left vehicle level sender G78
    141
  • 2.8 Removing and installing rear left vehicle level sender G76 :
    142
  • 2.9 Removing and installing headlight range control unit J431
    142
  • 2.10 Removing and installing headlight range control motor
    143
  • 3 Fog lights
    144
  • 3.1 Removing and installing fog light, up to 11.99
    144
  • 3.2 Removing and installing fog light, from 12.99
    144
  • 3.3 Removing and installing fog light, from 07.05
    145
  • 3.4 Adjusting fog light height adjustment
    146
  • 3.5 Renewing fog light bulb
    147
  • 4 Front turn signals
    149
  • 4.1 Removing and installing front turn signals, up to 06.05
    149
  • 4.2 Removing and installing front turn signals, from 07.05
    149
  • 4.3 Renewing turn signal bulb
    151
  • 4.4 Removing and installing front turn signals (Sport Edition)
    152
  • 4.5 Renewing turn signal bulb (Sport Edition)
    153
  • 5 Side turn signals
    154
  • 5.1 Removing and installing turn signal repeater
    154
  • 5.2 Removing and installing turn signal lights (Sport Edition)
    155
  • 5.3 Renewing turn signal bulb (Sport Edition)
    155
  • 6 Turning signal lights in exterior mirror
    157
  • 6.1 Removing and installing turn signal repeater bulb
    157
  • 7 Tail lights
    159
  • 7.1 Assembly overview up to 06.05
    159
  • 7.2 Assembly overview from 07.05
    160
  • 7.3 Removing and installing tail light, up to 06.05
    160
  • 7.4 Removing and installing tail light, from 07.05
    161
  • 7.5 Renewing tail light bulbs, up to 06.05
    164
  • 7.6 Renewing tail light bulbs, from 07.05
    164
  • 8 Reversing light
    167
  • 8.1 Removing and installing reversing light, up to 06.05
    167
  • 8.2 Removing and installing reversing light, from 07.05
    167
  • 8.3 Renewing reversing light bulb, up to 06.05
    168
  • 8.4 Renewing reversing light bulb, from 07.05
    169
  • 9 Rear fog light
    170
  • 9.1 Removing and installing rear fog light, up to 06.05
    170
  • 9.2 Removing and installing rear fog light, from 07.05
    170
  • 9.3 Renewing rear fog light bulb, up to 06.05
    170
  • 9.4 Renewing rear fog light bulb, from 07.05
    171
  • 10 Number plate lights
    172
  • 10.1 Removing and installing number plate light, up to 06.05
    172
  • 10.2 Removing and installing number plate light, from 07.05
    172
  • 10.3 Renewing number plate light bulb, from 07.05
    173
  • 11 Additional brake lights
    174
  • 11.1 Removing and installing high-level brake light, limousine
    174
  • 11.2 Removing and installing high-level brake light, Cabriolet, from 07.05
    174
  • 12 Steering column switch
    176
  • 12.1 Removing and installing steering column switch
    176
  • 12.2 Pin assignment on steering column switch
    177
  • 13 Ignition/starter switch D and lock cylinder
    179
  • 13.1 Removing and installing lock cylinder
    179
  • 13.2 Removing and installing ignition/starter switch D
    180
  • 13.3 Pin assignment for ignition/starter switch D
    181
  • 14 Parking aid
    182
  • 14.1 General description
    182
  • 14.2 Assembly overview - 4-channel parking aid
    182
  • 14.3 Removing and installing parking aid control unit J446 saloon
    183
  • 14.4 Removing and installing parking aid control unit J446 Cabriolet
    184
  • 14.5 Coding parking aid control unit J446
    184
  • 14.6 Adapting parking aid control unit J446
    185
  • 14.7 Removing and installing rear parking aid senders
    185
  • 14.8 Renewing rear parking aid senders
    187
  • 14.9 Bonding sender bracket in bumper cover
    188
  • 14.10 Testing parking aid senders
    189
  • 14.11 Removing and installing rear parking aid warning buzzer H15 - saloon
    190
  • 14.12 Removing and installing rear parking aid warning buzzer H15 convertible
    190
  • 14.13 Checking rear parking aid warning buzzer H15
    191
  • Lights, bulbs, switches - interior
    192
  • 1 Interior lights and switches
    192
  • 1.1 Removing and installing light switch E1
    192
  • 1.2 Removing and installing headlight range control/illumination regulators
    193
  • 1.3 Removing and installing window regulator switch, up to 05.08
    193
  • 1.4 Removing and installing window regulator switch, up to 05.08
    194
  • 1.5 Removing and installing mirror adjuster switch/change-over switches
    194
  • 1.6 Removing and installing front passenger side interior locking switch E198
    195
  • 1.7 Removing and installing tank filler flap/rear lid remote release switches
    196
  • 1.8 Removing and installing adjustable rear spoiler switch E127
    196
  • 1.10 Removing and installing switches in centre of dash panel
    198
  • 1.11 Removing and installing door contact switch
    199
  • 1.12 Removing and installing luggage compartment light switch F5
    200
  • 1.13 Removing and installing bonnet contact switch F266
    200
  • 1.14 Removing and installing front interior light W1
    200
  • 1.15 Removing and installing glove compartment light W6
    201
  • 1.16 Removing and installing illuminated vanity mirrors
    201
  • 1.17 Removing and installing rear reading lights
    202
  • 1.18 Removing and installing luggage compartment light W3
    203
  • 1.19 Removing and installing door warning lamps
    203
  • 1.20 Removing and installing convertible roof switch Cabriolet
    204
  • 2 Immobiliser
    207
  • 2.1 General description
    207
  • 2.2 Removing and installing immobiliser control unit J362
    208
  • 2.3 Adapting immobiliser control unit J362
    208
  • 2.4 Immobiliser reader coil D2
    210
  • 2.5 Ignition key
    210
  • 2.6 Adapting ignition keys
    210
  • 3 Anti-theft alarm (ATA) and interior monitoring
    213
  • 3.1 Assembly overview saloon
    213
  • 3.2 Assembly overview Cabriolet
    215
  • 3.3 Checking Cabriolet anti-theft alarm components
    216
  • 3.4 Checking anti-theft alarm components
    216
  • 3.5 Checking anti-theft alarm function
    217
  • 3.6 Anti-theft alarm sensors saloon
    217
  • 3.7 Anti-theft alarm sensors Cabriolet
    218
  • 3.8 Removing and installing interior monitoring switch E183
    220
  • 3.9 Removing and installing alarm horn H12
    221
  • 4 Horn
    223
  • 4.1 Removing and installing treble horn H2 / bass horn H7
    223
  • Wiring
    224
  • 1 Vehicle diagnosis tester
    224
  • 1.1 Connecting vehicle diagnostic tester
    224
  • 2 Removing and installing fuse holder and relay carrier
    226
  • 2.1 Removing and installing fuse holder on left of dash panel
    226
  • 2.2 Removing and installing relay plate and 13-position relay carrier
    227
  • 2.3 A-pillar coupling station
    227
  • 2.4 Removing and installing fuse holder on battery A
    228
  • 2.5 Removing and installing relay protective housing in engine compartment
    228
  • 2.6 Removing and installing cable duct in engine compartment
    228
  • 3 Control units
    230
  • 3.1 Tyre pressure monitor control unit J502
    230
  • 3.2 Convenience system central control unit J393
    231
  • 4 Repairs to wiring harnesses and connectors
    234
  • 4.1 Notes on safety
    234
  • 4.2 General notes concerning repairs to vehicle electrical system
    234
  • 4.3 Notes on repairs to wiring harnesses and connectors
    235
  • 4.4 Crimp connector
    236
  • 4.5 CAN bus line repair
    238
  • 4.6 Repairs to airbag and belt tensioner wiring
    238
  • 4.7 Optical fibre lines (OFL)
    239
  • 4.8 Wiring harness repair set VAS 1978 B
    239
  • 4.9 Release tool set VAS 1978/35
    240
  • 4.10 Crimping pliers V.A.S 1978/9A
    246
  • 5 Cleaning contact surfaces with contact surface cleaning set VAS 6410
    250
  • 5.1 Repairing ring terminals
    250
  • 5.2 Repairing threaded connections
    251
  • 5.3 Cleaning battery terminals
    252
  • 5.4 Anti-corrosion treatment
    253
  • 6 Renewal of aerial wiring
    255
  • 6.1 General description
    255
  • 6.2 Assembly overview - aerial wire
    255
  • 6.3 Installing a new aerial wire
    255
Manufacturer's designation Electrical system
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)
Suitable car types 1Y7, 9C1
Category Reparaturanleitung

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