Installation Instructions for Volkswagen Beetle & Beetle Convertible
(Excludes R-Line and GSR Models)

Part Numbers:

• 24922
• 60354
• 77309

Wiring Access Location:

• PC3, PC4

Tools Required:

• Wrenches: 18mm, 11/16"

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed the towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Remove Existing Bolts:

   • Remove the existing M12 bolts from the driver and passenger-side frame rails. Retain these bolts for use in Step 4.

2. Install Carriage Bolts and Spacers:

   • Use the reverse pullwire method to insert the 7/16" carriage bolts and spacers into the frame rails as shown in Figure 2. Leave the pullwires attached.

3. Position Hitch:

   • Raise the hitch into position, feeding the pullwires through the rearward holes on the hitch.

4. Reinstall Existing Bolts:

   • Use the M12 bolts removed in Step 1 to attach the hitch through the forward holes.

5. Secure Fasteners:

   • Remove the pullwires and attach the 7/16" conical washers and hex nuts to the carriage bolts.

6. Tighten All Fasteners:

   • Torque all M12 CL10.9 fasteners to 92 Lb.-Ft. (120 N*M).
   • Torque all 7/16"-14 GR5 fasteners to 50 Lb.-Ft. (68 N*M).

Hardware List:

• (2) Carriage Bolts: 7/16"-14 x 2.00" GR5
• (2) Spacers: 0.25" x 1.00" x 3.00"
• (2) Conical Washers: 7/16"
• (2) Hex Nuts: 7/16"-14
• (2) Pullwires: 7/16”

Safety Notes:

• Regularly inspect all fasteners and the hitch ball to ensure they are securely tightened.
• If the hitch is removed, plug all holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always observe safety precautions and wear eye protection when working beneath the vehicle.
• Do not use a torch to cut access or attachment holes.

Drawbar:

• Drawbar Kit: 3593
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Additional Notes:

• Check the hitch frequently to ensure all fasteners remain tight.

Installation Instructions for T-Connector Trailer Wiring Harness

Product Information:

• Part Number: N118688
• Application: Volkswagen Beetle

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet (or Wrench)
• Drill with 3/32” drill bit
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Philips Head Screwdriver
• Test-Probe

Step-by-Step Instructions:

1. Access the Taillight Wiring Harness:

   • Open the rear tailgate.
   • Remove the trunk threshold, floor panels, and trays.
   • Set aside all components carefully to avoid damage.

2. Remove Rear Trim Panels:

   • Partially remove the interior trim panels on both the driver’s and passenger’s sides.
   • Remove any fasteners holding the panels in place.

3. Install Driver’s Side T-Connector:

   • On the driver’s side, locate the vehicle’s wiring connectors.
   • Carefully separate the connectors without breaking the locking tabs.
   • Insert the T-Connector with the yellow wire between the vehicle’s wiring harness.
   • Ensure all connectors are clean and fully engaged.

4. Route the Green Wire to the Passenger Side:

   • Route the T-Connector with the green wire beneath the threshold cover to the passenger side.
   • Repeat Step 3 on the passenger side by inserting the T-Connector with the green wire between the vehicle’s wiring connectors.

5. Ground the White Wire:

   • Locate a suitable grounding point on the driver’s side near the T-Connector.
   • Drill a 3/32” hole into clean, bare metal.
   • Attach the white wire with the provided eyelet and screw.

   Caution: Verify the area behind the surface before drilling to avoid damage or injury.

6. Mount the Black Box Module:

   • Find a flat surface on the driver’s side to mount the T-Connector’s black box module.
   • Use the provided double-sided tape to secure it in place.

7. Route the Power Wire:

   • Connect the red power wire from the black box to the black 12-gauge power wire using the yellow butt connector.
   • Route the black wire:
     • Either through an existing grommet to the vehicle’s exterior frame, or
     • Along the interior thresholds into the engine compartment.
   • Avoid areas with hot pipes, sharp edges, or moving parts.

8. Connect the Fuse Holder:

   • Cut the yellow fuse holder wire and attach the ring terminal to one end.
   • Secure the ring terminal to the positive battery terminal.
   • Use the yellow butt connector to connect the fuse holder to the black power wire.
   • Insert the provided 10-amp fuse into the fuse holder.

   Warning: Follow all safety precautions when working near the vehicle’s battery.

9. Test the Wiring System:

   • Reconnect the negative battery terminal.
   • Test the wiring system using a test light or by connecting a trailer.
   • Verify the operation of:
     • Running Lights
     • Left and Right Turn Signals
     • Brake Lights

10. Secure the Harness:

    • Use the provided cable ties to secure the wiring harness under the vehicle or along the thresholds.
    • Avoid pinching or cutting the wires during reassembly.

11. Reassemble Vehicle Components:

    • Reinstall the trunk trim panels, threshold cover, floor panels, and trays.
    • Store the 4-flat connector in the rear cargo area when not in use.

Specifications:

• Maximum Stop/Turn Lights: 2.1 amps per side
• Maximum Taillights: 7.5 amps

Safety Notes:

• Test the trailer wiring system before towing.
• Do not exceed the stated amperage ratings.
• Periodically inspect wiring and connections for signs of wear or damage.

Warnings:

• Avoid routing wires near hot pipes, heat shields, or sharp edges.
• Overloaded circuits can cause fires. Follow the specified amperage limits.

Technical Support:

For further assistance, contact the manufacturer’s support team.

Note: Store the 4-flat connector in the rear cargo area when not in use to prevent damage.