Volkswagen New Beetle Workshop Manual

volkswagen :: Volkswagen New Beetle Turbo S L4-

1.8L Turbo (AWP) (2002)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations

Alarm Horn Relay: Locations

RELAY LOCATIONS

Relay Panel & Thirteenfold Auxiliary Relay Panel

Relay location on the thirteen position auxiliary relay panel, above relay panel:

1 - Alarm System Light Flasher Relay (404)
2 - Alarm System Light Flasher Relay (200)
3 - Back-up Light Relay (53)
3 - Lock Relay for Starter (Theft Warning System) (185)
4 - Lock Relay for Starter (Clutch pedal Switch) (53)
7 - Daytime Running Lights Change-over Relay (173)
8 - Daytime Running Lights Change-over Relay (173)
8 - Heated Exterior Mirror Relay (53)

9 - Alarm Horn Relay (53)
10 - Glow Plug Relay (180)
10 -

Third Speed Coolant Fan Control (FC) Relay (100)*

11 - Park/Neutral Position (PNP) Relay (126) (175)
12 - Power Supply (Terminal 30, B+) Relay (109)

Only applies to 1.8L turbo engines*

Relay panel:

1 - Dual Horn Relay (53)

2 - Load Reduction Relay (18) (100) (213)

4 - Fuel Pump (FP) Relay (409)

V - Wiper/Washer Intermittent Relay (192) (377) (389)

VI - Wiper/Washer Intermittent Relay (192) (377) (389)

Number in parentheses ( ) indicates production control number stamped on relay housing.NOTE

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 9105-

01 > May > 05 > Audio System - Poor Radio Reception

Technical Service Bulletin # 9105-01

Audio System - Poor Radio Reception

Group: 91
Number: 05-01
Date: May 2, 2005

Subject: Radio, Reception Diagnosis

Model(s): All with Premium V and VI Radio

1998 > 2006
Condition
Poor radio reception.

Service Procedure

For concerns of poor radio reception:

- Use the following as a guide for trouble shooting.

Tip:

This Technical Bulletin is divided into four sections:
^ Section 1: Includes antenna systems by vehicle.
^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using internal radio diagnostics.
^ Section 3: Includes antenna lead diagnosis.
^ Section 4: Antenna cables

Tip:
^ Perceived reception issues may be a result of environmental factors.
^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses.
^ Aftermarket window tint may interfere with reception.
^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is same, condition may be normal).
Section 1 - Antenna systems by vehicle

Tip:

For more detail see Repair Manual Group 91- Communication of the vehicle you are working on.
Passat (W8 only)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 15

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna Selection Control Module -J515- (Diversity box) -3-:
^ Location Wagon; behind left luggage compartment side trim, below rear side window.
^ Location, Sedan: under rear parcel shelf.
Antennas:
All models use four antennas -1-, -8-.
^ Location Wagon: Integrated with rear side windows.
^ Location Sedan: Integrated with rear window.
Antenna amplifiers:
All models use four antenna amplifiers -2-.
^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side windows.
^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim.
Touareg

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 16

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna Selection Control Module -J515- (Diversity box)
All models use an Antenna Selection Control Module -J515- item -8-.
^ Location: Behind rear section of molded headlining.
Antennas
All models use four antennas items -2-, 4- (qty. 2) & -7-.
^ Antennas (R130, R131) are integrated into rear hatch glass.
^ Antenna R11 in left rear side glass.
^ Antenna R93 in right rear side glass.
Antenna amplifiers
All models use four antenna amplifiers items -1-, -3-, -5- & -6-.
^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window.
^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid.
^ Item 5 - Antenna Amplifier 3 -R112- (for FM reception). In upper section of rear lid.
^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 17

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Phaeton

- Antenna Selection Control Module -J515- (Diversity box)
All models use an Antenna Selection Control Module -J515- item -4-.
^ Location: Above rear glass under headliner.
Antennas
All models use four antennas.
^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5­^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 18

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Jetta / Golf / Passat (non W8) - Antenna system
^ All models use External amplified antenna mast -1-.

Section 2 - Radio antenna system diagnosis through radio unit
Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the radio unit.
All models except Touareg and Phaeton:

- Select AM or FM.

