ENGINE PERFORMANCE – Volkswagen New Beetle Turbo S 2004 – SYSTEM WIRING DIAGRAMS

ENGINE PERFORMANCE

1.8L TURBO

1.8L Turbo, Engine Performance Wiring Diagram (1 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.8L Turbo, Engine Performance Wiring Diagram (1 of 3) for Volkswagen New Beetle Turbo S 2004:

• (a/t)
• (beside steering column) g42
• (not used)
• 29a
• Acc
• Cooling fans system
• Cruise control system
• Evaporative emission canister purge regulator valve (right side of engine compt, next to engine coolant reservoir)
• Fuel pump relay
• Fuse 15a
• Fuse 50a
• Fuse panel (behind left side of dash)
• Fuse red bracket (on battery cover)
• G607 (below left side of dash panel cover)
• Heated oxygen sensor (black) (below vehicle, behind 3-way catalytic conv)
• Heated oxygen sensor (black) (below vehicle, behind of 3-way catalytic conv)
• Hot at all times
• Ignition/starter switch
• Lock
• Mass airflow sensor (right side of air cleaner housing, in air intake duct)
• Motronic engine control module (below left side of dash panel cover)
• Nca
• Red
• Relay panel (behind left side of dash)
• Run
• S1/1
• S3/1
• S3/2
• S3/3
• S3/5
• S3/6
• Start
• Starting/ charging system
• Throttle position sensor (integral to throttle valve control module)

1.8L Turbo, Engine Performance Wiring Diagram (2 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.8L Turbo, Engine Performance Wiring Diagram (2 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below right side of dash panel cover) g609
• (beside steering column) g42
• (on top of transaxle differential housing) speedometer vehicle speed sensor
• (under left side of dash) data link connector
• 28a
• 32a
• 34a
• 43a
• Airbag control module (on center floor tunnel, below heater core housing)
• Engine speed (rpm) sensor (on lower left rear of cylinder block, near transmission flange)
• Fuel pump
• Fuse 10a
• Fuse 15a
• Fuse panel
• G607 (below left side of dash panel cover)
• Instrument cluster
• Knock sensor 1 (on left front of cylinder block)
• Knock sensor 2 (on left rear of cylinder block)
• Leak detection pump (in right rear wheelwell, above evap canister)
• Nca
• Red
• Secondary air injection pump motor (left rear of cylinder head)
• Secondary air injection pump relay (inside housing, to left of brake fluid reservoir)
• Secondary air injection solenoid valve (on right front of cylinder head, beneath cover)
• T32
• T32a
• Transmissions system

1.8L Turbo, Engine Performance Wiring Diagram (3 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.8L Turbo, Engine Performance Wiring Diagram (3 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below left side of dash panel cover) g607
• (left rear corner of engine compt) wastegate bypass regu- lator valve
• (on coolant flange) engine coolant temperature sensor
• (on intake manifold, near throttle body) intake air temperature sensor
• (on top of cylinder head) turbocharge recirculating valve
• 10a
• 13a
• Brake- light switch (above brake pedal)
• Camshaft adjustment valve 1
• Camshaft position sensor 2 (on front of cylinder head, behind timing belt cover)
• Charge air pressure sensor (on intercooler)
• Clutch vacuum vent valve switch (above clutch pedal)
• Cooling fans system
• Cruise control system
• Fuel injectors
• Fuse 10a
• Fuse 7.5a
• Fuse panel (behind left side of dash)
• G15 (on cylinder head)
• Hot at all times
• Ignition coils
• Motronic engine control module (below left side of dash panel cover)
• Nca
• Throttle valve control module (on throttle body, on left side of engine)
• To spark plug

1.9L TURBO DIESEL

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code ALH (1 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code ALH (1 of 3) for Volkswagen New Beetle Turbo S 2004:

