Volkswagen New Beetle. Manual - part 2084

z

Unbolt front exhaust pipe bracket on subframe -arrows- and unhook. 

Fig. 32: Removing Front Exhaust Pipe Bracket Bolts (Vehicles With 1.9L TDI Engine) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continued for all vehicles 

z

Support subframe using engine/transmission jack V.A.G 1383 A.  

z

Remove hex bolts -1-.  

z

Remove hex bolts -2- and -3-.  

z

Lower subframe using engine/transmission jack V.A.G 1383 A.  

z

Remove power steering gear bolts -1-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 33: Installing Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Take power steering gear out to right side.  

Installing 

NOTE:

z

Use new sealing rings for hose/line connections.  

z

Coat steering gear seals with lubricant, e.g. soft soap, before installing 
steering gear.  

z

After installing the steering gear to the universal joint shaft make sure that 
the seal lies against the cover without kinking and that the opening to the 
footwell is correctly sealed. Otherwise noises may be created and/or allow 
water to pass through.  

z

Make sure sealing surfaces are clean.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

z

Determine center position on steering rack. See PLAY, SECURITY AND BOOTS ON TIE ROD 
ENDS, CHECKING  

z

Install power steering gear onto subframe.  

Threaded sleeve -1- must seat in hole on subframe. 

Fig. 34: Identifying Power Steering Gear Threaded Sleeve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Install in reverse order. 

TIGHTENING TORQUE (POWER STEERING GEAR) 

Fastener/location

Torque settings

Power steering gear to subframe

(1)

20 N.m (15 ft lb ) plus an additional 1/4 turn 90°

Subframe to body

(1)

100 N.m (74 ft lb) plus an additional 1/4 turn 90°

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

POWER STEERING GEAR, ASSEMBLY OVERVIEW 

The power steering gear is not serviceable. If problems in the unit are suspected, determine the cause using 
pressure and leak tests. If a malfunction exists replace power steering gear. 

z

Part numbers are listed here for reference only. Always check with your parts department for the latest 
information.  

1. Splash plate 

z

Checking: See PLAY, SECURITY AND BOOTS ON TIE ROD ENDS, CHECKING 

Modification: 

Modified tie rod ball joints. See TIE ROD BALL JOINTS, MODIFIED 

z

Application see Parts catalog  

Universal joint to steering gear

(1)

30 N.m (22 ft lb)

Banjo bolt to steering gear M14 x 1.5

38 N.m (28 ft lb)

Banjo bolt to steering gear M16 x 1.5

45 N.m (33 ft lb)

Pendulum support to transmission

M10 x 70

50 N.m (37 ft lb)

M10 x 30

50 N.m (37 ft lb)

Tie rod to steering arm

(1)

45 N.m (33 ft lb)

(1)

ALWAYS use new bolts and/or nuts.

NOTE:

z

Replace self-locking nuts and bolts. Welding and straightening work on 
steering components is not allowed.  

z

Do not re-use any fasteners that are worn or deformed in normal use.  

z

Some fasteners are designed to be used only once, and are unreliable and 
may fail if used a second time. This includes, but is not limited to, nuts, 
bolts, washers, circlips and cotter pins. Always follow the 
recommendations in this manual. Replace these fasteners with new parts 
where indicated, and any other time it is deemed necessary by inspection. 

z

Do not attempt to weld or straighten the steering components or load 
bearing components of the suspension.  

z

To grease the rack only use steering gear grease Part No. AOF 063 000 04. 

z

Type of oil: Hydraulic oil Part No. G 002 000  

z

Oil system capacity: 0.7 ... 0.9 ltr (11.8 15.2 oz.).  

NOTE:

The following list refers to items in Fig. 35 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle