INDEX WARNING—
Your common common sense, sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your Volkswagen, read 00 read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your Volkswagen. Please also read any warnings and cautions that accompany the procedures in the manual.
A ABS See Anti-lock See Anti-lock brakes (ABS) Air conditioning belt routing 87-26 components 87-5 passenger compartment 87-18 replacement 87-9 underhood 87-24 compressor 87-31 mounting bracket 87-26 condenser 87-11 controls 87-18 evaporator 87-12 idler pulley 87-27 leaks 87-17 odor 87-13 O-rings 87-6 pressure relief valve 87-7 pressure switch 87-7 refrigerant 87-5 testing 87-14 water drain valve 87-25 Air filter element 03-41 Airbags 69-1 See also Seatbelts, also Seatbelts, Airbags Alarm 96-7 Alternator (generator) 27-14 carbon brushes, checking 27-18 removing and installing installing 4-cylinder 27-18 5-cylinder 27-19 See also Charging also Charging system Antenna 91-7 Anti-freeze 03-22, 19-6
Anti-lock brakes (ABS) components 45-4 control module 45-10 warning light functions 45-9 wheel speed sensors 45-11
1
Brake light switch 45-7 Bumpers 63-2
Anti-theft system 96-6 Automatic transmission ATF cooler 37-28 automatic shift-lock 37-13 basic settings 37-3 driveplate clearance 13-11 electrical components 37-6 transmission transmission range switch 37-7 vehicle speed sensor 37-7 removing and installing 37-17 selector lever cable 37-9 shift-lock cable 37-13 shift mechanism 37-9 torque convertor 37-27
B Back-up light switch manual transmission 34a-19 Battery 27-3 charging 27-5 removing and installing 27-8 tests 27-4 Bleeding brakes 47-12 Body–exterior equipment roof moldings 66-8 side-view mirror 66-1 wheel housing liner 66-6 Body components 50-2 front fender 50-3 front noise insulation 50-5 lock carrier 50-4 noise insulation 50-6 plenum close out panel 50-7 rear fender 53-2 Boost pressure 21-3 Brake fluid 03-24, 47-12 Brakes bleeding 47-12 booster 47-20 brake pressure regulator 47-10 caliper 47-3 front 46-3 master cylinder 47-19 master cylinder and brake booster 47-14 parking brake 46-12 rear 46-9 vacuum check valve 47-15 vacuum pump 47-15
C Caliper, brake 47-3 Campaign Circulars appendix D CD changer 91-8 Central locking 57-2 See also Keyl also Keyless ess remote e ntry Charging system 27-12 See also Alternator also Alternator (generator) Clutch actuating mechanism 30-2 assembly 30-13 disc, centering 30-13 hydraulics 30-5 bleeding 30-10 master cylinder 30-6 over-center over-center spring 30-3 pedal 30-2, 30-4 release mechanism 30-11 Comfort and convenience 57-26 Component locations (electrical) 97-12 Compression test 1.8L engine 15a-2 1.9L engine 15b-2 2.0L engine 15c-2 2.5L engine 15d-2 Connecting rods 13-12 Console, center 70-1 Convertible component locations appendix C door window service appendix B emergency closing 61-2 end position, checking 61-3 hydraulic system 61-5 maintenance 61-1 overview of components 61-4 power window pinch protection, resetting 61-3 rear side window service appendix B resetting open/close system 61-3 rollover protection protection and body reinforcements appendix C top outer shell replacement appendix B
2
INDEX Coolant See Anti-freeze See Anti-freeze Coolant pump replacing 1.8L engine 19-14 1.9L engine 19-17 2.0L engine 19-19 2.5L engine 19-26 Cooling system anti-freeze (coolant) 03-22, 19-6 components 4-cylinder 19-13 5-cylinder 19-24 draining and filling 19-11 fans and thermo-switch 19-7 pressure testing 19-6 radiator and cooling fan 19-3 thermostat 4-cylinder 19-23 5-cylinder 19-32 testing 19-10 troubleshooting troubleshooting 19-4 Crankshaft 13-18 front oil seal 13-4 rear oil seal 13-4 Cylinder block internal components 13-12 oil seals 13-2 CV joint 40-15 Cylinder head and valvetrain, 1.8L engine camshaft 15a-10 oil seals 15a-7 compression test 15a-2 cylinder head components 15a-32 cover 15a-6 service 15a-3 hydraulic cam followers 15a-14 leakdown test 15a-3 timing belt 15a-18 valves 15a-33 Cylinder head and valvetrain, 1.9L Engine camshaft 15b-15 oil seal 15b-5 compression test 15b-2 cylinder head ALH engine 15b-4 BEW engine 15b-20 components 15b-39 hydraulic cam followers 15b-17 timing belt 15b-23 valves 15b-40
