Volkswagen New Beetle. Manual - part 2093

 

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Volkswagen New Beetle. Manual - part 2093

 

 

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

  

Removing 

For vehicles with TDI engine 

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Remove noise insulation tray -arrows-. 

Fig. 64: Removing Noise Insulation Tray (1.9L TDI) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove left-side noise insulation -arrows-. 

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 65: Removing Left-Side Noise Insulation (1.9L TDI) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with 1.8 ltr. turbo and 2.0 ltr. engines 

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Remove center, left and right insulation trays: 

See NOISE INSULATION, ASSEMBLY OVERVIEW .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 66: Removing Center, Left And Right Insulation Trays (1.8L And 2.0L) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with TDI and 1.8 ltr. turbo engines 

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Remove connecting line between charge air cooler and the turbocharger.  

Continued for all vehicles 

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Loosen belt pulley hex socket head bolt. 

Counter-hold with a hex wrench if necessary. 

Fig. 67: Removing Belt Pulley Bolt 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

 

 

 

 

 

 

 

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