Volkswagen Cabriolet DIY Guide

Ellectriicall System E ectr ca System

Rellays Re ays
This guide is a repair manual supplement. For electric system troubleshooting procedures and complete wiring diagrams, please refer to your Bentley Service Manual.

1983-1989, K-Jetronic
01: 02: 03: 04: 05: 06: 07: 08: 09: 10: 11: 12: 13: 14: 15: 16: 17: 18: 23:

1990-1993, Digifant
01: 02: 03: 04: 05: 06: 07: 08: 09: 10: 11: 12: 13: 14: 15: 16: 17: 18: 23: Digifant control unit Fuel pump Seat belt warning; key-in-ignition warning open Air conditioning Horns open Load reduction fuse puller Intermittent wipers open Turn signals; Emergency flashers open; daytime running lights (Canada 1991+) Radiator fan after-run control unit* Automatic transmission starter interlock** Coolant low-level warning control unit A/C thermo-fuse; Power window fuse open Power convertible top thermo-fuse

open Fuel pump Seat belt warning; key-in-ignition warning Up-shift control unit (1983-1987) Air conditioning Horns open Load reduction open (up through 1986); fuse puller (1987+) Intermittent wipers open Turn signals; Emergency flashers open Cold-start enrichment Fuel injection power supply (aka Lambda relay) Hot-start pulse relay A/C thermo-fuse Idle stabilizer control unit open

Radiator after-run control unit: Mounted to driver's side fender Heated seat relays: under each seat

Heated seat relays: under each seat *If not in this location it is mounted to the driver's side fender **If not in this location, there are two interlock relays mounted to the back side of the kneebar
Electrical System

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Fuses Fuses

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= slots for jumping fuel pump relay

1983-1989
501: 502: 503: 504: 505: 506: 507: 508: 509: 510: 511: 512: 513: 514: 515: 516: 517: 518: 519: 520: 521: 522: Radiator cooling fan Brake lights; Cruise control Cigarette lighter; Radio; Clock; Interior lights Emergency flashers Fuel pump open Tail lights, running lights, side-marker lights ~ left Tail lights, running lights, side-marker lights ~ right Hi-beam headlight ~ right; hi-beam indicator Hi-beam headlight ~ left Windshield wipers/washers Heated seats (if installed) Rear window defroster HVAC blower fan Back-up lights; Shift console light (A/T only) Horns open Seat belt warning light; Horn relay; Coolant level/temp warning light; Console gauges; Cruise control (M/T) Turn signals; E-brake warning light License plate lights; Trunk light (1987+) Lo-beam headlight ~ left Lo-beam headlight ~ right 501: 502: 503: 504: 505: 506: 507: 508: 509: 510: 511: 512: 513: 514: 515:

1990-1993
Radiator cooling fan Brake lights; Cruise control (1991-1993) Cigarette lighter; Radio; Clock; Interior lights (1990) Emergency flashers Fuel pump; Heated oxygen sensor open Tail lights, running lights, side-marker lights ~ left Tail lights, running lights, side-marker lights ~ right Hi-beam headlight ~ right; hi-beam indicator Hi-beam headlight ~ left Windshield wipers/washers open Rear window defroster HVAC blower fan Back-up lights; Shift console light (A/T only); Cruise control (1990 M/T only) 516: Horns 517: Power windows (switch current) 518: Seat belt warning light; Horn relay; Coolant level/temp warning light; Heated seats; Console gauges; Cruise control (1990 A/T only) 519: Turn signals; E-brake warning light 520: License plate lights; Trunk light; Instrument panel lights (1991+) 521: Lo-beam headlight ~ left 522: Lo-beam headlight ~ right 5 A/C thermofuse: relay position 17 5 Power window fuse: relay position 17 5 Power convertible top: relay position 23
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5 A/C thermofuse: relay position 17

5=30A
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5=20A

5=15A

5=10A

Rellay Panell Piin-Outs Re ay Pane P n-Outs

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A
Pin A01 Dash Lights A02 Wiper Switch A03 A04 A05 A06 A07 A08 A09 Instrument Cluster Instrument Cluster Wiper Switch ~ High Speed Signal Wiper Motor Switch Emergency Flashers/Turn Signals Ignition System Description

Dashboard Wiring Harness

Blue Plug

A10 Emergency Flashers A11 A12 A13 A14 A15 A16 A17 A18 Wiper Switch ~ Intermittent Signal Emergency Flasher Switch E-brake Warning Light Instrument Cluster Instrument Cluster Emergency Flashers

A19 Wiper Switch ~ Washer A20 Emergency Flashers/Turn Signals

Goes To Wire Color G8; Dash Wiring Harness; Dimmer Switch Terminal 58b (A/T only) Gray/Blue Intermittent Wiper Relay Terminal 53S; Intermittent Wiper Switch Terminal Green 53 Up-shift Relay Terminal L; Up-shift Indicator Light Blue/Yellow Oil Pressure Warning System; G6; D1 Blue/Black D9; Intermittent Wiper Switch Terminal 53b Green/Yellow D17; Intermittent Wiper Switch Terminal 53e Green/Black Emergency Flasher Switch Terminal R to Turn Signal Switch; C8; D25; E11 Black/Green Ignition Switch Terminal 15; Airbag Control Unit Terminal 18 (1990+) Black M1, G7 White/Black Emergency Flasher Switch Terminal 49a to Turn Signal Switch; Flasher Black/White/Green Relay Terminal 49a Emergency Flasher Relay (internal) Intermittent Wiper Relay Terminal J; Intermittent Wiper Switch Terminal J Brown/Black Fuse 19; Emergency Flasher Switch Terminal 15 Black/Blue E7 C12; E-brake Warning Light Switch Blue/Brown Battery Warning Light; G4; C2; D4 Blue Turn Signal Indicator Light; A10 Blue/Red Emergency Flasher Switch Terminal 49; Flasher Relay Terminal 49 White Intermittent Wiper Relay Terminal T; Intermittent Wiper Switch Terminal T; Green/Red D5; G10; C9 Emergency Flasher Switch Terminal L to Turn Signal Switch; C19; E6; D11 Black/White

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Electrical System

A21 Headlights A22 Rear Window Defroster Switch Power A23 HVAC System A24 Light Switch A25 Horns; Gauges A26 Lights A27 Up-shift System A28 Instrument Cluster

Fuse 21; Fuse 22; Headlight Dimmer/Flasher Switch Terminal 56b Canada 1990: M2; Headlight Switch Terminal TFL via DRL Resistor Canada 1991+: M2; DRL Relay via DRL Resistor; Headlight Switch Terminal TFL Fuse 13; Rear Defroster Switch Fuse 14; HVAC Blower Fan; Headlight Switch Light Light Switch Terminal 58; Fuse 7 G5; G2; D7; L1; Console Gauges A/T 1990+: Relay 6 G9; E1 Up-shift Relay Terminal 2 (internal) Hi-beam Indicator Light; C16

Yellow Black/Yellow Black/Red Gray/Green Black Blue/White

B
Pin B01 B02 B03 B04 B05 B06 B07 Description Fog Light Switch (Europe Only) Instrument Cluster Fuel System Coolant Temperature Warning System