Cylinder head and valvetrain, 2.0L engine camshaft 15c-8 oil seal 15c-7 compression test 15c-2 cylinder head components 15c-24 cover 15c-6 service 15c-3 hydraulic cam followers 15c-10 leakdown test 15c-3 timing belt 15c-14 valves 15c-26 Cylinder head and valvetrain, 2.5L engine camshaft adjustment valve 15d-9 chain guard cover 15d-6 seal, replacing 15d-9 compression test 15d-2 cylinder head 15d-4 leakdown test 15d-3 timing chain 15d-10 valvetrain assembly 15d-10
D Dashboard 70-28 Diesel fuel injection 23-1 Disc brakes 46-1 Doors adjusting 57-9 assembly convertible 57-4 sedan 57-3 central locking 57-2 handle 57-12 keyless remote control 57-28 lock button 57-19 cylinder housing 57-11 removing door lock 57-13 panel 70-13 See also Windows also Windows Drive axles axle nut, tightening 40-8 constant velocity (CV) joint 40-9, 40-15 triple-roller joint 40-17 Drive belt 1.8L engine 15a-18 1.9L engine 15b-23 2.0L engine 15c-14 Driveplate 13-10
DSG transmission components 34b-9 electrical components 34b-8 oil changing 34b-3 checking level 34b-6 selector cable 34b-12 selector lever 34b-11 shift mechanism 34b-11 Dust and pollen filter 80-8
E EGR (exhaust gas recirculation) 26-16 Electrical system component locations 97-13 fuses 97-2 relays 97-7 test equipment 9-3 troubleshooting troubleshooting 9-4 voltage and polarity 9-1 wiring diagrams EWD-1 Electronic accelerator (E-gas) system 20-22 Emission controls 26-14 Engine general 1-1 mounts 4-cylinder 10-12 5-cylinder 10-20 removing and installing 4-cylinder 10-2 5-cylinder 10-13 Engine lubrication lubrication system 4-cylinder 17-5 5-cylinder 17-13 oil cooler 17-12 oil filter flange 4-cylinder 17-6 5-cylinder 17-14 oil pan 17-9 oil pressure warning system 17-2 oil pump 17-11 oil spray nozzles 17-12 Engine management See Fuel See Fuel injection Evaporative emissions (EVAP) 26-14
INDEX WARNING—
• Your common common sense, sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your Volkswagen, read 00 read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your Volkswagen. Please also read any warnings and cautions that accompany the procedures in the manual.
Exhaust system catalytic converter 26-26 combi-valve 26-25 exhaust manifold 26-6 front exhaust pipe and catalyst 4-cylinder 26-4 5-cylinder 26-9 installation installation details 26-12 replacement 26-3
F Fender front 50-3 rear 53-2 Flywheel 13-10 Fog light 94-11 Front suspension and drive axles coil spring, removing and installing installing 40-13 front suspension strut 40-10 subframe/stabilizer subframe/stabilizer bar/control arm assembly 40-3 control arm bushings 40-5 ball joint, checking axial/radial play 40-4 rear bushing for control arm 40-4 suspension struts 40-10 wheel bearings 40-5 wheel hub 40-8 Fuel, ignition, and exhaust systems diesel turbo direct injection (TDI) 2-5 emission controls 2-12 fuel injection 2-2 fuel supply 2-1 ignition system 2-12 motronic 5.9.2 overview 2-3 motronic ME 7 overview 2-9 Fuel filter 20-17
Fuel injection–diesel (TDI) basic fuel delivery, checking 23-7 diagnostic quick checks 23-4 EGR 26-26 engine control module 23-2 fuel injection system, components 1.9L: ALH 23-8 1.9L: BEW 23-27 fuel shut-off valve, checking 23-6 glow plugs 1.9L: ALH 23-22 1.9L: BEW 23-32 injection pump (1.9L: ALH) 23-11 removing and installing 23-13 timing, checking/adjusting 23-21 intake manifold assembly 1.9L: ALH 23-21 1.9L: BEW 23-28 readiness code OBD-34 testing and replacing glow plugs 1.9L: ALH 23-25 1.9L: BEW 23-34 throttle position sensor 23-22 troubleshooting troubleshooting 23-3 Fuel injection–gasoline adaptation 24-4 air cleaner assembly 1.8L engine 24-7 2.0L engine 24-17 2.5L engine 24-28 engine control module (ECM) 24-4 engine speed sensor 1.8L engine 24-10 2.0L engine 24-24 2.5L engine 24-30 exhaust gas recirculation recirculation (EGR) 26-26 fuel injection system components 1.8L: APH, AWP, AWP, AWV 24-5 1.8L: BKF, BNU 24-6 2.0L: AEG 24-13 2.0L: AVH, AZG 24-14 2.0L: BDC, BGD 24-15 2.0L: BEV 24-16 2.5L: BPR, BPS 24-27 fuel injector and fuel rail assembly 1.8L 24-7 2.0L: AEG, AVH, AZG 24-18 2.0L: BDC 24-19 2.0L BEV 24-20 2.0L BGD 24-21 2.5L 24-28 on-board diagnostics 24-3 readiness code OBD-34 safety precautions 24-2 Fuel pump 20-3
3
Fuel storage and supply evaporative emissions (gasoline engine) 20-14 fuel pump (fuel delivery unit) 20-11 troubleshooting troubleshooting 20-3 checking 20-5 system pressures 20-8 fuel tank and lines 20-17 fuel tank assembly 1.8L, 2.0L engines 20-17 1.9L engine 20-18 2.5L: BPR 20-19 2.5L: BPS 20-20 leak detection system 20-14 safety precautions 20-2 Fuel tank See Fuel See Fuel storage and supply Fuses 97-2
G Generator See alternator See alternator (generator) overview overview 27-14 Glow plugs (diesel) 1.9L: ALH 23-22 1.9L: BEW 23-32
H Hand brake See Parking See Parking brake Headlight assembly 94-2 HID (Xenon) 94-3 Heating and ventilation blower fan 80-9 center air outlet console 80-10 defroster air outlet panel 80-11 dust and pollen filter 80-8 heater assembly 80-12 central flap lever 80-12 heater core bulkhead seal 80-12 heating and ventilation ventilation controls 80-2 adjusting 80-6 cables, installing/adjusting 80-7 instrument panel crossmember 80-3 side window air vents 80-3 recirculation recirculation flap ser vo 80-13 See also Air also Air Conditioning Hood and lids front hood 55-2 lock assembly 55-4 release cable assembly 55-3 fuel fill lid 55-13 rear lids 55-5 convertible 55-6 sedan 55-5 rear lock cylinder carrier 55-11, 55-12
4
INDEX I Ignition System–Gasoline camshaft position sensor 28-14 disabling ignition system 28-2 ignition coil with power output stage, testing 1.8L engine 28-5 2.0L engine 28-6 2.5L engine 28-7 ignition system components 28-8 quick check 28-4 troubleshooting troubleshooting 28-3 Immobilizer 96-6 Instrument cluster 90-2 Instruments instrument cluster, removing and installing 90-2 malfunction recognition and display 90-2 multi-pin multi-pin c onnector terminal assignment 90-4 Intercooler 21-16 Interior lights 96-1
J Jacking 03-11
K Keyless remote control 57-28 changing batteries 03-54 Knock sensor See Fuel See Fuel injection–gasoline, fuel injection injection system components
L License plate light 94-21
Lights, accessories–exterior back-up lights 94-19 center brake light 94-20 fog light bulb, replacing 94-11 front lights 94-2 front turn signal bulb, replacing replacing 94-13 headlights aim, adjusting 94-7 bulb, replacing (halogen) 94-7 bulb, replacing (Xenon) 94-8 assembly, removing and installing 94-4 license plate light 94-21 rear lights 94-16 rear side marker lights 94-22 side-mounted turn signals 94-15 taillight 94-16 bulbs, replacing 94-18 removing and installing 94-17 Lights, accessories–interior glove compartment light 96-5 instrument panel dimmer switch 96-2 switches–center switches–center 9 6-4 interior light 96-4 interior lights and switches 96-1 interior lock switch–passenger side 96-3 light switch 96-2 luggage compartment light 96-5 make-up mirror light 96-5 mirror adjustment switch 96-3 remote fuel tank/rear lid unlock switch 96-3
