light VOLKSWAGEN BEETLE 2012 Service Manual

WARNING
Driving with a fuel tank that is almost empty can lead to stalling in traffic, a collision, and
serious personal injuries.
x When the fuel tank is almost empty, fuel supply to the engine can be interrupted,
especially when driving over bumps, across slopes, and up and down hills.
x Steering and braking assistance as well as ESC and related systems will not work if the
engine “sputters” or stalls due to lack of fuel.
x Always refuel when the tank is 1/4 full to reduce the risk of running out of fuel and stalling
in traffic.
NOTICE
x Failure to heed warning lights or text WARNINGS can result in vehicle damage.
x Never drive until the fuel tank is completely empty. The irregular fuel supply can cause the
engine to misfire. This allows unburned fuel to get into the exhaust system and damage the
catalytic converter or the diesel particulate filter.
The small arrow next to the gas pump symbol in the fuel gauge shows the side of the vehicle with
the fuel filler flap.
Misfueling guard for diesel vehicles

Fig. 113 With open fuel cap: Misfueling guard in the fuel filler neck.

slightly with light pressure to open the misfueling guard. If the misfueling guard cannot be opened this
way, see the nearest authorized Volkswagen dealer or authorized Volkswagen Service Facility and
have the fuel system checked.
WARNING
Spilled fuel can cause fires, explosions, burns, and other severe injuries.
x Do not refuel from devices other than correct, undamaged standard diesel fuel pump
nozzles.
x Always stop refueling once the pump nozzle switches off so that the tank does not
overflow.
NOTICE
x It is your responsibility to put the right fuel in your vehicle and any damage that results is
not covered under the Emissions warranties or any other Volkswagen Limited Warranty.
x If you put any amount of the incorrect fuel in the fuel tank, do not start the engine under any
circumstances. Immediately contact the nearest authorized Volkswagen dealer or authorized
Volkswagen Service Facility for assistance.
x If diesel fuel should get on any rubber hose, it must be wiped off immediately. The same
applies if diesel fuel gets onto other parts of the vehicle, especially paint, tires, or a plastic
part. Wash the contaminated vehicle parts right away with soap and warm water to help
prevent leaks and serious damage.
x Never force a fuel nozzle in the misfueling guard. If you have problems inserting a fuel
nozzle, first check to make sure you are using the correct diesel fuel. If you are, go to a pump
with the standard diesel nozzle. Forcing a fuel nozzle in the misfueling guard can damage it so
that it can no longer help prevent misfueling.
Fuel capacities

Checklist
If you are uncertain in any way, have the work done by an authorized Volkswagen dealer or
authorized Volkswagen Service Facility. Serious personal injury may result from improperly performed
work. Make sure that you check the following items regularly. The best thing is to check them every
time you refuel:
d Windshield washer fluid level.d Engine oil level.
d Engine coolant level.
d Brake fluid level.
d Tire pressure.
d Vehicle lighting necessary for driving safety:
– Turn signals
– Low beams and high beams
– Taillights
– Brake lights
– License plate lights
Information regarding changing light bulbs..
WARNING
Disregarding the safety-related checklist may lead to accidents and injuries.
x Please note and follow the points listed in the checklist.