- Press and hold the mix button (black arrow).

- Screen will appear that shows "Service Test mode" (white arrow).

- Press mix button briefly.

^ Test one indicates current antenna status, i.e. ON or OFF (arrow).

- Press mix button briefly again.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 19

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM).

- Press mix button briefly again.

^ Screen indicates number of stations broadcasting close to frequency band of selected station.
^ As the number increases for [mp] and (adj], static and signal crossing will increase.
To exit service mode:

- Depress and hold the mix button or switch radio OFF then back ON
Navigation units
^ No internal diagnosis functions. Continue to antenna lead diagnosis.
Section 3 - Antenna Lead Diagnosis
After initial radio diagnosis using internal service functions, use the following procedures:

- Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 20

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Check for proper connection. (follow steps for your type of system).

- For all systems, locate cable end-point at either diversity box or antenna mast base.

- Disconnect cable from either diversity box or antenna mast base.

- Carefully ground center wire in cable to chassis.
If reception returns:
^ Cable and radio are ok.

If reception does not return:
^ Problem is located further forward in the system.
For problems forward of the antenna system:

- Continue with Section 3a.
For problems at antenna system:
Skip to Section 3b.
For problems at antenna systems:
Tip:
All checks should be done outdoors away from buildings.
Section 3a - Problems forward of antenna system

- First verify connection at Radio (check for bent or crushed connections and proper fit).
If all connections appear ok:

- Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception).
If reception returns:
^ Problem is located between radio and antenna.

- Check connections near center console:
If connections are OK:

- Check resistance of cable from end to end.
^ If More than .4 ohms:

- Replace cable.
If reception does not return;

- Replace radio unit.
Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8)
If concern is only AM poor / no reception;
Locate AM antenna amplifier.
^ Touareg: located above left side window.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 21

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

^ Passat W8: Sedan above rear window.
^ Passat Wagon: located on left rear window.

- Check for proper connections at amplifier both from diversity box and to glass.
If connection issue is at glass or on glass:

- Glass must be replaced.
If connection problem to amplifier:

- Repair connection (replace cable or amplifier).

If no apparent connection problems:

- Replace amplifier.
If concern is poor FM reception:

- Disconnect all amplifiers, tune radio to high-powered station for your area.

- Connect amplifiers one at a time.
If reception is indicated:

- Disconnect that amplifier and move on to next amplifier.
If at any point in reconnecting amplifiers there is a loss in reception and there are no connection issues:

- Replace that amplifier and check again.
If there is no reception change when disconnecting and reconnecting all amplifiers:

- Replace diversity/antenna selection box.
Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast)

- Check connections at antenna base.

- Check for corrosion at mounting.
If corrosion is found:

- Clean mount and apply anti-seize gel to mounting.
If concern is no AM and/or little or poor AM/FM reception,

- Replace antenna base.
Section 4- Antenna cables
If antenna cables are required:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 22

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna cables - single DIN (Premium V) radio.

- Antenna cables - double DIN (Premium VI) radio.

- Antenna cables - Phaeton 2004 > 2006

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 23

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna cables - Satellite radio (Hard top vehicles)

- Antenna cables - New Beetle with Satellite radio (convertible)

- Antenna cables - W8 Passat

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 24

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna cables - Touareg 2004 > 2006
Tip:
Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the latest parts information.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control

Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception

Technical Service Bulletin # 9105-01

Audio System - Poor Radio Reception

Group: 91
Number: 05-01
Date: May 2, 2005

Subject: Radio, Reception Diagnosis

Model(s): All with Premium V and VI Radio

1998 > 2006
Condition
Poor radio reception.

Service Procedure

For concerns of poor radio reception:

- Use the following as a guide for trouble shooting.