M Maintenance body and interior 03-49 airbag inspection 03-50 clock and outside temperature, setting 03-51 dust and pollen filter 03-53 keys and remote controls, replacing batteries 03-54 radio anti-theft coding 03-56 engine compartment 03-13 air filter 03-41 battery service 03-30 coolant 03-22 engine oil 03-16 fluid leaks 03-28 ribbed V-belt 03-32 sound absorber panels 03-13 spark plugs 03-37 timing belt, checking 03-36 how to use this manual 03-2 identification identification plates and labels engine identification 03-6 transmission identification 03-7 vehicle identification number (VIN) 03-5 lifting vehicle 03-11 maintenance schedules 03-61 road test 03-60 towing 03-8 under car maintenance 03-42 brake inspection 03-43 exhaust 03-48 suspension 03-44 tire service 03-42 transmission 03-44 Manual transmission gear selector cables, assembly 34a-3 gear selector knob 34a-6 gear selector lever 34a-8 removing and installing 34-18 Master cylinder brake 47-14 clutch 30-6 Mirrors exterior 66-1 interior, rear view 70-8
Lid See Hood See Hood and lids Lifting vehicle 03-11
O Oil, changing 03-18 Oil filter 1.8L, 2.0L engine 03-19 1.9L engine 03-20 2.5L engine 03-21
INDEX WARNING—
• Your common common sense, sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your Volkswagen, read 00 read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your Volkswagen. Please also read any warnings and cautions that accompany the procedures in the manual.
P Parking brake 46-12 Piston projection at TDC (diesel)13-17 rings 13-17 Positive crankcase ventilation (PCV) 26-15 Power steering 48-14 Power windows 57-1
S Seatbelts, airbags airbags 69-13 control module 69-16 passenger front airbag 69-23 sensors (impact) 69-22 side airbag units 69-20 spiral spring/slip ring 69-19 unit in steering wheel 69-17 seatbelts, front convertible 69-8 sedan 69-7 seatbelts, inspecting 69-4 seatbelts, rear convertible 69-10 sedan 69-9 side airbag units 69-20 special precautions 69-2, 69-14 Seats front 72-1, 72-4 front adjustment cable 72-7 front seatback 72-6 head restraint guides 72-5 rear 72-8 release mechanism 72-11 Secondary air injection 26-20 Shift-lock 37-13 Shift-lock 37-13 Slave cylinder 30-8
R Radio antenna satellite 91-8 standard 91-7 anti-theft coding 03-56 CD changer 91-8 Ipod adapter 91-8 radio anti-theft system 91-15 radio head unit 91-14 radio reception 91-2 radio system 91-3 Rear hatch See Hood See Hood and lids Rear suspension overview 42-3 rear coil spring 42-7 rear shock absorbers 42-5 rear suspension bonded rubber axle beam bushing, installed installed position 42-4 upper spring seat and coil spring, installed installed position 42-4 rear wheel bearings 42-8 Recall campaigns appendix D Relays 97-2
Sound system See Radio See Radio Spark plugs, replacing 1.8L engine 03-37 2.0L engine 03-38 2.5L engine 03-39 Starter 27-23 bushing 27-25 service 27-22 Steering power steering fluid reservoir 48-16 hydraulic lines 48-18 pump 48-19 steering wheel 48-2 steering column 48-7 ignition lock cylinder and switch 48-11 lock housing 48-8 Suspension, front See Front See Front Suspension and Drive Axles Suspension, rear See Rear See Rear Suspension
T Taillight 94-7
5
Thermostat See Cooling See Cooling system Timing belt 1.8L engine 15a-18 1.9L engine ALH 15b-23 BEW 15b-29 2.0L engine 15c-14 Timing chain 2.5L engine 15d-10 Tire service 03-42 See Wheels–Tires, See Wheels–Tires, Wheel Alignment Transmission automatic 37-1 DSG transmission 34b-1 manual 34a-1 Trim–Interior center console70-1 interior equipment70-7 glove box 70-7 rear view mirror 70-8 roof handle 70-9 sun visor 70-10 instrument panel, removing an installing installing 70-28 trim panels A-pillar 70-10 B-pillar 70-11 C-pillar 70-12 door panel 70-13 inner plenum covers 70-16 rear panels 70-18 to 70-24 sill panel 70-25 steering column lower trim 70-26 Turbocharger assembly 1.8L engine 21-7 1.9L engine 21-13 boost pressure 21-3 diagnostics 21-2 intercooler 21-16
