ServiceSelf-Study Programme No. 211The New BeetleDesign and Functiones, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nn AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um enht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi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. This Self-Study Programme describes the function as well as the design of the N e w Beetle. 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. The New Beetle is based on the A4 platform.es, in part or in w l purpos hole ercia , is n m ot compe rm itte dun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um en211/014New.The Self-Study Programme is Please always refer to the relevant Service Literature for all inspection, not a Workshop Manual.adjustment and repair instructions.2ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yiImportant. Note.Contentsurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt ceThe New Beetle........................................................... 4News The engineering of the New Beetle Vehicle dimensions The aerodynamics and body structurerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enBody............................................................................... 10Occupant protection Crash-optimised foot controls Vehicle identification and mechanical anti-theft protection Body repairsEngines........................................................................... 16ht rig py Co t.Running gear................................................................. 26Front axle/rear axle Steering Brake systemElektrical system........................................................... 30Electrical components Sound system Convenience systemHeating and air conditioning system......................... 40Heating and air conditioning system Dust and pollen filterService ........................................................................... 42Body New special toolagen lksw Vo byAG.Prote cted byc o p yri gh t . C op yiGeneral information Assembly mounting Gearbox versions CAN databus Engines Motronic 5.9.2r fo ng3The New BeetleWS E N S W E N NEWSS W E N WS E N NEWSw Be T he N e sb a star i . . . e l t e orn!nal ternatio of the In a r w ta o s n e 94, is t 1, th Concep in Detroit in 19 ew Beetle. w N Autosho e form of the le aroused in th vehic reality oncept cept 1. has a c the Con assive s a Rarely t s re m te t, in c e h sp so muc very re ive in e ! s s re p Im d is assure successNEWG ro u pplatformn th loped o as devee basisof the Arm an 4 platfod is engineeredmuchame w in the say as the GolfIV.w The NeBeetle wes, in part or in w l purpos hole ercia , is n m ot compe rm itte dp e Grou ur of th gine . Volkswagec in favo G n n n A e A r io n G a is e re doe that a wag The de and meant s not h olks engine ge yV t. platform be used. T u b fr a e th on rt ot an ed ated a could n ris ts of are loc o contse is o in a e tr th o ven drive ar als ac au ning ge ith a prro The run omponents w ss c rm o tf pla cord. track reility ab y li an pt ceun lerrectness of i t to the co nform spec a t i h re o n in wit thi sBum per te o iva r rp fo g numper ective b to most eff currently has e th s a Beetle h odular system w e N The up m the Gro g! system bendin tant to is s r: re e d ff o an strong it is veryr systemdo c um en4ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiS W E N NEWSSafetyS W E N EWS N S NEWes, in part or in w l purpos hole ercia , is n m ot comwith all omplies Beetle c onal crash w e N The rnati ble inte crashapplica s thanks to its n . o ti re la tu u c g u re y str ed bod optimispe rm itte dun ledriver cludes ment in irbag and ip u q e rd ra Standa ssenge front pa airbag, gs. ba side airAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g n, amd . l Beetle ed instruments origina d e n u th f ro o iscent h illar, the ent re remin the B-p eets hig Equipm terior a b handles on ment m in ip u le q ic e h The ards. the ve , the gra . al stand design atures in the glove box technic panels d e n e Many fe a id v s o s b ll in ic a m dle door us overa Ergono The han e nets on the rmonio a h a g a e mak the stow ion. impressdo c um ensystem Sound sy-En t tr y s e and The souThe Easystemcan be new.ith the tested wself-diagnosis .s to f acces r ease o te a re g gives r seats. the rea stable. bly adju a ri a v ts are The seatrols are The con211/042ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi5The New BeetleThe engineering of the New Beetle(some features are optional)Body and safety • • • • • Fully galvanised body Safety steering column, for rake and reach Driver’s, front passenger’s and side airbags Pyrotechnical belt tensioners Crash-optimised pedal clusteres, in part or in w l purpos hole ercia , is n m ot compe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r adjustable o eo h ut ra a c s sility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um enEngines • • • •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 suspension6ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py i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)pe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt ce211/024es, in part or in w l purpos hole ercia , is n m ot comrrectness of i t to the co nform spec a t i h re o n in wit thi sRunning gear • • • • • • McPherson strut front