This DIY repair and service manual by Haynes, covers all 1998-2010 VW New Beetle models, with 1.8L turbo gasoline 4-cylinder, 2.0L gasoline engine, 2.5L gasoline 5-cylinder, and 1.9L ECO turbocharged 4-cylinder diesel engine.
Note: This manual does not include information specific to 2004-and-later Volkswagen models with TDI-PD diesel motors.
Book Excerpt: 1998-2010 VW New Beetle Repair Manual
CYLINDER HEAD | REMOVAL AND INSTALLATION
WARNING: The engine must be completely cool before beginning this procedure.
NOTE: The cylinder head can be removed with the intake and exhaust manifold/turbocharger attached.
REMOVAL (Refer to illustrations 10.10 and 10.12)
- Drain the engine coolant (see Chapter 1).
- Refer to Chapter 11 and remove the hood and the cowl cover.
- Refer to Section 5 and remove the timing belt. Follow Steps 1 through 20, and then proceed to Step 26.
After driving the camshaft sprocket off the taper on the camshaft, remove the camshaft sprocket and the timing belt tensioner from the engine.
After the timing belt, the timing belt tensioner and the camshaft sprocket have been removed, reinstall the passenger side engine mount to support the engine during the removal and installation of the cylinder head.
- Disconnect the vacuum hose from the EGR valve. Then disconnect the vacuum hose and wire harness from the air shut off valve solenoid at the back of the intake manifold.
- Remove the EGR cooler and pipes (see Chapter 6B).
- Refer to Chapter 4B and remove all the related components from the turbocharger: the front exhaust pipe, the wastegate vacuum hose, the turbocharger support bracket, the air intake duct and pipes from the turbocharger to the air cleaner housing, the oil supply pipe, the oil return pipe and the heat shield.
- Also referring to chapter 4B disconnect and remove the fuel supply and return lines from the injectors and the injection pump head. Be sure to remove all the lines together as an assembly.
- Unplug all electrical connectors, including the glow plug electrical bus connector from the cylinder head, labeling each wire or connector to aid the installation process.
- Refer to Chapter 3 and loosen the clips and disconnect the radiator hoses from the ports on the cylinder head. Loosen the clips and disconnect the coolant reservoir hose and the heater intake and outlet coolant hoses from the ports on the cylinder head.
Also disconnect the electrical connector from the coolant temperature sensor.
FENDERS | REMOVAL AND INSTALLATION
FRONT (Refer to illustrations 13.3a, 13.3b, 13.4a, 13.4b, 13.4c, 13.5, 13.6a, 13.6b and 13.7)
- Loosen the front wheel lug bolts, raise the vehicle, support it securely on jackstands and remove the front wheels.
The front bumper cover is part of the front body clip, which includes the bumper cover and both fenders. It's best to remove the clip as a unit, then separate the fender(s).
NOTE: This is a job for two people.
- Apply wide masking tape along the front edge of the cowl and doors to prevent scratching the paint during fender removal.
- Remove the screws and take out the plastic fenderwell liner (see illustrations).
- Remove the fender-to-cowl mounting bolts (see illustrations).
- Remove the headlight housings, disconnect the turn signal lights, and if equipped, disconnect the electrical connectors at the back of the fog lights (see Chapter 12). Remove the one body bolt inside the headlight housing opening (see illustration).
- Remove the screws along the bottom edge of the front bumper cover and the top of the hood opening (see illustrations).
Subject: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 VW New Beetle service, maintenance, repair. ISBN-10: 1563929945 | ISBN-13: 9781563929946 | Haynes 96009