WARNING
The engine compartment of any motor vehicle is a potentially dangerous area and can cause
serious personal injury.
x Always use extreme caution when doing any work in the engine compartment. Always
follow commonly accepted safety practices and use common sense. Never risk personal
injury.
x Never perform any work in the engine compartment unless you know exactly how to carry
out the job and have the correct technical information and the correct tools.
x If you are uncertain about what to do, have the work performed by an authorized
Volkswagen dealer, an authorized Volkswagen Service Facility, or another qualified
workshop. Serious personal injury may result from improperly performed work.
x We strongly recommend that you always have HID – High Intensity Discharge (Xenon)
headlights and HB2 (H4) bulbs replaced by a qualified technician. Serious personal injury
may result from improperly performed work.
x Never open or close the engine hood if steam or coolant is escaping. Hot steam or coolant
can cause serious burns. Always wait until you no longer see or hear steam or coolant
escaping from the engine.
x Always let the engine cool down completely before carefully opening the hood.
x Hot parts of the engine and the exhaust system will burn skin on contact.
x When the engine has cooled down and you are ready to open the hood:
– Firmly apply the parking brake and shift the transmission into Park (P) (automatic) or
Neutral (manual only).
– Take the vehicle key out of the ignition.
– On vehicles with Keyless Access, make sure that the remote control vehicle key is out
of range of the vehicle and that the vehicle cannot be started by depressing the starter
button..
– Always keep children and others away from the engine compartment and never leave
them unsupervised.
x The engine coolant system is under pressure when the engine is hot. Never unscrew the
coolant expansion tank cap when the engine is hot. Hot coolant can spray out and cause
severe burns and other serious injuries.
– Turn the cap slowly and very carefully in a counterclockwise direction while applying
light downward pressure on the top of the cap.
– Always protect your face, hands, and arms from hot escaping coolant or steam by
covering the cap with a large, thick rag.
x Never spill fluids on the engine or exhaust system when refilling. Spilling fluids onto hot
parts of the engine or exhaust system can cause a fire.

WARNING
High voltage systems in the engine compartment can cause electrical shocks or even
electrocution, severe burns, other serious injuries, and even death!
x Never short-circuit the electrical system. Be especially careful when using jumper cables.
The vehicle's battery could explode!
x To reduce the risk of electrical shock and personal injury while the engine is running or
being started:
– Never touch ignition cables. Never touch other components of the high voltage
electronic ignition system.
– Never touch the wiring of the HID – High Intensity Discharge (Xenon) headlights.
x Read and heed the important information and warnings on cleaning the engine
compartment.or! Bookmark not defined., Cleaning the engine compartment
WARNING
Moving parts in the engine compartment can cause serious personal injury on contact.
x Never reach into the area around or touch the radiator fan. Contact with the blades can
cause serious personal injury. Always remember that the radiator fan is temperature-
controlled and can come on suddenly even when the engine has been switched off for a while
and the key has been removed from the ignition.
x If you have to perform a check or repair when the engine is running, there are more risks
from the rotating parts, such as the drive belts, alternator, radiator fan, etc., and from the
high-voltage ignition system. Always use extreme care.
– Always make sure that jewelry, loose clothing and long hair do not get caught in
rotating engine parts. Before starting any work remove your jewelry, take off your necktie,
tie back and cover your hair, and do not wear clothing that can hang down and get caught
in moving engine parts.
– Always use extreme caution if the accelerator pedal has to be depressed to perform a
check. The vehicle will start to move even if the parking brake is on.
x Never leave any objects in the engine compartment, for example cleaning rags and tools.
Objects left behind can cause malfunctions, engine damage, and even fires.
WARNING
Operating fluids and some materials in the engine compartment can catch fire easily, causing
burns and other serious personal injuries!
x Never sm/+e near the engine compartment.
x Never work next to open flames or sparks.
x Never pour or spill operating fluids or other flammable liquids on the engine. These fluids
can ignite on hot engine parts and cause injuries.
x If work on the fuel system or the electrical system is necessary:
– Always disconnect the 12 Volt vehicle battery. Make sure the vehicle is unlocked when
you disconnect the battery, or the alarm will go off. Never touch the electrical wiring of the
ignition system.
– Never work near heaters, water heaters, or other open flames.
x Always have a functional, approved fire extinguisher nearby.

NOTICE
When changing or topping off fluids, make sure that you pour the fluids into the correct
reservoirs. Adding the wrong type of operating fluids will cause serious malfunctions and
engine damage.
Fluid leaks and spills are harmful to the environment. Regularly check the ground underneath
your vehicle for this reason. If you find spots of oil or other fluids, have your vehicle checked by your
authorized Volkswagen dealer or authorized Volkswagen Service Facility. Dispose of leaked operating
fluids properly.
Warning light

