Volkswagen New Beetle. Manual - part 2092

 

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Volkswagen New Beetle. Manual - part 2092

 

 

Removing 

Vehicles with TDI engine 

z

Remove noise insulation tray -arrows-. 

Fig. 56: Removing Noise Insulation Tray (1.9L TDI) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove left noise insulation -arrows-. 

Fig. 57: Removing Left Noise Insulation (1.9L TDI) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with 1.8 ltr. turbo and 2.0 ltr. engines 

z

Remove center, left and right insulation trays: 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

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 

z

Remove right noise insulation, if installed.  

Vehicles with TDI and 1.8 turbo engines 

z

Remove intake air duct between charge air cooler and turbocharger.  

Continued for all vehicles 

z

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.

z

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. 

z

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.  

z

Remove ribbed belt.  

z

Remove belt pulley hex socket head bolt.  

z

Clamp off suction hose with hose clamps -3094-.  

z

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

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

z

Remove Banjo union bolt -4-. 

{

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

z

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. 

z

Remove pump.  

Installing 

z

Fill power steering pump with hydraulic oil. 

Fill pump with oil via suction union. 

z

Turn hub by hand until oil emits from pressure side.  

z

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

z

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

  

 

 

 

 

 

 

 

Content   ..  2090  2091  2092  2093   ..