Volkswagen New Beetle

Body - Exterior

50 Body - Front (Page GR-50) z z z z z z z z z

Body, front

Front end, Assembly overview

Front fender, assembly overview

Lock carrier, removing and installing

Lock carrier, service position

Noise insulation, assembly overview

Plenum close out panel, removing and installing

Tools

Transparent foil protection for front fenders

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-1)

Tools

Special tools and auxiliary items required

3411 Guide rods

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-2)

Lock carrier, removing and installing

1 - Lock carrier with attachments

Removing:

- Remove front panel Page 50-6

- Disconnect bowden cable on lock and disconnect electrical connections.

- Remove bolts - 3 - and - 4 - and bumper support - 5 - .

- Unbolt radiator and condenser from lock carrier.

- Secure radiator and condenser in engine compartment.

Note:

Do not hang condenser from wires

Do not damage wires

- Remove bolts - 10 - .

- Remove lock carrier with connecting panel and lock.

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-3)

Installing:

- Align lock carrier to long members and secure.

- Adjust headlights.

2 - Bolt

Qty. 4

6 Nm (53 in. lb)

For radiator support

3 - Bolt

Qty. 4

30 Nm (22 ft lb)

4 - Bolt

Qty. 4

9 Nm (80 in. lb)

5 - Bumper carrier

With impact absorber

6 - Pop rivet

Qty. 4

7 - Insulation

Bonded with Butyl adhesive cord AKL 450 005 05

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-4)

8 - Connecting panel

Fastened to lock carrier with blind rivets.

9 - Blind rivet nut

Qty. 2

10 - Hood lock

Removing and installing Page 55-8

11 - Bolt

20 Nm (15 ft lb)

12 - Hex bolt (self-locking)

12 Nm (9 ft lb)

When reusing: clean bolt threads with a wire brush and nut threads with thread chaser; coat bolt with locking fluid D 185 400 A 2.

13 - Radiator and condenser

14 - Radiator

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-5)

Lock carrier, service position

- Remove front bumper Page 63-1

- Disconnect bowden cable on lock.

- Remove one bolt - 2 - on each long member and screw special tool 3411 onto right and left long member.

- Remove bolts - 1 - and - 3 - (left and right) and pull lock carrier with special tool 3411 forward.

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-6)

Front end, Assembly overview

Note:

Fenders and bumper cover can only be removed together as an assembly.

1 - Front end

Removing:

- Remove wheel house inner fender Page 66-1 .

- Remove wheel house bolts -2-, -3-, and -8-.

- Disconnect connectors for turn signals, fog lights and temperature sensor -9-.

- Remove nuts -6-.

- Remove spreader clips -10-

- Remove screws -4- and -7-.

- Pull front end, left and right, outward from threaded bolt; and with two technicians pull forward from vehicle.

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-7)

Installing:

- Before installing front end, check anti-abrasive film at contact surfaces; replace if necessary Page 50-11, item 11.

- When installing the front end, ensure the cushion - 5 - fits correctly on the upper long members on both sides.

2 - Bolt

With nut

6 Nm (53 in. lb)

3 - Combi bolt

6 Nm (53 in. lb)

4 - Bolt

Quantity 18

6 1 Nm (53 9 in. lb)

Install with locking compound D 185 400 A2

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-8)

5 - Insulation

6 - Hex nut

6 1 Nm (53 9 in. lb)

7 - Bolt

7.5 Nm (66 in. lb)

Qty. 4

Install with locking compound D 185 400 A2

8 - Bolt

With nut

6 Nm (53 in. lb)

9 - Exterior temperature sensor

10 - Spreader clip

Qty. 3

To remove: Press spreader pin through clip

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-9)

Front fender, assembly overview

Note:

The front fenders are both components of the front end, and are removed as an assembly

Page 50-6 .

1 - Fender

Removing:

- Remove front end Page 50-6, bolts -4- and -7-

Installing:

- Before fastening fender, install a zinc intermediate piece AKL 381 035 50 to each bolt position contact area.

2 - Bolt

Install with locking compound D 185 400 A2

3 - Clip

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-10)

4 - Bolt

Install with locking compound D 185 400 A2

Qty. 3

4.5 1 Nm (40 9 in. lb)

5 - Reinforcement

With holes

6 - Reinforcement

With weld nuts

7 - Bolt

Install with locking compound D 185 400 A2

Qty. 2

4.5 1 Nm (40 9 in. lb)

8 - Front bumper cover

9 - Reinforcement

With holes

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-11)

10 - Reinforcement

With welded nuts

11 - Abrasion protection

Check condition, replace if necessary

12 - Pop rivet

Qty. 20

13 - Bracket

Bolted to front of long member

14 - Bolt

Qty. 2

6 1 Nm (53 9 in. lb)

15 - Close - out panel

Riveted to fender

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-12)

Noise insulation, assembly overview

Note:

Minor deviations may be possible depending on vehicle equipment.

Gas engine vehicles

1 - Noise insulation assembly

Bolted to lock carrier

Bottom panel bolted to side panel

2 - Bolt

Qty. 2

3 - Bolt

Qty. 4

4 - Lock washer

Qty. 4

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-13)

Diesel engine vehicles

1 - Noise insulation

Bolted to lock carrier

2 - Bolt

Qty. 10

3 - Bolt

Qty. 2

4 - Lock washer

Qty. 4

Volkswagen New Beetle

Body - Exterior

Body, front (Page 50-14)

Plenum close - out panel, removing and installing

1 - Plenum close - out panel

Removing:

- Remove plenum closeout panel (outer).

- Remove seal from edge of closeout panel.

- If necessary, disassemble components from closeout panel

- Remove bolt - 4 - and nut - 3 - then remove brace - 5 - .

- Remove close - out panel - 1 - .

2 - Bolt

3 - Hex nut, 70 Nm (52 ft lb)

4 - Combi bolt

5 - Brace

Volkswagen New Beetle

Body - Exterior

Transparent foil protection for front fenders (Page 50-15)

Beginning with production, a new transparent foil protection is being installed on front and rear fenders

Materials:

Transparent foil protection (left/right)

1.- p/n 1C0 807 907 A/908 A

2.- p/n 1C0 821 713 B/714 B

3.- p/n 1C0 853 843 / 844 A

4.- p/n 1C0 853 387 A/ 388 A

5.- p/n 1C0 821 711 B/712 B

CAUTION!

Transparent foil protection must be applied at 15 - 30 C (60 - 90 F) on clean dry surface.

Volkswagen New Beetle

Body - Exterior

Transparent foil protection for front fenders (Page 50-16)

Sticker -6- must be installed under release lever to avoid nail scratches while opening.

(p/n 867 807 637)

- Locate sticker -7- as shown in illustration. (p/n 1HM 837 997)

- Verify rear lid rubber stop rests against center of sticker -7-.

CAUTION!

Note:

In order to increase thickness and strength of foil, two must be used on each side

(one over the other).

Volkswagen New Beetle

Body - Exterior

Transparent foil protection for front fenders (Page 50-17)

Sticker -6- must be installed under release lever to avoid nail scratches while opening.

(p/n 867 807 637)

- Front foil protection (left/right) must be applied before mounting front fender, as shown in illustration.

Rear foil protection (left/right) must be applied before mounting rear fender, as shown in illustration.

Note:

If film protection falls off Page 50-18 , application procedure.

Volkswagen New Beetle

Body - Exterior

Transparent foil protection for front fenders (Page 50-18)

Application procedure (general)

- Prepare a solution, 25% isopropylic alcohol and 75% water; do not use soap or detergents.

- Clean and dry the front and rear fenders.

- Remove foil from waxed paper and do not touch adhesive.

- Wet adhesive area on foil with alcohol/water solution.

- Use a soft plastic guide to set foil in place and remove excessive residue.

- Verify proper foil placement, to avoid air bubbles and/or wrinkles.

- Dry with a clean soft cloth.

Procedure for removing foil protection

- Heat any corner of foil with a heat gun.

- Remove foil starting with corner you heated, pull foil slowly, while applying heat.

It is very important to pull foil slowly for ease or removal and to avoid paint damage.

If adhesive residue remaines, use 3M Citrus Base Cleaner for final cleaning.

Volkswagen New Beetle

Body - Exterior

Transparent foil protection for front fenders (Page 50-19)

Transparent film protection, removing and installing

- Remove front wheel house liner.

Removing and installing, Page 66-1

- Remove nuts -1-.

- Remove bracket

Bolted to front of long member

- Carefully pull fender out and remove rocker panel transparent protection.

- Apply rear foil protection (left/right) before mounting rear fender, as shown in illustration.

Note:

Transparent protection must be placed exactly as before. New film protection must protrude 5 mm from fender.

Volkswagen New Beetle

Body - Exterior

Transparent foil protection for front fenders (Page 50-20)

- Remove front wheel house liner.

Removing and installing Page 66-2

- Remove screws -2-.

- Remove bracket -1-.

Bolted to front of long member

- Carefully pull fender out and remove rocker panel transparent protection.

- Apply rear foil protection (left/right) before mounting rear fender, as shown in illustration.

Note:

Transparent protection must be placed exactly as before. New film protection must protrude 5 mm from fender.