Tip:

This Technical Bulletin is divided into four sections:
^ Section 1: Includes antenna systems by vehicle.
^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using internal radio diagnostics.
^ Section 3: Includes antenna lead diagnosis.
^ Section 4: Antenna cables

Tip:
^ Perceived reception issues may be a result of environmental factors.
^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses.
^ Aftermarket window tint may interfere with reception.
^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is same, condition may be normal).
Section 1 - Antenna systems by vehicle

Tip:

For more detail see Repair Manual Group 91- Communication of the vehicle you are working on.
Passat (W8 only)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 30

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna Selection Control Module -J515- (Diversity box) -3-:
^ Location Wagon; behind left luggage compartment side trim, below rear side window.
^ Location, Sedan: under rear parcel shelf.
Antennas:
All models use four antennas -1-, -8-.
^ Location Wagon: Integrated with rear side windows.
^ Location Sedan: Integrated with rear window.
Antenna amplifiers:
All models use four antenna amplifiers -2-.
^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side windows.
^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim.
Touareg

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 31

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna Selection Control Module -J515- (Diversity box)
All models use an Antenna Selection Control Module -J515- item -8-.
^ Location: Behind rear section of molded headlining.
Antennas
All models use four antennas items -2-, 4- (qty. 2) & -7-.
^ Antennas (R130, R131) are integrated into rear hatch glass.
^ Antenna R11 in left rear side glass.
^ Antenna R93 in right rear side glass.
Antenna amplifiers
All models use four antenna amplifiers items -1-, -3-, -5- & -6-.
^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window.
^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid.
^ Item 5 - Antenna Amplifier 3 -R112- (for FM reception). In upper section of rear lid.
^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 32

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Phaeton

- Antenna Selection Control Module -J515- (Diversity box)
All models use an Antenna Selection Control Module -J515- item -4-.
^ Location: Above rear glass under headliner.
Antennas
All models use four antennas.
^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5­^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 33

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Jetta / Golf / Passat (non W8) - Antenna system
^ All models use External amplified antenna mast -1-.

Section 2 - Radio antenna system diagnosis through radio unit
Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the radio unit.
All models except Touareg and Phaeton:

- Select AM or FM.

- Press and hold the mix button (black arrow).

- Screen will appear that shows "Service Test mode" (white arrow).

- Press mix button briefly.

^ Test one indicates current antenna status, i.e. ON or OFF (arrow).

- Press mix button briefly again.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 34

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM).

- Press mix button briefly again.

^ Screen indicates number of stations broadcasting close to frequency band of selected station.
^ As the number increases for [mp] and (adj], static and signal crossing will increase.
To exit service mode:

- Depress and hold the mix button or switch radio OFF then back ON
Navigation units
^ No internal diagnosis functions. Continue to antenna lead diagnosis.
Section 3 - Antenna Lead Diagnosis
After initial radio diagnosis using internal service functions, use the following procedures:

- Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 35

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Check for proper connection. (follow steps for your type of system).

- For all systems, locate cable end-point at either diversity box or antenna mast base.

- Disconnect cable from either diversity box or antenna mast base.

- Carefully ground center wire in cable to chassis.
If reception returns:
^ Cable and radio are ok.

If reception does not return:
^ Problem is located further forward in the system.
For problems forward of the antenna system:

- Continue with Section 3a.
For problems at antenna system:
Skip to Section 3b.
For problems at antenna systems:
Tip:
All checks should be done outdoors away from buildings.
Section 3a - Problems forward of antenna system

- First verify connection at Radio (check for bent or crushed connections and proper fit).
If all connections appear ok:

- Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception).
If reception returns:
^ Problem is located between radio and antenna.

- Check connections near center console:
If connections are OK:

- Check resistance of cable from end to end.
^ If More than .4 ohms:

- Replace cable.
If reception does not return;

- Replace radio unit.
Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8)
If concern is only AM poor / no reception;
Locate AM antenna amplifier.
^ Touareg: located above left side window.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 36

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

^ Passat W8: Sedan above rear window.
^ Passat Wagon: located on left rear window.

- Check for proper connections at amplifier both from diversity box and to glass.
If connection issue is at glass or on glass:

- Glass must be replaced.
If connection problem to amplifier:

- Repair connection (replace cable or amplifier).

If no apparent connection problems:

- Replace amplifier.
If concern is poor FM reception:

- Disconnect all amplifiers, tune radio to high-powered station for your area.

- Connect amplifiers one at a time.
If reception is indicated:

- Disconnect that amplifier and move on to next amplifier.
If at any point in reconnecting amplifiers there is a loss in reception and there are no connection issues:

- Replace that amplifier and check again.
If there is no reception change when disconnecting and reconnecting all amplifiers:

- Replace diversity/antenna selection box.
Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast)

- Check connections at antenna base.