• (m/t)
• 29a
• A/c system
• Charge air pressure sensor (on intercooler, inside right front fender)
• Cruise control system
• Diesel direct fuel injection (dfi) engine control module (ecm) (below left side of dash panel cover)
• Egr vacuum regulator solenoid valve (on left side of firewall)
• Fuse 10a
• Fuse 15a
• Fuse bracket (on battery cover)
• Fuse panel (behind left side of dash)
• Fuse s176 110a
• G607 (below left side of dash panel cover)
• Generator
• Hot at all times
• Hot in run or start
• Mass airflow (maf) sensor (right side of air cleaner housing)
• Red
• Relay panel
• Throttle position (tp) sensor/ closed throttle position (ctp) switch/kickdown switch (above accelerator pedal)
• Transmissions system, abs system

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code ALH (2 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code ALH (2 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below left side of dash panel cover) g607
• 13a
• Brakelight switch/ brake vacuum vent valve switch (above brake pedal)
• Clutch vacuum vent valve switch (m/t) (above clutch pedal)
• Coolant glow plugs
• Coolant preheating relay (high heat output)
• Coolant preheating relay (low heat output)
• Engine glow plugs
• Fuse 10a
• Fuse 50a
• Fuse bracket (on battery cover)
• Fuse panel (behind left side of dash)
• G608 (below center of dash panel cover)
• Glow plug triggering control module
• Hot at all times
• Intake manifold flap changeover valve (on rear of intake manifold, right side of engine)
• Positive crankcase ventilation heating element in pcv hose, at rear of intake manifold)
• Red

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code ALH (3 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code ALH (3 of 3) for Volkswagen New Beetle Turbo S 2004:

• (m/t)
• 10a
• Cold start injector (on bottom of diesel direct fuel injection (dfi) pump)
• Diesel direct fuel injection (dfi) engine control module (ecm) (below left side of dash panel cover)
• Engine coolant temperature (ect) sensor (at rear of cyl head)
• Engine speed (rpm) sensor (on lower left rear of engine block)
• Fuel cut- off valve (on top of diesel direct fuel injection (dfi) pump)
• Fuel temperature sensor/modulating piston displacement sensor/quantity adjuster (on diesel direct fuel injection pump)
• Fuse 10a
• Fuse panel (behind left side of dash)
• Glow plug ind
• Hot in run
• Instrument cluster
• Malfunction indicator lamp (mil)
• Nca
• Needle lift sensor (integral to fuel inj no.3)
• T32
• T32a
• Wastegate bypass regulator valve (left of egr vacuum regulator solenoid valve)

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (1 of 4) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (1 of 4) for Volkswagen New Beetle Turbo S 2004:

• (not used)
• 29a
• 37a
• A/c system
• Acc
• Clutch vacuum vent valve switch (above clutch pedal)
• Cruise control system
• Diesel direct fuel injection (dfi) engine control module (ecm) (below left side of dash panel cover)
• Fuse 10a
• Fuse 15a
• Fuse 30a
• Fuse 5a
• Fuse bracket (on battery cover)
• Fuse panel (behind left side of dash)
• Fuse s176 110a
• G608 (below center of dash
• G608 (below center of dash panel cover)
• Heated oxygen sensor (below vehicle, front of 3-way catalytic conv)
• Hot at all times
• Ignition switch
• Lock
• M/t
• Mass airflow (maf) sensor (right side of air cleaner housing)
• Nca
• Positive crankcase ventilation (pcv) heating element (in fresh air intake hose, near thottle body)
• Red
• Relay panel
• Run
• Start
• T94
• Throttle position (tp) sensor/ closed throttle position (ctp) switch/kickdown switch (above accelerator pedal)
• W/ pcv heating element
• W/o pcv heating element

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (2 of 4) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (2 of 4) for Volkswagen New Beetle Turbo S 2004:

• A/c system
• Coolant glow plugs (m/t)
• Coolant preheating relay (high heat output) (m/t)
• Coolant preheating relay (low heat output) (m/t)
• Cruise control system
• Diesel direct fuel injection (dfi) engine control module (ecm) (below left side of dash panel cover)
• Engine glow plugs
• Fuel pump
• Fuel pump relay
• Fuse 50a
• Fuse bracket (on battery cover)
• G42 (beside steering column)
• G607 (below left side of dash panel cover)
• Glow plug triggering control module
• Hot at all times
• Red
• Starting/ charging system
• T94
• W/ pvc heating element
• W/o pvc heating element

