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Volkswagen New Beetle 1998-2009 including Convertible Repair Manual

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Filed Under (volkswagen) by admin on 04-09-2009

This comprehensive repair manual contains the repair information provided by Volkswagen to their factory-trained technicians, making it an invaluable resource for the Volkswagen New Beetle (NB platform) owner. It provides clear & complete step-by-step procedures to help you understand, care for, and repair your 1998 through 2008 Volkswagen New Beetle. Wiring diagrams, component locations, campaign circulars and technical bulletins are also included in this manual.
Engines covered:
* 1.8 Liter 4-Cyl. 5V Turbo
(engine codes: APH, AWV, AWP,BKF,BNU)
* 1.9 Liter 4-Cyl. 2V TDI
(engine codes: ALH, BEW)
* 2.0 Liter 4-Cyl. 2V
(engine codes: AEG, AVH, AZG, BDC, BEV, BGD)
* 2.5 Liter 5-Cyl. 4V
(engine codes: BPR, BPS)

1998 – 2005 Volkswagen New Beetle Air Conditioning Dust and pollen filter removing and installing

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Filed Under (volkswagen) by admin on 20-03-2011

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The filter is located in the right rear of the instrument panel under a cover. Components of dust and pollen filter: 1 – Frame 3 – Filter element 4 – Plastic nut, 2.5 Nm (20 in lb) 5 – Filter housing with seal Removing Push center cover -1- forward -arrow A- and lift up to remove. Remove screws -arrows-. Lift right plenum panel cover -1- and remove from clips at front and rear edge. Pull cover -1- toward center of vehicle and out of retainer in A-pillar to remove. Remove screws -arrows- and remove right closeout panel -1-. Remove rubber grommet -1-. Press tabs of filter housing in direction of -arrow-. Remove filter element with frame in upward direction -arrow A-. Installing Guide frame -1- into first slot on left and right sides of new filter element. Press frame with filter into housing -2- and engage retainers.

Volkswagen New Beetle Service Manual: 1998-2002

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Filed Under (volkswagen) by admin on 30-03-2010

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The Volkswagen New Beetle Service Manual: 1998.-.2002 1.8L turbo, 1.9L TDI diesel, 2.0L gasoline
Maintenance procedures: from routine oil changes to poly-ribbed belt replacement.
• Engine and cylinder head service, including timing belt and camshaft replacement.
• Component testing, removal and installation for engine lubrication, cooling, and exhaust systems.
• Turbocharger service, removal and installation, and intercooler components.
• Fuel supply system service, including fuel pump delivery volume test, electrical checks, EVAP system, as well as mechanical and electronic throttle control (E-gas).
• Fuel injection and ignition system component identification, electrical testing, technical data, and throttle valve control module adaptation using the factory scan tool.

• Drivetrain maintenance, troubleshooting, adjustment and repair, including hydraulic clutch, gearshift linkage, drive axles, and transmission removal and installation.
• Repair information for ABS/EDL/ASR/ESP brake and stability systems.
• Suspension system service including struts, CV joints, stabilizer bar, rear wheel bearings, wheel alignment specifications and steering system.
• Interior and exterior body equipment: airbags, bumpers, front and rear body sections, doors, hood, lids, lights, instrument panel/dashboard, sunroof, seatbelts, seats, trim panels.
• Heating and air conditioning repair, including A/C electrical component replacement, compressor, fresh air blower, sensors, and vacuum hose layout.

1998 – 2005 Volkswagen New Beetle Instrument panel removing and installing

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Filed Under (volkswagen) by admin on 24-03-2011

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WARNING! Disconnect battery Ground (GND) strap before working on electrical system, observing all cautions => Repair Manual; Electrical; Repair Group 27, Battery, disconnecting and reconnecting. Removing Note: Before disconnecting battery Ground (GND) strap obtain security code for radio with anti- theft coding. Remove driver’s airbag unit => page 69-50. Remove steering wheel => page 69-61. Note: For vehicles with steering angle sensor -G85- observe: => Suspension, Wheels, Steering; Repair Group 48 – Steering; Steering column, removing and installing; Sequence for vehicles with steering angle sensor -G85-. For vehicles without steering angle sensor -G85- observe: => Suspension, Wheels, Steering; Repair Group 48 – Steering; Steering column, removing and installing; For vehicles without steering angle sensor -G85-. Remove two screws -arrows-. Remove steering column switch upper trim -1-. Remove three screws -arrows-. Release steering wheel height adjustment -2-. Remove steering column switch lower trim-1-. Note: Handle for height adjustment can be removed (two screws) to ease removal of lower trim. Remove Hex socket (Allen key) head bolt -1-. Disconnect connectors -arrows- from steering column switches. Remove steering column switch. Remove screws -1-. Remove driver’s side footwell cover -2- from retainers -3-.

1997 Ford Explorer/Mountaineer Transmission ASSEMBLY

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Filed Under (Ford) by admin on 06-04-2011

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1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air. 2. Inspect the transmission case for the following: 1. Stripped bolt hole threads. 2. Gasket and mating surfaces for burrs or nicks. 3. Obstructions to vent and fluid passages. Cracks or warpage. 3. Inspect the extension housing for cracks, burrs or warpage. 4. Inspect case bearing for damage. Replace as needed. 5. Remove the case bearing. 1. Install the Bearing Cup Puller with Slide Hammer into case bearing. 2. Remove the case bearing. Use an oil stone to remove any nicks or burrs in the bearing case bore. 6. Install a new case bearing. 1. Assemble and install the Drive Handle and Bearing Installer. 2. Position new case bearing onto bearing installer tool. 7. Tap case bearing into case bearing bore. 8. Install the A4LD Holding Fixure Adapter. 1. Position the A4LD Holding Fixture Adapter on the rear of the transmission case. 2. Install the A4LD Holding Fixture Adapter bolts. 9. Attach the fixture arm of the Bench Mounted Holding Fixture to the A4LD Holding Fixture Adapter. 10. Install transmission into Bench Mounted Holding Fixture. Rotate the transmission so that the fluid pan rail is facing up. -MOUNTED HOLDING FIXTURE IS SECURE. 11. Using Shift Lever Seal Replacer, install the manual control lever shaft seal. Lubricate the manual control lever shaft seal with petroleum jelly. 12. Assemble the manual valve inner lever and parking lever actuating rod as shown. 13. Install the manual control lever shaft. 14. NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Install the manual control lever shaft spring pin. Tap the manual control lever shaft spring pin into the transmission case. 15. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft. 16. Install the manual valve inner lever nut on the manual control lever shaft and tighten. 17. Install the output shaft thrust washer (No. 11). Coat the output shaft thrust washer with petroleum jelly. 18. Install the park gear.