Volkswagen New Beetle. Manual - part 2091

 

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Volkswagen New Beetle. Manual - part 2091

 

 

Fig. 53: Clamping Suction Hose Using Hose Clamp 3094. 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Place drip tray underneath.  

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Disconnect pump pressure line.  

Connecting pressure gauge V.A.G 1402 

1. V.A.G 1402 Pressure gauge  

2. V.A.G 1402 Hose from pressure gauge  

3. V.A.G 1402/6 Hose from adapter set  

4. V.A.G 1402/1 A Adapter  

5. Oil seal  

NOTE:

The following list refers to items in Fig. 54 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

6. V.A.G 1402/2 Adapter  

7. Pressure line/hose with Banjo union bolt  

8. Banjo union bolt  

Fig. 54: Connecting Power Steering Pressure Gauge (Vehicles With Power Steering Pump In Upper 
Section)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove hose clamp 3094 from suction and return hoses.  

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Start engine and if necessary add fluid to reservoir.  

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Turn steering wheel approx. 10 times from lock to lock.  

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Now check delivery pressure.  

Requirements: 

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Ribbed belt/ribbed belt tension OK.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

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System not leaking.  

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Hoses/lines are not kinked or restricted. 

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With engine running at idle speed. Close cut-off valve (not longer than 5 seconds) and read off 
pressure.  

Specifications 

Gasoline engines: 85...95 bar (1233 - 1378 psi) 

Diesel engines: 96... 105 bar (1392 - 1523 psi) 

POWER STEERING PUMP: VEHICLES WITH POWER STEERING PUMP IN LOWER 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 

NOTE:

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If the reading is higher or lower than specified replace power steering 
pump:  

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Removing and installing power steering pump, vehicles with power 
steering pump in upper section. See POWER STEERING PUMP: VEHICLES 
WITH POWER STEERING PUMP IN UPPER SECTION, REMOVING AND 
INSTALLING .  

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If reservoir fluid level is low then check steering system for leaks.  

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For leaks at the pinion first check the lines/line connections for leaks and 
if necessary tighten and wipe dry.  

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If the pinion seal or the rack seals in steering gear housing are leaking 
then replace steering gear.  

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To check the rack seals loosen the hose clip on the boot and push boot to 
one side.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 55: 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 before use. Otherwise the pump may be damaged or noisy 
during operation.  

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Part numbers are listed here for reference only. Always check with your 
parts department for the latest information.  

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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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