Volkswagen New Beetle. Manual - part 546

 

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Volkswagen New Beetle. Manual - part 546

 

 

8. Hydraulic pump 

z

Removing and installing, see HYDRAULIC PUMP, REMOVING AND INSTALLING .  

9. Bypass valve 

z

Unscrewing the bypass valve releases pressure in the hydraulic system and the convertible top can 
be operated by hand.  

10. Fluid level indicator 

z

Hydraulic oil level must lie between min. and max. marks when convertible top is open.  

11. Right Contact Switch (Cover Installed)-F156- or Left Contact Switch (Cover Installed) -F155- for 

convertible top 

z

Qty. 2.  

12. Convertible Top Operation Switch -E137- 

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Installed in center console.  

Fig. 103: Locating Electro/Hydraulic Convertible Top Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

HYDRAULIC SYSTEM, FILLING AND BLEEDING 

If the hydraulic pump is overloaded, a thermal fuse breaks the current circuit and the system is switched off for 
a maximum of 35 seconds. Then the system is fully functional again. 

The bypass valve on the hydraulic cylinder is located behind a rubber cover behind the left luggage 
compartment side panel trim. Turning the bypass valve counterclockwise releases pressure in the system and the 
convertible top can be operated manually. 

Filling hydraulic system 

NOTE:

z

Electro/hydraulic convertible top is a closed hydraulic system. Filling is 
normally only required after opening the hydraulic circuit (e.g. after 
replacing a part).  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ACCESSORIES & EQUIPMENT Convertible Top - New Beetle

  

z

Removing left-hand trim in luggage compartment 

See LUGGAGE COMPARTMENT TRIM (CONVERTIBLE), REMOVING AND INSTALLING . 

z

The convertible top must be open to fill the system as the actual level can only be determined in this 
condition.  

z

Remove oil filler plug -1-.  

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Oil for convertible top: G 002 000.  

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Top-off hydraulic oil until the oil level is between the min. and max. marks -2-.  

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An oil can is suitable for filling the hydraulic oil.  

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Oil can must only be used for this purpose, this prevents hydraulic oil being contaminated by other oils.  

z

Tighten oil filler plug -1- (5 N.m). 

Fig. 104: Removing Oil Filler Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bleeding hydraulic system 

Hydraulic system is self-bleeding. System is bled by operating system several times. 

z

Loosen oil filler plug -1-.  

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Switch ignition on and off again, keep ignition key in ignition lock. 

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For reasons of stroke and the displacing effect of the piston rod, the 
hydraulic oil level must only be checked when the convertible top is open. 

z

Observe safety instructions for electrical convertible top, see 
CONVERTIBLE TOP .  

WARNING:

Do not fill system above "max." mark, otherwise the pressure in the 
system may be high enough to damage the system.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ACCESSORIES & EQUIPMENT Convertible Top - New Beetle

  

z

Operate convertible top switch and open and close top 4 to 5 times.  

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System bleeds itself when opening and closing the convertible top several times.  

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Convertible top must open and close smoothly without juddering.  

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Oil level must be between min. and max. marks -2- when convertible top is open.  

z

Tighten oil filler plug -1- (5 N.m). 

Fig. 105: Installing Oil Filler Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

HYDRAULIC PUMP, REMOVING AND INSTALLING 

Removing 

z

Disconnect the battery Ground (GND) strap observing all cautions. SeeBATTERY 
DISCONNECTING/RECONNECTING PRECAUTIONS
 .  

z

Removing left-hand trim in luggage compartment 

See LUGGAGE COMPARTMENT TRIM (CONVERTIBLE), REMOVING AND INSTALLING . 

z

Disconnect electrical connection from Convertible Top Hydraulic Pump -V118- -5- 

WARNING:

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The hydraulic system reacts with extreme sensitivity to all types of 
contaminants.  

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As soon as the system is opened the respective component must be 
covered, to prevent dirt entering the hydraulic system.  

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Before working on electrical system: Disconnect battery Ground 
(GND) strap.  

NOTE:

z

Obtain radio unit code before disconnecting battery. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ACCESSORIES & EQUIPMENT Convertible Top - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ACCESSORIES & EQUIPMENT Convertible Top - New Beetle

  

 

 

 

 

 

 

 

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