Question about 2003 Volkswagen New Beetle Convertible

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Wiring on top of battery case looks to be melting

If you look at the top of the battery box on a 2003 new beetle 2.0 there are two flip up covers there are like sixe wires that look to be connected to the positive battey cable here the wire on the far left is melting the plastic . what is causing this?

wiring on top of battery case looks to be melting casing help!!!

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  • dbarnett1968 Mar 11, 2009

    my car is doing the same thing. do you have a stereo system installed other than the stock monsoon?



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The wire that is getting so hot may have gotten chaffed and shorted out. do you have aftermarket accessories connected ? They may be drawing too much amperage.

Posted on Sep 14, 2009


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The first black wire on the left seems extra hot on top of the battery under the cover while the vehicle is running. I noticed this after changing the battery , I first thought alternator problems, but the...

I had the same problem on my 99 Beetle. It is the wire that goes from the battery back to the battery to charge the battery. After several attemps to repair it correctly, I wound up cutting the wire and running it directly to the + side of the battery. No more problems. Hope this helps.

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Removing VW polo 2005 battery?

Removing a battery from a Beetle is a bit complex and tricky. I just changed the battery in a 2003 2.0 Beetle. However, the process is very similar in a TDI Beetle. You will need more than your standard generic tool set in order to complete this task. Your tool list needs to consist of a pair of pliers (prefer locking type), a # 20 TORX head screwdriver (You will also need this if you ever plan on changing the Beetle's internal dash pollen filter for the A/C. ), a 10 mm and 13 mm sockets, a long extension and a wobble or universal to allow flexibility in tight spaces, an allen socket for removing the power steering reservoir, and a small adjustable wrench or a 10mm to remove the battery cables. If you are changing the battery you might as well buy a new Air filter since you will need to remove the air box in order to replace the battery. If you do change the air filter you will need a phillips head screwdriver.

1. Pop the hood.
2. Remove the two 10 mm bolts that hold down the air filter box.
3. Undo the clamp that holds the large tubing to the air box using your pliers. Move the tubing away from the box.
4. Unclip hose attached to the back of the air box near the large hose (under it).
5. remove the small breather hose from the air box.
6. Pull air box up and out.
7. Remove snap on cover from top of battery.
8. Remove small snap on wiring cover from back of the battery covering.
9. Unbolt power steering reservoir (next to battery case).

10. Disconnect the battery cables. Positive side first.
11. Remove the 13 mm bolt at the base of the battery along with the hold down clamp.
12. Pull the top wiring away from the battery case and then slide the battery towards the engine.
13. Remove the plastic battery case.
14. Remove the battery

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2004 Volkswagen New Beetle

Remove the 13 mm bolt hold at the bottom side of the battery.
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You will find another bolt holding the power steering reservoir, take it out. then after pull it out , this won't be easy.
After replacing the battery the radio will go into safe mode and you will have to retrieve the radio code, and also reset the windows' one touch up and down programming.

Aug 18, 2008 | 2003 Volkswagen New Beetle Convertible

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2003 volkswagen beetle covertible quarter panel removal

I do not recommend this job unless you are a seasoned mechanic, VW dealership charges $1000 for a reason. They almost earn it on this one. but heres how it's done or how I did it any way. the complete job took me 4 hours and I been at this for 30 years. But a lot of this time was figuring out how it came apart. First, drop the top, pull up on seat bottom and remove it, remove center panel, remove 3 allen bolts at bottom on seat back and remove. headrests, they just pull off, raise top just enough to make hinged panels flip up. remove nut at top rear corner of side panel. you can see the back side of the nut and bolt it is on from the panels that flip up. Remove Nylon push lock rivet where seat belt goes through panel on rear, top, corner. Pull out on panel to release it, there is 5 or 6 nylon locks that just pull out of holes in the body. It will sound like your breaking it when the locks pop loose, or mine did. then lift to gain access to remove seat belt bolts and unplug flip panel motors. remove cable end from its clip. Pull seat belts through panel. Set panel a side. remove torx head bolt around oval panel that speaker is mounted on. unplug speaker and regulator and pull wire harness thru hole. remove 2 allen and 5 hex bolts at top where window would come out if it worked. pull up on plate and move rubber window seal to the side to remove plate. remove 2 nuts at bottom of regulator and one about half way up towards front, lift regulator and window up through top to gain access to 3 nuts that hold window to regulator, from the top lift window out first then regulator. Reverse to assemble it.

Aug 12, 2008 | 2003 Volkswagen New Beetle Convertible

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