Volkswagen Beetle Cabriolet (2003) manual

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2 kb t= f ãé çê í~ å í kçíÉ qÜáë=ëÉäÑJëíìÇó= éêçÖê~ããÉ=É ñéä~áåë=íÜÉ=ÇÉëáÖå= ~åÇ= ÑìåÅíáçå=çÑ=åÉï=ÇÉîÉäçéãÉåí ëK= qÜÉ=ÅçåíÉåíë=ïáää=åçí=ÄÉ=ìéÇ~íÉÇK For curr ent testing, adjustment and repair instruc- tions, refer to the r elevant service literatur e. [...]

3 _êáÉÑ=ëìãã~ê ó K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K Q _çÇó K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K U lÅÅìé~åí=ë~Ñ Éí ó =K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K OQ m ç ï Éê=ìåáí ë =K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=K=[...]

4 båÖáåÉ Thr ee petr ol engines and a diesel engine have been taken ov er from the New Beetle r ange. _çÇó= The body of the New Beetle Cabriolet f eatur es a wide ra nge of welded and bolted reinfor ce- ments. T argeted r einfor cements, such as high tensile bars in the A and B pillars, doors and in the floor , pro vide optional response in[...]

5 S281_047 lÅÅìé~åí=ë~ÑÉíó Airbags for driver and fr ont passenger and fr ont belt tensioners assure passiv e and active saf ety . Roll-ov er protection opens out and locks in place within 0.25 seconds. bäÉÅíêáÅë=~åÇ=ÉèìáéãÉåí Overview of special f eatur es: ● Buttons in centr e tunnel for opening and closing semi-au[...]

6 S281_001 _êáÉÑ=ëìãã~êó S281_002 q ÉÅÜåáÅ~ä=Ç~í~ ORMV QMUN NRMS NTOQ NQUT NRMO aáãÉåëáçåë=~åÇ=ï ÉáÖÜíë L ength appro x. 4081 mm Width appro x . 1724 mm Height appro x . 1502 mm T ank capacity 55 ltr . L uggage compartment 20 1 ltr . T urning circle 10.9 m Fr ont track width 1506 mm Rear tr ack width 1487 mm Whe[...]

7 qÜÉ=s çäâë ï ~ÖÉå=Ñ~Åíçêó=áå=mìÉÄä~I=jÉ ñáÅç The New Beetle Cabriolet is built in P uebla. W ay back in 1964, a good hundred kilometr es to the south east of the countrie s capital of Mexico City , the company built one of the most important auto- mobile factories on the American continen. In the Puebla fact ory , there[...]

8 _çÇó Additional welded joints and r einforcements in the front end structur e r esult in crash optimised response. qÜÉ=ÄçÇó The bolted engine co ver is made of sheet alumi- nium to impr ov e torsional rigidity of the body . A batch of high tensile bars in the A pillar rein- forces the windo w frame and ther eby incr eases safety in a r o[...]

9 S281_048 hÉ ó W Safety cell Plastic Crash r elev ant parts Reinforcement bars The twin wall partition with thr ough-loading aper ture (ski sack) and bolted diagonal beams also incr eases torsional rigidity of the body . High tensile bars in the B-pillar and seat tra- verse limit deformation in a side impact situation and thereby off er a high l[...]

10 The r einfor cement bar on the B -pillar joined with the reinfor cement bar on the seat traverse increases stability in a side cr ash. The stability of the A-pillar is of particular importance for the safety of the occupants if the vehicle r olls over . On the New Beetle Cabriolet, these are rein- forced by the use of high tensile bars. S281_043[...]

11 Diagonal beams in the rear ar ea of the body structure contribute t owar ds increased rigidity . S281_055 The engine co ver is made of sheet aluminium. It incr eases the rigidity of the front end and impro ves the r esponse to vibr ations. S281_067[...]

12 _çÇó If the battery is discharged, the luggage com- partment can be opened via the rear lid lock (emergency opening). The lock cylinder of the r ear lid lock can be found in the V olkswagen emblem . It can be accessed by moving the V olkswagen emblem cov er in the direction of the arr ow . Since the side panel trim on the Cabriolet rea- ches [...]

13 The r ear side window can be lowered fully . This is made possible by a sophisticated window guide. The side windo w with seal is driven up flush with the convertible top seal and fr ont door window . S281_031 The fr ont window regulat or motor is attached to the window r egulator . The side impact pr otection carrier is attached diagonally in t[...]

14 qÜÉ=ïáåÇÄêÉ~â The windbr eak consider ably reduces air swirl in the interi or at high speeds. It can be folded in four places and r equires little space for st orage in the luggage compartment . S281_065 _çÇó The guide lug of the windbr eak is inserted in the upholstery slot abov e the through-loading aperture. T o lock the windbrea[...]