Dashboard Wiring Harness

Goes To E13 E10 Fuel Gauge; E5 E4 (no pin) Fuel Pump Relay Terminal 8 (internal) Coolant Temperature Gauge; D29 Ignition Switch Terminal 50; Fuel Pump Relay Terminal 7 (internal); Airbag Control Unit (1990+); C18; D24 D20; Intermittent Wiper Relay Terminal 15; Intermittent Wiper Switch Terminal 53a Load Reduction Relay Terminal 86; Light Switch Terminal X Fuse 3; E3; B12; Cigarette Lighter; Radio Digital Clock; E3; B11 Headlight Dimmer/Flasher Switch K5 High Oil Pressure Switch Fuse 6, C22 Seat Belt Relay Terminal L; Seat Belt Warning Light Upshift Relay Terminal G (internal); D3 Up-shift Relay Terminal 1; Tachometer; Fuel Pump Relay (internal); D26 Fog Light Relay Output E15; Rear Window Defroster Switch Terminal 86 Fuse 9; Fuse 10; Headlight Dimmer/Flasher Switch Terminal 56a Light Switch Terminal 30 C11 C15; L2 B27; A24; Fuse 8 B26; A24; Light Switch Terminal 58; Fuse 20; Relay 7 (internal) Fuse 4; Emergency Flasher Switch Terminal 30 Goes To E16; Brake Light Switch A/T 1990+: Shift Lock Control Unit; E16; Brake Light Switch Cruise Control: E16; Brake Light Switches; Vacuum Valve; Cruise Control Control Unit D+ on Alternator; A16; D4 Fuse 2; Brake Light Switch Cruise Control: C1; Fuse 2; Brake Light Switches E9; Front Parking Light; Side-marker Lights Fuse 21; Left Headlight Fuse 22; Right Headlight Fuse 1; Air Conditioning Relay Terminal 4 (internal); Radiator Fan Thermo Switch www.cabby-info.com

Red Plug
Wire Color Green/White Violet/Black Yellow/Red Red/Black Black/Gray Black/Yellow Red/Gray Red Red/Yellow Yellow White/Yellow White/Violet Red/Black Green/Yellow White/Green White Red Brown/Black Gray/Green Gray/Green Red/White

B08 Ignition System B09 Wiper Switch Power B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 Load Reduction/Ignition System Cigarette Lighter, Radio, Amplified Speakers Instrument Cluster Headlights Key-In Power Gauge Cluster (Oil Pressure Light Controller) Fog Light Switch Seat Belt Warning System Up-shift System Instrument Cluster Fog Light Switch Rear Window Defroster High Beam Switch, high beam output Light Switch Power Horns Light Switch Light Switch Emergency Flasher Switch Power Description Brake Light Switch, Cruise Control, A/T Shiftlock Control Unit

C
Pin C01

Engine Compartment/Management, Left

Yellow Plug
Wire Color Red/Black Blue Red/Yellow Gray/Black & Gray Yellow/Black Yellow Red Electrical System

C02 Alternator Exciter Circuit/Charging System C03 Brake Lights C04 Running Lights ~ Left C05 Headlights ~ Lo-beam C06 Headlights ~ Lo-beam C07 Radiator Cooling Fan Page 4 of 11

C08 C09 C10 C11

Emergency Flashers/Turn Signals Windshield Washer -

Turn Signal Light ~ Right Front G10; D5; A19; Windshield Washer Pump (no pin) B24 A15; Brake Fluid Level Switch Fuse 16; Horns Fuse 8; E18; Front Parking Light; Side-marker Lights B25; Horns (ground) Fuse 9; Right Headlight(s) Fuse 10; Left Headlight(s) Hot-start Pulse Relay Terminal 50; E-brake Warning Light; Thermo Time Switch; Fuel Pump Relay (internal); B8; D24 Turn Signal Light ~ Left Front; A20; E6; D11 Fuse 15; D16; Back-up Light Switch; Cooling Fan After-run Control Unit (1990+) Back-up Light Switch; E12 (A/T 1990+); D19 (A/T 1990+) Fuse 6, B16

C12 Brake Warning System C13 C14 C15 C16 C17 Horns Running Lights ~ Right Horns Headlights ~ Hi-beam Headlights ~ Hi-beam

Black/Green Green/Red Blue/Red or Blue/Brown Black/Yellow Gray/Red & Gray Brown White White/Black Red/Black Black/White Black Black/Blue White/Yellow

C18 Warning Lights C19 Emergency Flashers/Turn Signals C20 Back-up Lights C21 Back-up Lights C22 Fog Lights

D
Pin Description D01 Low Oil Pressure Switch D02 Fuel System D03 D04 D05 D06 D07 D08 D09 D10 D11 D12

