Volkswagen New Beetle. Manual - part 851
1. Release socket drive (1), and pull off grip (2). See Fig. 27 . Turn torque wrench grip 180°. Reinsert
socket drive. Set wrench direction of turn on socket drive to clockwise.
2. Remove protective cap from pulley. Place 6 mm hex bit socket into generator shaft. Counter-hold multi-
point socket (3400) with 17 mm box wrench. See Fig. 28 .
3. Insert torque wrench into hex bit socket. Loosen freewheel pulley by turning generator shaft clockwise.
Remove freewheel pulley once loosened.
4. To install freewheel pulley, insert multi-point socket (3400) in freewheel pulley. Tighten pulley by hand
onto generator drive shaft until stop.
5. Ensure wrench grip is turned 180°, as stated in step 1 . Set wrench direction on socket drive to counter-
clockwise. Set torque wrench tightening torque to 59 ft. lbs. (80 N.m). Place 6 mm hex bit socket into
generator shaft.
6. Counter-hold multi-point socket (3400) with 17 mm box wrench. Using torque wrench, turn generator
drive shaft counter-clockwise, and tighten freewheel pulley to specification. See TORQUE
SPECIFICATIONS . Clip protective cap onto freewheel pulley.
NOTE:
Freewheel pulley can be retrofitted in vehicles with a Bosch generator.
Freewheel pulley cannot be retrofitted in vehicles with Valeo generator. Valeo
generators must be replaced for Bosch generator.
2003 Volkswagen New Beetle GLS
1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle
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