97 Jetta Electrical Relay Diagram

Updated: 10-May-20

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Fuse & Relay Panel

The Bentley Service Manual has numerous errors in its list for relays and fuses. Most of those errors have been corrected here! However, it's wise to verify your relays using the relay part numbers listed below, especially for the 1980-1982 cars. The fuse/relay panel is located under the dash, driver's side, behind the kneebar. 1980-1982 fuse/relay panel part number: 171941821C 1983-1993 fuse/relay panel part number: 171941821D IMPORTANT NOTES: Fuse amperage: Green = 30 ; Yellow = 20; Blue = 15; Red = 10 . 1980-1982 Cabriolets use ceramic fuses; their amperage is listed on the diagram. 1980-1982 fuel pump relay: Originally installed in position L; due to a recall, the relay should have been moved to position 1 with a wiring loom bridge to position L. If your car has factory-installed heated seats, the relays for this option are under each front seat. If your car has a factory-installed 2-stage after-run cooling fan system ('88+), the relay for this fan is mounted to the left front fender. If your car has factory-installed power windows, there is a control unit beneath the dash on the passenger side. If your car has a factory-installed power top, there is a covered thermo-fuse above the relay panel. If your car has factory- or dealer-installed daytime running lights, there is most likely a relay attached to the top of the panel (not shown in the diagrams). ALL 1983-1993 Cabriolets are CE1

Relay Part Numbers

Relay part numbers, both original and replacement (including aftermarket where available), are now in a PDF, which also contains relay pin diagrams. Click here for the relay part number guide.

Ground Locations

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Wires

Warm wires Warm-to-the-touch wires are not at all unusual in these cars, due, in part, to the way they were wired at the factory. However, wires that become so warm or hot that they melt their insulation and/or smoke are cause for concern.  An overly warm wire is indicative of a circuit with high resistance.  This high resistance can be caused by various issues: bad ground connections, poor wire connections, faulty switch, faulty relay, etc. Wiring Diagrams Wiring diagrams can be found in the Bentley Service Manual as well as the Haynes Repair Manual.  NOTE: Those with 1986 Cabriolets should follow both the 1986 and the 1987 Bentley main wiring diagrams; much, but not all, of the wiring in a 1986 resembles the 1987 diagrams and the latter diagrams are easier to read.

Voltage Drop

Voltage drop is a common malady on Cabriolets due to a poorly designed electrical system. Voltage drop can be witnessed on the VDO volt gauge with the engine running: When turning on the headlights, for instance, the volts will drop from 14 down to 12 (the drop is actually more severe when reading the voltage at the battery, then at the headlight; this is because the volt gauge is not 100% accurate); the volt gauge needle will also bounce in rhythm with the turn indicators. If the charging system is in good working order and all ground wires/connections are in good shape, this is nothing to really worry about.  However, to combat voltage drop (and to increase headlight output), install headlight relays, clean all ground contacts and replace ground cables. Voltage readings (using a DVOM at the battery, not the in-car VDO gauge): Key-off battery voltage should be 12.6V with a surface charge; 12.3V without a surface charge. Charging voltage should be 12.8V - 14.7V.

Connecting the OBD Diagnostic Tool

Under the shift boot, towards the front. NOTE: Only Cabriolets equipped with Digifant I engines have the OBD I diagnostic port; furthermore, an OBD II diagnostic tool cannot be used to pull fault codes from an OBD I system unless it has an adapter!

Power Windows

Power Windows Don't Work (under construction) Step 1 Check fuse #17, and the fuse in relay position 17.  Fuses okay? Yes: Proceed to step 2.  No: Replace blown fuse(s). Step 2 Check for voltage at the power window control unit (located beneath the dash, passenger side; key to battery-on position).  Is there voltage?  Yes: Proceed to step 3.  No: Remove the control unit and check for broken wires, broken internal connections, melted wires/connectors, water.  If there is water intrusion: A) dry the control unit thoroughly; B) reseal the air plenum in the rain tray.  If the control unit is still unresponsive or has melted wires, you'll need to buy a new/used one (part #191959875); and make sure the fuses are good and of proper amperage. Step 3 Check for voltage at each window switch.  Is there voltage?  Yes:  No: Step 4 Please refer to this thread and/or this thread and/or this thread on VWvortex for additional info.

