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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.

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)

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6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS FORD: 2003-2005 Excursion 2003-2007 F-Super Duty 2004-2008 E-Series ISSUE Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.OL engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics. NOTE IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR. 1. Drain coolant from cooling system. 2. Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C. 3. Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles) 4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant) 5. Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle. NOTE MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT. 6. Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3) a. Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C. b. Replace cylinder head if leaking through casting, refer to WSM 303-01C. c. Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.

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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-.

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Removing Remove cover – 4 – with a screwdriver. Remove screws – 1 – and – 3 – and take triangular shaped trim – 2 – off towards rear – arrow – . Remove A pillar lower trim General body repairs, interior – Repair Group 68 Disconnect multi-pin connectors – 1 – on A pillar – 2 – . Take cover – 1 – for wiring harness – 2 – out of body opening in the inner A pillar. Pull wiring harness out of A pillar at boots – 1 – between door and A pillar. Remove bolt – 1 – of door arrester – 2 – . To prevent damage to paint work, mask lower edge of fender – 2 – in area of lower hinge – 3 – with textile reinforced adhesive tape – 1 – . Pull cover cap – 1 – off grub screw on lower hinge. Remove grub screw – 2 – on lower hinge. Torque setting: 13 Nm If access to the grub screw through the gap between door and A-pillar is not possible, or is extremely difficult, then proceed as follows: Release rear half of front wheel housing ( Front wheel housing liner) in area of A pillar so that access to the fender securing points along the A pillar is possible. Remove bolts – 1 – and nuts – 2 – . Carefully pull fender – 1 – off A pillar – arrow – and block fender (e.g. with a plastic wedge). Pull cover cap off grub screw if necessary and remove grub screw – 2 – from lower hinge. Torque setting: 13 Nm Remove block from fender after removing grub screw.