Opening the engine hood
x Before you open the hood, make sure that the windshield wiper arms are resting on the windshield
⇒ .
x Open the driver door and pull the inside hood release lever in the direction of the arrow ⇒ fig. 114
A. The engine hood is released from its latch by a spring ⇒ .
x Push the outside hood release lever*(arrow) and lift the hood all the way up.
x Pull the hood support out of its bracket in the direction of the arrow ⇒ fig. 115 A and insert it into
the opening in the hood*(arrow).
Closing the engine hood
x Lift the hood slightly ⇒ .
x Take out the hood support and clamp it in place in its bracket A.
x Lower the engine hood by hand until it is about 8 in. (20 cm) above its latch and then let it drop into
place to latch it. Do not push down on it afterwards!
If the hood does not close completely, open it again and close it properly.
When the hood is properly closed, you can see that it fits flush with the other body parts. The indicator
light in the instrument cluster display will go out..
WARNING
If the hood is not closed properly, it could fly up and block your view while you are driving.
This can lead to a crash and serious personal injuries.
x After closing the engine hood, check that the hood release lever is properly latched into
the hood latch. The engine hood must be flush with the surrounding auto body parts.
x If you ever notice that the hood latch is not properly secured when the vehicle is moving,
stop at once and close it.
x Never let anyone get in the way of the hood when closing it.
NOTICE
x Make sure the windshield wiper arms are resting on the windshield before you open the
hood. Otherwise, the windshield wipers and the hood may be damaged.
x Always put the windshield wiper arms down against the windshield before driving the
vehicle.
NOTICE
Before opening or closing the engine hood, make sure there is enough room to do so, for
example when the vehicle is in a garage.

The engine cooling system is filled at the factory with a mixture of specially conditioned water and at
least 40 percent of Volkswagen engine coolant additive G 13 (TL-VW 774 J). This engine coolant
additive is pink.
This mixture provides antifreeze protection down to -13 °F (-25 °C). It also helps to protect the light
alloy parts in the engine cooling system against corrosion. In addition, the mixture helps prevent
calcium deposits and increases the boiling point of the engine coolant.
To protect the engine, the mixture must always contain at least 40% coolant additive even in warm
weather or climates where antifreeze protection is not needed.
If more antifreeze protection is needed for climate conditions, the percentage of coolant additive can
be increased. However, the coolant additive percentage must never be more than 60%; otherwise,
antifreeze protection is reduced and the ability of the mixture to cool the engine is also reduced.
When adding engine coolant, use a mixture of distilled water and at least 40% coolant additive G 13
or G 12 plus-plus (TL-VW 774 G) for optimum corrosion protection ⇒ .
Do not mix G 13 with G 12 plus or G 11. Mixing these coolant additives together significantly reduces
corrosion protection ⇒  and can lead to engine damage that is not covered by any Volkswagen
Limited Warranty.
WARNING
Too little antifreeze protection in the engine cooling system can cause engine failure and
severe injuries.
x Always make sure there is enough of the correct coolant additive to provide proper
antifreeze protection at the coldest temperatures that can be expected where the vehicle will
be used.
x At extremely cold temperatures, the coolant could freeze, causing the vehicle to break
down. The heater would also not work, and vehicle occupants could be without protection at
subfreezing temperatures.
NOTICE
Never mix original Volkswagen engine coolant additives with other additives not approved by
Volkswagen. Mixing Volkswagen coolant additives with coolant additives made by other
manufacturers can seriously damage the engine and the engine cooling system.
x If the fluid in the engine coolant reservoir is any color but pink, then G 13 was mixed with a
different engine coolant. If this is the case, the engine coolant must be replaced immediately.
Otherwise serious malfunctions or engine damage can occur!
Engine coolant and engine coolant additives can pollute the environment. Collect leaking
operating fluids and dispose of them properly in accordance with applicable environmental laws and
regulations.
.

