Volkswagen New Beetle. Manual - part 2106

 

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Volkswagen New Beetle. Manual - part 2106

 

 

Fig. 17: Identifying Modified Stabilizer Bar Mounting (Golf, GTI & Jetta) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5.  

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:50 AM

Page 24 

© 2004 Mitchell Repair Information Company, LLC. 

On all models, disconnect and wire brake caliper aside without disconnecting brake hose. Support brake 
caliper with mechanics wire.  

6. Remove connecting link from control arm. Release speed sensor wiring from suspension strut.  

7. Additional work is required if right suspension strut is to be removed. Remove noise insulation. 

Disconnect axle shaft from transmission axle flange.  

8. The following work sequence is valid for both sides Remove lower strut-to-wheel bearing housing bolt 

and nut. Insert Spreader (3424) into slot. See Fig. 18 . See SPECIAL TOOLS . Using ratchet handle turn 
spreader 90°. 

Fig. 18: Removing Strut Assembly From Housing 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

9. Press brake disc in direction of suspension strut by hand. Otherwise the shock absorber tube could catch 

CAUTION: DO NOT allow caliper hang by brake hose. 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:50 AM

Page 25 

© 2004 Mitchell Repair Information Company, LLC. 

in the wheel bearing housing hole. Pull wheel bearing housing off shock absorber downward.  

10. Remove hex nut for upper shock absorber mounting (1) with ratchet handle and adapters (1 - Ratchet 

handle, 2 - T10001/8, 3 - T10001/11 and 4 - T10001/5). See Fig. 19 . Remove suspension strut. 

Fig. 19: Removing Hex Nut For Upper Shock Absorber Mounting (Golf, GTI & Jetta) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Installation (Except New Beetle) 

To install, reverse removal procedure. Ensure that strut-to-wheel bearing housing bolt is installed with point 
installed towards front of vehicle. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS 
Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL 
ALIGNMENT.  

Removal (New Beetle) 

1. Raise and support vehicle. Remove wheel. 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:50 AM

Page 26 

© 2004 Mitchell Repair Information Company, LLC. 

2. For vehicles with brake wear pad indicator, disconnect connector (1). See Fig. 15 .  

3. Remove heat shield (1) by pushing lip (A) with a screwdriver in, and push at the same time the heat 

shield (1) upward in direction of arrow. See Fig. 16 . For vehicles with brake wear pad indicator remove 
bolt (B) to remove support for brake wear pad indicator.  

4.  

On all models, disconnect and wire brake caliper aside without disconnecting brake hose. Support brake 
caliper with mechanics wire.  

5. Remove connecting link from control arm. Release speed sensor wiring from suspension strut.  

6. To remove right-side strut, remove noise insulation panel.  

7. On vehicles equipped with 1.9L TDI engines, remove noise insulation panel under engine. See Fig. 23 . 

Remove intake air duct between charge air cooler and turbocharger.  

8. On vehicles with 1.8L turbo and 2.0L engines, remove center, left and right insulation trays. See Fig. 20 . 

On vehicles with 1.9L TDI and 1.8L turbo engine, remove intake air duct between charge air cooler and 
turbocharger. 

CAUTION: DO NOT allow caliper hang by brake hose. 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:50 AM

Page 27 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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