New Beetle No. 51/1 Wiring diagram - WordPress.com · New Beetle No. 51/3 F8 - Kick Down Switch F60...
Transcript of New Beetle No. 51/1 Wiring diagram - WordPress.com · New Beetle No. 51/3 F8 - Kick Down Switch F60...
Deviate relay location and fuseplacements as well as the locations of multiple connectors seesection ”component locations”.
Fuse colors
30 A - green25 A - white20 A - yellow15 A - blue10 A - red7,5 A - brown5 A - beige
Edition 09/01
USA.5132.16.21
Wiring diagram
Relay location on the thirteen position auxiliaryrelay panel, above relay panel:
Note: Number in parentheses indicates productioncontrol number stamped on relay housing.
Relay panel:
2 Load Reduction Relay (100)
97--21956
75X 3030 30a 87F
10 Glow Plug Relay (180)
12 Power Suppy (Terminal 30, B+) Relay (109))
New Beetle No. 51/1
1,9L-Engine - Turbo Diesel Fuel Injection (DFI)/66 kW,
code ALH,
from June 2001
97-61711
1 2 3 4 5 6 7 8 9 10 11 12 13 14
B+D+
bl0,35
B
50 30
M
S22910A
29a
29
sw/li1,5
125
C
W
C1
G
D/30
ro6,0
5/31
J593
9
7/30
2
sw1,5
ro16,0
c
A2
500 501
1
S16250A
ro2,5
ro6,0
98
ro6,0
60
83
ro4,0
2
S16350A
4
S176110A
5
S177110A
sw2,5
99
br/ro0,5
A/+A/+
sw35,0
T4/1
br/ro1,0
T4/2
br/sw0,5
sw25,0
43
ro16,0
ro6,0
ro4,0
A32
A52
J226
ro/sw2,5
D/50T9/8
ro/sw2,5
21
*
ro2,5
T6/3
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
Battery, starter, Generator (GEN), Voltage Regulator (VR)
No. 51/2 New Beetle
A - BatteryB - StarterC - Generator (GEN)C1 - Voltage Regulator (VR)D - Ignition/Starter SwitchJ226 - Park/Neutral Position (PNP) RelayS162 - Fuse -1- in fuse bracket/batteryS163 - Fuse -2- in fuse bracket/batteryS176 - Fuse -4- (30), in fuse bracket/batteryS177 - Fuse -5- (30), in fuse bracket/batteryS229 - Fuse 29 in fuse holderT4 - 4-Pin connector, in engine compartment, leftT6 - 6-Pin Connector, brown, behind instrument
panel, leftT9 - 9-Pin Connector
500 - Threaded connection -1- (30) on the relay plate
501 - Threaded connection -2- (30) on the relay plate
A2 - plus connection (15), in instrument panelwiring harness
A32 - plus connection (30), in instrument panelwiring harness
A52 - Plus connection (30), in instrument panelwiring harness
* - Manual transmission only
- - - Automatic transmission only
97-61712
15 16 17 18 19 20 21 22 23 24 25 26 27 28
T121/37
T6/1
T121/51
G 79
T10c/1
T10c/5
T10c/6
T10c/4
T10c/3
gr/bl0,35
gr/ws0,35
gr/ro0,35
ge/gn0,35
ws/bl0,35
gr/ws0,5
ws/bl0,5
T121/69
T121/70
T121/50
T121/12
T121/63
T6a/6 T6a/4 T6a/5 T6a/3 T6a/2 T6a/1
T10c/2
ws0,5
rs0,5
br0,5
gn0,5
gr0,5
ge0,5
br/bl1,0
gr/bl0,5
gr/ro0,5
ge/gn0,5
6
sw/li1,5
c
sw/bl1,5
