Service
Self-Study Programme No. 211
The New Beetle Design and Function
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.
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.
This Self-Study Programme describes the function as well as the design of the N e w Beetle.
The New Beetle is based on the A4 platform.
211/014
New.
The Self-Study Programme is Please always refer to the relevant Service Literature for all inspection, not a Workshop Manual. adjustment and repair instructions.
2
Important. Note.
Contents The New Beetle........................................................... 4 News The engineering of the New Beetle Vehicle dimensions The aerodynamics and body structure
Body............................................................................... 10 Occupant protection Crash-optimised foot controls Vehicle identification and mechanical anti-theft protection Body repairs
Engines........................................................................... 16 General information Assembly mounting Gearbox versions CAN databus Engines Motronic 5.9.2
Running gear................................................................. 26 Front axle/rear axle Steering Brake system
Elektrical system........................................................... 30 Electrical components Sound system Convenience system
Heating and air conditioning system......................... 40 Heating and air conditioning system Dust and pollen filter
Service ........................................................................... 42 Body New special tool
3
The New Beetle
WS E N S W E N NEWS
G ro u p
platfor
w The Ne
m
Beetle w
n th loped o as deve
Bum pe
r system
e basis
of the A
S W E N WS E N NEWS w Be T he N 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 success
rm an 4 platfo
umper 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 very
4
sb a star i . . . e l t e
d is eng
ineered
much
ame w in the s
ay as th
e Golf
p e Grou ur of th gine in favo n n e r io a is c re The de that a nd meant ngine a platform be used. The e e front. ot at th could n located nsists of ain are co o ls a drive tr r ven a ning ge ith a pro n w ru ts e n h e T n o p m co platform rd. co track re
IV.
NEW
S W E N NEWS
S W E N EWS N S NEW
Safety
driver cludes ment in irbag and ip u q e rd ra Standa ssenge front pa airbag, gs. ba side air with 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 optimis
, 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. impress
system Sound
The Ea
sy-En
t tr y s e a
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 sea
nd The sou
system
trols are The con
211/042
can be
ith the tested w
self-dia
gnosis .
new.
5
The New Beetle The engineering of the New Beetle (some features are optional)
Body and safety • • • • •
Fully galvanised body Safety steering column, adjustable for rake and reach Driver’s, front passenger’s and side airbags Pyrotechnical belt tensioners Crash-optimised pedal cluster
Engines • • • •
6
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 suspension
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)
211/024
Running gear • • • • • •
McPherson strut front axle Power steering Torsion beam rear axle ABS or ABS with ESP Power steering 16“ wheels
7
The New Beetle Vehicle dimensions New Beetle
Golf IV
Design 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.
211/075
C Overall height A: Track width B front/rear: Overall width C: Wheelbase D: Overall length E: Turning circle: Luggage compartment:
1498mm 1508mm/1494mm 1724mm 2508mm 4089mm 10.9m 209l/527l
A WOB-SP 60
B
211_003 211/076
D 8
E
211/077
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.
211/118
Body structure The 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.
211/119
9
Body Occupant protection
Airbags Standard equipment in the New Beetle includes: • Full-size airbags for driver and front passenger • Side airbags for driver and front passenger
60° 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°. The side airbags are triggered individually by crash sensors depending on the direction of impact (from the left or right).
60°
60°
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.
211/006
Front passenger's airbag Driver's airbag
Side airbag (right) Airbag control unit (with crash sensor) Side airbag (left)
Crash sensor (right) Crash sensor (left)
211/053
10
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 the new “Isofix“ fastening system.
Crash concept of the steering system During 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.
•
•
•
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.
Bulkhead 50mm
150mm 50mm
38mm Universal joints
11
Body Crash-optimised foot controls In the event of major head-on collisions involving severe structural deformation, the brake pedal swivels away from the footwell area by means of an articulated support.
This function is defined by the deformation of the engine bulkhead and does not depend on the position of the brake pedal.
Central tube
Folding support
During 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.
Piston rod
The 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.
211/093
12
Vehicle identification The 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.
Example:
z
211/044
3VW N4B 1C 2WM000123 WVW 9C 211/117
1C: New Beetle for USA, Mexico, North American Region 9C: New Beetle for Europe and rest of world (RoW)
Vehicle classes:
Mechanical anti-theft protection The slip coupling makes it impossible to turn the steeringcolumn lock by force.
211/132 211/133
Encapsulated door locks and a reinforcement plate behind the door handle act as a deterrent to braking open the door.
211/028
A 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. 211/134
13
Body Body repairs Taillight The 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 wing
211/043
Headlights 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 wing
When fitting the headlight, pay attention to the guide rails.
Headlights can be adjusted by means of two Torx screws.
211/045
14
