Free PDF Manual Guide

Although the PnP kits and ECU’s are identical, the New Beetle’s EC’s location is different than the Jetta/Golf; therefore these instructions are split – the first section describes Golf/Jetta installation and the second section describes Beetle installation.
(2) The ECU connectors lock and unlock by pulling the “T-handle” located at the connector’s edge. Look at the locking handles on the PnP harness and familiarize yourself with the mechanism before trying to remove the OEM plugs.
(3) When trying to remove the OEM Plugs from the ECU, getting your fingers into the T-handles can be difficult. You can gently pry the T-handles back using a screw driver.
(4) The Golf/Jetta OEM ECU bracket will not reinstall with the Unichip PnP harness in place without modification. You can easily modify your bracket as outlined below or can by a modified bracket from UNA (UNA Part # 9950001).
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The fuse panel is located under the left side of the dash board by the driver’s knee on the Cabriolet, Fox, Jetta, Rabbit and Pickup. On the Golf and GTI models the panel is located by the driver’s right knee, under the dash panel.
NOTE: On all models, fuse specifications are listed on inside of panel cover.
WARNING: Always disconnect battery ground cable before servicing “high-current fuses. It is recommended that “high-current” fuses be replaced by a qualified technician.
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Tools required: – Cross head screwdriver, Flat blade screwdriver, 6mm and 7mm hose
clip drivers, Sharp craft knife.
1/ Open bonnet/hood. Remove the plastic engine cover. Remove the hose running between the throttle body housing and the top intercooler connection (bottom left hand corner of the picture above)
2/ Fit the new hose with the 25mm spout as shown above. If the hose is too long it will probably become misshapen, if this happens then remove and simply trim the ends with a sharp craft knife, only remove 10-15mm at any time and refit to check the hose shape after each cut if required. Once happy with the fit then secure with the hose clips supplied.
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Before starting work read the installation instructions.
The electrical installation kit may only be fitted by qualified specialists.
Follow guidance in the current repair manual when carrying out installation work on the vehicle.
The ABS control unit must be recoded for activation of the trailer stabilisation system.
Caution – disconnect battery
Damage to the vehicle electronics may result in loss of stored electronic data.
Before starting work read out error memory.
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Fuel system overview : Demand-Controlled Fuel System, Low Pressure System, High Pressure System. Fuel System Components : Fuel Pump Control Module J538, Transfer Fuel Pump G6, High Pressure Fuel Pump with Fuel Pressure Regulator Valve N276, High Pressure Fuel Pump, High Pressure Fuel Pump Operation, Low Fuel Pressure Sensor G410, Fuel Pressure Sensor G247, Cylinder Fuel Injectors N30–N33, Fuel Injector Operation, Pressure Limiting Valve, Connector Fitting with Restrictor.
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Quick and to the point, the reason to change your brake fluid is to save your ass! Brake fluid is a hydroscopic which means it attracts water, big deal right? Wrong, through the brake lines and through your resevoir brake fluid attracts water, water has a really low boiling point, the more water in your lines the lower your boiling point. So you smash the brake pedal to stop you from slaming into the car ahead of you but your brakes barely keep you from hitting him. Your pedal feel may be very “mushy” as some may say. Your pads and rotors are fine so what’s the deal. When you slammed your brakes their is a good chance your brake fluid boiled, in turn becoming a gas. Which we all know you can compress gas a lot! So your pedal sinks to the floor. Of course that is worst case scenerio but that is the situation that we are trying to avoid by changing our fluid. Another reason is with our expensive ABS ESP etc. etc. we want to prolong their life as long as we possibly can, new brake fluid will keep corrosion to an absolute minimum.
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This “how to” assumes you have some basic tools, and safety gear. Safety glasses should be worn at all times when working with tools and automotive fluids. Always use a hydraulic jack and safety stands when lifting or getting under a vehicle. If you are unsure on where to safety lift your vehicle, refer to its owners guide. Brake dust can contain asbestos which has been found to cause cancer. The writer of this how to assumes zero liability in how to use this guide, or any damages that may come from it to you, your property, or others and others property. If you are uncertain at any point, refer to a qualified automotive technician.
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COMPRESSOR CLUTCH CONTROL
Evaporator Temperature Switch
Although compressor clutch does not normally cycle on and off, an evaporator temperature switch turns off the compressor clutch if evaporator temperature decreases to 32øF (0øC). This prevents evaporator icing.

A/C Pressure Switch
A/C pressure switch is a triple-pressure switch, which monitors high side pressure. See Fig. 1. If pressure decreases to less than 17.4 psi (1.2 kg/cmý), A/C pressure switch interrupts power to compressor clutch (low-pressure cutout). Switch closes when pressure increases to more than 34.8 psi (2.4 kg/cmý).
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The K&Nо Drycharger included with this kit must be installed on the K&Nо air filter when used with this K&Nо cold air intake system. The K&N cold air intake system a performance product that can be used safely during mild weather conditions. During harsh and inclement weather conditions, you must convert your cold air intake system to a short ram configuration, or return your vehicle to the stock OEM air box and intake tract configuration. Failure to follow these instructions can void your warranty.
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Prior to testing separate components or systems, it is highly recommended that all procedures listed in F – BASIC TESTING article be performed. Since many computer controlled and monitored components will change voltage and resistance valves if they malfunction, it is also recommended that connector pin check diagnosis be performed.
NOTE: Testing of individual components does not isolate possible shorts or opens in the control harness of electronically controlled systems. Use an ohmmeter to isolate shorts or opens in harness. All voltage tests should be performed with a Digital Volt Ohmmeter (DVOM) with a minimum 10-megaohm input impedance, unless specifically stated different in testing procedures.
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