15 The st owage compartment can be locked using the ignition key . S281_033 S281_032 qÜÉ=íÜêçìÖÜJäç~ÇáåÖ=~éÉêíìêÉ With the aid of the thr ough-loading aperture ski sack, skis or other long objects can be transported without dirty- ing or damaging the interior . S281_059 qÜÉ=ÅÉåíêÉ=ÅçåëçäÉ The centr e console is [...]

16 S281_007 qÜÉ=Åçå îÉêíáÄäÉ=íçé The design of the conv ertible top shows, at a glance, that it is well capable of the demands from ev e- ryday and even winter use. qÜÉ=ÅìëÜáçåáåÖ=ã~í The cushioning mat is attached t o the convertible roof fr ame and br acing hoops . It consists of a 20 mm thick fabric fleece material.[...]

17 S281_037 qÜÉ=Åçå îÉêíáÄäÉ=íçé=ÜÉ~ÇäáåÉê The conv ertible top headliner is hooked into the convertible top fr ame and is made of fabric. qÜÉ=Åçå îÉêíáÄäÉ=íçé=Ñê~ãÉ The design of the conv ertible top frame is an opti mal balance between high rigidity and low weight thanks to an aluminium/ steel construct[...]

18 qÜÉ=äáåâ~ÖÉ=Ñä~éë The link age flaps ar e requir ed to allow unr estric- ted opening and closing of the convertible top. At the same time, they pr otect the mechanics of the convertible top fr ame housed below . The lar ge linkage flap is opened electrically once the opening or closing procedur e is initiated. It is connected to the [...]

19 The flap module is attached t o the side panel trim . The small link age flap is connected to the conv er tible top fr ame by means of a cable. When the conv ertible top is closed , the small lin- kage flap r emains open and the large link age flap closes automatically . Cable Linkage flap (small) Flap positioning motor Linkage flap (lar ge) Fla[...]

20 qÜÉ=ëÉãáJ~ìíçã~íáÅ=Åçå î Éê íáÄäÉ=íçé o ççÑ=çéÉå=ÑìåÅíáçå Prer equisites: ● The speed of the v ehicle must be less than 6 km/h . ● The ignition must be switched on. S281_010 S281_012 The conv ertible top indicator lamp is located in the display unit. When the convertible top is opened, the ambient te[...]

21 The opened conv ertible top should always be cov ered by the t onneau cov er before driving off to pr otect against dirt and damage. The conv ertible top is opened . It featur es thr ee fold points. It is folded in the form of a "Z" on the rear shelf and secured aut omatically by hooks to pr event unintended closing. S281_013 By actuat[...]

22 o ççÑ=ÅäçëÉ=ÑìåÅíáçå Prer equisites: ● The speed of the v ehicle must be less than 6 km/h . ● The ignition must be switched on. ● The t onneau cov er must be remo ved. By actuating the conv ertible top operating switch E13 7 , the closing procedur e is initiated. The left and right conv ertible top locking motors r elease t[...]

23 S281_034 S281_035 S281_036 The semi-aut omatic convertible top can also be closed by hand should the system fail in its function . T o carry out emergency oper ation, the following requir ements ar e necessary: ● The v ehicle is stationary . ● The ignition must be switched off. `çåî ÉêíáÄäÉ=íçé=ÉãÉêÖÉåÅó=çéÉê~íáç[...]

24 Additional early cr ash sensors in the fr ont longitudinal member react v ery quickly in accidents by igniting the airbags. In this way , crash related ignition is assur ed in heavy impact collisions. All airbags are triggere d by the airbag control unit. Included as standard on the New Beetle Cabriolet are: ● Full size airbags for driv er and[...]

25 S281_066 fëçÑáñ=ÅÜáäÇ=êÉëíê~áåí=ë ó ëíÉã Ther e ar e four retaining e yes under the r ear bench seat that allow installation of tw o child seats with the Isofix restr aint system. The r etaining ey es are welded t o the floor panel and offer secur e mounting points for the child seat for crash situations. qÜÉ=áãé~Å?[...]

26 Spring Roll-ov er bar solenoid N309 or N310 qÜÉ=êçääJç îÉê=éêç íÉÅíáçå The r oll-over pr otection is activated in serious accidents (roll-o ver , but also fr ont, side and rear collisions) or at extreme side tilt angles. In this way , an occupant safety z one is created in conjunction with the A-pillars. The airbag contr ol u[...]

27 The r oll-o ver pr otection is monitor ed together with the air- bag system. A fault is indicated by the airbag warning lamp K145 in the instrument panel insert . The r oll-over pr otection can be released by final control diagnosis (take note of saf ety precautions). Unnecessary r elease of the r oll- ov er protection should be av oided. S281_0[...]