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (3 of 4) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (3 of 4) for Volkswagen New Beetle Turbo S 2004:

• Brake- light switch (above brake pedal)
• Camshaft position sensor (on cylinder head, behind camshaft sprocket)
• Egr vacuum regulator solenoid valve (on left side of firewall)
• Egr valve #2
• Fuse 10a
• Fuse panel (behind left side of dash)
• G607 (below left side of dash panel cover)
• Hot at all times
• Instrument cluster
• Intake air temperature sensor (in intake air duct)
• Motor intake flap
• Nca
• T32
• T32a
• Transmission system
• Wastegate bypass regulator valve (left front of engine compt)

1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (4 of 4) for Volkswagen New Beetle Turbo S 2004

List of elements for 1.9L Turbo Diesel, Engine Performance Wiring Diagram, Engine Code BEW (4 of 4) for Volkswagen New Beetle Turbo S 2004:

• (on coolant flange) fuel temperature sensor
• Charge air pressure sensor (on intercooler, inside right front fender)
• Diesel direct fuel injection (dfi) engine control module (ecm) (below left side of dash panel cover)
• Egr vacuum regulator valve (on left side of firewall)
• Engine coolant temperature (ect) sensor (on rear of cyl head)
• Engine speed (rpm) sensor (left rear of cylinder block)
• Nca
• Pump/injector valves
• Red
• T60

2.0L

2.0L, Engine Performance Wiring Diagram, Convertible (1 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 2.0L, Engine Performance Wiring Diagram, Convertible (1 of 3) for Volkswagen New Beetle Turbo S 2004:

• (a/t)
• (beside steering column) g42
• (not used)
• (on thirteenfold auxiliary relay panel)
• 29a
• A/c system
• Acc
• Brake booster control module
• Cooling fans system
• Cruise control system
• Evaporative emission canister purge regulator valve (on right side of engine compt, next to engine coolant reservoir)
• Fuel pump relay
• Fuse 15a
• Fuse 40a
• Fuse 50a
• Fuse panel (behind left side of dash)
• Fuse red bracket (on battery cover)
• G607 (below left side of dash panel cover)
• Heated oxygen sensor (black) (in exhaust manifold)
• Hot at all times
• Ignition switch
• Leak detection pump (in right rear wheelwell)
• Lock
• Mass airflow (maf) sensor (on right side of air cleaner housing, in intake air duct)
• Motronic engine control module (below left side of dash panel cover)
• Nca
• Oxygen sensor (brown) (behind 3-way catalytic conv)
• Red
• Relay panel (behind left side of dash)
• Run
• S1/1
• S3/1
• S3/3
• S3/5
• S3/6
• Start
• Starting/ charging system
• Throttle position sensor (integral to throttle valve control module)

2.0L, Engine Performance Wiring Diagram, Convertible (2 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 2.0L, Engine Performance Wiring Diagram, Convertible (2 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below right side of dash panel cover) g609
• (beside steering column) g42
• 28a
• 32a
• 34a
• 43a
• Airbag control module (on center floor tunnel, below heater core housing)
• Engine speed (rpm) sensor (on lower left rear of engine block, near transaxle flange)
• Fuel pump
• Fuse 10a
• Fuse 15a
• Fuse panel
• G607 (below left side of dash panel cover)
• Instrument cluster
• Knock sensor 1 (on left front of engine block)
• Knock sensor 2 (on left rear of engine)
• Nca
• Positive crankcase ventilation heating element (in fresh air intake hose, near throttle body)
• Red
• Secondary air injection pump motor (on left rear of engine)
• Secondary air injection pump relay (inside housing, to left of brake fluid reservoir)
• T32/21
• T32/3
• T32a/19
• T32a/20
• T32a/5
• Transmissions system