axle Power steering Torsion beam rear axle ABS or ABS with ESP Power steering 16“ wheelsr te o iva r rp fo g ndo c um enht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi7The New BeetleVehicle dimensionsNew Beetle Golf IVDesign 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.211/075es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngOverall height A: Track width B front/rear: Overall width C: Wheelbase D: Overall length E: Turning circle: Luggage compartment:AG. Volkswagen AG d agen oes ksw not l o gu yV C b ara d e nte is r o e th or ac au 1498mm ssility ab y li an pt ce1508mm/1494mm 1724mm 2508mm 4089mm 10.9m 209l/527lrrectness of i t to the co nf o r m spec atio h re n in witAWOB-SP 60B211_003211/076thi sd o cu m enD8Eht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py i211/077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.es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t his211/118Body structureThe 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.do c um enht rig py Co t.Prote cted by c o py rig ht . C op yiagen lksw Vo byAG.211/1199BodyOccupant protectionAirbags Standard equipment in the New Beetle includes: • Full-size airbags for driver and front passenger • Side airbags for driver and front passenger60°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°.60°es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara The side airbags are triggered individually by d e nte is r o e crash sensors depending on the direction of th or au impact (from theac left or right). ssility ab y li an pt ce60°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.rrectness of i t to the co nf o r m spec atio h re n in wit211/006Front passenger's airbagDriver's airbagthi sd o cu m enCrash sensor (left)10AG.Airbag control unit (with crash sensor)ht rig py Co t.agen lksw Vo byProte cted by c o py rig ht . C op yiSide airbag (right)Side airbag (left)Crash sensor (right)211/053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 agen AG. Volkswagen AG do es n sw ot g the new “Isofix“ fastening system.by Volk ussed ris ho t auara nte eor acility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nrrectness of i t to the co nform spec at i h re o n wit in t hisCrash concept of the steering systemDuring 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.do c um enBulkhead•150mm 50mm•agen lksw Vo by38mm•AG.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.ht rig py Co t.Prote cted by c o py rig h t . Co py i50mmUniversal joints11BodyCrash-optimised foot controlsIn the event of major head-on collisions wagen AG involving severe structural deformation, the brake pedal swivels AG. Volks does agen w s k away from the footwell area by means of an articulated support. no t Voly db ise r tho au s sgu ara nte eo ra c function is defined by the deformation of the Thisility ab y li an pt ceun leurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pengine bulkhead and does not depend on the position of the brake pedal.rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enCentral tubeFolding supportDuring 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.r fo ngPiston rod211/09312ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiThe 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.Vehicle identificationThe vehicle identification number plate t attached to the plenum chamber (NAR) is n o in the engine compartment as in other Group vehicles. It is fixed below the rear seats as in earlier Beetle models.es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt ceExample:3VW N4B 1C 2WM000123 WVW 9C211/117zrrectness of i t to the co nf o r m spec atio h re n in wit211/044thi sd o cu m enVehicle classes:1C: New Beetle for USA, Mexico, North American Region 9C: New Beetle for Europe and rest of world (RoW)ht rig py Co t.Prote cted by c o py rig h t . Co py iThe slip coupling makes it impossible to turn the steeringcolumn lock by force.211/132 211/133Encapsulated door locks and a reinforcement plate behind the door handle act as a deterrent to braking open the door.211/028A 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.211/134AG.Mechanical anti-theft protectionagen lksw Vo by13Bodyun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt cepe rm itte dBody repairses, in part or in w l purpos hole ercia , is n m ot comTaillightThe 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 wingrrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um en211/043Headlights 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 wingWhen fitting the headlight, pay attention to the guide rails.211/045ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iHeadlights can be adjusted by means of two Torx screws.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.may enter the luggage compartment.es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara When installing the stop light, take d e nte is r o eo care to ensure that the rubber seal is uth ra a c s properly seated, otherwise water s211/047ility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witRemoving 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.thi sd o cu m enRemoving 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.ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi211/078211/02315EnginesGeneral informationAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nThe 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:rrectness of i t to the co nform spec at i h re o n wit in t his• • • • • • • •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 supportdo c um en211/135211/016The 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.13Intrinsic engine weight Engine torque Lateral forces16AG.Assembly mounting2ht rig py Co t.agen lksw Vo byProte cted by c o py rig ht . C op yi211/049AG. Volkswagen AG d Gearbox versions agen oes kswVol by d e ris A manual gearbox and tho u a gearbox ss are used:an automatic5-speed manual gearbox 02J not gu ara nte eo ra cility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot compe rm itte d• •5-speed manual gearbox 02J 4-speed automatic gearbox 01Mun lerrectness of i t to the co nform spec a t i h re o n in wit thi sThe 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.211/1364-speed automatic gearbox 01Mr te o iva r rp fo g ndo c um enCAN databusThe 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.ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi211/137211/05017Engines1.9-ltr. TDI engine (66 kW) - ALHThe 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 cartridge211/135es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngn AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cePower output kW80Torque Nm300Specifications:rrectness of i t to the co nf o r m spec atio h re n in wit7027560250Code: Bore: Stroke: Displacement: Compression ratio: Power output:502254020030175ALH 79.9mm 95.5mm 1896cm3 19.5 : 1 66kW (90 bhp) at 3750 rpm Torque: 210Nm at 1900 rpm Exhaust emission standard: D-3 standard Engine management: Bosch Electronic Diesel Control (EDC)thi sd o cu m en2015010100100030005000Engine speed rpm211/05718ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yiGearbox versions The 1.9-ltr. TDI engine is available in connection with • •wage 5-speed manual gearbox 02J ksand Vol y db 4-speed automatic gearbox 01M. iseThe 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.es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngr ho ut a ssn AG. Volkswagen AG do es n ot g ua ran tee or acility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in wit211/048211/088thi sd o cu m enVacuum pump• • • •Vacuum brake servo Intake manifold flap changeover valve Exhaust gas recirculation valve, and Charge-pressure limiting valveAG.The vacuum pump produces additional vacuum to safely operate the following vacuum-controlled components reliably under all operating conditions:Prote cted byht rig py Co t.The vacuum pump is located on the cylinder head and is driven directly by the camshaft.agen lksw Vo byc o p yri gh t. C op yi211/05119Engines2.0-ltr. engine (85 kW) - AQYThe 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:AG. Volkswagen AG d agen oes ksw not l • Crossflow cylinder head o gu yV b ara d e nte Two-piece intake manifold • ris eo tho u ra • Exhaust manifold of stainless a c s sility ab y li an pt cesteelun lees, in part or in w l purpos hole ercia , is n m ot compe rm itte d• ••Air-swept injectors 2nd lambda probe downstream of catalytic converter Secondary air pumprrectness of i t to the co nform spec a t i h re o n in wit thi s211/016SpecificationsPower output kW96Torque Nm223r te o iva r rp fo g n7259473624122000Engine speed rpm4000600020agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi851801551281017447211/055ht rig py Co t.203Code: Bore: Stroke: Displacement: Compression ratio: Power output:do c um enAQY 82.5mm 92.8mm 1984cm3 10.5 : 1 85kW (115 bhp) at 5200 rpm Torque: 170Nm at 2400rpm Exhaust emission standard: D-4 standard Engine management: Motronic 5.9.2Deviations from US version: • • • Code AEG Compression ratio 10.0 : 1 Max. output is at 5400rpm and max. torque is 165Nm at 2600rpmGearbox versions The 2.0-ltr. crossflow engine is available with: • • 5-speed manual gearbox 02J and 4-speed automatic gearbox 01M.es, in part or in w l purpos hole ercia , is n m ot compe rm itte dun leAG. Volkswagen AG d agen oes ksw not of the 2.0-ltr. engine is l o The engine block gu yV b ara d e nte identical to the A4 platform 1.8-ltr. engine is r o eo th u r a a c ssility ab y li an pt ceblock.rrectness of i t to the co nform spec a t i h re o n in wit thi sht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiThe 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.r te o iva r rp fo g ndo c um en21EnginesMotronic 5.9.2The Motronic 5.9.2 has a string of features which • Air mass meter with reverse flow recognition and Volkswagen AG facilitate engine starting, improve fuel economy swagen AG.integrated doesair temperature sensor intake k not l o gu yV and reduce exhaust emission. b ara • yActivation of cruise control system via the d e nte s i r These include: o eo h t throttle valve control unit. ra au • • Hall sender configured as a quick-start sender Distributorless electronic ignitiones, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngsscility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witAir mass meter G70 with intake manifold perature sensor sender G72 Engine speed sender G28Fuel pump relay J17Fuel pump G6 (pre-supply pump)Control unit for Motronic J220Injector cylinders 1-4 N30, N31, N32, N33thi sd o cu m enHall sender G40Ignition transformer N152Lambda probe G39Lambda probe 2 G108Idling speed switch F60 and Throttle valve potentiometer G69 Throttle valve positioner potentiometer Coolant temperature sender G62 Knock sensors 1 and 2 G61 and G66 clutch pedal switch F36 Brake light switch F and Brake pedal switch F36 Diagnosis plug connection22ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiSolenoid valve 1 for activated charcoal canister-system N80Heater for lambda probe Z19Heater for lambda probe 2 Z28Throttle valve positioner V60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.es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um en211/138A 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.agen lksw Vo byAG.