Lights

Reverse Lights Do Not Work If the fuse/relay and bulbs are okay, replace the reverse (back-up) light switch located on top of the transmission (on automatics, the switch is connected to/near the shift lever). To test the reverse light switch: Disconnect the electrical plug, jump the black and black/blue wire terminals, turn the ignition switch to the battery-on position. If the lights turn on, the switch is faulty. Headlight Types Click here to download headlight types document Headlight Relays Whether you are upgrading your headlights or not, it is a very wise idea to relay the headlights.  The stock headlight wiring uses paltry 16 gauge wires, uses the headlight switch as a power source, and contains lengthy wire runs, all of which cause resistance and, ultimately, voltage drop at the headlights thereby reducing each lamp's luminosity.  Adding relays powers the headlights directly from the battery/alternator, will reduce voltage drop in the electrical system, will extend the life of the alternator, headlight switch and ignition switch, will increase the light output giving you whiter & brighter light, and will reduce the chances of the headlight switch overheating. DIY headlight relay guide Concept1 headlight relay harness 4Crawler headlight relay harness LMC Truck headlight relay harness (part #47-3660 36-3580; requires splicing if you have the dual-round grille) A standard Halogen sealed-beam headlamp produces 100% of its light output at 12.8 volts (or 13.2 volts in Europe) or above.  Take a voltage reading at one of your headlights.  What does your meter read?  My meter read 10.86 volts at each lamp, lo-beam.  Using voltage drop figures found on the Web, at 10.86 volts, each of those headlamps was producing less than 53% of their possible light output.  After adding relays to the headlight circuit, each headlight's voltage jumped up to 13.36 volts, which means the lamps are now producing 100% of their possible light output. Further information regarding headlight wiring, voltage drop, adding relays, etc. can be found at Daniel Stern Lighting. Headlight Switches Three different headlight switch types were used in 1981+ Cabriolets.  If you're replacing the switch, use the information below to ensure you're buying the correct one!  For example, AutohausAZ lists the 321-K switch for a 1990 Cabriolet, which is the wrong one!  (Click on the linked part numbers to see examples.) Part #321941531G 1981 through 1986 Same switch as below, but with old light symbol (i.e. the two switches are interchangeable) Part #321941531K 1987 to mid-1989 (up to VIN K-009000) Same switch as above, but with modern light symbol (i.e. the two switches are interchangeable) Part #323941531G Mid-1989 through 1993 (from VIN K-009001) Part #323941531H Canadian Cabriolets with Daytime Running Lights (from VIN K-011306) Headlight switch terminal translations (thanks to Andrew K.): TFL = Daytime Running Lights (DRLs) NSL = Rear Fog Lamp SRA = Headlight Cleaning System City Lights If you are installing city lights on a North American Cabriolet, wire the lights to the stock wiring based on how you want the lights to be used. Stock wiring in the car: Black = turn signal Gray = parking/running light Brown = ground If you're installing Euro bumper lights that include city lights, you'll need to splice the two ground wires together prior to wiring them to the car's brown ground wires. Disabling Day-time Running Lights Canadian Cabriolets built from 1990-1993 have day-time running lights (DRLs) from the factory, as Canadian law requires DRLs.  If, for whatever reason, you want/need to disable the factory DRL system:Pull the headlight switch and place electrical tape over the TFL pin; reinstall switch.  If your switch does not have a wire going to the TFL pin, or is without a TFL pin: Your car may have hard-wired day-time running lights (DRLs) from the factory.  To disable DRLs on these cars (thanks to Rob for the info): Locate the yellow 20-gauge wire on the back of the headlight switch; either push/pull it out of the harness connector, or cut it and cap/tape it off.  You can also disconnect the same yellow 20-gauge wire from the A-21 pin on the back of the relay panel. Installing LEDs Want to brighten up your lights, or change their color, or reduce the power drain?  Replace the original incandescent bulbs with LEDs.  LEDs have come a long way in the last several years.  Rather than buying LEDs and the appropriate resistors, you can now buy LEDs that include resistors for a plug-and-play application in most instances. Download the DIY Guide for a how-to.  Click here for a breakdown of what you need.

Engine Sensors, Senders & Switches

Windshield Wipers

Adding variable wiper option Look for relay #357955531 or #3B0955531 (has a printed 99. on it in OEM form) found in the following vehicles: 1995-1997 Cabrio & Eurovan 1992-1994 Corrado SLC 1993-1996 Golf/Jetta 2.0L 1990-1997 Passat Or, order a new one from an auto parts store.  It is a plug and play swap; replace your existing relay with the new one. To program the variable feature: "Pull the lever into the intermittent position, and, as the wiper does it's sweep, click back into the stop position, if you want a 3 second gap, then wait 3 seconds, and click back into the intermittent position. Bam, you just programmed a 3 second timing." If ^that doesn't work: "Pull the stalk towards you to (for windshield washers) while the wipers are set to intermittent. This initiates the timer. If left alone at this point it will default to the 20s interval. Pull the stalk towards you again and it will set the timer to that interval, anywhere from 5 to 20 seconds."

Horns

Where are the horns? The dual-tone horns are mounted to a bracket, which is mounted to the front left frame rail.  Click here for a photo.

Rev Limiters

The K-Jetronic Cabriolets have a rev limiter built into the fuel pump relay.  When the rpm reaches the built-in limit, the fuel pump relay shuts off the fuel pumps.  This is a safety feature; however, the relay can be replaced with a "no-rev" or "hi-rev" version so that the cut-off point is eliminated or increased to approximately 7500 rpm.  Digifant Cabriolets have a rev limiter built into the ECU and cannot be altered. Fuel Pump Relay Part Numbers and Replacement Equivalents (K-Jetronic only) - see fuel system page for additional info NOTE: A large batch of KAE relays were made with the wrong circuitry; if you have purchased these relays and the car is still having fuel issues, open the relay to check its circuitry).  Click here for a visual.

Panel Diagrams
1980 - 1982 K-Jetronic	1983 - 1984 K-Jetronic	1985 - 1987 K-Jetronic	July 1987 - 1989* K-Jetronic	1990 - 1993 Digifant
Diagram Actual Panel	Diagram Actual Panel	Diagram Actual Panel	Diagram Actual Panel	Diagram Actual Panel
Click here for a manual supplement containing relay & fuse diagrams, relay panel pin-out schematics, and a guide to reading current flow wiring diagrams. * Up to 1993 outside North America.

1980 - 1986	1987 - 1989	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 A/C compressor to battery (or engine block) Ignition Control Unit to battery Ground locations: Fuse/relay panel Steering column Cold-start valve (K-Jetronic only) Trunk, rear left and right Dash wiring harness Ignition distributor	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 (K-Jetronic only) Trunk, rear left and right Dash wiring harness Engine bay, front left and right ('88+)	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+)
Please use the Bentley Service Manual wiring diagrams for complete wire routing for your particular car. Keep your electrical system tip-top by cleaning your electrical connections! K-Jetronic photos of main grounds. Digifant photos of main grounds.

Oil System	Part Number	Function	Location
Oil temperature gauge sender single, white nail-head connector	049-919-563A	Sends oil temp to gauge	Top of oil filter flange
Oil pressure switch & gauge sender 0.3 bar	035-919-561-	Warns, with a flashing light, when oil pressure falls to near zero and sends pressure reading to center console bar gauge	Left side of cylinder head*
Oil pressure switch 1.8 bar ~ 1 pin, white	056-919-081E	Warns, with flashing light and buzzer, when oil pressure falls too low at higher (2000+) rpm	Top of oil filter flange*
Cooling System	Part Number	Function	Location
Coolant temp gauge sender (K-Jetronic) single, black nail-head connector	049-919-501	Sends coolant temperature to dash gauge and warning system	Top of upper radiator hose flange on cylinder head (1.8L)
Coolant temp gauge sender (Digifant) black connector	251-919-501D	Sends coolant temperature to dash gauge and warning system	Coolant flange on cylinder head
Coolant temp sensor (Digifant) blue connector	025-906-041A	Provides an engine temp input to the Digifant control unit that is used to boost fuel delivery to improve cold-running driveability	Coolant flange on cylinder head
Coolant level sensor (Digifant)	251-919-372A	Senses level in coolant expansion tank; when the level is too low, the sensor sends a signal to the warning light in the instrument cluster	In coolant expansion tank
Cooling fan thermo switch 95-84°C, 2-pin, single-speed fan 95-84°C/102-91°C, 3-pin, 2-speed fan	191-959-481B (2-pin) 321-959-481E (2-pin) 191-959-481C (3-pin)	Switches the cooling fan on/off	Lower, left corner of radiator
Oxygen sensor thermo switch (K-Jetronic lambda) 1980-1983	056-919-369AA (25°C)	Bypasses O2 sensor input during cold running for open loop fuel enrichment based on coolant temperature Note: Original switch is not replaceable; original assembly is NLA. Click on image link at right for replacement details.	Left side of cylinder head in one of the heater hoses
OXS/Lambda probe thermo switch (K-Jetronic lambda) 1984+	035-919-369D (25°C) 027-919-369B (45°C)	Bypasses O2 sensor input during cold running for open loop fuel enrichment based on coolant temperature (25°C  is standard; 45°C is for cold climates)	Underside of upper radiator hose flange on cylinder head
Thermostat	056-121-113D (87°C)	Controls coolant flow	Inside the lower radiator hose flange on the water pump housing
Thermo-time switch (K-Jetronic) brown two-pin connector	043-906-163A	Controls operation of cold-start valve when engine is cold based on coolant temperature	Top of upper radiator hose flange on cylinder head
Electrical System	Part Number	Function	Location
Reverse light switch & up-shift indicator manual transmission	171-919-823A (4-speed) 171-919-823 (5-speed, 1.7L) 191-919-823 (5-speed, 1.8L)	Turns back-up lights on when transmission is put into reverse; disables up-shift system, if installed, when in 5th or reverse gears (see guide for specifics)	On top of transmission bell housing
Reverse light switch manual transmission  - 1980 (USA), 1988+	020-945-415A	Turns back-up lights on when transmission is put into reverse (see guide for specifics)	On top of transmission bell housing
Reverse light switch manual transmission  - 4-speed (Europe)	084-941-521 (1.1L, 1.3L) 085-941-521 (1.5L, 1.6L, 1.8L)	Turns back-up lights on when transmission is put into reverse (see guide for specifics)	On top of transmission bell housing
Reverse light switch (aka park-neutral safety switch) automatic transmission	311-927-147B (to late '90) 155-927-147 (from late '90)	Turns back-up lights on when transmission is put into reverse; prevents car from starting unless gearshift is in Park or Neutral	Base of shift lever in passenger compartment
Brake light switch up to chassis E-22076	113-945-515H  (2-pin) 113-945-515G  (3-pin)	Turns the brake lights on any time the brake pedal is pressed; works via brake fluid pressure	On/in brake master cylinder
Brake light switch from chassis E-22077	191-945-515B	Turns the brake lights on any time the brake pedal is pressed; works via electric signal	On brake pedal
Cruise control cut-out switch manual transmission	811-907-343B	Turns off cruise control system when clutch pedal is pressed; wired into brake light switch	On clutch pedal
Cold-running enrichment vacuum switch (K-Jetronic) 1988-1989	171-919-825B	Interrupts cold-running enrichment above idle	At front of intake manifold off of the vacuum line going to brake master cylinder
Cooling fan after-run thermo switch 1988+	191-919-521B (K-Jet, blue) 191-919-521D (Digi, yellow)	Controls operation of 2-stage cooling fan after-run system based on engine bay temperature (K-Jet: 110°C; Digifant: 100°C). Note: Replacements may not be same color; just be sure that the temp rating is the same.	Back side of cylinder head cover between #3 and #4 cylinders
Idle switch (K-Jetronic) aka Idle Boost Valve	026-906-283C (no A/C) 026-906-283C (A/C)	Boosts idle speed when rpm's drop to near the stall point; boosts idle speed when A/C compressor engages	Mounted to right strut tower
Idle switch (Digifant) aka Idle Stabilizer Valve	037-906-457D	Regulates and stabilizes idle speed	Between valve cover and intake manifold
Full-throttle switch aka enrichment switch, wide open throttle switch	067-133-093 (JH to 1990) 067-906-028 (JH from 1991) 037-133-093D (2H)	Signals control unit with a signal when the throttle valve is fully open for full-throttle enrichment	On throttle body
Mechanical air flow sensor (K-Jetronic)		Measures intake air flow which then operates the control plunger in the fuel distributor for the proper metering of fuel	Under rubber boot on air filter housing, next to the fuel distributor
Electronic air flow sensor (Digifant)		Measures intake air flow; signals from this sensor and the ignition distributor are sent to the ECU for the proper metering of fuel	Side of intake air filter housing
Oxygen sensor	035-906-265B ~ K-Jetronic 034-906-265F ~ K-Jet '88+ 030-906-265K ~ Digifant II 030-906-265G ~ Digifant I	Sends signal of combustion efficiency to the ECU for fine-tuning of the air-to-fuel mixture (each fuel injection system processes the signals differently; consult Bentley Manual for further info)	Mounted in exhaust manifold or catalytic converter
Up-shift indicator vacuum switch manual transmission, 1981-1987	171-919-825B	Relays engine load to the up-shift control unit	Connected to vacuum line to/from distributor
Knock sensor (Digifant)	054-905-377A	Detects harmful detonation in combustion chambers; when it does, ignition timing is retarded in small increments until harmful detonation stops	Front of engine block
* Bentley Service Manual has this gauge's location listed incorrectly. Table is for reference only; please verify what your car has before ordering parts.

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Fuse & Relay Panel

Relay Part Numbers

Ground Locations

Wires

Voltage Drop

Power Windows

Lights

Sensors, Senders, Switches

Windshield Wipers

Horns

Rev Limiters

Bulb Cross-reference

Installing LEDs

Disabling DRLs

Adding Headlight Relays

Lights-on Warning Relay

Reverse Light Switches

Connecting OBD Scan Tool

Increasing Alternator Output

Refurbing Dash Switches

Diagnosing Electrical Issues

Installing CE2 MFA Cluster

Aiming the Headlights

Side-markers to Turn Signals

Installing Fog/Auxiliary Lights

Installing Mk3 Courtesy Light

Fixing Slow Wipers

Variable Speed Wipers

Wiper Motor Swap

DIY Power Window Controller

Instrument Cluster Diagrams

How to Read Wiring Diagrams

Source: http://www.cabby-info.com/electrical.htm

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