V Valve cover See Cylinder See Cylinder head and valvetrain Vehicle Identification Number (VIN) 03-5 See also Maintenance also Maintenance Ventilation See Heating See Heating and ventilation ventilation
6
INDEX W Warning light functions (ABS) 45-9 Water pump See Coolant See Coolant pump Wheel Alignment See Wheels–Ti See Wheels–Tires, res, Wheel Alignment Wheel bearing front 40-5 rear 42-8 Wheels–tires, wheel alignment alignment requirements 44-4 thrust angle, calculating 44-6 wheel alignment 44-2 checking 44-4 specifications specifications 44-5 Window glass 57-23 power windows 57-1 Wipers and washers headlight washer system 92-8 jets 92-9 reservoir 92-9 rubber wiper inserts, replacing 92-2 windshield washer overview 92-6 wiper assembly 92-3 wiper blade park position 92-3 wiper motor 92-4 Wiring diagrams electrical wiring diagrams EWD-1 fuses and relays 97-2 ground locations 97-12 how to read wiring diagrams EWD-4 symbols used in wiring diagrams EWD-6 terminal (circuit) identification EWD-4 wiring repairs EWD-6
established 1950 Automotive Reference™
BentleyPublishers .com
Volkwagen New Beetle Volkwagen B eetle Service Manual: 1998-2010 including convertible Price: $139.95 Bentley Stock No: VB10 Publication Date: 2010.sept.1 ISBN: 978-0-83 978-0-8376-1640-7 76-1640-7 Hardcover, 8 3/8 in. x 11 in. Case quantity: 1 1664 pages, 2647 photos, illustrations and diagrams
R epair Manual: 1998-2010 is a The Volkswagen New Beetle Repair comprehensive source of service information and specifications for the New Beetle from 1998 to 2010. Whether you’re a professional or a do-it-yourself Volkswagen Volkswagen owner, this manual will help you understand, care for and repair your vehicle. Fully detailed exploded views including front body assembly.
Features:
50 Body-Front
• Maintenance procedures for everything from routine oil changes to replacing key battery in remote control. This manual tells you what to do and how and when to do it. • Engine and cylinder head service, repair and reconditioning, including camshaft timing belt replacement. • Explanation of Motronic 5.9.2, ME7 and Diesel Turbo Direct Injection (TDI) engine management systems.
See how to perform routine maintenance procedures, such as checking fluids.
• Emission control tests, repairs and adjustments, including Exhaust Gas Recirculation (EGR) and Secondary Air Injection (AIR) system. • Drivetrain maintenance, troubleshooting, adjustment and repair,, including hydraulic clutch, gearshift linkage, and repair drive axles. • Suspension component replacement, including front struts, rear shocks, rear coil springs, s prings, and wheel bearing/hub units. • Coverage of ABS/EDL/ASR/ESP brake and drivetrain systems. • Heating and air conditioning repair, including A/C component replacement Bentley repair manuals provide the highest level of clarity and comprehensiveness comprehensivene ss for service and repair procedures. If you’re looking an indispensable source concerning operation, maintenance and repair, look no further than Bentley.
03 Maintenance
Models, engines and transmissions covered Models and engines
1.8L turbo gasoline (engine code: APH, AWV AWV,, AWP, AWP, BKF, BNU) 1.9L TDI diesel (engine code: ALH, BEW) 2.0L gasoline (engine code: AEG, AVH, AZG, BDC, BEV, BGD 2.5 L gasoline (engine code: BPR, BPS) Transmissions (remove, install, external service)
Manual 5-speed 02J Manual 5- and 6-speed 02M Manual 5-speed 0A4 Automatic 4-speed 01M Automatic 6-speed 09G DSG 6-speed 02E
Bentley Publishers, 1734 1734 Massachusetts Avenue, Cambridge, MA 02138-180 4 USA Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235 http://www.bentleypublis http://www .bentleypublishers.com/contact-sales hers.com/contact-sales bentley_vb10_new.product.announcement.pdf
