Volkswagen New Beetle. Manual - part 2096

Fig. 76: Identifying Pressure Line And Suction Hose (vehicles With 2.0 ltr. & 1.9L TDI Engine Without 
A/C And Vehicles With 1.8 ltr. Turbo Engine And A/C) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Securing pressure line and suction hose on vehicles with 2.0 ltr. engine and A/C 

1. Power steering pump 

z

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

z

Before installing fill with oil. See Note. See POWER STEERING PUMP, RESERVOIR, 
HYDRAULIC LINES  

2. Suction hose  

3. Spring-type clip  

4. Pressure line  

5. Banjo union bolt 

z

38 N.m (28 ft lb)  

6. Sealing rings 

z

Always replace  

7. Lock nut  

8. Mounting bracket  

9. Hex bolt 

z

22 N.m (16 ft lb)  

10. Hex bolt 

z

40 N.m (30 ft lb)  

11. Mounting bracket  

12. Cylinder block  

NOTE:

The following list refers to items in Fig. 77 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 77: Identifying Pressure Line And Suction Hose (2.0 ltr. Engine And A/C) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Securing pressure line and suction hose on vehicles with unit injector TDI engine 

1. Power steering pump 

z

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

z

Before installing fill with oil Note. See POWER STEERING PUMP, RESERVOIR, 
HYDRAULIC LINES  

2. Banjo union bolt 

z

38 N.m (28 ft lb)  

3. Sealing rings 

z

Always replace  

4. Pressure line  

5. Spring-type clip  

6. Sleeve 

z

For power steering pumps from the company Kayaba only  

7. Hex bolt 

z

22 N.m (16.2 ft lb)  

8. Clamp  

9. Suction hose  

10. Cylinder block  

11. Mounting bracket  

12. Hex bolt 

z

40 N.m (30 ft lb)  

NOTE:

The following list refers to items in Fig. 78 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

z

M10x25  

13. Hex bolt 

z

40 N.m (30 ft lb)  

z

M8x28  

14. Oil filter  

15. Transmission  

16. Hex bolt 

z

38 N.m (28 ft lb)  

Fig. 78: Identifying Pressure Line And Suction Hose (Vehicles With Unit Injector 1.9L TDI Engine) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Securing pressure line on 5-speed manual transmission 02J 

1. Pressure line  

2. Speed nut  

3. Mounting bracket  

4. Hex bolt 

z

22 N.m (16 ft lb)  

5. Mounting bracket  

6. Pressure hose  

NOTE:

The following list refers to items in Fig. 79 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 79: Identifying Securing Pressure Line On 5-Speed Manual Transmission 02J 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Securing pressure line on 6-speed manual transmission 02M 

1. Pressure line  

2. Hex nut 

z

22 N.m (16 ft lb)  

3. Mounting bracket  

4. Securing bolt on starter  

5. Hex bolt 

z

22 N.m (16 ft lb)  

6. Mounting bracket  

7. Hex nut 

z

22 N.m (16 ft lb)  

8. Mounting bracket  

NOTE:

The following list refers to items in Fig. 80 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle