Volkswagen New Beetle Repair Manual 1998-2005 by Chilton

CYLINDER HEAD | CLEANING AND INSPECTION

1. Thorough cleaning of the cylinder head and related valve train components, followed by a detailed inspection, will enable you to decide how much valve service work must be done during the engine overhaul.
   
   NOTE: If the engine was severely overheated, the cylinder head is probably warped (see Step 12).
   
   CLEANING
   
   
2. Scrape all traces of old gasket material and sealant off the head gasket, intake manifold and exhaust manifold mating surfaces. Be very careful not to gouge the cylinder head. Special gasket-removal solvents that soften gaskets and make removal much easier are available at auto parts stores.



3. Remove all built-up scale from the coolant passages.



4. Run a stiff wire brush through the various holes to remove deposits that may have formed in them.



5. Run an appropriate-sized tap into each of the threaded holes to remove corrosion and thread sealant that may be present. If compressed air is available, use it to clear the holes of debris produced by this operation.


WARNING! Wear eye protection when using compressed air!


6. Clean the exhaust manifold and intake manifold stud threads with a wire brush.



7. Clean the cylinder head with solvent and dry it thoroughly.



8. Compressed air will speed the drying process and ensure that all holes and oil passages are clean.

DOOR LATCH, LOCK CYLINDER AND OUTSIDE HANDLE | REMOVAL AND INSTALLATION

LATCH
(Refer to illustrations 17.5, 17.6 and 17.7)

1. Remove the door trim panel (see Section 15). The door latch, radio speaker and window regulator are all attached to a large metal carrier, which must be removed from the door as a unit.



2. Refer to Steps 9 and 10 and remove the lock cylinder.



3. Lower the window glass until the glass track bolts can be loosened (see Section 18). With the glass separated from the regulator, pull the glass up by hand and tape it in the UP position.



4. Refer to Steps 2 and 3 in Section 16 and disconnect the electrical harness for the door, feeding the wires into the door cavity.



5. Remove the two Torx-head mounting screws from the end of the door (it may be necessary to use an impact-type screwdriver to loosen them) and detach the latch from the door (see illustration).



6. Remove the bolts securing the carrier to the door, and then lift it up and out, working towards the hinged end of the door (see illustration). At the rear of the carrier, disconnect the electrical connector at the door lock solenoid.



7. To remove the latch from the carrier, use a punch to drive out the two pins, then flip the latch over and disconnect the cable and the linkage rod (see illustration).



8. Installation is the reverse of the removal procedure.

• Tune-up and routine maintenance
• Gasoline engines
• Diesel engine
• General engine overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission (manual and automatic)
• Driveline
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams