ROA Parts For Volkswagen Restoration Wire Harness Instructions 1971 Super Beetle 1971 Super Beetle Wiring Harness Kit This wiring harness kit fits 12-volt Bug sedan and convertible models. Ifyour Bug has electrical upgrades, such as an alternator, or additional equipment, some modifications will be required, Basic automotive electronic knowledge is essential for proper installation of this wiring harness. Thor- oughly read these installation instructions and study the diagrams to familiarize yourself with the basic layout of your vehicle's electrical system. Document the routing of the old wiring harness and sub-harnesses prior to removal. A digital camera is a Useful tool for this step. If your car was recently painted, you will need to address certain areas of the body/chassis in order to achieve proper electrical continuity. Use a file, sandpaper or emery cloth to remove paint from the mount- ing locations of the headlights, taillights, front directional indicator bulb holder, negative battery strap, transmission to chassis strap, etc. Use touch-up paint or nail polish to seal the surrounding areas of the connection to prevent corrosion. Component List + Main Harness (1) Dome Light Harness (1) Headlight Harness (1) Brake Light Harness (1) Miscellaneous Wires/Sub Harnesses (37) Grommets (9) Headlight Plugs (2) 1-1 Connectors (13) 1-1 Male Connectors (9) 1-2 Connectors (1) . 2-2 Connectors (2) + Main Hamess to Body Clips (2) + Piggy back connectors (2) 2017/01/30 wotsburgwese2013.'Installation. 1. Disconnect negative cable from battery. Review the instructions, and identify the various sub-hamesses and supplemental wires. 2. Now the fun begins! Disconnect the main harness connections from their respective locations. Note that the main harness travels along the heater channel and the dome light harness travels through the roof member at the left-hand side of the Bug. With all the wires disconnected behind the dash push the main harness through the grommet in the trunk floor towards the interior of the car. Next, remove the rear seat bottom and left side rear door panel. Along the left heater channel on the interior of the car lift up the carpet where it meets the floor. Along this path you will find 2 clips holding the harness snug to the heater channel. Remove these with a screw driver releasing the harness. Disconnect the wires from the voltage regulator. Next open the engine lid and remove any insulation material that may be present within the cavity located at the upper left corner of the compartment (where main harness exits), The main harness runs under the firewall sound deadener so you may want to remove the engine to gain better access to remove the sound deadener, Disconnect all the wires from the corresponding components. Attach a dragline onto the rear portion of the wiring harness (fish tape or heavy cord ‘material). Overlap the dragline and main harness for about one foot and use duct tape or plastic tape to attach the dragline securely to the main harness. Wrap the tape tightly as to create a strong, streamlined bundle. With the dragline securely attached to the old main harness, pull the harness from the rear as an assistant helps guide the dragline under the rear seat. With the old harness removed slide the supplied large 50mm grommet, part # 111971919, onto the tail end of the new main harness and up towards the middle of the loom making sure that the grommet is positioned with the open cup facing forward. Attach the rear of the new main harness onto the dragline under the rear seat in the same fashion as prior. Coat the new harness liberally with wire lube (surgical lube works well, KY Jelly, Astroglide, etc.) and pull the new harness into place from the rear while an assistant helps guide the harness from under the rear seat. Be sure to keep lubricating the new harness as it is being fed while keeping the hamess bundle asstraight as possible. if the harness becomes stuck, do not force the issue. Reverse the procedure and observe the path of travel and remedy any obstacle. With the harness pulled into position use the supplied 2 new clips to attach the new harness to the side of the heater channel, Feed the front end of the hamess through the underside of dash into the trunk area using the new grommet supplied, part # 111971907 See diagram on page (5) for proper connec- tions on the main harness. 