Hot steam and hot engine coolant can cause serious burns.
x Never open the hood if you see steam or coolant escaping from the engine compartment.
Always wait until you no longer see or hear steam or coolant escaping from the engine.
x Always let the engine cool down completely before carefully opening the hood. Hot
components will burn skin on contact.
x When the engine has cooled down and you are ready to open the hood:
– Firmly apply the parking brake and shift the transmission into Park (P) (automatic) or
Neutral (manual only).
– Take the vehicle key out of the ignition.
– On vehicles with Keyless Access, make sure that the remote control vehicle key is out
of range of the vehicle and that the vehicle cannot be started by depressing the starter
button..
– Always keep children and others away from the engine compartment and never leave
them unsupervised.
x The engine coolant system is under pressure when the engine is hot. Never unscrew the
coolant expansion tank cap when the engine is hot. Hot coolant can spray out and cause
severe burns and other serious injuries.
– Turn the cap slowly and very carefully in a counterclockwise direction while applying
light downward pressure on the top of the cap.
– Always protect your face, hands, and arms from hot escaping coolant or steam by
covering the cap with a large, thick rag.
x Never spill fluids on the engine or exhaust system when refilling. Spilling fluids onto hot
parts of the engine or exhaust system can cause a fire. Under some conditions, the ethylene
glycol in engine coolant can catch fire.
NOTICE
x Use distilled water only when adding coolant! All other types of water contain chemical
compounds that can cause extensive corrosion damage to the engine. This can even lead to
engine failure. If you have added non-distilled water, take the vehicle immediately to an
authorized Volkswagen dealer or an authorized Volkswagen Service Facility to have the
coolant system drained, flushed, and refilled completely with the proper coolant.
x Refill engine coolant only up to the top edge of the marked fill range . Excess engine
coolant may be forced out of the engine cooling system when it gets hot and cause damage.
x In the case of significant engine coolant loss, refill engine coolant only when the engine is
completely cooled down. Significant engine coolant loss is a sign of leaks in the cooling
system. Have the engine cooling system checked immediately by an authorized Volkswagen
dealer or an authorized Volkswagen Service Facility. Otherwise the engine may be damaged!

WARNING
Working on the batteries or the electrical system in your vehicle can cause serious acid
burns, fires, explosions, or electrical shocks. Always read and heed the following WARNINGS
and safety precautions before working on the batteries or the electrical system.
x Before working on the electrical system, always switch off the ignition and all electrical
consumers and disconnect the negative (-) cable from the standard 12 Volt battery.
x When you change a light bulb, always switch off the light first.
x Always keep children away from battery acid and vehicle batteries in general.
x Always wear eye protection. Never let battery acid or lead particles come into contact with
your eyes, skin, or clothing.
x Sulfuric battery acid is very corrosive. It can burn unprotected skin and cause blindness.
Always wear protective gloves and eye protection. To reduce your risk of injury, never tilt the
batteries, as this could spill acid through the vents and burn you.
x If you get battery acid in your eyes or on your skin, immediately rinse with cold water for
several minutes and then get immediate medical attention. If you swallow any battery acid,
get medical attention immediately.
x When disconnecting the batteries from the vehicle electrical system, always disconnect
the negative cable (-) first and then the positive cable (+).
x Always switch off all electrical consumers before reconnecting 12 Volt batteries.
Reconnect the plus cable (+) first and then the negative cable (-). Never reverse the polarity of
the connections. This could cause a fire.
x A highly explosive mixture of gases is given off when the battery is being charged.
x Do not sm/+e and avoid fires, sparks, and open flames when working. Never create sparks
or electrostatic charges when handling cables and electrical equipment. Never short circuit
the battery terminals. High-energy sparks can cause serious personal injury.
x Never use or attempt to charge a damaged or frozen battery, or a battery that was frozen
but has thawed. Charging a frozen or thawed battery could cause explosions and chemical
burns! Replace damaged or frozen vehicle batteries immediately. A dead battery can freeze at
temperatures around +32 °F (0 °C).
x If the battery has a vent line or tube, make sure that it is properly connected to the battery.
WARNING
California Proposition 65 Warning
x Battery posts, terminals, and related accessories contain lead and lead components,
chemicals known to the State of California to cause cancer and reproductive harm. Wash
your hands after handling.
NOTICE
x Do not expose the vehicle battery to direct sunlight for an extended period of time as
ultraviolet rays may damage the battery housing.
x If the vehicle is left standing in the cold for a long time, protect the vehicle battery from
freezing. A battery will be permanently damaged by freezing.
Emergency starting and starting the engine with a very weak vehicle battery or after the vehicle
battery has been replaced may change or delete system settings (including time, date, personal
convenience settings, and programming). Check the settings and correct as necessary once the
vehicle battery has built up a sufficient charge.