2.0L, Engine Performance Wiring Diagram, Convertible (3 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 2.0L, Engine Performance Wiring Diagram, Convertible (3 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below left side of dash panel cover) g607
• (on coolant flange) engine coolant temperature sensor
• 13a
• 37a
• Brake- light switch (above brake pedal)
• Camshaft position sensor (below upper toothed belt guard)
• Clutch vacuum vent valve switch (above clutch pedal)
• Cruise control system
• Fuel injectors
• Fuse 10a
• Fuse 7.5a
• Fuse panel (behind left side of dash)
• Hot at all times
• Ignition coil
• Intake manifold changeover valve (on intake manifold, at left side of engine)
• Intake manifold tuning valve 2 (on intake manifold, at left side of engine)
• Motronic engine control module (below left side of dash panel cover)
• Nca
• Throttle valve control module (on throttle body)
• To spark plug

2.0L, Engine Performance Wiring Diagram, Except Convertible (1 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 2.0L, Engine Performance Wiring Diagram, Except Convertible (1 of 3) for Volkswagen New Beetle Turbo S 2004:

• (beside steering column) g42
• (not used)
• (on thirteen fold auxiliary relay panel)
• 29a
• A/c system
• Acc
• Cooling fans system
• Cruise control system
• Evaporative emission canister purge regulator valve (on right side of engine compt, next to engine coolant reservoir)
• Fuel pump relay
• Fuse 15a
• Fuse 50a
• Fuse panel (behind left side of dash)
• Fuse red bracket (on battery cover)
• G607 (below left side of dash panel cover)
• Heated oxygen sensor (black) (in exhaust manifold)
• Hot at all times
• Ignition/starter switch
• Leak detection pump (in right rear wheelwell)
• Lock
• Mass airflow (maf) sensor (on right side of air cleaner housing, in intake air duct)
• Motronic engine control module (below left side of dash panel cover)
• Nca
• Oxygen sensor (brown) (behind 3-way catalytic conv)
• Red
• Relay panel (behind left side of dash)
• Run
• S1/1
• S3/1
• S3/2
• S3/3
• S3/5
• S3/6
• Start
• Starting/ charging system
• Throttle position sensor (integral to throttle valve control module)

2.0L, Engine Performance Wiring Diagram, Except Convertible (2 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 2.0L, Engine Performance Wiring Diagram, Except Convertible (2 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below right side of dash panel cover) g609
• (beside steering column) g42
• (in fresh air intake hose, near throttle body) positive crankcase ventilation heating element
• (on top of transaxle differential housing) speedometer vehicle speed sensor
• 28a
• 32a
• 34a
• 43a
• Airbag control module (on center floor tunnel, below heater core housing)
• Engine speed (rpm) sensor (on lower left rear of engine block, near transaxle flange)
• Fuel pump
• Fuse 10a
• Fuse 15a
• Fuse panel
• G607 (below left side of dash panel cover)
• Instrument cluster
• Knock sensor 1 (on left front of engine block)
• Knock sensor 2 (on left rear of engine block)
• Nca
• Red
• Secondary air injection pump motor (on left rear of engine)
• Secondary air injection pump relay (inside housing, to left of brake fluid reservoir)
• T32
• T32a
• Transmissions system

2.0L, Engine Performance Wiring Diagram, Except Convertible (3 of 3) for Volkswagen New Beetle Turbo S 2004

List of elements for 2.0L, Engine Performance Wiring Diagram, Except Convertible (3 of 3) for Volkswagen New Beetle Turbo S 2004:

• (below left side of dash panel cover) g607
• (on coolant flange) engine coolant temperature sensor
• 13a
• 37a
• Brake- light switch (above brake pedal)
• Camshaft position sensor (below upper toothed belt guard)
• Clutch vacuum vent valve switch (above clutch pedal)
• Cruise control system
• Fuel injectors
• Fuse 10a
• Fuse 7.5a
• Fuse panel (behind left side of dash)
• Hot at all times
• Ignition coil
• Motronic engine control module (below left side of dash panel cover)
• Nca
• Throttle valve control module (on throttle body)
• To spark plug