sw/ro1,5
F 8F 60
sw/li1,5
A104
gn/ro0,35
Q
sw/li0,35
sw/gr1,5
sw/gn1,5
T4k/1 T4k/2 T4k/3 T4k/4
T11/1G1
T11/2G2
T11/3G3
T11/4G4
T11/687
65
bl0,5
br/ro0,5
T11/731
608
71 36
gn/sw0,35
bl/sw0,35
T11/9 T11/10 T11/11
ro6,0
10
sw1,5
sw1,5
sw1,5
sw1,5
J 248J 370
D1 ST 30
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
DFI Engine control module (ECM),kick down switch,throttle position (TP) sensor, closedthrottle position (CTP) switch,glow plug relay,control module for glow plug triggering
New Beetle No. 51/3
F8 - Kick Down SwitchF60 - Closed Throttle Position (CTP) SwitchG79 - Throttle Position (TP) SensorJ248 - Diesel Direct Fuel Injection (DFI) Engine
Control Module (ECM)J370 - Control module for glow plug triggeringQ6 - Glow plugs (engine)T4k - 4 Pin ConnectorT6 - 6-Pin Connector, brown, behind instrument
panel, leftT6a - 6-Pin ConnectorT10c - 10-Pin Connector, blue, behind instrument
panel, leftT11 - 11-Pin ConnectorT121 - 121-Pin Connector, on DFI ECM
608 - Ground Connection (in center plenum chamber)
A104 - Plus connector -2- (15), in instrument panelwiring harness
97-61713
J248
29 30 31 32 33 34 35 36 37 38 39 40 41 42
G28
ge0,5
T121/102
ws0,5
T121/110
T3/3 T3/2 T3/1
sw0,5
200
ro/li0,35
ge/sw1,0
T121/30T121/68
245
sw0,35
li/ro0,35
T121/31
69
f
br/bl0,35
G70
T121/29 T121/9
li0,5
T14/4
T121/104
br/gn0,35
li0,35
127
4 1
3
G62 G2
2
br/ws0,5
T121/112
bl/br0,35
108
gn0,35
T121/49
3
ge/sw0,35
T10/10
33
T121/71
ge/sw0,5
T10c/710c/9
T10/5
34
T121/73
gr/gn0,35
li/ro0,5
br/bl0,35
70
T121/52
T
3 1
ge/sw0,5
gr/gn0,5
4 2
G31
3741
T10a/8
bl/ro0,35
bl/ro0,5
L9
bl/ro0,5
J293
T14/8
bl/ro0,5
E35
T10j/2
T121/34
T10a/7
gn0,35
gn0,5
J217
T68/12
293
T14/3
gn0,5
J
bl/sw0,35
34
19
gr/gn0,5
*
**
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
DFI Engine control module (ECM), engine coolant temperature (ECT) sensor, enginespeed (RPM) sensor, charge air pressure sensor, mass air flow (MAF) sensor
No. 51/4 New Beetle
E 35 - A/C SwitchG2 - Engine Coolant Temperature (ECT) SensorG28 - Engine Speed (RPM) SensorG31 - Charge Air Pressure SensorG62 - Engine Coolant Temperature (ECT) SensorG70 - Mass Air Flow (MAF) SensorJ217 - Transmission Control Module (TCM)J248 - Diesel Direct Fuel Injection (DFI) Engine
Control Module (ECM)J293 - Coolant FC (Fan Control) Control ModuleT3 - 3-Pin connector, on engine, frontT10 - 10-Pin connector, white, behind instrument
panel, leftT10a - 10-Pin connector, orange, behind instrument
panel, leftT10c - 10-Pin connector, blue, behind instrument
panel, left
T10j - 10-Pin connectorT14 - 14-Pin connector, in plenum chamberT68 - 68-Pin connector, on TCMT121 - 121-Pin connector, on DFI ECM