3. Remove the dome light from the roof, and disconnect the wires. Remove the wires from each dome light switch located behind each door jamb, and remove the red wire from the fuse box. Attach a dragline onto the wires at the roof opening and carefully feed the dragline though the slot, while and assistant pulls the dome light harness from the front. Attach the dragline onto the new dome light harness and feed through the front, while an assistant gently pulls the dragline at the roof opening. Connect harness per diagram on page (7) 4, Install new headlight harness, see diagram on page (6). When routing the wires through the supplied rubber grommets make sure to use lubricant to ease the wires through. Use the supplied headlight plugs and refer to the diagram on page (6) to correctly locate the wires into the plug. Route the horn wire bundle through journal in trunk (left side of the trunk, next to brake tubes). 5, __ Install brake light switch harness . Route the harness through the slot in the body on the drivers side of the fuel tank . Place 3 of the supplied 1-1 connectors onto the headlight harness wires,yellow/black, black/red and red and plug these 3 wires into the corrosponding colored wires from the brake light harness. 6. __ Install miscellaneous supplemental wires, see page (9-11) for illustrations: + Install left and right front turn signal/park light harnesses. Use the illustration on page (8) for correct installation. You want to make sure that you connect the black wire to the brighter side of the bulb (see note in upper corer of page (8) for more info). + Install taillight harnesses (5 wires bundled in white conduit, 525mm length), see diagram on page (6). Install the 1-1 connectors and the 1-2 connector as outlined in the diagram onto the corresponding wires of the main harness. Connect each taillight harness to their respective positions as outlined within the diagram. Use the supplied grommets (center portion has a closed membrane, use knife to open small slice in center) to route each harness through the quarter panel. + Forthe back-up lights follow the diagram on page (8) to install the necessary wires. + Install icense light harness (grey and brown wires in black conduit, 1250mm length) , see diagram on page (9). The grey license light wire connects onto the 1-2 connector of the right taillight harness. Route the wire to the license light assembly while observing its proximity to the fan. Keep the slack of the wire as far away from the fan as possible. Use two of the 1-1 connectors to plug into license light. Its best if you have the dash switches removed from the dash with the terminal identification in clear view when installing the balance of dash wiring. + Attach ignition and tum signal switch wires (part of ignition switch and not included). See wire diagram on page 12 for exact locations of the following wires. Larger red wire to fuse box. Smaller red wire to main harness using supplied 1 to 1 connector(T11). Black ignition wire to fuse box. + Attach the dash ground wire hamess (brown wire many connectors) using the diagram shown on page (11). + Attach mise. power wire harness using the diagram shown on page (7). + Attach choke power wire from terminal 15 of the coil, to choke element located on the side of the carburetor and to idle shut off valve. (black wire, 425mm length, one end finished with female quick- connect terminal and opposite end finished with short black wire with quick disconnect ends). . Install the heavy red wire in the PVC sleeve, 920mm long between the starter, terminal 50 through the rear of the floor pan on the drivers side using the supplied grommet and using a 1-1 connector connecter to the remaining thick red wire out of main harness at the voltage regulator. + [you will be running the ignition key buzzer use the three wires at the bottom of page (11) to complete this circuit. : We have supplied an extra wire to use on high/low beam relays that have a #30 terminal. You may not need this.K With installation now complete, double check all connections. Connect red wire from battery cable to voltage regulator terminal #30, Carefully connect battery and test each system for proper operation. Installation of male push-on connector sleeve. —a Sleeves are provided in the kit and easly side into postion on the mele connector Within the following pages we use the diagram below with a red marking to indicate the exact position of the wire within the relay panel. In this example the wire would be running to the High Beam Relay at the terminal marked in red. This relay panel sts on top of the fuse box. 