INDEX 1

Anti-lock brakes (ABS) Brake light switch

WARNING— components 45-4 45-7
control module 45-10
• Your common sense, good judgement, Bumpers
warning light functions 45-9
and general alertness are crucial to 63-2
wheel speed sensors 45-11
safe and successful service work.
Before attempting any work on your Anti-theft system 96-6
Volkswagen, read 00 Warnings and
Cautions and the copyright page at
Automatic transmission C
ATF cooler 37-28
the front of the manual. Review these
automatic shift-lock 37-13 Caliper, brake
warnings and cautions each time you
basic settings 37-3 47-3
prepare to work on your Volkswagen.
driveplate clearance 13-11
Please also read any warnings and Campaign Circulars
electrical components 37-6
cautions that accompany the appendix D
transmission range switch 37-7
procedures in the manual.
vehicle speed sensor 37-7 CD changer
removing and installing 37-17 91-8
selector lever cable 37-9
Central locking
shift-lock cable 37-13
A 57-2
shift mechanism 37-9
See also Keyless remote entry
torque convertor 37-27
ABS Charging system
See Anti-lock brakes (ABS) 27-12
Air conditioning See also Alternator (generator)
B
belt routing 87-26 Clutch
components 87-5 Back-up light switch actuating mechanism 30-2
passenger compartment 87-18 manual transmission 34a-19 assembly 30-13
replacement 87-9 disc, centering 30-13
underhood 87-24 Battery
hydraulics 30-5
compressor 87-31 27-3
bleeding 30-10
mounting bracket 87-26 charging 27-5
master cylinder 30-6
condenser 87-11 removing and installing 27-8
over-center spring 30-3
controls 87-18 tests 27-4
pedal 30-2, 30-4
evaporator 87-12 Bleeding brakes release mechanism 30-11
idler pulley 87-27 47-12
leaks 87-17 Comfort and convenience
odor 87-13 Body–exterior equipment 57-26
O-rings 87-6 roof moldings 66-8
Component locations (electrical)
pressure relief valve 87-7 side-view mirror 66-1
97-12
pressure switch 87-7 wheel housing liner 66-6
refrigerant 87-5 Compression test
Body
testing 87-14 1.8L engine 15a-2
components 50-2
water drain valve 87-25 1.9L engine 15b-2
front fender 50-3
2.0L engine 15c-2
Air filter element front noise insulation 50-5
2.5L engine 15d-2
03-41 lock carrier 50-4
noise insulation 50-6 Connecting rods
Airbags plenum close out panel 50-7 13-12
69-1 rear fender 53-2
See also Seatbelts, Airbags Console, center
Boost pressure 70-1
Alarm 21-3
96-7 Convertible
Brake fluid component locations appendix C
Alternator (generator) 03-24, 47-12 door window service appendix B
27-14 emergency closing 61-2
carbon brushes, checking 27-18 Brakes
end position, checking 61-3
removing and installing bleeding 47-12
hydraulic system 61-5
4-cylinder 27-18 booster 47-20
maintenance 61-1
5-cylinder 27-19 brake pressure regulator 47-10
overview of components 61-4
See also Charging system caliper 47-3
power window pinch protection,
front 46-3
Antenna resetting 61-3
master cylinder 47-19
91-7 rear side window service appendix B
master cylinder and brake booster
resetting open/close system 61-3
Anti-freeze 47-14
rollover protection and body
03-22, 19-6 parking brake 46-12
reinforcements appendix C
rear 46-9
top outer shell replacement
vacuum check valve 47-15
appendix B
vacuum pump 47-15
2 INDEX