- Check for corrosion at mounting.
If corrosion is found:

- Clean mount and apply anti-seize gel to mounting.
If concern is no AM and/or little or poor AM/FM reception,

- Replace antenna base.
Section 4- Antenna cables
If antenna cables are required:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 37

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna cables - single DIN (Premium V) radio.

- Antenna cables - double DIN (Premium VI) radio.

- Antenna cables - Phaeton 2004 > 2006

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 38

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna cables - Satellite radio (Hard top vehicles)

- Antenna cables - New Beetle with Satellite radio (convertible)

- Antenna cables - W8 Passat

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Antenna Control Module: > 9105-01 > May > 05 > Audio System - Poor Radio Reception > Page 39

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Antenna cables - Touareg 2004 > 2006
Tip:
Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the latest parts information.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Lighting Relay > Component Information > Locations

Antitheft Lighting Relay: Locations

RELAY LOCATIONS

Relay Panel & Thirteenfold Auxiliary Relay Panel

Relay location on the thirteen position auxiliary relay panel, above relay panel:

1 - Alarm System Light Flasher Relay (404)
2 - Alarm System Light Flasher Relay (200)
3 - Back-up Light Relay (53)
3 - Lock Relay for Starter (Theft Warning System) (185)
4 - Lock Relay for Starter (Clutch pedal Switch) (53)
7 - Daytime Running Lights Change-over Relay (173)
8 - Daytime Running Lights Change-over Relay (173)
8 - Heated Exterior Mirror Relay (53)

9 - Alarm Horn Relay (53)
10 - Glow Plug Relay (180)
10 -

Third Speed Coolant Fan Control (FC) Relay (100)*

11 - Park/Neutral Position (PNP) Relay (126) (175)
12 - Power Supply (Terminal 30, B+) Relay (109)

Only applies to 1.8L turbo engines*

Relay panel:

1 - Dual Horn Relay (53)

2 - Load Reduction Relay (18) (100) (213)

4 - Fuel Pump (FP) Relay (409)

V - Wiper/Washer Intermittent Relay (192) (377) (389)

VI - Wiper/Washer Intermittent Relay (192) (377) (389)

Number in parentheses ( ) indicates production control number stamped on relay housing.NOTE

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Technical Service Bulletins > Customer Interest for Central Control Module: > 6007-06

> Jun > 07 > Body - Sunroof Malfunctions or is Inoperative

Central Control Module: Customer InterestBody - Sunroof Malfunctions or is Inoperative

60 07 06
June 19, 2007

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Central Control Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 51

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting offlowcharts.
Condition

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Central Control Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 52

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Vehicle Information
Sunroof and Central Control Module -J393- Diagnosis
Technical Background

Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof beinginterrupted while in operation, or a faulty central control module.
Production Solution

No production change required.
Service
Symptoms
Sunroof inoperative.
Sunroof will not close (stuck open or stuck open in the tilt position).
Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position).
Warranty
When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb.
Required Parts and Tools

No Special Parts required.
No Special Tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Control

Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative

Central Control Module: All Technical Service BulletinsBody - Sunroof Malfunctions or is Inoperative

60 07 06
June 19, 2007

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Central Control Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 58

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting offlowcharts.
Condition

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Central Control Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 59

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Vehicle Information
Sunroof and Central Control Module -J393- Diagnosis
Technical Background

Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof beinginterrupted while in operation, or a faulty central control module.
Production Solution

No production change required.
Service
Symptoms
Sunroof inoperative.
Sunroof will not close (stuck open or stuck open in the tilt position).
Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position).
Warranty
When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb.
Required Parts and Tools

No Special Parts required.
No Special Tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.

> Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations

Heated Mirror Relay: Locations

RELAY LOCATIONS

Relay Panel & Thirteenfold Auxiliary Relay Panel

Relay location on the thirteen position auxiliary relay panel, above relay panel:

1 - Alarm System Light Flasher Relay (404)

2 - Alarm System Light Flasher Relay (200)

3 - Back-up Light Relay (53)

3 - Lock Relay for Starter (Theft Warning System) (185)

4 - Lock Relay for Starter (Clutch pedal Switch) (53)

7 - Daytime Running Lights Change-over Relay (173)

8 - Daytime Running Lights Change-over Relay (173)

8 - Heated Exterior Mirror Relay (53)

9 - Alarm Horn Relay (53)
10 - Glow Plug Relay (180)
10 -

Third Speed Coolant Fan Control (FC) Relay (100)*

11 - Park/Neutral Position (PNP) Relay (126) (175)
12 - Power Supply (Terminal 30, B+) Relay (109)

Only applies to 1.8L turbo engines*

Relay panel:

1 - Dual Horn Relay (53)

2 - Load Reduction Relay (18) (100) (213)

4 - Fuel Pump (FP) Relay (409)

V - Wiper/Washer Intermittent Relay (192) (377) (389)

VI - Wiper/Washer Intermittent Relay (192) (377) (389)

Number in parentheses ( ) indicates production control number stamped on relay housing.NOTE

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 6007-06 > Jun > 07

> Body - Sunroof Malfunctions or is Inoperative

Sunroof / Moonroof Module: Customer InterestBody - Sunroof Malfunctions or is Inoperative

60 07 06
June 19, 2007

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest

for Sunroof / Moonroof Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 72

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting offlowcharts.
Condition

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest

for Sunroof / Moonroof Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 73

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Vehicle Information
Sunroof and Central Control Module -J393- Diagnosis
Technical Background

Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof beinginterrupted while in operation, or a faulty central control module.
Production Solution

No production change required.
Service
Symptoms
Sunroof inoperative.
Sunroof will not close (stuck open or stuck open in the tilt position).
Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position).
Warranty
When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb.
Required Parts and Tools

No Special Parts required.
No Special Tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 6007-

06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative

Sunroof / Moonroof Module: All Technical Service BulletinsBody - Sunroof Malfunctions or is Inoperative

60 07 06
June 19, 2007

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Sunroof / Moonroof Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 79

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting offlowcharts.
Condition

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Sunroof / Moonroof Module: > 6007-06 > Jun > 07 > Body - Sunroof Malfunctions or is Inoperative > Page 80

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Vehicle Information
Sunroof and Central Control Module -J393- Diagnosis
Technical Background

Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof beinginterrupted while in operation, or a faulty central control module.
Production Solution

No production change required.
Service
Symptoms
Sunroof inoperative.
Sunroof will not close (stuck open or stuck open in the tilt position).
Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position).
Warranty
When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb.
Required Parts and Tools

No Special Parts required.
No Special Tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: >

WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement

Technical Service Bulletin # WJ-CAN

Recall - ABS Control Unit Inspection/Replacement

WJ-CAN

Subject:

2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit
March 2002

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 90

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 91

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Owner Letter

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 92

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Volkswagen Canada, Inc.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 93

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 94

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Owner Letter

Work Procedure
Work Procedure

Special Tools:

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 95

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Overview:

This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Controlmodule

- Diagnostic tool - V.A.G. 1551 or VAS 5051

- Brake pedal loading device - V.A.G. 1869/2 or equivalent

- Brake bleeding tool - VAS 5234 or US 1116

Section A
Section A - Check ABS Control Module Part Number

- Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column

- Switch ignition to "ON" position

- On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button

- Select "03 - Brake Electronics."

- Read control module part number and code located in the upper right corner of the screen

­If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF"position and proceed to Section B

­If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS5051 from vehicle and turn ignition to "OFF" position

Section B
Section B - Check ABS Control Module Supplier Code

- Drive vehicle into hoist area

­Raise vehicle on hoist-

Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing

Tire and wheel removal is not necessaryNOTE:

- Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 96

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

The label showing supplier code is upside down in vehicleNOTE:

­If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstallrubber grommet and proceed to Section C

­If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubbergrommet and lower vehicle on hoist

Section C
Section C - ABS Control Module Removal and Installation

- Obtain radio code and record radio preset stations

- Turn Ignition Switch to "OFF" position

- Open hood and place fender cover in position

- Disconnect the ground cable (GDN) from the negative (-) battery terminal

- Disconnect electrical connector -1- from mass air flow sensor -2-

- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only)

