Volkswagen New Beetle Repair Manual: 1998-2010 - Complete Index

INDEX 1

WARNING—

• Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your Volkswagen, 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

ABSSee Anti-lock brakes (ABS)

Air conditioningbelt routing 87-26components 87-5

passenger compartment 87-18replacement 87-9underhood 87-24

compressor 87-31mounting bracket 87-26

condenser 87-11controls 87-18evaporator 87-12idler pulley 87-27leaks 87-17odor 87-13O-rings 87-6pressure relief valve 87-7pressure switch 87-7refrigerant 87-5 testing 87-14water drain valve 87-25

Air filter element 03-41

Airbags 69-1

See also Seatbelts, Airbags

Alarm 96-7

Alternator (generator)27-14carbon brushes, checking 27-18removing and installing

4-cylinder 27-185-cylinder 27-19

See also Charging system

Antenna 91-7

Anti-freeze 03-22, 19-6

Anti-lock brakes (ABS)components 45-4control module 45-10warning light functions 45-9wheel speed sensors 45-11

Anti-theft system 96-6

Automatic transmissionATF cooler 37-28automatic shift-lock 37-13basic settings 37-3driveplate clearance 13-11electrical components 37-6

transmission range switch 37-7vehicle speed sensor 37-7

removing and installing 37-17selector lever cable 37-9shift-lock cable 37-13shift mechanism 37-9torque convertor 37-27

B

Back-up light switchmanual transmission 34a-19

Battery 27-3charging 27-5removing and installing 27-8tests 27-4

Bleeding brakes 47-12

Body–exterior equipmentroof moldings 66-8side-view mirror 66-1wheel housing liner 66-6

Bodycomponents 50-2front fender 50-3front noise insulation 50-5lock carrier 50-4noise insulation 50-6plenum close out panel 50-7rear fender 53-2

Boost pressure21-3

Brake fluid03-24, 47-12

Brakesbleeding 47-12booster 47-20brake pressure regulator 47-10caliper 47-3front 46-3master cylinder 47-19master cylinder and brake booster 47-14

parking brake 46-12rear 46-9vacuum check valve 47-15vacuum pump 47-15

Brake light switch 45-7

Bumpers63-2

C

Caliper, brake47-3

Campaign Circularsappendix D

CD changer 91-8

Central locking 57-2See also Keyless remote entry

Charging system27-12See also Alternator (generator)

Clutchactuating mechanism 30-2assembly 30-13disc, centering 30-13hydraulics 30-5

bleeding 30-10master cylinder 30-6

over-center spring 30-3pedal 30-2, 30-4release mechanism 30-11

Comfort and convenience 57-26

Component locations (electrical)97-12

Compression test1.8L engine 15a-21.9L engine 15b-22.0L engine 15c-22.5L engine 15d-2

Connecting rods13-12

Console, center70-1

Convertiblecomponent locations appendix Cdoor window service appendix Bemergency closing 61-2end position, checking 61-3hydraulic system 61-5maintenance 61-1overview of components 61-4power window pinch protection, resetting 61-3

rear side window service appendix Bresetting open/close system 61-3rollover protection and body reinforcements appendix C

top outer shell replacement appendix B

2 INDEX

CoolantSee Anti-freeze

Coolant pumpreplacing

1.8L engine 19-141.9L engine 19-172.0L engine 19-192.5L engine 19-26

Cooling systemanti-freeze (coolant) 03-22, 19-6components


draining and filling 19-11fans and thermo-switch 19-7pressure testing 19-6radiator and cooling fan 19-3thermostat

4-cylinder 19-235-cylinder 19-32testing 19-10

troubleshooting 19-4

Crankshaft 13-18front oil seal 13-4rear oil seal 13-4

Cylinder blockinternal components 13-12oil seals 13-2

CV joint 40-15

Cylinder head and valvetrain, 1.8L engine

camshaft 15a-10oil seals 15a-7

compression test 15a-2cylinder head

components 15a-32cover 15a-6service 15a-3

hydraulic cam followers 15a-14leakdown test 15a-3timing belt 15a-18valves 15a-33

Cylinder head and valvetrain, 1.9L Engine

camshaft 15b-15oil seal 15b-5

compression test 15b-2cylinder head

ALH engine 15b-4BEW engine 15b-20components 15b-39

hydraulic cam followers 15b-17timing belt 15b-23valves 15b-40

Cylinder head and valvetrain, 2.0L engine

camshaft 15c-8oil seal 15c-7

compression test 15c-2cylinder head

components 15c-24cover 15c-6service 15c-3

hydraulic cam followers 15c-10leakdown test 15c-3timing belt 15c-14valves 15c-26

Cylinder head and valvetrain,2.5L engine

camshaft adjustment valve 15d-9chain guard cover 15d-6

seal, replacing 15d-9compression test 15d-2cylinder head 15d-4leakdown test 15d-3timing chain 15d-10valvetrain assembly 15d-10

D

Dashboard70-28

Diesel fuel injection 23-1

Disc brakes 46-1

Doorsadjusting 57-9assembly

convertible 57-4sedan 57-3

central locking 57-2handle 57-12keyless remote control 57-28lock

button 57-19cylinder housing 57-11removing door lock 57-13

panel 70-13See also Windows

Drive axles axle nut, tightening 40-8constant velocity (CV) joint 40-9, 40-15

triple-roller joint 40-17

Drive belt1.8L engine 15a-181.9L engine 15b-232.0L engine 15c-14

Driveplate13-10

DSG transmissioncomponents 34b-9electrical components 34b-8oil

changing 34b-3checking level 34b-6

selector cable 34b-12selector lever 34b-11shift mechanism 34b-11

Dust and pollen filter80-8

E

EGR (exhaust gas recirculation)26-16

Electrical systemcomponent locations 97-13fuses 97-2relays 97-7test equipment 9-3troubleshooting 9-4voltage and polarity 9-1wiring diagrams EWD-1

Electronic accelerator (E-gas) system20-22

Emission controls 26-14

Enginegeneral 1-1mounts


removing and installing4-cylinder 10-25-cylinder 10-13

Engine lubricationlubrication system


oil cooler 17-12oil filter flange


oil pan 17-9oil pressure warning system 17-2oil pump 17-11oil spray nozzles 17-12

Engine managementSee Fuel injection

Evaporative emissions (EVAP)26-14

INDEX 3

WARNING—


Exhaust systemcatalytic converter 26-26combi-valve 26-25exhaust manifold 26-6front exhaust pipe and catalyst


installation details 26-12replacement 26-3

F

Fenderfront 50-3rear 53-2

Flywheel 13-10

Fog light 94-11

Front suspension and drive axlescoil spring, removing and installing 40-13

front suspension strut 40-10subframe/stabilizer bar/control arm assembly 40-3control arm bushings 40-5ball joint, checking axial/radial play 40-4

rear bushing for control arm 40-4suspension struts 40-10wheel bearings 40-5wheel hub 40-8

Fuel, ignition, and exhaust systemsdiesel turbo direct injection (TDI) 2-5emission controls 2-12fuel injection 2-2fuel supply 2-1ignition system 2-12 motronic 5.9.2 overview 2-3motronic ME 7 overview 2-9

Fuel filter 20-17

Fuel injection–diesel (TDI)basic fuel delivery, checking 23-7diagnostic quick checks 23-4EGR 26-26engine control module 23-2fuel injection system, components

1.9L: ALH 23-81.9L: BEW 23-27

fuel shut-off valve, checking 23-6glow plugs

1.9L: ALH 23-221.9L: BEW 23-32

injection pump (1.9L: ALH) 23-11removing and installing 23-13timing, checking/adjusting 23-21

intake manifold assembly1.9L: ALH 23-211.9L: BEW 23-28

readiness code OBD-34testing and replacing glow plugs

1.9L: ALH 23-251.9L: BEW 23-34

throttle position sensor 23-22troubleshooting 23-3

Fuel injection–gasolineadaptation 24-4air cleaner assembly

1.8L engine 24-72.0L engine 24-172.5L engine 24-28

engine control module (ECM) 24-4engine speed sensor

1.8L engine 24-102.0L engine 24-242.5L engine 24-30

exhaust gas recirculation (EGR) 26-26

fuel injection system components1.8L: APH, AWP, AWV 24-51.8L: BKF, BNU 24-62.0L: AEG 24-132.0L: AVH, AZG 24-142.0L: BDC, BGD 24-152.0L: BEV 24-162.5L: BPR, BPS 24-27

fuel injector and fuel rail assembly1.8L 24-72.0L: AEG, AVH, AZG 24-182.0L: BDC 24-192.0L BEV 24-202.0L BGD 24-212.5L 24-28

on-board diagnostics 24-3readiness code OBD-34safety precautions 24-2

Fuel pump 20-3

Fuel storage and supplyevaporative emissions (gasoline engine) 20-14

fuel pump (fuel delivery unit) 20-11troubleshooting 20-3checking 20-5system pressures 20-8

fuel tank and lines 20-17fuel tank assembly

1.8L, 2.0L engines 20-171.9L engine 20-182.5L: BPR 20-192.5L: BPS 20-20

leak detection system 20-14safety precautions 20-2

Fuel tankSee Fuel storage and supply

Fuses97-2

G

GeneratorSee alternator (generator) overview 27-14

Glow plugs (diesel)1.9L: ALH 23-221.9L: BEW 23-32

H

Hand brakeSee Parking brake

Headlight assembly 94-2HID (Xenon) 94-3

Heating and ventilationblower fan 80-9center air outlet console 80-10defroster air outlet panel 80-11dust and pollen filter 80-8heater assembly 80-12

