The rear axle ...

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

Rear axle bearing

The large-sized rear axle bearings are 25 °

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

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

211/059

44mm adjustment for height

Steering 40mm adjustment fore and aft

The New Beetle has power steering as standard.

The steering column can be adjusted 44mm for

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

Both settings can can be changed simultaneously

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

211/018

Lever for locking steering column

27
 Running gear

Brakes

The New Beetle has disc

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

The front disc brakes are

ventilated.

At the rear wheels, brake

calipers made of aluminium
reduce the unsprung masses.

211/089 211/038

ABS with Electronic Stability Programme (ESP)

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

ABS/ESP control unit

211/060

28
Components of the ESP

Angle of turn Yaw rate

sender sender

Active
brake
servo Lateral acceleration
sender

Hydraulic unit with Wheel speed

ABS/ESP control sensor
unit

211/061

Design Function examples

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

29
 Electrical system

Wiring harnesses

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

The wiring harness of the headlights supplies

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

Engine control unit

Automatic
gearbox control
unit

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

211/009

Wiring harness, engine compartment

Wiring harness, engine

Wiring harness, headlights

30
Control units in the plenum chamber

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

The plenum chamber is locked by two locking

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

Automatic
gearbox control
Engine control unit
unit

G
A
B
R
I
A

211/062

31
 Electrical system

Control units Immobiliser control unit J362

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

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

Automatic gearbox control unit J217

211/056

Radiator fan control unit J293

211/115

Important. ABS control unit

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

211/110

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

211/116

211/140

Airbag control unit J234

(centre tunnel below dash panel)

211/114

Door control units J386 /J387

at window lifter motor
211/102

Motronic control unit J220

211/112
211/109

33
 Electrical system

The dash panel insert

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

For vehicles with automatic gearbox, the selector

lever position is displayed on the LCD display.

211/037a

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

34
Immobiliser

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

EPC

211/064

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

35
 Electrical system

Radio/Sound system

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

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

211/023A

Additional features:

• The radio has a special front panel which is

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

211/131

36
Variable intermittent wipe

The New Beetle also features four intermittent

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

Intermittent wipe cycle length = wiping time +

pause time

200/093

Windscreen washer jets for the

windscreen

The windscreen washer jets are secured to the

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

The windscreen washer jets in the optional

“winter package“ are heated.

211/065

37
 Electrical system

The convenience system ...

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

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

Functions of the central control unit

Central locking Anti-theft alarm system

Rear lid

Interior lighting control Self-diagnosis

Radio-wave remote control Interface to vehicle electrical

system

Tilting/sliding sunroof
- Convenience locking
- Enable

Functions of the door control units

Door central locking with Safe Electrically adjustable and

function heated door mirrors

Electrical windows with roll- Self-diagnosis via the central

back function control unit

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

For vehicles without power

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

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

211/067

1 Connector station, right-hand A-pillar

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

39
 Electrical system

Opening the boot

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

Boot switch

211/068
40
Locking the tank flap

The fuel filler flap may be unlocked electrically

or mechanically. Mechanical emergency tank flap unlocking

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

Tank flap switch

Cable
pul

211/069

41
 Heating, air conditioning system

There is a choice of two equipment versions for

the heating and air conditioning system in the
New Beetle:

• a heater, and Only a manually operated air

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

A plate-type evaporator is used for the air

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

Heating Fresh air/air recirculation flap Servomotor Air recirculation mode

211/142

The fresh air/air recirculation flap is

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

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

211/144

When a manual air conditioning

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

42
Dust and pollen filter with activated charcoal

The dust and pollen filter consists of a The dust and pollen filter is located in the plenum
combination of a fleece material and an chamber which can only be accessed through
activated charcoal granulate. the vehicle interior.

Dust and pollen are filtered by the fleece. The Removing the dust and pollen filter:
activated charcoal reduces odour and noxious
gases. • Remove the upper, three-section cover
The gases are bound or chemically changed on located in between the dash panel and
the surface of the activated charcoal. defrost duct.
Consider ozone, for example. It is almost fully
• Remove the locking unit on the right.
converted into oxygen.
• Located on the air distributor housing below
this is the dust and pollen filter.

Activated charcoal granulate

Fleece material

211/145

43
 Service

Service

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

211/130

After disconnecting the plug and socket

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

VAS 5061

211/001

Repairing high-strength sheet-metal

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

During panel beating, the high-strength panel

exhibits higher buckling strength. The panel is
springier.

211_073
211/073

44
Here are the new special tools for the New Beetle

Tool number and designa- Usage

tion

10-222A/8

Adapter

for removing the engine

211/145 211/146

3344A
Releasing tool

for removing the radio

211/147 211/148

3423

Gripper

for removing the front wheel

bearing
211/149 211/150

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

Guide pins

for installing the cylinder head

211/151/152 211/153

3411

Guide rods

For moving the lock carrier

with attachments to servicing
position 211/154
211/155

45
 notes

46
47
 211

For internal use only © VOLKSWAGEN AG, Wolfsburg

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

❀ Printed on chlorine-free
bleached cellulose paper.