- Remove clamp -3- and disconnect intake air hose from mass air flow sensor

- If applicable, remove secondary air hose -4- from air filter box -5-

- Remove screws -6- securing air filter box and remove air filter box

- If applicable, remove and move aside secondary air relay box and harness from supporting clip

- If applicable, disconnect electrical connector on brake fluid reservoir

- Release ABS control module electrical connector by pulling latch upward -arrow 1-

- Pull electrical connector off ABS control module -arrow 2-

- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws

- Lower vehicle

- Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle

- Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor

- Raise vehicle

- Close left front and left rear caliper bleed screws when brake fluid stops flowing

- Lower vehicle

- Do not remove brake pedal depressor from brake pedal at this time

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 97

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of systemNOTE:

- Place sufficient lint-free cloths under the ABS control module and hydraulic unit

­Place sufficient lint-free cloths under the ABS control module and hydraulic unit-

Remove brake lines -3- on the side of hydraulic unit

CAUTION:-

DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT.

- MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS

- From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2-

If parts from repair kit are being reused, make certain the parts are free of debris and contaminatesIMPORTANT:

The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control moduleNOTE:

CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 98

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit

The black colored plug is a smaller diameter and used for the brake line inserted into the smaller holeNOTE:

- Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket

- Remove hydraulic unit with control module from bracket and place on a clean level work bench

­Remove the new ABS control module (1C0 907 379 J) from package-

Insert new adaptor -3- from kit into new ABS control module

- Push adaptor down until clips -4- snap into position

CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEINGDAMAGED

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 99

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit

­Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down tostop

CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABSCONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE

- Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.)

- Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws

Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallationNOTE:

- Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.)

Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are cleanNOTE:

- Remove yellow plastic plugs and red bracket from hydraulic unit

- Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.)

- Clean all debris and contaminants from all removed plugs and bracket

IMPORTANT:

Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated forevery 3 vehicles

- Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.)

­Remove lint-free clothes from under the ABS control module and hydraulic unit-

Place electrical connector -1- into ABS control module and push in direction of -arrow 2-

- Lock electrical connector to ABS control module by pushing latch down -arrow 3-

- If applicable, reinstall secondary air relay box and reinsert harness in support clip

- If applicable, reconnect electrical connector to brake fluid reservoir

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 100

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

- Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.)

- If applicable reconnect air hose -4- from secondary air pump to air filter box -5-

- Reconnect vacuum line -7- to air box (TDI vehicles only)

- Reconnect air intake hose to mass air flow sensor and secure with clamp -3-

- Reconnect electrical connector -1- to mass air flow sensor -2-

- Reconnect the ground cable (GDN) from the negative (-) battery terminal

- In the vehicle, remove brake pedal depressor from the brake pedal

- Proceed to Section D

Section D
Section D - Code ABS Control Module

- Connect VAS 5051 to data link connector located under dash left of steering column

- Turn ignition switch to "ON" position

- On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button

- Select "03 - Brake Electronics"

- Select "07 - Code control unit"

- Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J

- Press the "Q" button to confirm

On the display, in the upper right corner, the control module part number and coding are displayedNOTE:

- Press (<) button

- Select "06 - End output"

- Disconnect VAS 5051 from vehicle

- Recode radio and reset radio preset stations

- Reset clock

- Where applicable, reset power window pinch protection

- Turn ignition to "OFF" position

- Proceed to Section E

Section E

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Recalls for Electronic Brake Control Module: > WJ-CAN > Mar > 02 > Recall - ABS Control Unit Inspection/Replacement > Page 101

New Beetle Turbo S L4-1.8L Turbo (AWP) (2002)

Section E - Brake Bleeding

- Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle

IMPORTANT:

When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit mustbe bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting".

WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleedingunit VAS 5234 or US 1116

Use only Volkswagen approved brake fluidNOTE:

CAUTION:-

BRAKE FLUID IS POISONOUS.

- BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE.

- CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE.

- Open bleed screws in the prescribed sequence and bleed brake calipers

Bleeding Sequence1

- Left front brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper

- With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw

- Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle

- Ensure that brake fluid in the reservoir is at the correct level

- Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system

IMPORTANT:

Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle mustoccur.

Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit toVolkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ)
ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL.