Volkswagen New Beetle 1999 & New Beetle Cabrio 2003 Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Volkswagen New Beetle 1999 & New Beetle Cabrio 2003 Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 185
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Volkswagen New Beetle 1999 & New Beetle Cabrio 2003 Maintenance Manual – PDF DOWNLOAD
1 Engine list 5
2 Service work 10
2 1 Information on LongLife service and time or distance dependent service 10
2 1 1 Service identification 10
2 1 2 LongLife service 10
2 1 3 Time or distance dependent service 11
2 1 4 Flexible service interval display 12
2 2 Service tables 12
2 2 1 Service intervals 13
2 2 2 VW engine oil standards 14
2 2 3 Toothed belt change intervals 15
2 2 4 Filter change intervals 15
2 2 5 Spark plug change intervals 17
2 2 6 Additional work ► 1999 17
2 2 7 Additional work 2000 ► 20
2 2 8 Additional work 2010 ► 24
2 2 9 Service tables with market-specific deviations 27
3 General 29
3 1 Lifting vehicle 29
3 2 Sticker 30
3 2 1 Attaching hotline sticker 30
3 2 4 Attaching „LongLife engine oil“ sticker: 31
3 2 5 Attaching „data sticker“ in customer service schedule 32
3 3 Connecting vehicle diagnosis tester 32
3 4 Severe operating conditions 33
3 5 Vehicle data sticker 33
3 6 Vehicle identification number 34
3 7 Countries with elevated sulphur content in diesel fuel 34
3 8 List of hot countries for changing ATF in the AG4 (01M gearbox) 35
3 9 Engine oil 35
3 10 Engine code and engine number 35
3 11 RME fuel (biodiesel) 35
3 12 Service intervals 36
3 13 Type plate 36
4 Descriptions of work 37
4 1 Removable towing bracket: Check and clean if necessary 39
4 2 Swivel joints: Visual check 41
4 3 Front passenger front airbag: Check activation / deactivation for vehicles without seat occupied recognition 41
4 4 Ambient temperature display: Select temperature units 42
4 5 Automatic gearbox: Changing ATF (01M gearbox) 43
4 6 Automatic gearbox: Changing ATF strainer (01M gearbox) 43
4 7 Automatic gearbox: Check gear oil in final drive (01M gearbox) 43
4 8 Automatic gearbox: Check ATF level, top-up if necessary (01M gearbox) 43
4 9 Automatic gearbox: Check ATF level, top-up if necessary (09G gearbox) 43
4 10 Automatic gearbox: Change ATF (09G gearbox) 43
4 11 Battery: Check using battery tester with printer -VAS 5097A- 43
4 12 Battery: Check battery terminal clamps for secure seating 43
4 13 Checking tyres: Condition, wear pattern, inflation pressures, tread depth 45
4 13 1 Checking condition of tyre 45
4 13 2 Checking wear pattern 45
4 13 4 General notes 46
4 13 5 Checking tyre inflation pressure, correcting if necessary, (for North American and Mexican markets) 47
4 13 6 Checking tyre inflation pressure, correcting if necessary, (for rest of the world markets) 48
4 14 Brake system: Perform visual check for leaks and damage 50
4 15 Front and rear brake pads/linings: Checking thickness 50
4 15 1 Front brake pads: 51
4 15 2 Rear brake pads: 52
4 15 3 Rear drum brake pads: 53
4 16 Brake and clutch system: Change brake fluid 53
4 16 1 Instructions for use and safety 53
4 16 2 Brake fluid specification 53
4 16 3 Procedure, changing brake fluid 54
4 17 Brake fluid level: Check 56
4 17 1 Procedure, brake fluid level: Check 57
4 18 Anti-theft wheel bolts: Installing 57
4 19 Digital clock: Set time and display mode 58
4 20 Direct shift gearbox – DSG -: Change oil and oil filter ( 02E gearbox) 59
4 21 Window regulators: Perform initialisation (activation) 59
4 22 Performing vehicle system test 59
4 23 Protective bellows: Visual check 60
4 24 Checking first aid box expiry date 61
4 25 Poly V-belt: Check condition 61
4 26 Poly V-belt: Adjust tension on engines without automatic tensioning roller 61
4 27 Fuel filter: Renew (diesel engine) 62
4 27 2 Renewing fuel filter: Fuel filter system without regulating valve 64
4 28 Fuel filter: Drain water (diesel engine) 65
4 29 Cooling system: Check frost protection and coolant level 66
4 29 1 Checking frost protection, replenish coolant additive if necessary 66
4 29 2 Check coolant level, replenish coolant if necessary 67
4 30 Air filter: Clean housing and renew filter element 69
4 30 1 Air filter: Cleaning housing and renewing filter element, cleaning strainer if fitted 69
4 31 Engine cover panel -top-: Removing and installing 70
4 31 3 Removing and installing engine cover, 1 8l injection engines 71
4 31 6 Removing and installing engine cover, 2 5l injection engines 74
4 32 Engine compartment cover (noise insulation) -bottom-: Removing and installing 75
4 33 Engine oil level: Check 76
4 34 Engine oil: Drain or extract; renew oil filter and replenish engine oil 76
4 34 1 Draining or extracting engine oil 76
4 34 2 Renewing oil filter 77
4 34 3 Renewing oil filter, 1 4 l injection engine 78
4 34 4 Renewing oil filter, 1 6l, 1 8l, 2 0l injection engines 78
4 34 5 Renewing oil filter, 2 3l petrol engines: 79
4 34 6 Renewing oil filter, SDI/TDI diesel engines: 80
4 34 7 Renewing oil filter, 2 5l injection engines 81
4 34 8 Renewing oil filter, TDI unit injector diesel engines 85
4 34 9 Replenishing engine oil 86
4 35 Engine and components in engine compartment (from above and below): Perform visual check for leaks and damage 86
4 36 Performing road test 86
4 37 Wheel securing bolts: Tighten to specified torque 87
4 38 Reading radio code with fault reader 89
4 39 Radio: Activate anti-theft coding 90
4 39 1 General information 90
4 39 2 Activating anti-theft coding on Volkswagen radio systems 90
4 40 Tyre repair set: Check 91
4 41 Manual gearbox/final drive: Check oil level 92
4 41 1 5-speed manual gearbox 02K 92
4 41 2 5-speed manual gearbox 02J 93
4 41 3 5 and 6-speed manual gearbox 02M 93
4 42 Window wash/wipe system and headlight washer system: Check function 94
4 42 1 Checking windscreen wash/wipe system anti-freeze concentration and replenishing fluid if necessary 94
4 42 2 Window washer system: Check jet setting, adjust jets if necessary 95
4 42 3 Headlight washer system: Check jet setting, adjust jets if necessary 97
4 43 Windscreen wiper blades: Checking park position, if wiper blades »judder«: Checking setting angle 97
4 43 1 Wiper blades: Checking park position and adjusting if necessary 97
4 43 2 Wiper blades: Check setting angle, adjust if necessary 98
4 44 Wiper blade protection: Remove 99
4 44 1 Removing wiper blade protection, version 1 100
4 44 2 Removing wiper blade protection, version 2 101
4 44 3 Changing wiper blade protection, version 3 -transport wiper blade- 101
4 45 Headlight setting: Check, if necessary adjust 102
4 45 1 Headlight adjustment: Check 102
4 45 2 Adjusting headlights with halogen bulbs 105
4 45 3 Adjusting headlights with gas discharge lamps in „Guided Functions“ operating mode 106
4 45 4 Adjusting headlights with gas discharge lamps in „Vehicle Self-diagnosis“ operating mode 107
4 45 5 Adjusting fog lights and other additional lights 109
4 46 Sunroof: Check function, clean and grease guide rails 110
4 47 Sliding sunroof drains: Check flow and clean if necessary 110
4 48 Service interval display: Reset 112
4 48 1 Service interval display: Resetting in vehicles ►04 1999 112
4 48 2 Service interval display: Resetting in vehicles 05 1999 ► 113
4 49 Service interval display: Recoding / adapting 117
4 50 Power assisted steering: Check oil level 124
4 50 1 Fluid cold 124
4 50 2 Oil at operating temperature (above approx 50 °C): 125
4 51 Track rod ends: Check clearance, security and boots 126
4 52 Dust and pollen filter: Renew filter element 126
4 53 Transportation devices: Remove blocking pieces from front axle springs 127
4 54 Transportation anchorage openings: Sealing with caps 129
4 55 Door arrester: Grease 129
4 56 Underbody sealant: Visual check for damage to underbody sealant, underbody panels, routing of lines and plugs 130
4 57 Convertible top end position latch (with electric convertible top actuation): Visual check with convertible top open 130
4 58 Convertible top protective film: Removing (convertible) 131
4 58 1 Opening convertible top electrically 131
4 58 2 Removing convertible top protective film 132
4 59 Camshaft drive toothed belt: Check 133
4 59 1 Checking toothed belt condition 133
4 60 Camshaft drive toothed belt: Checking for wear (SDI/TDI diesel engines) 134
4 61 Toothed belt and idler roller for camshaft drive: Renewing, SDI / TDI diesel engines 134
4 62 Camshaft drive toothed belt: Renewing (unit injector diesel engines) 135
4 63 Camshaft drive belt tensioner: Renewing (unit injector diesel engines) 135
4 64 Camshaft drive toothed belt and toothed belt tensioner: Renewing (4-cylinder 5-valve petrol engines) 135
4 65 Spark plugs: Renew 135
4 65 2 Renewing spark plugs, 2 3l engine 138
4 65 3 Renewing spark plugs, 1 8l engine 140
4 65 4 Renewing spark plugs, 1 6l engine 141
4 65 5 Renewing spark plugs, 2 0l engine 141
4 65 6 Renewing spark plugs, 2 5 l petrol injection engines 142
5 Exhaust emissions test 144
5 1 Exhaust emissions test for petrol engines without OBD 144
5 2 Exhaust emissions test for petrol engines with OBD 152
5 3 Exhaust emissions test for petrol engines, methods to activate disturbance variable for control circuit test according to basic procedure 160
5 3 1 Engine code: AWH 161
5 4 Exhaust emissions test for diesel engines 162
5 4 1 Exhaust emissions test for diesel engines without OBD with diesel tester V A G 1743 162
5 4 2 Exhaust emissions test for diesel engines without OBD with emissions testing station VAS 6300 166
5 4 3 Exhaust emissions test for diesel engines with OBD with emissions testing station VAS 6300 174
6 Glossary 184
S.V 26/01/2025
