Volkswagen New Beetle. Manual - part 2312

Removal & Installation

1. Remove cover from engine. With ignition switch turned off, disconnect negative battery cable. Remove

power steering reservoir from battery carrier. Do not loosen hoses. Secure power steering reservoir to
lock carrier. Remove battery. Remove battery carrier.

2. Pull intake hose (1) and connector (2) off mass air flow sensor. Remove bolts (3, 4 and 5). See Fig. 29 .

Remove complete air cleaner. Disconnect connector from speedometer sensor.

3. Remove electrical connections for solenoid valves (1), vehicle speed sensor (2), multifunction TR switch

(3) and transaxle vehicle speed sensor (4) at transaxle. See Fig. 12 . Unclip wiring harness from retainer
on transaxle and place to one side. Remove bracket for power steering pressure lines/hoses, with retainer
for wiring harness, from transaxle.

4. Position selector lever in "P" position and press selector lever cable (1) off selector shaft lever (2) with a

screwdriver. See Fig. 30 . Remove circlip (3) at selector lever cable support bracket and remove selector
lever cable. Do not kink selector lever cable.

5. On vehicles with 2.0L engine, unscrew sensor (1) from speedometer drive. Remove bolt (2). Remove heat

shield (3) from engine exhaust manifold. See Fig. 31 . On all models, remove ground cable (1) from
upper engine/transaxle securing bolt. Disconnect electrical connections (3) and (4) on starter. Separate
connector (2) and pull out of retainer. See Fig. 14 . Remove wiring harness retainer on starter. Remove
upper bolt at starter.

6. Clamp off ATF cooler hoses with Hose Clamps (3094) and disconnect at ATF cooler. See Fig. 15 . Seal

off ATF cooler with clean plugs. Remove upper engine/transaxle securing bolts. Assemble Support
Device (10-222 A) with Adapters (10-222 A/8). See Fig. 32 . Do not seat the Adapter (10-222 A/8) on
the securing bolts for the front end/fender. Support weight of engine/transaxle assembly on support
device spindles. Remove left front wheel bolts. Raise and support vehicle. Remove left front wheel.

7. Remove sound insulation tray (arrows). See Fig. 17 . Remove left sound insulation (arrows). See Fig. 18 .

Remove charge air pipe between charge air cooler and exhaust gas turbocharger (if equipped). Remove
right sound insulation.

8. Remove ATF oil pan protective plate (arrows). See Fig. 19 . Remove power steering pressure lines/hoses

from starter and transaxle. Remove lower bolt at starter. Remove starter. Remove right hand inner
constant velocity joint protective cover from engine (if installed). Disconnect drive axles at transaxle
flanges. Raise right drive axle and secure out of the way.

9. Remove pendulum support (arrows). See Fig. 21 . Remove additional radiator fan on right hand side of

vehicle (if part of original equipment). Unclip cap for torque converter nut cover. Remove nut (arrow)
from torque converter using Special Socket (V 175). See Fig. 22 . Turn crankshaft 120 degrees further for
each nut. Turn steering to left lock. Mark installation position of ball joint bolts on left hand control arm

before disconnecting battery.

WARNING:

Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.
When servicing vehicle, use care to avoid accidental air bag deployment.
SIR system-related components are located in various locations
throughout interior and exterior of vehicle, depending on application. Do
not use electrical test equipment on or near these circuits. If necessary,
deactivate SIR system before servicing components. See appropriate AIR
BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

2003 Volkswagen New Beetle GLS

2001-04 AUTOMATIC TRANSMISSIONS Removal & Installation - 01M

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and remove 3 bolts.

10. Disconnect left coupling rod (1) from control arm and turn rod upward. Swing wheel bearing housing

outward. Guide left hand drive axle (2) out between assembly carrier and transaxle. See Fig. 23 . Lift
drive axle and secure to suspension strut with wire. Disconnect exhaust system after front exhaust pipe at
double clamp. Remove front exhaust system supports from assembly carrier, if necessary.

11. Remove left assembly mounting (2) hex bolts (arrows) from left mount (1). See Fig. 24 . Carefully tilt

engine and transaxle by lowering left hand support device spindle about 2.36" (60 mm) on Support
Device (10-222 A).

12.

Remove left mount (1) from transaxle (arrows). See Fig. 25 . Using 2 bolts (M 8 x 25), bolt Support Rail
(VW 457/1) to both pendulum support securing holes (A) on subframe. Insert spacers totaling .24" (6
mm) between subframe and Support Rail (VW 457/1). Install Support Device (3300 A) and tighten with
bolt (B). See Fig. 27 .

13. Tilt engine and transaxle forward with Support Device (3300 A). Set up Transaxle Support (3282).

Transaxle Support (3282) is set up with the Adjusting Plate (3282/2) for removing transaxle. See Fig. 7 .
The symbols on the adjusting plate indicate the supports required. Move Transaxle Jack (VAG 1383 A)
with Transaxle Support (3282) underneath and support transaxle. See Fig. 8 .

14. Place safety support pin on oil pan and secure to transaxle housing (arrow). See Fig. 9 . Turn right hand

drive flange so that flattened side (arrow) is in a vertical position. See Fig. 28 . Remove lower
engine/transaxle connecting bolts. Press transaxle off engine while pressing torque converter out of drive
plate. Press torque converter against ATF pump.

15. Lower transaxle slightly. While lowering, guide power steering pressure line past transaxle. Swivel

transaxle and carefully lower transaxle, guiding right hand drive flange past engine and Support Device
(3300 A). Ensure that multifunction TR switch does not contact assembly carrier. Secure torque converter
to prevent it from falling out.

16. To install transaxle, reverse removal procedure. When installing the torque converter, ensure that both

drive pins engage in the ATF pump inner wheel recesses. Before installing, ensure that dowel sleeves are
correctly located. When installing transaxle, observe torque converter contact impression on drive plate.

17. Replace selector cable anchorage locking washer. Check selector lever cable adjustment, and adjust if

necessary. Check and top off ATF level. See SERVICING - 01M & 01V article. See TORQUE
SPECIFICATIONS .

NOTE:

In the following step, to secure support rail to subframe, a NEW hole must
be drilled in support rail. Drill a .335" (8.50 mm) diameter hole (arrow) at
recessed section of support rail. See Fig. 26 .

2003 Volkswagen New Beetle GLS

2001-04 AUTOMATIC TRANSMISSIONS Removal & Installation - 01M

Helpmelearn Repair Manuals

Wednesday, December 14, 2005 8:58:18 AM

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