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.1Legend: 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 6 8 7ht rig py Co t.Prote cted by c o py rig ht . C op yiSecondary air system2354211/13923Engines2nd 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.211/071Fuel tank purging systemes n sw The activated charcoal canister not located in the Front right housing, as in other VW models, ot wheel olkis gu yV b ara d e but behind the wheel housing liner under the rear right wing. The activated charcoal system is nte is or eo h t technically the same as the system fitted to the Golf 4. ra auAG. Volkswagen AG d agen ourposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun lesscility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en211/085r fo ng24ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iFuel evaporation system for USAThe US version of the New Beetle has a fuel The operation evaporation container holds the n AG. Volkswagen AG do e g a evaporation system which complies with the es n vapours which are given off during normal fuel ksw ot g Vol y ua b stringent US laws. vehicle operation. The filling evaporation ran ed s i tee r o The evaporation system can be checked for container retains these fuel vapours as well as h t o ra au c of air displaced from the fuel leaks and throughflow characteristics with the the large volumes ss aid of the leak detector pump. tank (during refuelling operation). Since the fuel evaporation control system is mechanical, no additional on-board diagnostic capabilities are required to check the system and clear problems.ility ab y li an pt cees, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngrrectness of i t to the co nf o r m spec atio h re n in witFilling evarpoation containerConstant pressure valveGravity float valueEvaporation circuitthi sd o cu m enAir bleed valveSolenoid valve for activated charcoal canister N80Operating evaporation containerht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi211/087Evaporation tank25Running gearGeneral informationThanks 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.AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Basis (platform) d e nte is r o eo h New part ut ra a c s s Adaptable partility ab y li an pt cees, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngThe front axle ...rrectness of i t to the co nf o r m spec atio h re n in witis 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.thi sd o cu m en26ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py i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 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.AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th Self-steering cannot be u ra a c s effectively corrected s if the25 °ility ab y li an pt cerubber mountings are not fitted properly.es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nrrectness of i t to the co nform spec at i h re o n wit in t his211/05944mm adjustment for heightSteering40mm adjustment fore and aftThe 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.do c um enLever for locking steering columnht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi211/01827Running gearBrakesThe 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.Front axle Ø 280x22mm Rear axle Ø 232x9mm211/089211/038nA ABS with Electronic Stability Programme (ESP) wage olkssystem and ensures maximum stability in any driving situation.es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngyV db ise r tho The New Beetle is fitted with the Electronic Stability au Programme (ESP) s s This additional safety package made by ITT Automotive is based on theG. Volkswagen AG d oes not gu ara nte eo as standard. ra cconventional ABS/EDL 20 IEility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witABS/ESP control unit211/060thi sd o cu m en28ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py ies, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisComponents of the ESPAngle of turn senderYaw rate senderActive brake servoLateral acceleration senderdo c um enDesign 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/ESPht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiHydraulic unit with ABS/ESP control unitWheel speed sensor211/061Function 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.29Electrical systemWiring harnessesThe 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. The engine wiring harness connects all enginespecific components to the vehicle electrical system via connector T10a; it also connects these components directly to the engine control unit.Engine control unitAG. Volkswagen AG d agen oes ksw not l o gu yV Automatic b ara d e nte s i r gearbox control o eo h ut ra a unit c s spe rm itte dility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot comun lerrectness of i t to the co nform spec a t i h re o n in wit thi sMOTO RT.A.211_009Connector station in the plenum chamber211/009r te o iva r rp fo g ndo c um enWiring harness, engine compartment Wiring harness, engine Wiring harness, headlights30ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iControl units in the plenum chamberThe plenum chamber in the New Beetle is only accessible from the vehicle interior on account of the bodyshell stying. 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.es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witEngine control unitAutomatic gearbox control unitAIRBAGthi sd o cu m enht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi211/06231Electrical systemControl unitsDue 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.211/111Immobiliser control unit J362 in the dash panel insertAutomatic gearbox control unit J217n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss211/056ility ab y li an pt ceurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun lerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enRadiator fan control unit J293211/11532agen lksw Vo byAG.The above-mentioned items are contained in the chapter on "Fitting locations" in the current flow diagram folderProte cted byht rig py Co t.c o p yri gh t . C op yiImportant. Note.ABS control unit (at the hydraulic unit)r fo ng211/110Control unit for sliding sunroof adjustment J245Central control unit for convenience electrics J393 (under the dash panel to the left)pe rm itte dun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or 211/116 u ac a ssility ab y li an pt ce211/140es, in part or in w l purpos hole ercia , is n m ot comAirbag control unit J234 (centre tunnel below dash panel)rrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um en211/114Door control units J386 /J387 at window lifter motor211/102Motronic control unit J220211/109ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi211/11233Electrical systemn AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or The a dash panel insert u ac ssility ab y li an pt ceurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leis 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.rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enr fo ngThe dash panel insert has the following selfdiagnosis functions, which can be activated via address word 1 7 : 01 Interrogate control unit version 02 Interrogate fault memory 03 Actuator diagnosis 05 Erase fault memory 06 End of output 07 Encode control unit 08 Read measured value block 10 Adaption34ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi211/037aThe dash panel insert can be encoded for different country spec versions and engine variants. The A d a p t i o n function can be used to enter the mileage in a new dash panel insert and calibrate the fuel gauge.ImmobiliserAn 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.un leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sEPCility ab y li an pt ceurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d prrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enr fo ng211/064This 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.AG.ht rig py Co t.agen lksw Vo byProte cted by c o py rig ht . C op yi35Electrical systemRadio/Sound systemThe 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.es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt ce211/023Arrectness of i t to the co nform spec at i h re o n wit in t hisAdditional 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.ht rig py Co t.Prote cted by c o py rig h t . Co py i•do c um en36agen lksw Vo byAG.211/131Variable intermittent wipeThe 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 time200/093urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pWindscreen washer jets for the windscreenun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enThe 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.r fo nght rig py Co t.211/065agen lksw Vo byAG.Prote cted by c o py rig h t . Co py i37Electrical systemThe convenience system ...assumes the functions illustrated. The central control unit and the door control unit are responsible for the control functions. On vehicles equipped with power windows, the central control unit and the door control units communicate over the CAN databus.Functions of the central control unitCentral locking Rear lid Anti-theft alarm systemes, in part or in w l purpos hole ercia , is n m ot comTilting/sliding sunroof - Convenience locking - Enablepe rm itte dun leSelf-diagnosis . Volkswagen AG G A n e does wag not olks gu yV b ara d e nte is r o eo th Interface to vehicle electrical Radio-wave remote control u ra a c s system sInterior lighting controlility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um enFunctions of the door control unitsElectrical windows with rollback function38AG.Door central locking with Safe functionElectrically adjustable and heated door mirrorsSelf-diagnosis via the central control unitht rig py Co t.agen lksw Vo byProte cted by c o py rig ht . C op yi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.The convenience system has