Volkswagen New Beetle. Manual - part 2192

For work steps required after reconnecting battery, see Fig. 4 .

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Do not loosen or remove ground strap from body. Disconnect 
terminal from battery only.  

 

2003 Volkswagen New Beetle GLS 

2002-04 AUTOMATIC Diagnosis - New Beetle, 09G

  

Fig. 4: Reconnecting Battery Work Steps 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

NOTE:

If desired, print this page and use the table above as a checklist.

 

2003 Volkswagen New Beetle GLS 

2002-04 AUTOMATIC Diagnosis - New Beetle, 09G

  

TRANSMISSION 

When an automatic transmission is replaced the following fluid levels must be checked:  

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ATF in planetary gearbox and final drive. See SERVICING - A/T (09G) article.  

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Filling level and specification. See SERVICING - A/T (09G) article.  

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Do not run the engine or tow a vehicle with the transmission oil pan removed or when there is no ATF in 
transmission.  

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Secure torque converter to prevent it falling out when the transmission is removed.  

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Clean joints and connecting points thoroughly before loosening.  

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When installing the transmission ensure that the dowel sleeves between the engine and the transmission 
are seated correctly.  

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Place parts that have been removed on a clean surface and cover so that they are not soiled. Use foil and 
paper. Do not use fluffy cloths!  

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Only install clean components: Only unpack replacement parts immediately prior to installation.  

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Carefully cover opened components or seal them if the repair cannot be performed immediately.  

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Replace the transmission if any of the selector elements are scorched or burned.  

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A basic (default) setting must be performed each time the transmission is reinstalled.  

GASKETS, SEALS 

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Always replace O-rings, seals and gaskets.  

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After removing seals/gaskets etc. always check the contact surfaces on housings or shafts for burrs and 
damage and correct before reinstalling.  

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The open side of an oil seal faces toward the oil.  

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Before installing an oil seal moisten the outer surfaces and the sealing lip sparingly with ATF.  

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Moisten O-rings with ATF to prevent damage to the O-ring when installing.  

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Only use ATF in the areas of the ATF. Other lubricants will cause the hydraulic elements to malfunction. 

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After installing, check ATF level in planetary gearbox/final drive and correct levels as necessary. 

a. ATF in planetary gearbox and final drive. See SERVICING - A/T (09G) article.  

b. Filling level and specification. See SERVICING - A/T (09G) article.  

NUTS, BOLTS/SCREWS 

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Loosen and tighten the nuts, bolts/screws for securing the covers and housings in a diagonal sequence.  

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Do not cant particularly sensitive parts, e.g. valve body, and loosen and tighten in stages using diagonal 
sequence.  

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The torque settings indicated refer to the non-lubricated screws and bolts.  

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Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert 
bolts/screws with AMV 185 100 A1. 

 

2003 Volkswagen New Beetle GLS 

2002-04 AUTOMATIC Diagnosis - New Beetle, 09G

  

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All threaded holes where locking fluid is employed must be cleaned with a thread tap to remove remnants 
of locking fluid. Otherwise there is a danger that a bolt/screw will shear when reinstalling.  

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Always replace self-locking nuts and bolts/screws.  

VALVE BODY 

The valve body is allocated according to the transmission code. Check with local parts distributor for 
appropriate application. 

GUIDED FAULT FINDING, VEHICLE SELF-DIAGNOSIS AND MEASURING TECHNOLOGY 

Before servicing the automatic transmission, determine the cause of the malfunction as precisely as possible 
with the Vehicle Diagnosis, Test and Information System VAS 5051 and with the aid of "Guided fault finding", 
"Vehicle self-diagnosis" and "Measuring technology". 

ELECTRICAL/ELECTRONIC COMPONENT LOCATIONS 

COMPONENT IDENTIFICATION 

 

2003 Volkswagen New Beetle GLS 

2002-04 AUTOMATIC Diagnosis - New Beetle, 09G