200 - Ground connection (shielding), in enginecompartment wiring harness
L9 - Wire connection -1-, in A/C wiring harness
* - A/C clutch cut-out signal from ECM/TCM** - A/C “ON” signal from -E35-
- - - - Automatic transmission only
97-61714
J248
43 44 45 46 47 48 49 50 51 52 53 54 55 56
T121/111
ge/bl0,35
li/sw0,35
gr/gn0,35
G149 N146G81
T121/108
T121/106
ws/gn0,35
T121/99 T121/116
T121/121
br/ro1,0
br/ro1,0
F25
br/ro1,0
T10f/3
T10f/6
T10f/5
ro/li1,5
T121/103
br/bl0,35
T10f/2
T10f/1
T10f/7
T10f/4
200
T121/109
gr0,5
T121/101
bl0,5
T2a/1 T2a/2
br/ge0,35
T121/86
G80
f
sw0,5
103
T121/38
br/ro0,5
T10/5
3
J217
T68/3
T121/6
J104
T47/15
T10/3
A122
or/br0,35
or/br0,35
or/br0,35
J217
T68/25
T121/7
J104
T47/11
T10/2
A121
or/sw0,35
or/sw0,35
or/sw0,35
br/ro0,35
ro/li1,5
ws0,5
sw0,5
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
DFI Engine control module (ECM), needle lift sensor, fuel temperature sensor,modulating piston displacement sensor, quantity adjuster
New Beetle No. 51/5
G 80 - Needle Lift SensorG 81 - Fuel Temperature SensorG149 - Modulating Piston Displacement SensorJ104 - ABS Control Module (w/EDL)J217 - Transmission Control Module (TCM)J248 - Diesel Direct Fuel Injection (DFI) Engine Control
Module (ECM)N146 - Quantity AdjusterT2a - 2-Pin connector, on engine, frontT10 - 10-Pin connector, white, behind instrument
panel, leftT10f - 10-Pin connector, on engine, frontT47 - 47-Pin connectorT68 - 68-Pin connector
T121 - 121-Pin connector, on DFI ECM
200 - Ground connection (shielding), in enginecompartment wiring harness
A121 - Connection (high bus) in instrument panelwiring harness
A122 - Connection (low bus) in instrument panelwiring harness
F25 - Wire connection -1-, in Diesel Direct FuelInjection (DFI) system wiring harness
97-61715
57 58 59 60 61 62 63 64 65 66 67 68 69 70
li/gr0,35
1N239
2
T121/81
J248
ro/bl0,35
1
N18
2
T121/61
ge/sw1,0
br/sw1,0
2
1
T121/114
T10f/9
T10f/10
ro/br0,35
1
N75
2
T121/62
ge/sw1,0
ge/sw1,0
ge/sw1,5
ge/sw1,0
31
E30
S23410A
34a
34
104
bl1,5
T6/5
ge/sw1,0
T14/6
gr/ws0,35
T121/16
126
T10a/1
gr/ws0,35
K
sw/ws1,0
N109
T121/120
T10f/8
N108
T121/18
6/87
2/30
9/85
bl4,0
105
J317
ro4,0
T10c/8
13
bl/ge0,5
B147
ge/sw1,0
ge/sw1,0
bl/ge0,35
ge/sw1,0
S23410A
34
ge/sw1,0
20
sw/gn0,35
T121/88
sw/gn0,5
T14/10
10A
10
10a
S10
sw/ro1,0
A80
sw/ro2,5
E1/1
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
DFI ECM, power supply relay, EGR vacuum regulator solenoid valve, wastegatebypass regulator valve, fuel cut-off valve, change-over valve for int. man. flap.
