1,9L-Engine - Turbo Diesel Fuel Injection (DFI)/66 kw, code ALH,

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1 New Beetle No. 5/,9L-Enine - Turbo Diesel Fuel Injection (DFI)/66 kw, code ALH, fm June 00 Deviate relay location and fuseplacements as well as the locations of multiple connectors see section component locations. Relay location on the thirteen position auxiliary relay panel, above relay panel: 0 Glow Plu Relay (80) Power Suppy (Terminal 0, B+) Relay (09)) Relay panel: 75X 0 0 0a 87F Load Reduction Relay (00) Note: Number in parentheses indicates pduction contl number stamped on relay housin. Fuse colors 0 A - reen 5 A - white 0 A - yellow 5 A - ue 0 A - red 7,5 A - bwn 5 A - beie Edition 09/0 USA.5.6.

2 No. 5/ New Beetle 9 5/ J59 7/ ,5 A 8 9 S9 0A 5 J 6 T9/8 D/50 A/+ A/+ /li 9a 5,0 br/,5 /,5 / 5,0 c T/ T/ T6/ 98 A br/ br/,5,5 = ack = red br = bwn = ue D+ B+ G W C C 50 0 M B 5 S77 0A S76 0A S6 50A S6 50A D/0 60 A A - Battery B - Starter C - Generator (GEN) C - Voltae Reulator (VR) D - Iition/Starter Switch J6 - Park/Neutral Position (PNP) Relay S6 - Fuse -- in fuse bracket/battery S6 - Fuse -- in fuse bracket/battery S76 - Fuse -- (0), in fuse bracket/battery S77 - Fuse -5- (0), in fuse bracket/battery S9 - Fuse 9 in fuse holder T - -Pin connector, in enine compartment, left T6-6-Pin Connector, bwn, behind instrument T9-9-Pin Connector Threaded connection -- (0) on the relay plate 50 - Threaded connection -- (0) on the relay plate A - plus connection (5), in instrument panel A - plus connection (0), in instrument panel A5 - Plus connection (0), in instrument panel - Manual transmission only --- Automatic transmission only Battery, starter, Generator (GEN), Voltae Reulator (VR) Edition 09/0 USA.5.6.

3 New Beetle No. 5/ A0 /li /li / / D ST 0 T/9 J 70 T/0 T/ /li T6/ 7 J 8 c / T/ G / T/ G T/ G / /r T/ G Tk/ Tk/ Tk/ Tk/ 65 T/6 87 br/ T/7 br/ 5 / T0c/ r/ ws/ 69 T0c/ 5 r/ws r/ 70 T0c/ 6 r/ r/ 50 T0c/ e/ e/ T0c/ ws/ r/ws 6 T0c/ e T6a/6 T6a/ T6a/5 T6a/ T6a/ T6a/ r br rs ws Q 6 F 60 F 8 G 79 = ack = red br = bwn = ue F8 - Kick Down Switch F60 - Closed Thttle Position (CTP) Switch G79 - Thttle Position (TP) Sensor J8 - Diesel Direct Fuel Injection (DFI) Enine Contl Module (ECM) J70 - Contl module for low plu trierin Q6 - Glow plus (enine) Tk - Pin Connector T6-6-Pin Connector, bwn, behind instrument T6a - 6-Pin Connector T0c - 0-Pin Connector, ue, behind instrument T - -Pin Connector T - -Pin Connector, on DFI ECM Gund Connection (in center plenum chamber) A0 - Plus connector -- (5), in instrument panel Edition 09/0 USA.5.6. DFI Enine contl module (ECM),kick down itch,thttle position (TP) sensor, closed thttle position (CTP) itch,low plu relay,contl module for low plu trierin

4 No. 5/ New Beetle L9 J 9 T/ / / / r/ e/ E5 T0j/ J9 T/8 / T0a/8 T0a/7 9 / r/ T0/5 e/ T0/0 J7 T68/ J /li 0 9 li/ br/ 5 /br br/ 0 7 ws 0 e 0 69 T 0c/ 9 T0c/7 li T/ e/ li/ br/ li T/ T/ T/ = ack = red br = bwn = ue 5 G70 e/ r/ 7 G G6 08 G 00 G8 f E 5 - A/C Switch G - Enine Coolant Temperature (ECT) Sensor G8 - Enine Speed (RPM) Sensor G - Chare Air Pressure Sensor G6 - Enine Coolant Temperature (ECT) Sensor G70 - Mass Air Flow (MAF) Sensor J7 - Transmission Contl Module (TCM) J8 - Diesel Direct Fuel Injection (DFI) Enine Contl Module (ECM) J9 - Coolant FC (Fan Contl) Contl Module T - -Pin connector, on enine, fnt T0-0-Pin connector, white, behind instrument T0j - 0-Pin connector T - -Pin connector, in plenum chamber T68-68-Pin connector, on TCM T - -Pin connector, on DFI ECM 00 - Gund connection (shieldin), in enine compartment L9 - Wire connection --, in A/C - A/C clutch cut-out sial fm ECM/TCM - A/C ON sial fm -E Automatic transmission only T0a - 0-Pin connector, orane, behind instrument T0c - 0-Pin connector, ue, behind instrument DFI Enine contl module (ECM), enine coolant temperature (ECT) sensor, enine speed (RPM) sensor, chare air pressure sensor, mass air flow (MAF) sensor Edition 09/0 USA.5.6.

