1998 – 2005 Volkswagen New Beetle Oil pan removing and installing

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Filed Under (volkswagen) by admin on 22-03-2011

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Special tools, testers and auxiliary items required Jointed wrench 3185 Socket T10058 Torque wrench V.A.G 1331 Hand drill with plastic brush Protective goggles Flat scraper Silicone sealing compound D 176 404 A2 Locking fluid D 000 600 A2 Removing Remove center and right sound insulation Engines with oil pan protection Body Exterior – Repair Group 50. Remove bolts – 2 – and take sleeves – 3 – off front and rear parts of oil pan protection. Press spreader pin out upward and remove spreader rivets – 4 – . Remove oil pan protection – 1 – . Engines with LongLife Service Pull 3-pin connector off Oil level thermal sensor -G266-. Continuation for all engines Drain engine oil. Note: Observe disposal regulations! Remove oil pan bolts. Note: Loosen oil pan bolts with jointed wrench 3185 and remove with socket T10058. Remove oil pan. Loosen pan with light blows of a rubber headed hammer if necessary. Remove sealant residue on cylinder block with a flat scraper.

1998 – 2005 Volkswagen New Beetle Body Interior B-pillar trim removing and installing

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Filed Under (volkswagen) by admin on 22-03-2011

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Removing Remove side panel trim => page 70-51. Remove relay anchorage for front seat belt => page 69-3. Remove door inner seal -2- from B-pillar -4-. Remove handle strap => page 68-51. Unclip B-pillar upper trim -1- to rear off B-pillar -4-. Installing Install in reverse order of removal. Note: Check clips -3- before installing trim and replace as necessary. Make sure door inner seal is seated correctly after installing trim.

1998-2008 Volkswagen New Beetle Headlamps Removal and Installation

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Filed Under (volkswagen) by admin on 21-03-2011

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Note: Removal and installation of right headlamp is illustrated. Removal and installation of left headlamp is the same. Special tools, testers and auxiliary items required 5 mm hex socket wrench Removing Insert hex wrench into headlamp lock – arrow – . Turn hex socket wrench – 1 – approximately 180 degree in direction of – arrow – (clockwise) in order to release headlamp housing from retainer. Return the headlamp lock – 1 – 90 degree as shown. Note: In order for the headlamp housing to slide in an out freely, the “U” section of the headlamp lock must be in the lowest position (90 degree ). Should the headlamp be difficult to remove from vehicle, turn hex socket wrench – 1 – alternately in both directions while pulling headlamp housing out of retainer. Note: Headlamp retainer – 1 – contains headlamp lock – 2 – position (lock-unlock). Depress lock tab – arrow – while pulling headlamp forward out of retainer. Note: The electrical connection is integrated with both the headlamp and retainer and is disconnected automatically upon removal of headlamp. CAUTION! Headlamp lock on retainer must not be turned while headlamp is removed. . Installing Install in reverse order of removal, noting the following: Note: In order for the headlamp housing to slide in an out freely, the “U” section of the headlamp lock must be in the lowest position (90 degree ). Should headlamp housing be difficult to install in vehicle, turn hex socket wrench – 1 – alternately in both directions while pushing headlamp housing into retainer.

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.

2004 Volkswagen New Beetle GL Side window removing and installing

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Filed Under (volkswagen) by admin on 02-12-2010

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Removing Open convertible top. Remove side trim –> 70 – INTERIOR TRIM Remove loudspeaker. Remove outer window recess seal. Fig. 457: Identifying Loudspeaker And Outer Window Recess Seal Remove upper retaining plate.Raise door window until combination nuts of door window are visible in installation opening – arrow -. Remove combination nuts. Lower side window to center position until combination nuts are visible in installation opening – arrow -. Remove combination nuts. Tilt side window toward inside and remove upward from window recess. Installing Installation is performed in the reverse order of removal. NOTE: Side window, adjusting When installing, check side window adjustment. Side trim, loudspeaker removed and convertible top closed. NOTE: Observe that flushness and joint between door window and side window is guaranteed. If side inclination (side distance) is not suitable, it can be corrected via adjuster at carrier plate.