central flap lever 80-12heater core bulkhead seal 80-12

heating and ventilation controls 80-2adjusting 80-6cables, installing/adjusting 80-7instrument panel crossmember 80-3side window air vents 80-3

recirculation flap servo 80-13See also Air Conditioning

Hood and lidsfront hood 55-2

lock assembly 55-4release cable assembly 55-3

fuel fill lid 55-13rear lids 55-5


rear lock cylinder carrier 55-11, 55-12

4 INDEX

I

Ignition System–Gasolinecamshaft position sensor 28-14disabling ignition system 28-2ignition coil with power output stage, testing 1.8L engine 28-52.0L engine 28-62.5L engine 28-7

ignition systemcomponents 28-8quick check 28-4troubleshooting 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 connector terminal assignment 90-4

Intercooler 21-16

Interior lights 96-1

J

Jacking 03-11

K

Keyless remote control 57-28changing batteries 03-54

Knock sensorSee Fuel injection–gasoline, fuel injection system components

L

License plate light 94-21

LidSee Hood and lids

Lifting vehicle 03-11

Lights, accessories–exteriorback-up lights 94-19center brake light 94-20fog light bulb, replacing 94-11front lights 94-2front turn signal bulb, replacing 94-13headlights

aim, adjusting 94-7bulb, replacing (halogen) 94-7bulb, replacing (Xenon) 94-8assembly, removing and installing 94-4

license plate light 94-21rear lights 94-16rear side marker lights 94-22side-mounted turn signals 94-15taillight 94-16

bulbs, replacing 94-18removing and installing 94-17

Lights, accessories–interiorglove compartment light 96-5instrument panel

dimmer switch 96-2switches–center 96-4

interior light 96-4interior lights and switches 96-1interior lock switch–passenger side 96-3

light switch 96-2luggage compartment light 96-5make-up mirror light 96-5mirror adjustment switch 96-3remote fuel tank/rear lid unlock switch 96-3

M

Maintenancebody and interior 03-49

airbag inspection 03-50clock and outside temperature, setting 03-51

dust and pollen filter 03-53keys and remote controls, replacing batteries 03-54

radio anti-theft coding 03-56engine compartment 03-13

air filter 03-41battery service 03-30coolant 03-22engine oil 03-16fluid leaks 03-28ribbed V-belt 03-32sound absorber panels 03-13spark plugs 03-37timing belt, checking 03-36

how to use this manual 03-2identification plates and labels

engine identification 03-6transmission identification 03-7vehicle identification number (VIN) 03-5

lifting vehicle 03-11maintenance schedules 03-61road test 03-60towing 03-8under car maintenance 03-42

brake inspection 03-43exhaust 03-48suspension 03-44tire service 03-42transmission 03-44

Manual transmissiongear selector cables, assembly 34a-3gear selector knob 34a-6gear selector lever 34a-8removing and installing 34-18

Master cylinderbrake 47-14clutch 30-6

Mirrorsexterior 66-1interior, rear view 70-8

O

Oil, changing 03-18

Oil filter1.8L, 2.0L engine 03-191.9L engine 03-202.5L engine 03-21

INDEX 5

WARNING—


P

Parking brake 46-12

Pistonprojection at TDC (diesel)13-17rings 13-17

Positive crankcase ventilation (PCV)26-15

Power steering 48-14

Power windows 57-1

R

Radioantenna

satellite 91-8standard 91-7

anti-theft coding 03-56CD changer 91-8Ipod adapter 91-8radio anti-theft system 91-15radio head unit 91-14radio reception 91-2radio system 91-3

Rear hatchSee Hood and lids

Rear suspensionoverview 42-3rear coil spring 42-7rear shock absorbers 42-5rear suspension

bonded rubber axle beam bushing, installed position 42-4

upper spring seat and coil spring, installed position 42-4

rear wheel bearings 42-8

Recall campaignsappendix D

Relays97-2

S

Seatbelts, airbagsairbags 69-13

control module 69-16passenger front airbag 69-23sensors (impact) 69-22side airbag units 69-20spiral spring/slip ring 69-19unit in steering wheel 69-17

seatbelts, frontconvertible 69-8sedan 69-7

seatbelts, inspecting 69-4seatbelts, rear


side airbag units 69-20special precautions 69-2, 69-14

Seatsfront 72-1, 72-4front adjustment cable 72-7front seatback 72-6head restraint guides 72-5rear 72-8

release mechanism 72-11

Secondary air injection26-20

Shift-lock 37-13

Slave cylinder 30-8

Sound systemSee Radio

Spark plugs, replacing1.8L engine 03-372.0L engine 03-382.5L engine 03-39

Starter27-23bushing 27-25service 27-22

Steeringpower steering

fluid reservoir 48-16hydraulic lines 48-18pump 48-19

steering wheel 48-2steering column 48-7

ignition lock cylinder and switch 48-11

lock housing 48-8

Suspension, frontSee Front Suspension and Drive Axles

Suspension, rearSee Rear Suspension

T

Taillight 94-7

ThermostatSee Cooling system

Timing belt1.8L engine 15a-181.9L engine

ALH 15b-23BEW 15b-29

2.0L engine 15c-14

Timing chain2.5L engine 15d-10

Tireservice 03-42See Wheels–Tires, Wheel Alignment

Transmissionautomatic 37-1DSG transmission 34b-1manual 34a-1

Trim–Interiorcenter console70-1interior equipment70-7

glove box 70-7rear view mirror 70-8roof handle 70-9sun visor 70-10

instrument panel, removing an installing 70-28

trim panelsA-pillar 70-10B-pillar 70-11C-pillar 70-12door panel 70-13inner plenum covers 70-16rear panels 70-18 to 70-24sill panel 70-25steering column lower trim 70-26

Turbochargerassembly

1.8L engine 21-71.9L engine 21-13

boost pressure 21-3diagnostics 21-2intercooler 21-16

V

Valve coverSee Cylinder head and valvetrain

Vehicle Identification Number (VIN) 03-5

See also Maintenance

VentilationSee Heating and ventilation

6 INDEX

W

Warning light functions (ABS) 45-9

Water pumpSee Coolant pump

Wheel AlignmentSee Wheels–Tires, Wheel Alignment

Wheel bearingfront 40-5rear 42-8

Wheels–tires, wheel alignmentalignment requirements 44-4thrust angle, calculating 44-6wheel alignment 44-2

checking 44-4specifications 44-5

Windowglass 57-23power windows 57-1

Wipers and washersheadlight washer system 92-8

jets 92-9reservoir 92-9

rubber wiper inserts, replacing 92-2windshield washer overview 92-6wiper assembly 92-3wiper blade park position 92-3wiper motor 92-4

Wiring diagramselectrical wiring diagrams EWD-1fuses and relays 97-2ground locations 97-12how to read wiring diagrams EWD-4symbols used in wiring diagramsEWD-6

terminal (circuit) identification EWD-4wiring repairs EWD-6

established 1950Automotive Reference™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

Volkwagen New Beetle Service Manual: 1998-2010 including convertible

Price: $139.95Bentley Stock No: VB10Publication Date: 2010.sept.1ISBN: 978-0-8376-1640-7Hardcover, 8 3/8 in. x 11 in.Case quantity: 11664 pages, 2647 photos, illustrations and diagrams

The Volkswagen New Beetle Repair Manual: 1998-2010 is a comprehensive source of service information and specifica-tions for the New Beetle from 1998 to 2010. Whether you’re a professional or a do-it-yourself Volkswagen owner, this manu-al will help you understand, care for and repair your vehicle.

Features:

• 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 recondition-ing, including camshaft timing belt replacement.

• Explanation of Motronic 5.9.2, ME7 and Diesel Turbo Direct Injection (TDI) engine management systems.

• Emission control tests, repairs and adjustments, includ-ing Exhaust Gas Recirculation (EGR) and Secondary Air Injection (AIR) system.

• Drivetrain maintenance, troubleshooting, adjustment and repair, including hydraulic clutch, gearshift linkage, and drive axles.

• Suspension component replacement, including front struts, rear shocks, rear coil springs, and wheel bearing/hub units.

• Coverage of ABS/EDL/ASR/ESP brake and drivetrain systems.

• Heating and air conditioning repair, including A/C com-ponent replacement

Models, engines and transmissions covered

Models and engines

1.8L turbo gasoline (engine code: APH, AWV, AWP, BKF, BNU)1.9L TDI diesel (engine code: ALH, BEW)2.0L gasoline (engine code: AEG, AVH, AZG, BDC, BEV, BGD2.5 L gasoline (engine code: BPR, BPS)

Transmissions (remove, install, external service)

Manual 5-speed 02JManual 5- and 6-speed 02MManual 5-speed 0A4Automatic 4-speed 01MAutomatic 6-speed 09GDSG 6-speed 02E

Fully detailed exploded views including front body assembly.50 Body-Front

BentleyPublishers.com

See how to perform routine maintenance procedures, such as checking fluids. 03 Maintenance

bentley_vb10_new.product.announcement.pdf

Bentley repair manuals provide the highest level of clarity and comprehensiveness for service and repair procedures. If you’re looking an indispensable source concerning operation, mainte-nance and repair, look no further than Bentley.

Documents

Volkswagen New Beetle Repair Manual: 1998-2010 - Complete Index