Work Procedure
Work Procedure
- Open hood and check for yellow dot on battery tray next to battery hold down plate (arrow)
- If yellow dot is present, NO OTHER WORK IS REQUIRED
- If yellow dot is not present, proceed as follows:
- Switch ignition off, open battery cover and disconnect battery ground (GND) cable from the negative (-) battery terminal then the power cable from the positive (+) terminal of the battery
HINT: Use tape to hold battery cover in the open position
- Remove bolt -A- holding power steering fluid reservoir in position, and remove bolt -B- holding battery side cover
- Carefully unsnap both ends of battery side cover from battery tray and remove side cover. If side cover is damaged, replace (P/N 1C0 937 589B)
- Remove bolt and battery clamp (arrow), then remove battery and battery blanket together
- Open fuse cover panel on battery, unsnap and remove wire cover -C-
- Remove (2) bolts -D- between air cleaner and battery and remove plastic wire guide
- Remove (6) bolts -E- from battery tray, push out plastic wire holder -F-
Properly tag removed battery trays and hold pending further instruction.
- Review condition of all wire harnesses underneath or near battery tray
- Wires that exhibit chafed insulation must be repaired as follows:
- Insulation chafed with NO copper wire exposed: wrap wire with electrical tape
- Insulation chafed - copper wire exposed: use VAS 1978 wiring repair kit
- Loosen tie wrap (arrow) around wire harnesses
- Remove and discard the clip -G- holding the wire harness (Clip removal is ONLY ON MANUAL TRANSMISSION VEHICLES)
- Disconnect connector -K-
- Disconnect connector -H-, remove and discard the right angle cover at the rear of this connector, then reconnect connector -H-
- Hold harness down from connector -H- and reconnect connector -K- over the harness
- Rearrange wires ensuring they are straight and loose, not twisted or tight
- Install felt strip (N 907 734 05) by removing paper on ends, to expose adhesive. Slide felt lengthwise under wires then wrap around and secure with (2) tie wraps (N 020 910 1) (arrows).
NOTE: ON VEHICLES WITH AUTOMATIC TRANSMISSION, DO NOT WRAP THE TRANSMISSION HARNESS OR THE BACK-UP LIGHT SWITCH HARNESS WITH THE FELT.
- Cut off excess tie wrap material.
- Install new battery tray (1C0 804 373B) with yellow dot
- Reinstall wire holding clip
- Secure battery tray with (4) bolts -L- by first cleaning threads with wire brush, applying adhesive (D 185 400 A2) or Loctite equivalent
- Tighten to 8 Nm (72 in. lb.)
- Reinstall (2) bolts -M- and tighten to 8 Nm (72 in. lb.)
- Reinstall wire guide to battery tray using (2) bolts
- Reinstall battery with battery blanket
- Reinstall battery clamp and torque bolt to 22 Nm (16 ft lb.)
- Reinstall battery side cover by snapping ends on to battery tray then securing with (1) bolt
- Reconnect the positive (+) cable to the battery, then the ground (GND) cable (-) to the battery
- Reinstall wire cover onto battery cover
- Reset clock and activate radio with code
- Reset the power window pinch protection by inserting key in driver's door, and lowering then raising the door window - release key and quickly turn to lock position two times
- Set throttle adaptation using the VAG 1551 and the following procedure:
- Plug VAG 1551 into vehicle under dash on driver s side and turn ignition to "ON" position
- Enter 01 then push Q button
- Enter 02 then push Q button
- Clear any faults present
- Push arrow button
- Enter 04 then push Q button
- Enter 060 then push Q button
- Wait a minimum of 30 seconds before pushing the arrow button
- Press the arrow button to exit
Questions and Answers Relating to Recall Campaign UA
Information for VW dealership employees
What is happening?
Volkswagen is conducting a voluntary recall campaign involving all New Beetles sold to date or in dealer inventory in the United States (approximately 8,500 cars) and Canada (approximately 1,600 cars).
Volkswagen has determined that wires in the engine compartment could potentially chafe from rubbing against the battery tray. This could potentially cause the air conditioning compressor to fail, as it did in 3 cases to date. Hypothetically this could also cause a failure with the fuel pump and stall the car without warning; however, this latter scenario has not been reported.
Important facts
Volkswagen has taken a very proactive approach to this voluntary recall. Because of the "love affair" that so many New Beetle owners have with their cars, Volkswagen is contacting them via overnight mail and requesting that they contact their Volkswagen dealer as soon as possible to arrange for the necessary repairs to be completed. Volkswagen has also made it possible for each dealership to develop a special "Customer Care" package so as to put a smile on each New Beetle owner s face.
How will customers be notified?
All owners of affected New Beetles will be notified by overnight mail. They will be informed of the nature of the recall and urged to make an appointment at their authorized Volkswagen dealership for the necessary repairs.
When will notices be sent?
Notification letters were sent on May 14 th, for delivery on May 15 th , 1998. Some customers may also learn of the recall through news reports following the public announcement on May 15 th.
What kind of work is involved?
The recall work involves replacing the battery tray, inspecting and rerouting nearby wires, and installing a protective wire cover. The work will take about 1 hour.
Are parts available for the repairs?
Yes, based on the dealer's allocation, an initial supply of parts will be shipped to each dealer for arrival on May 15th . Additional parts to support the level of repairs performed by the dealer can be ordered from the facing depot.
What about vehicles in dealer inventory?
Any affected car is subject to the recall. Cars in dealer inventory may not be sold, leased, or loaned to a customer until the service is performed.
Other questions or concerns
Should you have any other questions, or unique circumstances that require more detailed information, contact your Ownership Technical Specialist (OTS) or other member of your Area Executive (AE) Team.