Coolant Cylinder head and valvetrain, DSG transmission

See Anti-freeze 2.0L engine components 34b-9
camshaft 15c-8 electrical components 34b-8
Coolant pump
oil seal 15c-7 oil
replacing
compression test 15c-2 changing 34b-3
1.8L engine 19-14
cylinder head checking level 34b-6
1.9L engine 19-17
components 15c-24 selector cable 34b-12
2.0L engine 19-19
cover 15c-6 selector lever 34b-11
2.5L engine 19-26
service 15c-3 shift mechanism 34b-11
Cooling system hydraulic cam followers 15c-10
Dust and pollen filter
anti-freeze (coolant) 03-22, 19-6 leakdown test 15c-3
80-8
components timing belt 15c-14
4-cylinder 19-13 valves 15c-26
5-cylinder 19-24
Cylinder head and valvetrain,
draining and filling 19-11 E
2.5L engine
fans and thermo-switch 19-7
camshaft adjustment valve 15d-9
pressure testing 19-6 EGR (exhaust gas recirculation)
chain guard cover 15d-6
radiator and cooling fan 19-3 26-16
seal, replacing 15d-9
thermostat
compression test 15d-2 Electrical system
4-cylinder 19-23
cylinder head 15d-4 component locations 97-13
5-cylinder 19-32
leakdown test 15d-3 fuses 97-2
testing 19-10
timing chain 15d-10 relays 97-7
troubleshooting 19-4
valvetrain assembly 15d-10 test equipment 9-3
Crankshaft troubleshooting 9-4
13-18 voltage and polarity 9-1
front oil seal 13-4 wiring diagrams EWD-1
D
rear oil seal 13-4
Electronic accelerator (E-gas) system
Cylinder block Dashboard 20-22
internal components 13-12 70-28
Emission controls
oil seals 13-2
Diesel fuel injection 26-14
CV joint 23-1
Engine
40-15
Disc brakes general 1-1
Cylinder head and valvetrain, 46-1 mounts
1.8L engine 4-cylinder 10-12
Doors
camshaft 15a-10 5-cylinder 10-20
adjusting 57-9
oil seals 15a-7 removing and installing
assembly
compression test 15a-2 4-cylinder 10-2
convertible 57-4
cylinder head 5-cylinder 10-13
sedan 57-3
components 15a-32
central locking 57-2 Engine lubrication
cover 15a-6
handle 57-12 lubrication system
service 15a-3
keyless remote control 57-28 4-cylinder 17-5
hydraulic cam followers 15a-14
lock 5-cylinder 17-13
leakdown test 15a-3
button 57-19 oil cooler 17-12
timing belt 15a-18
cylinder housing 57-11 oil filter flange
valves 15a-33
removing door lock 57-13 4-cylinder 17-6
Cylinder head and valvetrain, panel 70-13 5-cylinder 17-14
1.9L Engine See also Windows oil pan 17-9
camshaft 15b-15 oil pressure warning system 17-2
Drive axles
oil seal 15b-5 oil pump 17-11
axle nut, tightening 40-8
compression test 15b-2 oil spray nozzles 17-12
constant velocity (CV) joint 40-9,
cylinder head
40-15 Engine management
ALH engine 15b-4
triple-roller joint 40-17 See Fuel injection
BEW engine 15b-20
components 15b-39 Drive belt Evaporative emissions (EVAP)
hydraulic cam followers 15b-17 1.8L engine 15a-18 26-14
timing belt 15b-23 1.9L engine 15b-23
valves 15b-40 2.0L engine 15c-14
Driveplate
13-10
 INDEX 3

