Battery, Disconnecting and Reconnecting

Battery, Disconnecting and Reconnecting

CAUTION:
- Always ensure the vehicle electrical system is protected by disconnecting the battery negative ( - ) terminal (interrupted current flow to ground) prior to servicing key areas of the electrical system as specified.
- Do not loosen or remove ground strap from body. Disconnect terminal from battery only.
- Disconnecting the battery positive ( B+) terminal must only be performed as required to remove battery from vehicle, and must only be carried out after the negative ( - ) terminal is disconnected.
- When reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified.

Battery - New Beetle Sedan through 05.99, disconnecting and reconnecting.

Special tools, testers and auxiliary items needed

- VAG 1331 Torque wrench (or equivalent 5 - 50 Nm).

Battery, disconnecting

CAUTION:
Before beginning repairs on the electrical system
- Obtain anti-theft radio security code.
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.
- Do not loosen or remove ground strap from body. Disconnect terminal from battery only.

- First disconnect negative ( - ) battery terminal from battery (tightened to 6 Nm).

In order to disconnect positive ( + ) battery terminal, first remove fuse holder on top of battery, as follows:

- Press locking lugs together -arrows- and remove cover.

- Remove positive bus securing bolt -1- on (+) positive terminal clamp.
- Remove securing bolts -A- and remove cables to fuses, noting installed positions.
- Disconnect electrical connection -2-.

- Relieve tension on fuse holder mounting in direction of -arrow A- and release clip with screwdriver in direction of -arrow B-.
- Lift fuse holder from battery.

- Release positive ( + ) battery terminal clamp fastener -arrow- and remove terminal from battery post (tightened to 6 Nm).

Battery, reconnecting

NOTE:
- In order to prevent damage to the battery housing, battery terminals must be placed on battery posts without using force (by hand only).
- Battery posts and terminals must no longer be greased.

- Reconnect battery in reverse order of disconnecting. Ensure battery terminals are torqued as specified.
- Perform work steps specified in table.

NOTE: Refer to appropriate wiring diagram for installed positions of cables to fuses if necessary.

Battery - New Beetle Sedan 06.99 through 11.02, disconnecting and reconnecting.

Special tools, testers and auxiliary items needed

- Press locking lugs together -arrow- and fold open cover with fuse holder.
- Unclip cover with fuse holder from battery insulation enclosure and set aside.
- Disconnect negative ( - ) battery terminal from battery (tightened to 6 Nm).
- Disconnect positive ( + ) battery terminal clamp and remove cable (tightened to 6 Nm).

Battery, reconnecting

NOTE:
- In order to prevent damage to the battery housing, battery terminals must be placed on battery posts without using force (by hand only).
- Battery posts and terminals must no longer be greased.

- Reconnect battery in reverse order of disconnecting. Ensure battery terminals are torqued as specified.
- Perform work steps specified in table.

NOTE: Refer to appropriate wiring diagram for installed positions of cables to fuses if necessary.

Battery - New Beetle Sedan from 12.02 and New Beetle Convertible from 08.02, disconnecting and reconnecting

Special tools, testers and auxiliary items needed

- Release positive ( + ) battery terminal cable from clips -1-.
- Remove battery cover by pressing the locks -2-.

NOTE: Illustration shows vehicle with Tiptronic automatic transmission. Other vehicles may have a different battery's positive ( + ) cable configuration that is engine-transmission dependent. As such, clip removal operations may vary slightly.

- Unclip fuse holder from battery container pressing the lock with a screwdriver -1- and pushing the fuse holder towards the rear part of the vehicle -arrow-.
- First disconnect negative ( - ) battery terminal from battery (tightened to 6 Nm).
- Then disconnect positive ( + ) battery terminal clamp (tightened to 6 Nm). and remove cable.

Battery, reconnecting.

NOTE:
- In order to prevent damage to the battery housing, battery terminals must be placed on battery posts without using force (by hand only).
- Battery posts and terminals must no longer be greased.

- Reconnect battery in reverse order of disconnecting. Ensure battery terminals are torqued as specified.
- Perform work steps specified in table.

NOTE: Refer to appropriate wiring diagram for installed positions of cables to fuses if necessary.

Work steps required after reconnecting battery

NOTE: If desired, print this page and use the table above as a checklist.