1998-2008 Volkswagen New Beetle Service & Repair Manual

1998-2008 VOLKSWAGEN NEW BETTLE SERVICE AND REPAIR MANUAL

GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European ALFA ROMEO (1991-95) APPLICATION - ALFA ROMEO D-P Driver's & Passenger's Side D-P2 Driver's & Passenger's Side (Dual-Stage) DS Driver's Side HI Head Impact KI Knee Impact SI Side Impact PS2 WARNING: Accidental air bag deployment is possible. Personal injury may result. Avoid area near steering wheel and instrument panel even if air bags have deployed. Dual-stage air bag modules may be present that could contain an undeployed stage. When disposing of a deployed dual-stage air bag, always treat it as a "live" module. See appropriate AIR BAG RESTRAINT SYSTEM article. Make/Model Year Location Table Spider 1991-94 DS Alfa Romeo - 1 164 1995 D-P Alfa Romeo - 1 1991-94 DS Alfa Romeo - 1 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

Passenger's Side (Dual-Stage) Alfa Romeo-1 AUDI (1989-04) APPLICATION - AUDI Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; All impact sensors; Clockspring; Control unit; Knee bolster; Seat belts & mounting points; Wiring harness; Proper operation of air bag system requires that any repair made to the vehicle structures return it to its original production configuration.; DO NOT attempt wiring repairs.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; WARNING: Accidental air bag deployment is possible. Personal injury may result. Avoid area near steering wheel and instrument panel even if air bags have deployed. Dual-stage air bag modules may be present that could contain an undeployed stage. When disposing of a deployed dual-stage air bag, always treat it as a "live" module. See appropriate AIR BAG RESTRAINT SYSTEM article. Make/Model Year Location Table Allroad 2001-04 D-P, SI, HI Audi - 4 A4 2002-04 D-P, SI, HI Audi - 4 1999-01 D-P, SI, HI Audi - 2 1996-98 D-P, SI Audi - 2 A6 2000-04 D-P, SI, HI Audi - 4 1998-99 D-P, SI Audi - 4 1995-97 D-P Audi - 1 A8 2004 D-P2 SI, HI, Audi - 6 KI 2002-03 D-P, SI, HI Audi - 4 2000-01 D-P, SI, HI Audi - 3 1997-99 D-P, SI Audi - 3 Cabriolet 1995-98 D-P Audi - 1 1994 DS Audi - 1 Coupe 1990-91 DS Audi - 1 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

D-P Driver's & Passenger's Side D-P2 Driver's & Passenger's Side (Dual-Stage) DS Driver's Side HI Head Impact KI Knee Impact SI Side Impact PS2 S4 2004 D-P, SI, HI Audi - 3 2000-02 D-P, SI, HI Audi - 3 1993-94 D-P Audi - 1 1992 DS Audi - 1 S6 2002-04 D-P, SI, HI Audi - 4 1995-96 D-P Audi - 1 S8 2002-03 D-P, SI, HI Audi - 4 2000-01 D-P, SI, HI Audi - 3 TT 2003-04 D-P, SI Audi - 5 2000-02 D-P, SI Audi - 3 V8 Quattro 1993-94 D-P Audi - 1 1990-92 DS Audi - 1 80 Series 1990-92 DS Audi - 1 90 Series 1995 D-P Audi - 1 1990-94 DS Audi - 1 100 Series 1993-94 D-P Audi - 1 1990-92 DS Audi - 1 200 Series 1989-91 DS Audi - 1 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

Passenger's Side (Dual-Stage) Audi-1 Audi-2 Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Instrument panel (A6, S4, S6 & 100); Spiral spring; Air bag control unit; Front seat belts; Upper instrument panel (V8 Quattro); Side air bag control sensors (1) ; Seat back padding & cover (1) ; Energy reserve module (1989-93 models only); Seat belts & mounting points; Voltage transformer (1989-93 models only); Wiring harness; If any components are damaged or bent, they must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Manufacturer recommends replacing all components (except wire harness) every 15 years.; (1) On side of deployment (if equipped). Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Air bag control unit (ACU) (1) ; Spiral spring; Flap & mounting frame for passenger-side air bag module; Side impact air bag sensor(s) (2) ; Seat back cushion(s) & cover (2) ; Deployed seat belt pretensioners; Moulded headliner (3) ; A-pillar through D-pillar trim panels (3) ; Seat belts & mounting points; Instrument panel; Side impact air bag sensor(s) (4) ; Air bag control unit (ACU) (5) ; If any components are damaged or bent, they must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Manufacturer recommends replacing all components (except wire harness) every 15 years.; After replacing air bag module(s) or air bag control unit, attach supplied stickers (only tear-off strips) to registration card and send to manufacturer.; (1) On A4, S4 built on or after 10-98, replace Air Bag Control Unit (ACU) if front air bags deploy or every third head, side and-or seat belt pretensioner deployment. (2) On side of deployment. (3) On vehicles with head impact air bags. If head impact air bags have deployed. (4) Replace if floor pan is deformed in sensor area. (5) Replace if body tunnel is damaged within 7.87" (200 mm) of ACU. 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

