Volkswagen New Beetle. Manual - part 2067

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Clamp off suction line with hose clamps -3094-.  

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Open spring-type clip -1- and disconnect suction line. 

Fig. 70: Disconnecting Power Steering Pump Suction Line (Vehicles With Power Steering Pump In 
Upper Section) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Unscrew banjo union bolt -2-. 

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Seal pressure line/hose with a plastic bag or similar.  

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Remove hex bolts -1- and -2-.  

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Remove pump. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 71: Removing Power Steering Pump Bolts (Vehicles With Power Steering Pump In Upper 
Section) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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Fill power steering pump with hydraulic oil. 

Fill pump with oil via suction union. 

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Turn hub by hand until oil emits from pressure side.  

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Install power steering pump into bracket and tighten bolts to 25 N.m (18 ft lb).  

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Install suction line and spring-type clip. 

The mark -arrow A- must align with casting seam -arrow- 

The spring-type clip must close off mark -arrow B-.

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 72: Installing Suction Line And Spring-Type Clip (Vehicles With Power Steering Pump In 
Upper Section) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install new sealing rings onto Banjo union bolt.  

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Tighten Banjo union bolt to 38 N.m (28 ft lb). 

The remainder of the installation is the reverse of removal. 

POWER STEERING PUMP WITH HYDRAULIC LINES/HOSES, ASSEMBLY OVERVIEW 

I. Vehicles with power steering pump in upper section  

II. Vehicles with power steering pump in lower section  

NOTE:

The following list refers to items in Fig. 73 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

1. Reservoir 

Disassembling and assembling instructions. See DISASSEMBLING AND ASSEMBLING 
RESERVOIR 

2. Securing pressure hose/line 

Vehicles with TDI engine and A/C 

Disassembling and assembling instructions. See SECURING PRESSURE LINE AND SUCTION 
HOSE ON VEHICLES WITH TDI ENGINE AND A/C 

3. Pressure hose/line mounting 

Vehicles with 2.0 ltr. and TDI engine without A/C 

Vehicles with 1.8 ltr. turbo engine with A/C 

Disassembling and assembling instructions. See SECURING PRESSURE LINE AND SUCTION 
HOSE ON VEHICLES WITH 2.0 LTR., & TDI ENGINE WITHOUT A/C AND VEHICLES 
WITH 1.8 LTR. TURBO ENGINE AND A/C 

Vehicles with 2.0 ltr. engine with A/C 

Vehicles with 1.8 ltr. turbo engine without A/C 

Disassembling and assembling instructions. See SECURING PRESSURE LINE AND SUCTION 
HOSE ON VEHICLES WITH 2.0 LTR. ENGINE AND A/C . 

4. Securing suction hose  

5. Pressure hose/line mounting 

On 5-speed manual - transmission 02J 

Disassembling and assembling instructions. See SECURING PRESSURE LINE ON 5-SPEED 
MANUAL TRANSMISSION 02J . 

On 6-speed manual transmission 02M 

Disassembling and assembling instructions. See SECURING PRESSURE LINE ON 6-SPEED 
MANUAL TRANSMISSION 02M . 

6. Power steering pump 

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Checking delivery pressure. See POWER STEERING PUMP, RESERVOIR, HYDRAULIC 
LINES .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle