Volkswagen New Beetle. Manual - part 2115

 

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Volkswagen New Beetle. Manual - part 2115

 

 

BODY LEANS OR SWAYS IN CORNERS 

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS .  

2. Verify the vehicle leans or sways in corners. Does the vehicle operate normally? If yes, then system is 

okay. If no, go to next step.  

3. Inspect the rear coil springs and torsion bars for wear or damage. Are the components worn or damaged? 

Are the components worn or damaged? If yes, go to step 5 . If no, go to next step.  

4. Inspect the stabilizer shaft link for wear or damage. Is the stabilizer shaft link worn or damaged? If yes, 

go to step 6 . If no, go to step 2 .  

5. Replace the springs. Refer to the appropriate procedure: 

z

Coil Spring Replacement in Rear Suspension.  

z

Torsion Bar Replacement in Front Suspension.  

After repair is complete, go to step 7 .  

6. Replace the stabilizer shaft link. Refer to GENERAL DIAGNOSIS - H2 . After repair is complete, go to 

next step.  

7. Operate the vehicle in order to verify the repair. Did you correct the condition? If yes, then system is 

okay. If no, go to step 3 .  

MEMORY STEER 

DEFINITION: The steering wheel does not return to center after completing a turn.  

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS .  

2. Verify that memory steer is present. Does the system operate normally? If yes, system is okay. If no, go 

to next step.  

3. Check the tire inflation and adjust to specifications. Did you adjust the tire pressure? If yes, go to step 13 . 

If no, go to next step.  

4. Raise and support the vehicle. Lubricate the tie rod ends and the ball joints if applicable. Inspect the 

suspension system for worn or damaged components. Repair as necessary. Did you find and correct the 
condition? If yes, go to step 13 . If no, go to next step.  

5. Rotate the steering wheel ONE revolution in both directions. Rotate the steering wheel back to the 

original position. Was the steering wheel abnormally difficult to rotate in either direction? If yes, go to 
next step. If no, go to step 9 .  

6.  

Remove the steering column pinch bolt in order to disengage the column from the steering system. Note 
the position of the steering wheel and rotate the steering wheel ONE revolution in both directions. Rotate 
the steering wheel back to the original position. Was the steering wheel abnormally difficult to rotate in 
either direction? If yes, go to step 12 . If no, go to next step.  

7. Remove the front tire and wheel assemblies. Disconnect both of the outer tie rod ends from the steering 

NOTE:

Do NOT rotate the steering wheel more than one complete revolution. 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

knuckles. Use your hands in order to move the tie rod ends. Are either of the tie rod ends abnormally 
difficult to move? If yes, go to step 10 . If no, go to next step.  

8. Inspect for binding ball joints. Use your hands to push and pull the steering knuckle inboard and 

outboard. Are either of the steering knuckles abnormally difficult to move? If yes, go to step 11 . If no, go 
to next step.  

9. Inspect the wheel alignment and adjust as necessary. Refer to SPECIFICATIONS & PROCEDURES . 

Did you complete the wheel alignment? After performing wheel alignment, go to step 13 .  

10. Replace the outer tie rod end. After replacing tie rod end, go to step 13 .  

11. Replace the damaged ball joint. Refer to Upper Control Arm Replacement or Lower Ball Joint 

Replacement in Front Suspension. After repairs, go to step 13 .  

12. Repair the steering column as necessary. Refer to Steering Column. After repairs, go to next step.  

13. Operate the vehicle in order to verify the repair. Did you correct the condition? If yes, system is okay. If 

no, go to step 3 .  

NOISE DIAGNOSIS - FRONT SUSPENSION 

DEFINITION: A loud bang or thump that can usually be felt and/or heard when the vehicle is driven over 
bumps. This condition is commonly noticed when the vehicle trim height is too low.  

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS .  

2. Attempt to duplicate the condition. Road test the vehicle. Did you duplicate the condition? If yes, go to 

next step. If no, system is okay.  

3. Is the noise reactive to vehicle load or speed? If yes, go to next step. If no, go to step 7 .  

4. Inspect the tires for proper tire Inflation and adjust as necessary. Inspect for unusual tire wear. Inspect the 

wheel nuts for looseness and tighten as necessary. Did you find and correct the condition? If yes, go to 
step 14 . If no, go to next step.  

5. Inspect the front wheel bearings. Refer to WHEEL BEARING DIAGNOSIS . Did you find and correct 

the condition? If yes, go to step 14 . If no, go to next step.  

6. Inspect for front axle noises. Did you find and correct the condition? If yes, go to step 14 . If no, go to 

next step.  

7. Bounce the front of the vehicle in order to duplicate the noise. Did you duplicate the noise? If yes, go to 

next step. If no, go to step 9 .  

8. Raise and support the vehicle. Inspect the front suspension components for looseness. Inspect the front 

suspension components for damage and repair as necessary. Did you find and correct the condition? If 
yes, go to step 14 . If no, go to next step.  

9. Install the J-39570 Chassis Ear or equivalent. See SPECIAL TOOLS . Bounce the front of the vehicle, 

using the J-39570 or equivalent in order to locate the source of the noise. If necessary road test the 
vehicle. Repair or replace any damaged components as necessary. Did you find and correct the condition? 
If yes, go to step 14 . If no, go to next step.  

10. Inspect the ball joints and steering components for lack of lubrication where applicable, looseness in the 

ball joints, looseness in the steering linkage, or looseness in the tie rods. Did you find and correct the 
condition? If yes, go to step 14 . If no, go to next step. 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

11. Inspect for damaged shock absorbers. Did you find and correct the condition? If yes, go to step 14 . If no, 

go to next step.  

12. Inspect the front stabilizer shaft and stabilizer shaft links for damage and repair as necessary. Did you 

find and correct the condition? If yes, go to step 14 . If no, go to next step.  

13. Inspect for control arm damage and repair as necessary. Did you find and correct the condition? If yes, go 

to next step.  

14. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If 

no, go to step 3 .  

NOISE DIAGNOSIS - REAR SUSPENSION 

DEFINITION: Any noise emitted from the rear of the vehicle that is induced by VEHICLE SPEED or 
DRIVING TERRAIN as related to the rear suspension.  

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS .  

2. Attempt to duplicate the condition. Road test the vehicle. Did you duplicate the condition? If yes, go to 

next step. If no, system is okay.  

3. Is the noise reactive to vehicle load or speed? If yes, go to next step. If no, go to step 6 .  

4. Inspect and adjust the tire Inflation. Inspect for unusual tire wear. Inspect the wheel nuts for looseness. 

Did you find and correct the condition? If yes, go to step 10 . If no, go to next step.  

5. Inspect the rear axle for rear axle noises. Did you find and correct the condition? If yes, go to step 10 . If 

no, go to next step.  

6. Bounce the rear of the vehicle in order to duplicate the noise. Did you duplicate the noise? If yes, go to 

next step. If no, go to step 9 .  

7. Raise the vehicle. Inspect the rear suspension components for looseness and tighten as necessary. Inspect 

the rear suspension components for damage and repair as necessary. Did you find and correct the 
condition? If yes, go to step 10 . If no, go to next step.  

8. Inspect the rear shock absorber. Did you complete the inspection? If yes, go to step 10 . If no, go to next 

step.  

9. Install the J-39570 Chassis Ear or equivalent. See SPECIAL TOOLS . Bounce the rear of the vehicle, 

using the J-39570 or equivalent, in order to locate the source of the noise. If necessary road test the 
vehicle. Repair or replace any defective component as necessary. Did you find and correct the condition? 
If yes, go to next step. If no, system is okay.  

10. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If 

no, go to step 3 .  

POOR DIRECTIONAL STABILITY 

DEFINITION: Driver is unable to maintain consistent, predictable vehicle driving control in any direction.  

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

2. Verify that the directional stability is poor. Does the system operate normally? If yes, system is okay. If 

no, go to next step.  

3. Inspect the front stabilizer fasteners for looseness. Inspect for damaged stabilizer bar, stabilizer bushings, 

or damaged and missing stabilizer links. Did you find and correct the condition? If yes, go to step 10 . If 
no, go to next step.  

4. Inspect control arms, ball joints, and inner and outer tie rod ends for wear and damage. Did you find and 

correct the condition? If yes, go to step 10 . If no, go to next step.  

5. Inspect the wheel bearing. Did you find and correct the condition? If yes, go to step 10 . If no, go to next 

step.  

6. Inspect the vehicle trim height. Did you find and correct the condition? If yes, go to step 10 . If no, go to 

next step.  

7. Inspect the steering column for looseness. Did you find and correct the condition? If yes, go to step 10 . If 

no, go to next step.  

8. Inspect the steering gear mounting bolts for looseness. Did you find and correct the condition? If yes, go 

to step 10 . If no, go to next step.  

9. Inspect and adjust the wheel alignment as necessary. Did you complete the alignment? Go to next step.  

10. Operate the vehicle in order to verify the repair. Did you correct the condition? If yes, system is okay. If 

no, go to step 3 .  

RIDE DIAGNOSIS 

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS .  

2.  

Verify that the ride is too soft or too hard. Does the vehicle ride normally? If yes, then system is okay. If 
no, go to next step.  

3. Inspect the tires for the proper inflation pressure. Is the tire inflation pressure correct? If yes, go to step 7 . 

If no, go to next step.  

4. Inspect the vehicle trim height. Refer to TRIM HEIGHT INSPECTION PROCEDURE . Did you find 

and correct the condition? If yes, go to step 7 . If no, go to next step.  

5. Inspect the strut and shock absorbers. Refer to STRUTS OR SHOCK ABSORBERS ON-VEHICLE 

TESTING . Inspect torsion bars and springs. Did you find and correct the condition? If yes, go to step 7 . 
If no, go to next step.  

6. If equipped with the Air Suspension system refer to Air Suspension. Did you find and correct a 

condition? If yes, go to next step. If no, system is okay.  

7. Drive the vehicle in order to verify the repair. Did you correct the condition? If yes, system is okay. If no, 

go to step 3 .  

STRUTS OR SHOCK ABSORBERS ON-VEHICLE TESTING 

1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If 

NOTE:

Verify the vehicle suspension package RPO. 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

 

 

 

 

 

 

 

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