No. 51/6 New Beetle
E 1 - Light switchJ248 - Diesel Direct Fuel Injection (DFI) Engine
Control Module (ECM)J317 - Power Supply (Terminal 30, B+) RelayN 18 - EGR Vacuum Regulator Solenoid ValveN 75 - Wastegate Bypass Regulator ValveN108 - Cold Start InjectorN109 - Fuel Cut-off ValveN239 - Change-over valve for intake manifold flapS10 - Fuse 10 in fuse holderS234 - Fuse 34 in fuse holderT6 - 6-Pin connector, brown, behind instrument
panel, leftT10a - 10-Pin connector, orange, behind instrument
panel, left
T10c - 10-Pin connector, blue, behind instrumentpanel, left
T10f - 10-Pin connector, black, on engine, frontT14 - 14-Pin connector, in plenum chamberT121 - 121-Pin connector, on DFI ECM
A80 - Connector -1- (X) in instrument panel wiringharness
B147 - Plus connector -2- (87), in wiring harness
E30 - Connector (87a), in wiring harness engine
97-61716
J248
71 72 73 74 75 76 77 78 79 80 81 82 83 84
ws/ge0,35
T121/65T121/46
sw/ws0,35
T121/14
E45
3
2F47
ro/sw1,0
1
4F
99
E227
ws0,35
T121/45
bl/gr0,35
T121/44
ro0,35
T10h/3 T10h/9
T10h/1
T10h/2
sw/ge0,35
sw/ge0,35
T10b/7
T10b/5
T10b/4 T10b/2
T10b/6
T10b/3
ws0,35
bl0,35
sw/bl0,35
ro/ge0,35
A18
A100
ro/sw0,35
T121/32
bl/ge1,0
ws/ro0,35
T121/66
T10/4
2
3
bl/ge1,0
ws/ro1,0
F36
ws/ge1,0
T10h/4
T10h/5
93
S1310A
13a
ro/br1,0
13
ro4,0
11
bl/ge1,0
101
bl/ge1,0
2 0 1
T121/33
17
gn/sw0,35
ro/sw1,0
*
*
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
DFI Engine control module (ECM), button for cruise control (set), cruise controlswitch, brake light switch, clutch & brake switches
New Beetle No. 51/7
E 45 - Cruise Control SwitchE227 - Button for cruise control (set)F - Brake Light SwitchF36 - Clutch Vacuum Vent Valve SwitchF47 - Brake Pedal Switch (cruise control/Diesel Direct
Fuel Injection)J248 - Diesel Direct Fuel Injection (DFI) Engine
Control Module (ECM)S13 - Fuse 13 in fuse holderT10 - 10-Pin connector, white, behind instrument
panel, leftT10b - 10-Pin connector, black, near steering columnT10h - 10-Pin connector, black, behind instrument
panel, left
T121 - 121-Pin connector, on DFI ECM
A18 - wire connection (54), in instrument panelwiring harness
A100 - Connector -2- (87), in instrument panelwiring harness
* - Manual transmission only
97-61717
J248
T121/21
sw/bl0,35
T121/22
sw/br0,35
Q 7
br/ro2,5
T121/4 T121/5
156
br/ro2,5
br/ro2,5
607
6/85
4/86
J359
ro4,0
bl/ge1,0
D98
sw4,0
sw2,5
sw2,5
8/87 15/85
13/86
J360
11/30
17/87
ro4,0
D50
2/30
bl/ge1,0
T121/1
ro/li2,5
T121/2
ro/li2,5
D74
102
ro6,0
11
T121/20
gA27
T10a/6
bl/ws0,35
84
85 86 87 88 89 90 91 92 93 94 95 96 97 98
T6/6
bl/ws0,35
sw2,5
L32
sw/br1,0
bl/ge1,0
ro/li4,0
* *
*
*
*
1 2 3br/ro1,5
N79
2
bl/ge1,0
1
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
DFI Engine control module (ECM), relay for preheating coolant: low heatoutput, high heat output, spark plugs (coolant)
No. 51/8 New Beetle
J248 - Diesel Direct Fuel Injection (DFI) EngineControl Module (ECM
J359 - Realy for preheating coolant, low heat output *J360 - Relay for prehaeating coolant, high heat
output*N 79 - Positive Crankcase Ventilation (PCV) Heating
ElementQ7 - Spark plugs (coolant)T6 - 6-Pin connector, brown, behind instrument
panel, leftT10a - 10-Pin connector, orange, behind instrument
panel, leftT121 - 121-Pin connector, on DFI ECM
607 - Ground Connection (in left plenum chamber)
156 - Ground connection, in Diesel Direct FuelInjection (DFI) wiring harness
A27 - Wire Connection (vehicle speed signal), ininstrument panel wiring harness
D50 - Plus connection (30), in engine compartmentwiring harness
D74 - Wire connection (86), in engine compartmentwiring harness
D98 - Wire connection (glow plugs), in enginecompartment wiring harness
L32 - Wire connection -1-, in heater wiring harness
* - Manual Transmission only
97-61718
g g
1
2
G G32
1
2
269
li/sw0,35
br/ws0,35
T14/9
38
br/ws0,5
br/ws1,0
br/ws0,5
h
i
j
li/ro0,35
br/ws0,5
bl4,0
A99
10A
43a
43
bl/ge1,0
S243
bl1,5
15A
32a
32
S232
ro/li4.0
78
bl4,0
60
ro/li1,5
T14/5
5288
T6/4
99 100 101 102 103 104 105 106 107 108 109 110 111 112
64
bl1,5
7,5A
5a
S5
sw/bl0,5
76
A20
sw/bl0,35
5
14
sw2,5
B147
ro/li4,0
4,0ro/li
10A
7
S7
7a
sw/gn1,0
114
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
Sender for fuel gauge, engine coolant level (ECL) sensor
New Beetle No. 51/9
G - Sender for fuel gaugeG32 - Engine Coolant Level (ECL) SensorS5 - Fuse 5 in fuse holderS7 - Fuse 7 in fuse holderS232 - Fuse 32 in fuse holderS243 - Fuse 43 in fuse holderT6 - 6-Pin connector, brown, behind instrument
panel, leftT14 - 14-Pin connector, in plenum chamber
269 - Ground connector (sensor ground) -1-,ininstrument panel wiring harness
A20 - Wire connection (15a), in instrument panelwiring harness
A99 - Connector -1- (87), in instrument panelwiring harness
B147 - Plus connector -2- (87), in wiring harness
97-61719
T32/7T32/28
J285
K3
gn0,35
g
h
i
j
T32/10
K2
1
H11
T32/22
li/ro0,35
br/ws0,35
gn/sw0,35
T32a/5
gr/ws0,35
57
bl0,35
T32/12
F1
1 2
G22
607
3
T14/3
ws/bl0,5
gn0,35
g
h
K
T14/1
gn/sw0,5
114 115 116 117 118 119 120 121 122 123 124 125 126113
K29
K 28
61
sw/ws1,0
T14/2
sw/gn1,0
br1,0
B135
sw/gn1,0
100
Edition 09/01
USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
Oil pressure switch, Speedometer Vehicle Speed Sensor (VSS), instrument cluster, oil pres-
sure warning buzzer, warning and indicator lights
No. 51/10 New Beetle
F1 - Oil Pressure SwitchG22 - Speedometer Vehicle Speed Sensor (VSS)H11 - Oil Pressure Warning BuzzerJ285 - Control module with indicator unit in
instrument panel insertK2 - Generator (GEN) Warning LightK3 - Oil Pressure Warning LightK28 - Engine Coolant Level/Temperature (ECL/ECT)
Warning LightK29 - Glow Plug Indicator LightT14 - 14-Pin connector, in plenum chamberT32 - 32-Pin connector, blue, on instrument clusterT32a - 32-Pin connector, green, on instrument cluster
607 - Ground Connection (in left plenum chamber)
B135 - Plus connector -1- (15a) in wiring harness interior
97-61720
bl/ws0,35
li/sw0,35
li0,35
38
J285
G1
T32/3T32/5T32/8
G5
K105
3G
A27g
h
128 129 130 131 132 133 134 135 136 137 138 139 140127
K83
Edition 09/01USA.5132.16.21
Wiring diagram
ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = violetge = yellow
Instrument cluster, fuel gauge, engine coolant temperature (ECT) gauge,tachometer, Malfunction Indicator Lamp (MIL) low fuel level warning light
New Beetle No. 51/11
G1 - Fuel GaugeG3 - Engine Coolant Temperature (ECT) GaugeG5 - TachometerJ285 - Control module with indicator unit instrument
panel insertK83 - Malfunction Indicator Lamp (MIL)K105 - Low Fuel Level Warning LightT32 - 32-Pin connector, blue, on instrument cluster
A27 - Wire Connection (vehicle speed signal), ininstrument panel wiring harness