Engine Compartment/Management, Right

Goes To Oil Pressure Switch (1.8 bar); G6; A4 Fuse 17 Digifant I: Fuse 17; R1 Up-shift Switch Terminal 5; B18 Oxygen Sensor Mileage Counter Box; A16; G4; C2 A19; G10; C9 (no pin) G2; G5; A25; Coolant Low-level Control Unit (A/T 1990+) Up-shift Vacuum Switch; Up-shift Control Unit Terminal US A5; Wiper Motor Terminal 53b (no pin) E6; C19; A20 Wiper Motor Terminal 53; Intermittent Wiper Relay Terminal 53 Fuel Pump Relay Terminal 6 (internal); Digifant Control Unit Terminal 3 (no pin) D23 C20 1990+ A/T: Fuse 15; Back-up Light/Starter Cut-out Switch; Shift Lock Control Unit; Starter Interlock Relay A6; Wiper Motor Terminal 53e (no pin) E12; C21; Back-up Light Switch/Starter Cut-out Switch (A/T only) Fuse 11; Wiper Motor Terminal 53a Oil Pressure Switch (.3 bar); B15 Main Panel Ground Coil Terminal 15; D15 Digifant I: D25; Ignition Coil Power Stage B8; C18; Fuel Pump Relay Terminal 7; Starter Terminal 50, or Auto. Trans. Starter Interlock Relay Terminal 31 C8; E11; A7 Ignition Coil Terminal 1; Idle Stabilizer Relay Terminal 1; Fuel Pump Relay (internal); B19 (no pin) (no pin) Coolant Temperature Gauge Sender; Coolant Low-level Control Unit (1990+); B7 www.cabby-info.com

White Plug
Wire Color Blue/Black Black White/Green Blue Black/Blue White/Red Green/Yellow Green Yellow/Blue and Red/Yellow White/Violet Black Green/Black Black/Blue Black/Gray Yellow Brown Black Red/Black or Red Red/Black Yellow/Red or Yellow/Blue Electrical System

Up-shift Indicator Alternator Exciter Circuit/Charging System Intermittent Wipers Idle Stabilizer Control Unit; Seat Belt Warning; Oil Temperature Gauge Up-shift Indicator Wiper Motor ~ High Speed Emergency Flashers/Turn Signals Wiper Motor ~ Low Speed

D13 Fuel System D14 D15 Resistance Wire, Coil Pin 15 (Europe only) D16 Back-up Lights D17 D18 D19 D20 D21 D22 Wiper Motor Switch Back-up Lights Wiper Motor Switch Oil Pressure Warning System Wiper Motor

D23 Ignition System D24 Ignition System D25 Emergency Flashers/Turn Signals D26 Ignition System D27 D28 D29 Coolant Temperature Warning System

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E
Pin E01 E02 E03 E04 E05 E06 E07 E08 E09 E10 E11 E12 E13 Description Lights Interior Lighting Instrument Cluster Emergency Flashers/Turn Signals Heated Seats Running Lights ~ Left Rear Fog Light (Europe Only) Emergency Flashers/Turn Signals Back-up Lights -

Rear Wiring Harness

Goes To License Plate Lights; Trunk Light; Fuse 20 Relay 11 Courtesy Light; B11; B12 B4 Fuel Gauge Sending Unit; B3 Turn Signal Light ~ Left Rear A14; Relay 11 Relay 11; G3; G1 Fuse 7; C4; Tail Light B2 Turn Signal Light ~ Right Rear D19; C21; Back-up Lights; C21 (A/T 1990+) B1 Fuel Pump; Transfer Fuel Pump; Aux. Air Regulator; Control Pressure Regulator; Fuse 5 to Fuel Pump Relay; Oxygen Sensor (1988+) B21; Rear Window Defroster Element C1; Brake Lights ~ Left, Right, High-Mount in Trunk Lid C14; Tail Light

Black Plug
Wire Color Gray/Green Red Violet/Black Black/White Black/Gray Gray/Black Green/White Black/Green Black Red/Yellow and Red/White White & Black Black/Red Gray/Red

E14 Fuel System E15 E16 E17 E18 Rear Window Defroster Brake Lights Running Lights ~ Right