Fuel injection–diesel (TDI) Fuel storage and supply

WARNING— basic fuel delivery, checking 23-7 evaporative emissions
diagnostic quick checks 23-4 (gasoline engine) 20-14
• Your common sense, good judgement,
EGR 26-26 fuel pump (fuel delivery unit) 20-11
and general alertness are crucial to
engine control module 23-2 troubleshooting 20-3
safe and successful service work.
fuel injection system, components checking 20-5
Before attempting any work on your
1.9L: ALH 23-8 system pressures 20-8
Volkswagen, read 00 Warnings and
1.9L: BEW 23-27 fuel tank and lines 20-17
Cautions and the copyright page at
fuel shut-off valve, checking 23-6 fuel tank assembly
the front of the manual. Review these
glow plugs 1.8L, 2.0L engines 20-17
warnings and cautions each time you
1.9L: ALH 23-22 1.9L engine 20-18
prepare to work on your Volkswagen.
1.9L: BEW 23-32 2.5L: BPR 20-19
Please also read any warnings and
injection pump (1.9L: ALH) 23-11 2.5L: BPS 20-20
cautions that accompany the
removing and installing 23-13 leak detection system 20-14
procedures in the manual.
timing, checking/adjusting 23-21 safety precautions 20-2
intake manifold assembly
Fuel tank
1.9L: ALH 23-21
See Fuel storage and supply
1.9L: BEW 23-28
Exhaust system readiness code OBD-34 Fuses
catalytic converter 26-26 testing and replacing glow plugs 97-2
combi-valve 26-25 1.9L: ALH 23-25
exhaust manifold 26-6 1.9L: BEW 23-34
front exhaust pipe and catalyst throttle position sensor 23-22
4-cylinder 26-4 G
troubleshooting 23-3
5-cylinder 26-9
installation details 26-12 Fuel injection–gasoline Generator
replacement 26-3 adaptation 24-4 See alternator (generator) overview
air cleaner assembly 27-14
1.8L engine 24-7
Glow plugs (diesel)
2.0L engine 24-17
F 2.5L engine 24-28
1.9L: ALH 23-22
1.9L: BEW 23-32
engine control module (ECM) 24-4
Fender engine speed sensor
front 50-3 1.8L engine 24-10
rear 53-2 2.0L engine 24-24 H
Flywheel 13-10 2.5L engine 24-30
exhaust gas recirculation (EGR) Hand brake
Fog light 94-11 26-26 See Parking brake
Front suspension and drive axles fuel injection system components
Headlight
coil spring, removing and installing 1.8L: APH, AWP, AWV 24-5
assembly 94-2
40-13 1.8L: BKF, BNU 24-6
HID (Xenon) 94-3
front suspension strut 40-10 2.0L: AEG 24-13
subframe/stabilizer bar/control arm 2.0L: AVH, AZG 24-14 Heating and ventilation
assembly 40-3 2.0L: BDC, BGD 24-15 blower fan 80-9
control arm bushings 40-5 2.0L: BEV 24-16 center air outlet console 80-10
ball joint, checking axial/radial play 2.5L: BPR, BPS 24-27 defroster air outlet panel 80-11
40-4 fuel injector and fuel rail assembly dust and pollen filter 80-8
rear bushing for control arm 40-4 1.8L 24-7 heater assembly 80-12
suspension struts 40-10 2.0L: AEG, AVH, AZG 24-18 central flap lever 80-12
wheel bearings 40-5 2.0L: BDC 24-19 heater core bulkhead seal 80-12
wheel hub 40-8 2.0L BEV 24-20 heating and ventilation controls 80-2
2.0L BGD 24-21 adjusting 80-6
Fuel, ignition, and exhaust systems 2.5L 24-28 cables, installing/adjusting 80-7
diesel turbo direct injection (TDI) 2-5 on-board diagnostics 24-3 instrument panel crossmember 80-3
emission controls 2-12 readiness code OBD-34 side window air vents 80-3
fuel injection 2-2 safety precautions 24-2 recirculation flap servo 80-13
fuel supply 2-1
See also Air Conditioning
ignition system 2-12 Fuel pump 20-3
motronic 5.9.2 overview 2-3 Hood and lids
motronic ME 7 overview 2-9 front hood 55-2
lock assembly 55-4
Fuel filter 20-17
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 Lights, accessories–exterior M
back-up lights 94-19
Ignition System–Gasoline center brake light 94-20 Maintenance
camshaft position sensor 28-14 fog light bulb, replacing 94-11 body and interior 03-49
disabling ignition system 28-2 front lights 94-2 airbag inspection 03-50
ignition coil with power output stage, front turn signal bulb, replacing 94-13 clock and outside temperature,
testing headlights setting 03-51
1.8L engine 28-5 aim, adjusting 94-7 dust and pollen filter 03-53
2.0L engine 28-6 bulb, replacing (halogen) 94-7 keys and remote controls, replacing
2.5L engine 28-7 bulb, replacing (Xenon) 94-8 batteries 03-54
ignition system assembly, removing and installing radio anti-theft coding 03-56
components 28-8 94-4 engine compartment 03-13
quick check 28-4 license plate light 94-21 air filter 03-41
troubleshooting 28-3 rear lights 94-16 battery service 03-30
rear side marker lights 94-22 coolant 03-22
Immobilizer 96-6
side-mounted turn signals 94-15 engine oil 03-16
Instrument cluster 90-2 taillight 94-16 fluid leaks 03-28
bulbs, replacing 94-18 ribbed V-belt 03-32
Instruments
removing and installing 94-17 sound absorber panels 03-13
instrument cluster, removing and
Lights, accessories–interior spark plugs 03-37
installing 90-2
timing belt, checking 03-36
malfunction recognition and display glove compartment light 96-5
how to use this manual 03-2
90-2 instrument panel
dimmer switch 96-2 identification plates and labels
multi-pin connector terminal
engine identification 03-6
assignment 90-4 switches–center 96-4
transmission identification 03-7
interior light 96-4
Intercooler 21-16 interior lights and switches 96-1 vehicle identification number
(VIN) 03-5
Interior lights 96-1 interior lock switch–passenger side
lifting vehicle 03-11
96-3
light switch 96-2 maintenance schedules 03-61
road test 03-60
luggage compartment light 96-5
J make-up mirror light 96-5
towing 03-8
mirror adjustment switch 96-3 under car maintenance 03-42
Jacking 03-11 brake inspection 03-43
remote fuel tank/rear lid unlock switch
exhaust 03-48
96-3
suspension 03-44
tire service 03-42
K
transmission 03-44
Keyless remote control Manual transmission
57-28 gear selector cables, assembly 34a-3
changing batteries 03-54 gear selector knob 34a-6
gear selector lever 34a-8
Knock sensor
removing and installing 34-18
See Fuel injection–gasoline, fuel
injection system components Master cylinder
brake 47-14
clutch 30-6
L Mirrors
exterior 66-1
License plate light 94-21 interior, rear view 70-8
Lid
See Hood and lids
O
Lifting vehicle 03-11
Oil, changing 03-18
Oil filter
1.8L, 2.0L engine 03-19
1.9L engine 03-20
2.5L engine 03-21
 INDEX 5

