Volkswagen New Beetle. Manual - part 2094

 

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Volkswagen New Beetle. Manual - part 2094

 

 

Fig. 68: Turning Belt Tightening Device In Direction Of Arrow (Vehicles With Power Steering 
Pump In Upper Section)
 
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.  

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Remove ribbed belt.  

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Remove belt pulley hex socket head bolt.  

Removing suction line and suction hose 

z

Pull connector off suction line.  

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Loosen spring -type clips with special tool VAS 5024.  

z

Remove suction line and suction hose  

z

Clamp off return supply hose with hose clamps -3094-. 

Fig. 69: Clamping Off Return Supply Hose With Hose Clamps -3094- 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

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Clamp off suction line with hose clamps -3094-.  

z

Open spring-type clip -1- and disconnect suction line. 

Fig. 70: Disconnecting Power Steering Pump Suction Line (Vehicles With Power Steering Pump In 
Upper Section)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Unscrew banjo union bolt -2-. 

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

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Remove hex bolts -1- and -2-.  

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Remove pump. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 71: Removing Power Steering Pump Bolts (Vehicles With Power Steering Pump In Upper 
Section)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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 ft lb).  

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Install suction line and spring-type clip. 

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

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 72: Installing Suction Line And Spring-Type Clip (Vehicles With Power Steering Pump In 
Upper Section)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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 WITH HYDRAULIC LINES/HOSES, ASSEMBLY OVERVIEW 

I. Vehicles with power steering pump in upper section  

II. Vehicles with power steering pump in lower section  

NOTE:

The following list refers to items in Fig. 73 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

 

 

 

 

 

 

 

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