G
Pin Description G01 Power Windows; Heated Seats G02 Idle Boost Control G03 Heated Seat Control Units G04 Alternator Exciter Wire G05 Seat Belt/Brake Warning System G06 Oil Pressure Warning System G07 G08 Interior Lighting G09 Lights G10 Headlight Washer Relay (Europe only)

Individual Circuits
Goes To Fuse 12; E8; G3 D7; G5; A25; Idle Boost Control Unit A/T only: G5; D7; A25; Fuse 18; Back-up Light/Starter Cut-out Switch Fuse 12; E8; G1; Heated Seats Control Units; Heated Seats Switch A16, D4 G2; D7; A25; Fuse 18; Seat Belt Indicator Light; E-brake Indicator Light (A/T 1990+) D1; A4 A9; M1 A1; Instrument Cluster Wiring Harness; A/T Shift Console Light; Power Convertible Top Switch Light A26; E1 A19; D5; C9

Wire Color Black Black/Red and Black Black Gray/Blue Green/Red

H
Pin Description H01 Radiator Cooling Fan H02 HVAC System H03 HVAC System H04 HVAC System H05 HVAC System H06 HVAC System

HVAC Wiring Harness

Goes To A/C Relay; Fuse 1; C7; Cooling Fan Thermo Switch; Cooling Fan HVAC Fan Switch Speed 1; HVAC Blower Fan; A/C Relay; H6 A/C Relay; Battery via Fuse 23 A/C Relay; A/C Thermostat; A/C Compressor Clutch; Idle Stabilizer Valve HVAC Fan Switch Speed 4; A/C Relay (internal) HVAC Fan Switch Speed 1; HVAC Blower Fan; A/C Relay; H2

Brown Plug
Wire Color Red/Black Red/Black and Black/Yellow Red Green Black Red/Black and Black/Yellow

Seat Belt/Coolant level Warning Wiring Harness

Goes To Seat Belt Relay Terminal G; Seat Belt Switch Seat Belt Relay Terminal 2 (internal) Relay Panel Power Seat Belt Relay Terminal 86; Door Contact Switch (left); Seat Belt Switch Ignition Switch Terminal SU; Seat Belt Warning Relay Terminal 85; Power Convertible Top Switch; Relay 5 (internal)

White
Wire Color Gray/Red Gray & Black/Green Brown/Red

Pin Description K01 Seat Belt Warning System K02 Seat Belt Warning System K03 K04 Seat Belt Warning System K05 Ignition Switch Key-In Power

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Electrical System

L
Pin L01 L02 L03 L04 Description Horns Horns Horns Horns Description

Horn Wiring Harness

Goes To A25; Horns Relay Terminal 86 B25; Horns Relay Terminal 87 Horns Relay Terminal 30; Dash Wiring Harness Horns Relay Terminal 85; Horn Button

Black Plug
Wire Color Black Brown/Black Brown Brown/Blue

M
Pin M01 M02 Headlights

Steering Column Switch or Headlight/Dimmer Switch Wiring Harness

Goes To A9; G7 A21

Black Plug
Wire Color -

N
Pin N N Description Fuel System Power ~ CIS Fuel System Power ~ Digifant Description Battery Automatic Transmission (1990+) Power Seat Height Adjust Fuse Power Windows Ignition Switch Power Fuel System Power ~ CIS Headlight Washer Relay (Europe only)

Individual Circuit, Fuel Injection

Goes To Fuel Pump Relay Terminal 87 and Fuse 5 (internal); Fuel Injection Power Supply Relay Terminal 86 Fuel Pump Relay Terminal 87 and Fuse 5 (internal); Fuel Injectors

Red Plug
Wire Color Red/Black Red

P
Pin P P P P P P P

Individual Circuits, Battery Power

Goes To Main Fusebox Battery Power Starter Interlock Relay Terminal 30 Main Fusebox Battery Power Fuse 37 (Relay Position 17); Power Window Control Unit Ignition Switch Terminal 30 Fuel Injection Power Supply Relay Terminal 30 Main Fusebox Battery Power

Wire Color Red Red Red Red Red Red Red

R
Pin Description R01 Airbag System R02 Digifant ECU, Injectors

ECU Power Supply Wiring Harness

Goes To Digifant Relay Terminal 86; Airbag Control Unit; D2 Digifant Control Unit Terminal 14; Digifant Relay Terminal 87

Green Plug
Wire Color Black Black/Yellow

Please consult wiring diagrams for your particular car for precise wire routing and colors.

