Volkswagen New Beetle. Manual - part 2108

 

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Volkswagen New Beetle. Manual - part 2108

 

 

2. Further installation is in reverse order. After installing, check position of steering wheel during a test 

drive. If steering wheel is not in straight ahead position the front axle alignment must be checked.  

3. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Check wheel alignment. 

See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.  

Removal (New Beetle) 

1. Lift vehicle until load on front axle is relieved. Loosen right-side 12-point axle shaft nut. Remove wheel. 

For vehicles with 1.9L TDI engine, remove noise insulation panel. See Fig. 23 . Remove left-side noise 
insulation panel. See Fig. 24 . 

Fig. 23: Locating Noise Insulation Panel (New Beetle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: The vehicle must be standing on its wheels when loosening or tightening 

the 12-point nut. Otherwise there is risk of an accident. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 32 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 24: Locating Left Side Noise Insulation Panel (New Beetle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

2. 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 engines, remove intake air duct between charge air cooler and 
turbocharger.  

3. Continuation for all vehicles, remove right-side noise insulation. Mark installation position of ball joint 

bolts on control arm. Remove ball joint-to-control arm bolts.  

4.  

Install tool 3283. See Fig. 5 . Press axle shaft out of hub. Pull wheel bearing housing together with ball 
joint out from control arm. Swing suspension strut outward and hold away from body with a piece of 
wood. To do this pull the drive shaft out from wheel bearing.  

5. Secure drive axle to body with wire. The drive axle must not hang down by inner CV or triple rotor joint. 

Do not flex inner CV or triple-rotor joint more than 25 degrees from its original angle. The inner joint 
will otherwise be damaged through overflexing.  

6. Remove pendulum support-to-subframe bolts (1) and (2). See Fig. 21 . Remove steering gear bolts (5). 

NOTE:

When pressing drive axle out make sure that sufficient clearance is 
available. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 33 

© 2004 Mitchell Repair Information Company, LLC. 

Remove stabilizer bar link rod nuts (7). On vehicles equipped with 1.9L TDI engines, remove exhaust 
system bolts (6).  

7. Support suspension assembly with transmission jack. Remove subframe bolts (3) and (4). Lower 

subframe and remove from vehicle.  

Installation (New Beetle) 

1. Before inserting bolts for subframe, position steering gear on subframe and insert bolts for steering gear. 

The threaded sleeve (1) must seat in subframe hole. See Fig. 22 .  

2. Further installation is in reverse order. After installing, check position of steering wheel during a test 

drive. If steering wheel is not in straight ahead position the front axle alignment must be checked.  

3. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Check wheel alignment. 

See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.  

SUBFRAME BUSHINGS 

Removal & Installation 

1. Remove subframe. See SUBFRAME . Using hydraulic press and appropriate bushing press tools, press 

bushing from subframe. See Fig. 25 . See SPECIAL TOOLS .  

2.  

Coat new bushings with Bushing Lubricant (G 294 421). Using appropriate press tools, press NEW 
bushings into control arm.  

CAUTION: Never use grease as a lubricant for bushings. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 34 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 25: Removing & Installing Subframe Bushings 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

WHEEL BEARING (WHEEL BEARING HOUSING REMOVED FROM VEHICLE) 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 35 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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