28 The 1.4 ltr . 4-cylinder petrol engine with 4 valv e technology (55 kW) is installed together with a 5- speed manual gearbox (02T). qÜÉ=ÉåÖáåÉ=~åÇ=ÖÉ~êÄç ñ=ÅçãÄáå~íáçåë All engines were taken o ver fr om the New Beetle. T h ere is a new combination in the form of a 6-speed automatic gearbo x with 2.0 ltr . 4-cylinder p[...]

29 SJëéÉÉÇ=~ìíçã~íáÅ=ÖÉ~êÄç ñ=MVd The 6-speed aut omatic gearbox 09G is a compact, lightweight, electronically controlled gearbox designed for tr ansverse installation. The six forwar d gears and the r everse gear ar e realised by a simple planetary gear set with post actuated double planetary gear set (Ravi- gneaux planetary gear[...]

30 `çå îÉ ê íáÄäÉ=íçé=çéÉê~íáçå S281_021 S281_023 S281_019 S281_025 S281_024 S281_026 Convertible top oper ation con- trol unit J256 Right tonneau co ver switch F328 Right linkage flap motor V290 Convertible top st owage switch F171 Switch to open conv er tible right lock F325, F326 and convertible top right lock motor V292 Con[...]

31 S281_018 S281_024 S281_022 S281_020 S281_014 S281_005 Convertible top oper ation hydraulic pump V118 L eft tonneau co ver switch F348 L eft linkage flap mot or V289 Switch to open conv er tible left lock F323, F324 and convertible top left lock motor V291 Convertible top oper ation switch E137[...]

32 `çå îÉêíáÄäÉ=íçé=çéÉê~íáçå=Åçåíêçä=ìåáí=gORS Convertible top oper ation is via control unit J256. The conv ertible top control unit J256 can be found on the r ear right of the luggage compar tment behind the side panel trim. `çåî Éê íáÄäÉ=íçé=Ñêçåí=ëïáíÅÜ=cOMO The right hook on the conv ert[...]

33 `çåî Éê íáÄäÉ=íçé=ëíç ï ÉÇ=ëïáíÅÜ=cNTN=çå=êáÖÜí= Üó Çê~ìäáÅ=ÅóäáåÇÉê The switches send a signal t o the convertible top contr ol unit as soon as the piston of the hydraulic cylinder r eaches the upper and lower stops. The input signal is used t o switch off the hydraulic pump. q çååÉ~ì=Åçî?[...]

34 aççê=ï ~êåáåÖ=ä~ãéë In place of lock buttons in the driv er and front passenger door panel trim, there are indicat or lamps that show the lock status of the front doors. A flashing indicator lamp shows that the v ehicle is locked. The saf e function and , if necessary , the anti-theft warning system are activ ated. A permanently lit[...]

35 p ïáíÅÜÉë The switches for r emotely unlocking the tank flap E204 and r emotely unlocking the re ar lid E188 can be found in the left side panel trim. The r ear lid r emote release switch E188 can be deactivated using the ignition key . The switch is deactiv ated when the key slot points to the "lock symbol". o É~ê=ïáåÇç?[...]

36 `çåîÉåáÉåÅÉ=~åÇ=ë~ÑÉíó=ÉäÉÅíêçåáÅë S281_060 The optional 6 x CD changer is installed in the stowage compartment of the centre console. qÜÉ=~ìÇáç=ë óë íÉãë Audio systems "alpha" with 6 loudspeakers or "gamma " with 10 loudspeakers can be installed in the New Beetle Cabriolet. The y were[...]

37 One of the four sensors works as a so-called master , three as slav es . The master is connected via a bi-dir ectional inter- face to the conv enience control unit J393. T he slaves are actuated by the master . The conv enience contr ol unit activates an acoustic and optical alarm when the interior is penetrated. S281_050 S281_051 Evaluation is [...]

38 pÉêîáÅÉ péÉÅá~ä=íççäë aÉëáÖå~íáçå q ççä ^ééäáÅ~íáçå VA S 6 1 3 8 L ocking pliers Pliers for closing zip bet- ween convertible top cov er and cushioning mat. VA S 6 1 4 8 Industrial stapler Stapler for securing zip bet- ween convertible top cov er and cushioning mat. V. A . G 1 8 8 7 Fitting brackets Fitting b[...]

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For internal use only © V OLKSW AGE N AG, W olfsburg All rights and the right to make technical alterations r eserved 000.2811.0 1.20 T echnical status 03/ 03 ; This paper was manufactured fr om pulp that was bleached without the use of chlorine. OUN[...]