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Electrical System

How To Read Current Fllow Wiiriing Diiagrams How To Read Current F ow W r ng D agrams
1 2 3 4 5 6

16 15 14

13

12

7 11 8

9 10
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1 -

Circuits 15: Originates at ignition switch. Supplies power when ignition switch is in ON or START position. X: Load-reduction relay circuit. Originates at ignition switch. Supplies power only when ignition switch is in ON position. Circuit is interrupted when starter is actuated. 30: Battery positive (+) voltage. Supplies power whenever battery is connected (i.e. not dependent on ignition switch position). 31: Ground; battery negative (-). Connection designation ~ relay control module on relay panel Shows the individual terminals in a multi-point connector. Relay position number Reference of internal connection continuation Letters indicate where connection continues on the previous and/or following diagram Connections at rear of panel Designations of each pin connection. For example, C13 is referring to connector C, pin number 13. See page 3. Wire size and wire color(s) Color abbreviations are listed in a key on each diagram. Terminal designation on component Component In this example, from left to right, the components are: Horns, horn button, fan motor, window heating element. Ground connection locations Locations are defined in the diagram index. Current track number Wire connection designation in wire harness Locations are defined in the diagram index. Connector in wire or wire harness T1 = 1-point terminal connector; T2 = 2-point terminal connector; etc. Locations are defined in the diagram index. Current track continuation Number in box indicates the current track number where wire is continued. Internal connection inside relay panel D7 connects internally to G2, G5 and A25. Terminal number on relay 85 = Ground side of switching relay 86 = Power-in side of switching relay 87 = Relay switch contact 87a = Normally closed switch contact 87b = Normally open switch contact Fuse Indicates fuse position number and amperage. How the horn circuit works: Pressing the horn button closes the contacts sending an electrical signal to relay 6, which triggers terminal 30 to contact terminal 87, completing the path to ground, which closes the circuit sending power to the horns making them honk.

2 3 4 5 6 7 8 9 10 11 12 13 14 15 -

16 -

Multi-point connector at component

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Internal connections in component

Wire connection ~ fixed

Wire connection ~ detachable

Wire connection in wiring harness

Light bulb

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Electrical System

Ground Locatiions Ground Locat ons

1980-1986 Main ground cables/straps: Battery to the left frame rail; frame rail to the transmission Valve cover to the ignition coil bracket Fender to hood A/C compressor to battery (or engine block) Ignition Control Unit to battery Ground locations: Fuse/relay panel Steering column Cold-start valve (CIS only) Trunk, rear left and right Dash wiring harness

1987-1989 Main ground cables/straps: Battery to the left frame rail; frame rail to the transmission Valve cover to the ignition coil bracket Fender to hood A/C compressor to engine block (or alternator) Ignition Control Unit to battery Ground locations: Fuse/relay panel Steering column Cold-start valve (CIS only) Trunk, rear left and right Dash wiring harness Engine bay, front left and right ('88+)

1990-1993 Main ground cables/straps: Battery to the left frame rail; frame rail to the transmission Valve cover to the ignition coil bracket Fender to hood Digifant ECU to firewall A/C compressor to engine block (or alternator) Ground locations: Fuse/relay panel Instrument cluster wiring harness Steering column Trunk, rear left and right Engine bay, front left and right Horns ('91+)

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Electrical System

Wiire Siize Conversiions W re S ze Convers ons

Metric Size 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0 16.0 25.0 American Wire Gauge (AWG) Size 22 20 18 16 14 12 10 8 4 2 16 gauge: 10 amps max 14 gauge: 15 amps 12 gauge: 20 amps 10 gauge: 30 amps 8 gauge: 40 amps If your runs are going to be longer than about 30 feet of total wire length, bump up to the next size wire to reduce voltage drop on a 12V system. General wire size guidelines

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Electrical System