S Thermostat
WARNING— See Cooling system
• Your common sense, good judgement, Seatbelts, airbags
Timing belt
and general alertness are crucial to airbags 69-13
1.8L engine 15a-18
safe and successful service work. control module 69-16
1.9L engine
Before attempting any work on your passenger front airbag 69-23
ALH 15b-23
Volkswagen, read 00 Warnings and sensors (impact) 69-22
BEW 15b-29
Cautions and the copyright page at side airbag units 69-20
2.0L engine 15c-14
the front of the manual. Review these spiral spring/slip ring 69-19
warnings and cautions each time you unit in steering wheel 69-17 Timing chain
prepare to work on your Volkswagen. seatbelts, front 2.5L engine 15d-10
Please also read any warnings and convertible 69-8
Tire
cautions that accompany the sedan 69-7
service 03-42
procedures in the manual. seatbelts, inspecting 69-4
See Wheels–Tires, Wheel Alignment
seatbelts, rear
convertible 69-10 Transmission
sedan 69-9 automatic 37-1
side airbag units 69-20 DSG transmission 34b-1
P special precautions 69-2, 69-14 manual 34a-1

Parking brake 46-12 Seats Trim–Interior

front 72-1, 72-4 center console70-1
Piston front adjustment cable 72-7 interior equipment70-7
projection at TDC (diesel)13-17 front seatback 72-6 glove box 70-7
rings 13-17 head restraint guides 72-5 rear view mirror 70-8
Positive crankcase ventilation (PCV) rear 72-8 roof handle 70-9
26-15 release mechanism 72-11 sun visor 70-10
instrument panel, removing an
Power steering 48-14 Secondary air injection
installing 70-28
26-20
Power windows 57-1 trim panels
Shift-lock 37-13 A-pillar 70-10
B-pillar 70-11
Slave cylinder 30-8
C-pillar 70-12
R Sound system door panel 70-13
See Radio inner plenum covers 70-16
Radio rear panels 70-18 to 70-24
antenna Spark plugs, replacing
sill panel 70-25
satellite 91-8 1.8L engine 03-37
steering column lower trim 70-26
standard 91-7 2.0L engine 03-38
anti-theft coding 03-56 2.5L engine 03-39 Turbocharger
CD changer 91-8 assembly
Starter
Ipod adapter 91-8 1.8L engine 21-7
27-23
radio anti-theft system 91-15 1.9L engine 21-13
bushing 27-25
radio head unit 91-14 boost pressure 21-3
service 27-22
radio reception 91-2 diagnostics 21-2
radio system 91-3 Steering intercooler 21-16
power steering
Rear hatch fluid reservoir 48-16
See Hood and lids hydraulic lines 48-18
V
Rear suspension pump 48-19
overview 42-3 steering wheel 48-2
Valve cover
rear coil spring 42-7 steering column 48-7
See Cylinder head and valvetrain
rear shock absorbers 42-5 ignition lock cylinder and switch
rear suspension 48-11 Vehicle Identification Number (VIN)
bonded rubber axle beam bushing, lock housing 48-8 03-5
installed position 42-4 See also Maintenance
Suspension, front
upper spring seat and coil spring, See Front Suspension and Drive Ventilation
installed position 42-4 Axles See Heating and ventilation
rear wheel bearings 42-8
Suspension, rear
Recall campaigns See Rear Suspension
appendix D
Relays
97-2 T

Taillight 94-7
6 INDEX

Warning light functions (ABS)

45-9
Water pump
See Coolant pump
Wheel Alignment
See Wheels–Tires, 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 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

Service Manual: 1998-2010
including convertible
Price: $139.95
Bentley Stock No: VB10
Publication Date: 2010.sept.1
ISBN: 978-0-8376-1640-7
Hardcover, 8 3/8 in. x 11 in.
Case quantity: 1
1664 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.
Fully detailed exploded views
Features: including front body assembly.
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 recondition-
ing, including camshaft timing belt replacement.
• Explanation of Motronic 5.9.2, ME7 and Diesel Turbo
See how to perform routine
Direct Injection (TDI) engine management systems. maintenance procedures, such
as checking fluids.
• Emission control tests, repairs and adjustments, includ- 03 Maintenance
ing Exhaust Gas Recirculation (EGR) and Secondary Air
Injection (AIR) system.
Models, engines and transmissions
• Drivetrain maintenance, troubleshooting, adjustment and
covered
repair, including hydraulic clutch, gearshift linkage, and
drive axles. Models and engines
• Suspension component replacement, including front 1.8L turbo gasoline (engine code: APH, AWV, AWP,
struts, rear shocks, rear coil springs, and wheel bearing/hub BKF, BNU)
1.9L TDI diesel (engine code: ALH, BEW)
units.
2.0L gasoline (engine code: AEG, AVH, AZG, BDC,
• Coverage of ABS/EDL/ASR/ESP brake and drivetrain BEV, BGD
systems. 2.5 L gasoline (engine code: BPR, BPS)

• Heating and air conditioning repair, including A/C com- Transmissions (remove, install, external service)
ponent replacement Manual 5-speed 02J
Manual 5- and 6-speed 02M
Bentley repair manuals provide the highest level of clarity and Manual 5-speed 0A4
comprehensiveness for service and repair procedures. If you’re Automatic 4-speed 01M
looking an indispensable source concerning operation, mainte- Automatic 6-speed 09G
DSG 6-speed 02E
nance and repair, look no further than Bentley.

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA

Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235
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