Volkswagen New Beetle. Manual - part 2351

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  2349  2350  2351  2352   ..

 

 

Volkswagen New Beetle. Manual - part 2351

 

 

Fig. 63: Positioning Transmission Support (3282) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

23. Carefully lower transmission, guiding right-hand flange shaft in area of flywheel and left-hand flange 

shaft, in area of subframe. When lowering transmission, change position of transmission, using 
transmission support (3282) spindles. DO NOT damage power steering line when lowering transmission. 

Installation 

1. Apply grease to ball stud and inner surface of release bearing. Clean input shaft splines and lightly grease 

with G000 100 grease. Ensure clutch disc slides on input shaft spines.  

2. Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block. Install if 

necessary. Ensure that intermediate plate is correctly positioned on engine.  

3. Install pressure plate bolts finger tight. Using clutch centering tool (3190A), align clutch disc and pilot 

bushing holes. Tighten pressure plate bolts to specification using a crosswise pattern. See TORQUE 
SPECIFICATIONS 
.  

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:55 AM

Page 65 

© 2004 Mitchell Repair Information Company, LLC. 

4. If flywheel was removed, using flywheel lock (3067) or similar device to hold crankshaft from turning. 

Tighten flywheel bolts to specification. See TORQUE SPECIFICATIONS .  

5. Bolt support rail (T10036) to both pendulum support securing holes on subframe (arrows). See Fig. 61 . 

Install support (3300 A) so it is almost touching assembly mounting and secure (arrows). Press engine 
forward carefully. Do NOT damage power steering line.  

6. Install transmission to engine. Do NOT damage power steering line. Install lower rear 

engine/transmission connecting bolt (arrow A). See Fig. 61 . Install lower engine/transmission securing 
bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Remove pressing device 3300 
A (arrows). Remove bolt (A). Remove support rail (T10036).  

7. Install gate selector cable (A) with relay lever in direction of arrow. See Fig. 60 .  

8. Install left mount (1) on transmission (arrows). See Fig. 59 . Align engine/transmission in installation 

position. Install NEW hex bolts (arrows) for left assembly mounting (2) in mount (1). See Fig. 58 .  

9.  

Install NEW hex bolts (arrows) for right assembly mounting in engine mounting. See Fig. 57 .  

10. Install pendulum support. See Fig. 56 . Use NEW bolts for securing. Tighten to specification. See Fig. 

64 .  

11. Install drive axle shafts to transmission. Tighten bolts to specification. See TORQUE 

SPECIFICATIONS .  

12. Reconnect exhaust system. Install starter and secure with lower bolt. Install retainer for power steering 

line on starter and on transmission.  

13. Install upper engine/transmission securing bolts. Tighten upper engine/transmission securing bolts to 

specification. See TORQUE SPECIFICATIONS .  

14. Install ground strap at upper engine/transmission securing bolt. See Fig. 51 . Attach connector to 

speedometer sensor (arrow). See Fig. 48 .  

15. Install slave cylinder line/hose in clamp. See Fig. 50 . Remove special tool (3094). Install upper securing 

bolt on starter.  

16. Install cable retainer (A) on starter (arrow 3). See Fig. 49 . Attach connectors for starter (arrow 1) and 

back-up light (arrow 2).  

17. Install cable support bracket on transmission (arrows). See Fig. 46 . Tighten bolts to specification. See 

TORQUE SPECIFICATIONS .  

18. Install gear selector cable (B) with transmission selector lever (arrow 2). See Fig. 47 . Tighten NEW self-

locking hex nut (arrow 2) to 18 ft. lbs. (25 N.m). Secure gate selector cable (A) with relay lever using 
lock washer (arrow 1). Install power steering line (arrow 3).  

19. Install battery and battery carrier. Install complete air cleaner housing by tightening bolts (4 and 5). See 

Fig. 17 . Install intake hose (1). Attach connector (2) and hose (3) to Mass Air Flow sensor.  

20. Install insulation tray below engine/transmission, if so equipped. Lower vehicle. Install engine cover. 

Adjust gear selector mechanism. See SELECTOR MECHANISM under ADJUSTMENTS.  

21. Bleed clutch system, if necessary. See BLEEDING . Check transmission oil level, if necessary. 

WARNING:

DO NOT remove support bar (10-222A) until bolts securing left and 
right assembly mountings have been tightened to torque 
specification. 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:55 AM

Page 66 

© 2004 Mitchell Repair Information Company, LLC. 

OVERHAUL 

CLUTCH MASTER CYLINDER 

Information not available from manufacturer.  

CLUTCH SLAVE CYLINDER 

Information not available from manufacturer.  

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

Application 

Ft. Lbs. (N.m) 

Axle Shaft-To-Transmission Flange Bolt 

M8 

30 (40) 

M10 

52 (70) 

Cable Support Bracket-To-Transmission Bolt 

18 (25) 

Clutch Pedal Mounting Plate Nut 

(1)

18 (25) 

Clutch Master Cylinder Nut 

(1)

18 (25) 

Cross Support-To-Body Bolt 

18 (25) 

Exhaust System Nut 

22 (30) 

Flywheel-To-Crankshaft Bolt 

(1)

Step 1 

44 (60) 

Step 2 

Additional 90° Turn 

Gearshift Selector Assembly 

Gear Selector Cable Mounting Bolt 

18 (25) 

Gear Selector Lever Self-Locking Nut 

(1)

18 (25) 

Shift Housing-To-Body 

18 (25) 

Support Bracket Bolt 

18 (25) 

Selector Housing Nut 

18 (25) 

Selector Lever-To-Transmission 

15 (20) 

Pendulum Support Bolt 

(1)

 , 

(2)

Pressure Plate Bolt 

(1)

 , 

(3)

1-Piece Flywheel 

16 (22) 

2-Piece Flywheel 

15 (20) 

Starter Bolt 

48 (65) 

Transmission-To-Body Bolt 

(5)

74 (100) 

Transmission Mount-To-Transmission 

(1)

 , 

(6)

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:55 AM

Page 67 

© 2004 Mitchell Repair Information Company, LLC. 

Step 1 

37 (50) 

Step 2 

Additional 90° Turn 

Transmission-To-Engine Bolt 

(4)

Transmission Selector Lever Nut 

(1)

15 (20) 

Wheel Lug Bolt 

89 (120) 

INCH Lbs. (N.m)

Slave Cylinder/Release Bearing Bolt 

106 (12) 

(1)

Always replace with NEW fastener. Always replace self-locking nuts.

(2)

See Fig. 64 .

(3)

Loosen or tighten bolts gradually, in a crosswise pattern.

(4)

See Fig. 65 .

(5)

See Fig. 66 .

(6)

See Fig. 67 .

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:55 AM

Page 68 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  2349  2350  2351  2352   ..