Audi-3 Audi-4 Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Air bag control unit (1) ; Spiral spring; Passenger-side air bag module lid & retaining frame; Side impact air bag sensor(s) (2) ; Seat back cushion(s) & cover (2) ; Rear seat side pad (3) ; Deployed seat belt pretensioners; Moulded headliner (4) ; A-pillar through D-pillar trim panels (4) ; Seat belts & mounting points; Instrument panel; Side impact air bag sensor(s) (5) ; Air bag control unit (6) ; If any components are damaged or bent, they must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Manufacturer recommends replacing all components (except wire harness) every 15 years.; After replacing air bag module(s) or air bag control unit, attach supplied stickers (only tear-off strips) to registration card and send to manufacturer.; (1) On Allroad-Quattro, A4, S4, and TT on or after 10-98, replace Air Bag Control Unit (ACU) if front air bags deploy or every third head, side and-or seat belt pretensioner deployment. On A8, S8 and all models before 10-98, replace ACU after any air bag deployment. (2) On side of deployment. (3) If equipped with rear seat side impact air bags and folding rear seat. (4) On vehicles with head impact air bags. (5) Replace if floor pan is deformed in sensor area. (6) Replace if body tunnel is damaged within 7.87" (200 mm) of ACU. Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Air bag control module (1) ; Spiral spring; Deformed passenger- side air bag module supports; Instrument panel; Front impact air bag sensors (if equipped); Side impact air bag sensor(s) (2) ; Front-rear seat back cushion & seat cover (2) ; Foldable rear seat side pad (3) ; Deployed seat belt Seat belts & mounting points; Instrument panel; Side impact air bag sensor(s) (5) ; Air bag control module (6) ; If any components are damaged or bent, they must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Manufacturer recommends replacing all components (except wire harness) every 15 years.; After replacing air bag module(s) or air bag control 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

Audi-5 Audi-6 pretensioners; A-pillar, B- pillar, C-pillar & D-pillar trim panels (4) ; module, attach supplied stickers (only tear-off strips) to registration card and send to manufacturer.; (1) After 10-98, replace air bag control module if front air bags deploy or every third head, side and-or seat belt pretensioner deployment. (2) On side of deployment. (3) If equipped with rear seat side impact air bags and folding rear seat. (4) On vehicles with head impact air bags. (5) Replace if floor pan is deformed in sensor area. (6) Replace if body tunnel is damaged within 7.87" (200 mm) of air bag control module. Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Air bag control module (1) ; Passenger-side air bag module flap & frame (2) ; Spiral spring; Side impact air bag sensor(s) (3) >,> (4) ; Deployed seat belt pretensioners; Air bag control module; Instrument panel; Side impact air bag sensor(s); Seat belts & mounting points; If any components are damaged or bent, they must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; (1) Replace Air Bag Control Module (ACM) if front air bags have deployed or every third head, side and-or seat belt pretensioner deployment. Replace ACM if housing is damaged or if there is tunnel deformation within 8" (200 mm) of ACM. (2) DO NOT bend frame back into shape. (3) On side of deployment. (4) Replace any side impact sensor if floor pan around sensor has been deformed. Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Air bag control module (1) ; Spiral spring; Instrument panel with air bag guide; Passenger-side air bag module retainers and bolts and air bag module Seat belts & mounting points; Seats & seat backs; Instrument panel; Side impact air bag sensor(s); Air bag control module; If any components are damaged or bent, they must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Manufacturer 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

BMW (1986-04) APPLICATION - BMW mounting nuts; Knee bag mounting bolts (2) ; Glove box with mounting bolts (3) ; Front impact air bag sensors; Side impact air bag sensor(s) (4) ; A- pillar, B-pillar, C-pillar & D- pillar trim panels (5) ; Deployed seat belt pretensioners; recommends replacing all components (except wire harness) every 15 years.; After replacing air bag module(s) or air bag control module, attach supplied stickers (only tear-off strips) to registration card and send to manufacturer.; (1) Replace Air Bag Control Module (ACM) if front air bags have deployed or every third head, side and-or seat belt pretensioner deployment. Replace ACM if housing is damaged or if there is tunnel deformation within 8" (200 mm) of ACM. (2) If knee air bag has deployed. (3) If passenger's knee air bag has deployed. (4) On side of deployment or if floor pan around sensor has been deformed. (5) If head impact air bags have deployed. WARNING: Accidental air bag deployment is possible. Personal injury may result. Avoid area near steering wheel and instrument panel even if air bags have deployed. Dual-stage air bag modules may be present that could contain an undeployed stage. When disposing of a deployed dual-stage air bag, always treat it as a "live" module. See appropriate AIR BAG RESTRAINT SYSTEM article. Make/Model Year Location Table L7 1986-87 DS BMW - 2 M Coupe-Roadster 2000-02 D-P2, SI BMW - 1 1998-99 D-P, SI BMW - 1 M3 2001-04 D-P2, HI, SI BMW - 3 1998-00 D-P, SI BMW - 1 1995-97 D-P BMW - 1 1990-91 DS BMW - 2 M5 2000-03 D-P2, SI, HI BMW - 3 1990-93 DS BMW - 2 X3 2004 D-P2, SI, HI BMW - 3 X5 2000-04 D-P2, SI, HI BMW - 3 Z3 2000-02 D-P2, SI BMW - 1 1998-99 D-P, SI BMW - 1 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

D-P Driver's & Passenger's Side D-P2 Driver's & Passenger's Side (Dual-Stage) DS Driver's Side HI Head Impact KI Knee Impact 1996-97 D-P BMW - 1 Z4 2003-04 D-P2, SI, KI BMW - 1 Z8 2001-03 D-P2, SI BMW - 1 3 Series 2000-04 D-P2, SI, HI BMW - 3 1998-99 D-P, SI, HI BMW - 1 1994-97 D-P BMW - 1 1990-93 DS BMW - 2 5 Series 2000-04 D-P2, SI, HI BMW - 3 1998-99 D-P, SI, HI BMW - 1 1997 D-P, SI BMW - 1 1994-95 D-P BMW - 1 1989-93 DS BMW - 2 6 Series 2004 D-P2, SI, HI BMW - 3 1989 DS BMW - 2 7 Series 2000-04 D-P2, SI, HI, BMW - 3 KI, 1998-99 D-P, SI, HI BMW - 1 1997 D-P, SI BMW - 1 1993-96 D-P BMW - 1 1988-92 DS BMW - 2 8 Series 1993-97 D-P BMW - 1 1991-92 DS BMW - 2 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

SI Side Impact PS2 Passenger's Side (Dual-Stage) BMW-1 BMW-2 BMW-3 Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Control-diagnostic module; Control unit (after third deployment); Seat belts (if worn during impact); Deployed seat belt pretensioners; Contact ring; Impact sensors; Passenger-side air bag module cover-door; Battery safety terminal (if equipped); AIR BAG warning light; Instrument panel; Control unit; Knee bolster; Glove box; Integrated seats; Seat belts & mounting points; Seat belt pretensioners; Steering column; Steering wheel; Wiring harness; Repair only those cables which show visible signs of damage. If no visible damage can be identified, entire cable must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed sir bag modules; All impact sensors; Control unit (after third deployment); Contact ring; Control unit; Seat belts (if worn during impact); Deployed seat belt pretensioners; Battery safety terminal (if equipped); Knee bolster; Seat belts & mounting points; Steering column; Steering wheel; Wiring harness; Glove box; Instrument panel; AIR BAG warning light; Repair only those cables which show visible signs of damage. If no visible damage can be identified, entire cable must be replaced.; After vehicle is repaired, ensure AIR BAG warning light is functioning properly.; Replace After Deployment Inspect & If Damaged Replace Component (Even If Air Bag Did Not Deploy) Comments Deployed air bag modules; Control module (after third deployment); Seat belts (if worn during impact); Passenger-side air bag module cover-door; Deployed seat belt AIR BAG warning light operation; Instrument panel & support tube; Knee bolster; Seat belts & mounting points; Seat belt pretensioners; Steering column; Steering wheel; Wiring harness; Repair only those cables which show visible signs of damage. If no visible damage can be identified, entire cable must be replaced.; After vehicle is repaired, ensure 2001 Volkswagen New Beetle GL GENERAL INFORMATION Air Bag/SRS Component Inspection & Replacement Tables - European

1998-2008 Volkswagen New Beetle Service & Repair Manual

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