5 New Beetle No. 5/5 A A br/ or/br or/br ws or/ or/ T0/5 T0/ T0/ br/ T68/ J7 T7/5 J0 or/br T68/5 J7 T7/ J0 or/ 8 J8 6 7 r 09 0 br/e 86 br/ 0 e/ li/ 08 r/ 06 ws/ 99 6 br/ br/ br/ Ta/ Ta/ T0f/ T0f/ 7 T0f/ T0f/ T0f/ T0f/ 6 f G80 00 G8 G9 /li /li N6 T0f/5 F5 = ack = red br = bwn = ue G 80 - Needle Lift Sensor G 8 - Fuel Temperature Sensor G9 - Modulatin Piston Displacement Sensor J0 - ABS Contl Module (w/edl) J7 - Transmission Contl Module (TCM) J8 - Diesel Direct Fuel Injection (DFI) Enine Contl Module (ECM) N6 - Quantity Adjuster Ta - -Pin connector, on enine, fnt T0-0-Pin connector, white, behind instrument T0f - 0-Pin connector, on enine, fnt T7-7-Pin connector T68-68-Pin connector T Pin connector, on DFI ECM 00 - Gund connection (shieldin), in enine compartment A - Connection (hih bus) in instrument panel A - Connection (low bus) in instrument panel F5 - Wire connection --, in Diesel Direct Fuel Injection (DFI) system Edition 09/0 USA.5.6. DFI Enine contl module (ECM), needle lift sensor, fuel temperature sensor, modulatin piston displacement sensor, quantity adjuster

6 No. 5/6 New Beetle /0 J7 6/87 9/85 /e 05 /e T0c/8 8 J8 r/ws 6 K 88 0 / /ws T/0 br/ 0 /br 6 li/r 8 / 6 = ack = red br = bwn = ue r/ws 6 N09 T0a/ T0f/ 8 / /,5 / E/ 0a S0 0A 0 A80 T0f/9 N08 T0f/0 B7 e/ e/ T/ 6 e/ e/ e/ S 0A a T6/5 0 e/ e/ N75 N9 e/ e/ e/ N8 E E - Liht itch J8 - Diesel Direct Fuel Injection (DFI) Enine Contl Module (ECM) J7 - Power Supply (Terminal 0, B+) Relay N 8 - EGR Vacuum Reulator Solenoid Valve N 75 - Wasteate Bypass Reulator Valve N08 - Cold Start Injector N09 - Fuel Cut-off Valve N9 - Chane-over valve for intake manifold flap S0 - Fuse 0 in fuse holder S - Fuse in fuse holder T6-6-Pin connector, bwn, behind instrument T0a - 0-Pin connector, orane, behind instrument T0c - 0-Pin connector, ue, behind instrument T0f - 0-Pin connector, ack, on enine, fnt T - -Pin connector, in plenum chamber T - -Pin connector, on DFI ECM A80 - Connector -- (X) in instrument panel wirin harness B7 - Plus connector -- (87), in E0 - Connector (87a), in enine DFI ECM, power supply relay, EGR vacuum reulator solenoid valve, wasteate bypass reulator valve, fuel cut-off valve, chane-over valve for int. man. flap. Edition 09/0 USA.5.6.

7 New Beetle No. 5/7 7 / J8 /ws ws 6 /r 5 99 ws/ 66 / ws/e 65 /e T0h/ /e ws T0h/ 9 T0h/ / /e T0h/ ws/ T0/ / T0h/ ws/e T0h/5 S 0A a T0b/ 7 T0b/ T0b/ 5 T0b/ T0b/ 6 T0b/ /br 0 E5 E7 0 /e /e F6 A8 F7 /e F / 9 /e = ack = red br = bwn = ue A E 5 - Cruise Contl Switch E7 - Button for cruise contl (set) F - Brake Liht Switch F6 - Clutch Vacuum Vent Valve Switch F7 - Brake Pedal Switch (cruise contl/diesel Direct Fuel Injection) J8 - Diesel Direct Fuel Injection (DFI) Enine Contl Module (ECM) S - Fuse in fuse holder T0-0-Pin connector, white, behind instrument T0b - 0-Pin connector, ack, near steerin column T0h - 0-Pin connector, ack, behind instrument T - -Pin connector, on DFI ECM A8 - wire connection (5), in instrument panel A00 - Connector -- (87), in instrument panel - Manual transmission only Edition 09/0 USA.5.6. DFI Enine contl module (ECM), button for cruise contl (set), cruise contl itch, brake liht itch, clutch & brake itches

8 No. 5/8 New Beetle A7 /ws 8 D50 /ws T0a/6 /e /e T6/6 /e J8 0 /86 /0 /86 /0 J59 J60,5 br/ 5,5 br/,5 /li,5 /li /br / /e 6/85,5 8/87 5/85 /br 7/87 L /li D7 N79,5,5 D98 0 = ack = red br = bwn = ue,5 br/ br/ 56 Q J8 - Diesel Direct Fuel Injection (DFI) Enine Contl Module (ECM J59 - Realy for preheatin coolant, low heat output J60 - Relay for prehaeatin coolant, hih heat output N 79 - Positive Crankcase Ventilation (PCV) Heatin Element Q7 - Spark plus (coolant) T6-6-Pin connector, bwn, behind instrument T0a - 0-Pin connector, orane, behind instrument T - -Pin connector, on DFI ECM Gund Connection (in left plenum chamber) 56 - Gund connection, in Diesel Direct Fuel Injection (DFI) A7 - Wire Connection (vehicle speed sial), in instrument panel D50 - Plus connection (0), in enine compartment D7 - Wire connection (86), in enine compartment D98 - Wire connection (low plus), in enine compartment L - Wire connection --, in heater - Manual Transmission only DFI Enine contl module (ECM), relay for preheatin coolant: low heat output, hih heat output, spark plus (coolant) Edition 09/0 USA.5.6.

9 New Beetle No. 5/9 A99 h i j,5 li/ li/ 5 7 S5 7,5A S7 0A S 0A S 5A a 7a a a / / /e.0 /li 78 A0 B7 69 / /li /li 76 T6/ T/5 T/9 /li 88 5 G 8 G = ack = red br = bwn = ue G - Sender for fuel aue G - Enine Coolant Level (ECL) Sensor S5 - Fuse 5 in fuse holder S7 - Fuse 7 in fuse holder S - Fuse in fuse holder S - Fuse in fuse holder T6-6-Pin connector, bwn, behind instrument T - -Pin connector, in plenum chamber A99 - Connector -- (87), in instrument panel B7 - Plus connector -- (87), in 69 - Gund connector (sensor und) --,in instrument panel A0 - Wire connection (5a), in instrument panel Edition 09/0 USA.5.6. Sender for fuel aue, enine coolant level (ECL) sensor

10 No. 5/0 New Beetle h i j h 57 / li/ r/ws 00 T/0 T/8 T/ T/7 6 T/ K Ta/5 / K9 K B5 J85 / /ws T/ ws/ T/ / T/ K H K 8 = ack = red br = bwn = ue G br F F - Oil Pressure Switch G - Speedometer Vehicle Speed Sensor (VSS) H - Oil Pressure Warnin Buzzer J85 - Contl module with indicator unit in instrument panel insert K - Generator (GEN) Warnin Liht K - Oil Pressure Warnin Liht K8 - Enine Coolant Level/Temperature (ECL/ECT) Warnin Liht K9 - Glow Plu Indicator Liht T - -Pin connector, in plenum chamber T - -Pin connector, ue, on instrument cluster Ta - -Pin connector, reen, on instrument cluster Gund Connection (in left plenum chamber) B5 - Plus connector -- (5a) in interior Oil pressure itch, Speedometer Vehicle Speed Sensor (VSS), instrument cluster, oil pressure warnin buzzer, warnin and indicator lihts Edition 09/0 USA.5.6.

11 New Beetle No. 5/ A7 h 8 li/ /ws li T/8 T/5 T/ G G J85 K05 K 8 G5 = ack = red br = bwn = ue G - Fuel Gaue G - Enine Coolant Temperature (ECT) Gaue G5 - Tachometer J85 - Contl module with indicator unit instrument panel insert K8 - Malfunction Indicator Lamp (MIL) K05 - Low Fuel Level Warnin Liht T - -Pin connector, ue, on instrument cluster A7 - Wire Connection (vehicle speed sial), in instrument panel Edition 09/0 USA.5.6. Instrument cluster, fuel aue, enine coolant temperature (ECT) aue, tachometer, Malfunction Indicator Lamp (MIL) low fuel level warnin liht

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