Volkswagen New Beetle. Manual - part 847

 

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Volkswagen New Beetle. Manual - part 847

 

 

On batteries with hose for central venting, ensure venting hose is not kinked. Only then can battery vent 
freely. On batteries without hose for central venting, ensure opening on upper side of battery cover is not 
blocked.  

5. Install battery hold-down and bolt (3). See Fig. 13 . Tighten bolt to specification. See TORQUE 

SPECIFICATIONS . Reinstall power steering fluid reservoir and bolts (3 and 4). Reconnect battery 
terminals.  

Fig. 13: Removing Battery (Sedan May 1999-Nov. 2002) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

GENERATOR 

NOTE:

The battery is correctly installed when the center groove in the battery foot 
strip aligns with threaded hole in the battery carrier (arrows). See Fig. 11 . 

CAUTION: Always replace ribbed belt if found to be faulty. This will avoid related 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 18 

© 2004 Mitchell Repair Information Company, LLC. 

Removal & Installation (1.8L & 2.0L Engines) 

1. Disconnect battery. Raise and support vehicle. Remove bolts (arrows) on sides of insulation panel. See 

Fig. 14 . Lower and remove cover.  

2.  

Remove bolts (1). See Fig. 15 . Release clips (2). Pull heat shield out of retainer (3).  

3. On vehicles equipped with 2.0L aspirated engine, pry out caps (arrows), and release fasteners underneath. 

See Fig. 16 . Remove nut (1). Pull dipstick out. Remove engine cover.  

4. On vehicles equipped with 1.8L engine, pry out cap (1), and remove nut underneath (2). See Fig. 17 . Pull 

over out from retainers. Remove engine cover.  

5.  

On all vehicles, loosen belt by turning tensioner in direction of arrow. See Fig. 18 . Block tensioner with 
special tool (3090). See Fig. 19 . Remove belt. Remove belt tensioner.  

6. Remove nut from terminal 30/B+ connection. Disconnect electrical connector (2). See Fig. 20 . Remove 

harness retainer (3). Remove M8 hex bolts connecting generator to bracket. Lift generator out from 
engine compartment.  

7. To install, reverse removal procedure. Where applicable, drive threaded sleeves (A) approximately 4 mm 

in direction of arrow. See Fig. 21 . Tighten all generator bolts to specification. See TORQUE 
SPECIFICATIONS 
.  

8. Ensure all assemblies are securely mounted and turn freely. For aid in belt routing, see Fig. 1 . Counter-

hold tensioner, and remove special tool (3090). Slowly release tensioner to engage ribbed belt.  

9. Start engine, and check belt running. To complete installation, reverse removal procedure. 

break-downs or operating problems. 

CAUTION: If a used ribbed belt is to be reused, mark direction of rotation before 

removing. When installing used ribbed belts observe the direction of 
rotation marked on removal. Installing opposite to the direction of rotation 
leads to belt damage. 

NOTE:

DO NOT reuse clips (2). See Fig. 15 . Always replace after releasing. 

NOTE:

Mark direction of rotation of serpentine belt if it is to be reused. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 19 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 14: Locating Insulation Panel Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 20 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 15: Locating Heat Shield Bolts & Clips 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 21 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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