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Brown i goed Miscellaneous Wires Grey to T connector {TI7}on main harness 1250 mm License light Left ond Right tailight harness 380 mm Speedo ilumination light Headlight switch #586 Instrument light wires Speedo illumination light 255 mm = ‘Wiper motor o switch #530 = 255 mm Ee Wiper motor fo switch #53b = B 255 mm E Wiper motor fo swilch #31b xs 255 mm S| ‘Wiper motor to switch #53, ‘Sending unit insulated tab 530mm __ Feelgauge Fuel gouge to fuel tank sending unit ‘Ground tab on sending unit Ground pos' next to speedo 425 mm Ignition coil #15 Choke to idle valve To headlight harness, ed 620 mm rite connecter 16g, EEE Broke woring light, #KMiscellaneous Wires, continued tocig eb i esta ee 680mm ao Pa mn al Sh 894 errr] a a 1 | =_— Flasher #49a ‘Tum signal switch, (marked in red) block/green/white ‘Turn indicator light on speedo “Yam ot usa bon relay panel relay side. Wie _locing tab ) a 1 Oe 7 o Flasher #49 or + (marked in red) to emergency flasher switch #+ 630 mm. “Turn switch black/green to emergency flasher switch #R eo ee OO Tum switch black/white fo emergency Flasher switch #L eee Emergency flasher switch #15 to fuse box {marked in red) ene = i es Emergency flasher switch #30 to fuse box (marked in red) : =n locking ob pox yl yi ae #56b Hecdlight relay to fuse box (marked in red) LTA ee Ss, eee 56a or "E” Headlight relay to fuse box (marked in red) ae = Headlight switch #30 to fuse box {marked in red} Lu ii i u i a= 680mm e Headlight switch #58 to fuse box {marked in red) Lil (ul Li u Li pea High beam warning light on speedo to fuse box {marked in red) ease 10‘Miscellaneous Wires, continued a mma —_ocking tab i enor ay pe ye mm — Say Te = Headlight switch #56 Bp) eee = BES] Hecdlight relay a Ga ieee #56 {shown in red) 560 mm Headlight switch 4X to connector T8 (black/yellow from steering column) roma Pon #18710 920 mm To T1d connector {red nex! fo voltage regulator under rear seal) fo starter #50 Locking lb Brake warning light #31 Flasher relay #31 Tab on speedo bolt right Ground to body next to speedo Emergency light switch #31 260 mm Wiper motor #31 Wiper switch #31 Ground near speedo ' Ifyou are running the door buzzer instal the following three wires. i 300 mm = : Left door post switch to connector T12 (white wire from steering column] 1 _Yewetine bono potest. _ Pee Logking tab ' ce ' oa] |=) pee 800 rm _ gees Loft door post switch ' memes stig ob i Bae ee TU: ‘Warning buzzer #85 to fuse box (marked in red) peal ' ' lfyou have « headlight relay with o #30 terminal ths wire will be needed, ' essa — e sta ab : ia —— a LLL LLG La) Reciag tender i 1 High beam relay #30 to fuse box (marked in red) owetaag e209 0nS : Wu ¢ ) earn | ; ; %) (>) We = a £3} ie T 1 1 FS a ce 2 #4) ea” | 2 . hy Faaa Py = EB oy 2 j = — J = 1971 Super Beetle Export 5 ° 0° ° oO ol oO 0 Oo 0 i aa <= aMn Battery Starter Generator Voltage regulator Starter/Ignition switch Windshield wiper switch Light switch ‘Tum indicator switch Rear window defog switch Emergency flasher switch Interior light switch, left Interior light switch, right Fuel gauge sending unit Hom button Hom Ignition key warning buzzer Tum Signal/Emergency roloy Dimmer switch Dimmer relay Stop light switchs Oil pressure switch Backup light switch Rear window defog relay High beam warning light Generator warning light Turn indicator warning light Oil pressure warning light Speedometer light Rear window defog indicator light Hazard warning light Brake warning light Sealed-beam unit, left Sealed-beam unit, right Rear right tail/stop light Rear left tail/stop light Front left turn light Rear left turn light Front right turn light Rear right turn light Parking light Coil ‘Automatic choke Electric ile jet sl $2 1 12 13 T4178 9 To ™m m2 113 4 TIS 116 17 ne Fuse box, 12 fuse Fuse, backup lights, engine compartment Fuse, rear window defogger, under rear seat Double connector, laf front quarter panel Double connector, right front quarter panel Triple connector, behind speedometer Single connector, behind speedometer Double connector, behind speedometer Double connector, behind speedometer Single connector, behind speedometer Single connector, behind speedometer Single connector, behind engine sound deadner Single connector, under rear seat 4 connector, behind engine sound deadner, left Triple connector, behind engine sound deadner, right Y connector, behind engine sound deadner, right Double connector, on engine door Windshield wiper motor Interior light Backup light, left Back-up light, right license plate light Rear window defogger Battery ground strap Steering column to steering box ground jumper ‘Chassis to transaxle ground strap B