Volkswagen New Beetle. Manual - part 2065

 

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Volkswagen New Beetle. Manual - part 2065

 

 

See NOISE INSULATION, ASSEMBLY OVERVIEW .

Fig. 58: Removing Center, Left And Right Insulation Trays (1.8L And 2.0L) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continued for all vehicles 

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Remove right noise insulation, if installed.  

Vehicles with TDI and 1.8 turbo engines 

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Remove intake air duct between charge air cooler and turbocharger.  

Continued for all vehicles 

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Loosen belt pulley hex socket head bolt. 

Counter-hold using hex. wrench if necessary. 

Fig. 59: Removing Belt Pulley Bolt 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Turn tightening device in direction of arrow to relieve tension on ribbed belt. 

Fig. 60: Turning Belt Tightening Device In Direction Of Arrow 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Mark direction of travel of ribbed belt with a crayon or marker before removing the ribbed belt. 
Reinstalling a used belt in the opposite direction could damage the belt.  

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Remove ribbed belt.  

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Remove belt pulley hex socket head bolt.  

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Clamp off suction hose with hose clamps -3094-.  

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Open spring-type clip -3- and pull off suction hose. 

Use special tool V.A.S 5024 for this. 

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Remove Banjo union bolt -4-. 

{

Seal pressure line/hose with a plastic bag or similar.  

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Unbolt hex bolts -1- and -2-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 61: Power Steering Pump Suction Hose (Vehicles With Power Steering Pump In Lower 
Section)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove pump.  

Installing 

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Fill power steering pump with hydraulic oil. 

Fill pump with oil via suction union. 

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Turn hub by hand until oil emits from pressure side.  

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Install power steering pump into bracket and tighten bolts to 25 N.m (18.4 ft lb).  

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Install suction hose and install spring-type clip. 

Fig. 62: Installing Suction Hose And Spring-Type Clip (Vehicles With Power Steering Pump In 
Lower Section)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

The mark -arrow A- must align with casting seam -arrow-

The spring-type clip must close off with mark -arrow B-. 

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Install new sealing rings onto banjo union bolt.  

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Tighten banjo union bolt to 38 N.m (28 ft lb). 

The remainder of the installation is the reverse of removal. 

POWER STEERING PUMP: VEHICLES WITH POWER STEERING PUMP IN UPPER SECTION, 
REMOVING AND INSTALLING 

Special tools and equipment 

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3094 Hose clamps  

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V.A.G 1331 Torque wrench  

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VAS 5024 Assembly pliers 

Fig. 63: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The power steering pump is not serviceable. If problems in the pump are suspected, determine the cause with 
the help of pressure tests, leak test. If malfunctioning replace complete unit. 

NOTE:

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Pumps supplied as replacement parts are not filled with oil. Therefore it is 
essential to fill the pump with hydraulic oil Part No. G 002 000 and to rotate 
it by hand, otherwise the pump may be damaged or noisy during 
operation.  

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Type of oil hydraulic oil Part No. G 002 000  

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

 

 

 

 

 

 

 

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