self-diagnostic capability. The address word is 4 6 . For vehicles without power windows, the address word is 3 5 .AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt ce3 4 2 1 5pe rm itte dun lees, in part or in w l purpos hole ercia , is n m ot com17 7 9 8 14 11 12 13 10rrectness of i t to the co nform spec a t i h re o n in wit thi s61516r te o iva r rp fo g n211/067do c um enAG.1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17Connector station, right-hand A-pillar Window lifter switch, front passenger's door E107 Aerial for central locking and anti-theft alarm system R47 Interior locking switch, front passenger's side E198 Door control unit, front passenger's side J387 Locking unit for central locking, front passenger's side F221 Mirror adjustment switches E43 and E48 Interior locking switch, driver's side E150 Rear lid remote control motor V151 Locking unit for central locking, driver's side F220 Door control unit, driver's side J386 Rear lid remote control switch E188/tank flap switch E204 Connector station, left-hand A-pillar Window lifter switch, front left E40/front right E81(driver) Central control unit for convenience system J393 Contact switch for anti-theft alarm system/anti-rodent system F120 Tank flap lock motor V155ht rig py Co t.agen lksw Vo byProte cted by c o py rig h t . Co py i39Electrical systemOpening the bootThe 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, 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.Boot switches, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um en40ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi211/068Locking the tank flapThe fuel filler flap may be unlocked electrically or mechanically. Unlocking the tank flap electricallype rm itte des, in part or in w l purpos hole ercia , is n m ot comun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt ceMechanical 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.rrectness of i t to the co nform spec a t i h re o n in wit thi sThe 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.r te o iva r rp fo g ndo c um enTank flap switchCable pul211/069ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi41Heating, air conditioning systemThere 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 Only a manually operated air conditioning system is available for the New Beetle.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.AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Servomotor Air recirculation mode Fresh air/air recirculation flapurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leility ab y li an pt ceHeating211/142The 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.211/141rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enr fo ng211/143When 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.42ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiManual air conditioning systemFresh air/air recirculation flapAir conditioning system211/144Dust and pollen filter with activated charcoalThe 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 olkswagen AG en AG. V agthe oes thiswis dust and pollen d filter. no olkst gu ara nte eo ra c• •es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nssyV db ise r tho auility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisActivated charcoal granulateFleece materialdo c um en211/145ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py i43ServiceService Removing seatAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot comBefore 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.pe rm itte dun lerrectness of i t to the co nform spec a t i h re o n in wit thi s211/130VAS 5061Repairing high-strength sheet-metal panelsFor 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.44ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iAfter 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.r te o iva r rp fo g ndo c um en211/001211_073211/073Here are the new special tools for the New Beetleurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enTool number and designationUsage10-222A/8 Adapter for removing the engine211/145211/146r fo ng211/1473423 Gripper for removing the front wheel bearing211/149 211/1503450/2A, 3450/3 Guide pins for installing the cylinder head3450/2A3450/3211/151/1523411 Guide rods For moving the lock carrier with attachments to servicing position211/154AG.for removing the radioagen lksw Vo by211/148 211/153 211/1553344A Releasing toolht rig py Co t.Prote cted by c o py rig ht . C op yi45agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iht rig py Co t.ility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en46notesr fo ngun leurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sn AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sdo c um en47ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yir te o iva r rp fo g nes, in part or in w l purpos hole ercia , is n m ot compe rm itte dun le211es, in part or in w l purpos hole ercia , is n m ot compe rm itte dun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um enFor internal use only © VOLKSWAGEN AG, Wolfsburg All rights reserved. Technical specifications subject to change without notice. 840.2810.30.20 Technical status: 10/98Y Printed on chlorine-freebleached cellulose paper.ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi