Volkswagen New Beetle: Body

Volkswagen New Beetle: Body
Volkswagen New Beetle
Body - Exterior
66 Exterior equipment (Page GR-66)
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Wheel house liner, removing and installing
Front wheel house liner
Rear wheel house liner
Rear view mirror
Mirror glass, removing and installing
Mirror housing, removing
Outside rear view mirror, removing and installing
Tools
Roof mouldings, removing and installing
Rear spoiler
Guide tube and motor bracket, removing
Rear spoiler, adjusting
Rear spoiler, removing
Spoiler on rear lid
Protective strips
Sill panel strips, replacing
Volkswagen New Beetle
Body - Exterior
Wheelhousing liner, removing and installing (Page 66-1)
Front wheelhousing liner
1 - Wheelhousing liner
- Remove wheel. Wheel bolt torque = 102 Nm (75 ft lb).
- Remove screws - 2 - and remove wheelhousing liner.
2 - Screw
Qty. 14
3 - Spreader nut
4 - Speed nut
On bumper cover
Volkswagen New Beetle
Body - Exterior
Wheelhousing liner, removing and installing (Page 66-2)
Rear wheelhousing liner
Note:
Wheelhousing liners differ slightly depending on equipment, with regard to position and
number of mounting elements.
1 - Wheelhousing liner
- Remove wheel. Wheel bolt torque = 120 Nm (89 ft lb).
- Remove only right screw and wheelhousing liner.
- Remove screws and remove wheelhousing liner.
2 - Hex nut
70 Nm (52 ft lb)
3 - Bolt
Volkswagen New Beetle
Body - Exterior
Wheelhousing liner, removing and installing (Page 66-3)
4 - Spreader nut
5 - Cover
Right side only
6 - Speed nut
7 - Speed nut
On bumper cover or fender
Volkswagen New Beetle
Body - Exterior
Wheelhousing liner, removing and installing (Page 66-4)
Tools
Special tools and equipment
80-200 Removal lever
VAS 1978 Wiring harness repair kit
Volkswagen New Beetle
Body - Exterior
Rear view mirror (Page 66-5)
Mirror glass, removing and installing
WARNING!
Use protective eye wear and gloves.
Removing
- Protect housing edge from paint damage. with reinforced tape - 2 - .
- Press in mirror - 1 - up in housing - arrow - .
- Press off mirror - 1 - with tool 80-200 from tab in housing and remove contact for
heated mirror on the backside of mirror.
Installing
- Connect contacts for heated mirror on mirror glass.
- Press mirror glass in center on bracket in housing.
Volkswagen New Beetle
Body - Exterior
Rear view mirror (Page 66-6)
Mirror housing, removing
- Remove mirror glass
Page 66-5 .
- Press screwdriver - 4 - in direction of arrow (this will cause clip - 4 - to release the
mirror housing).
- Pull mirror housing - 1 - off mirror carrier - 3 - upward.
Volkswagen New Beetle
Body - Exterior
Rear view mirror (Page 66-7)
Outside rear view mirror, removing and installing
- Remove front door trim
Repair Manual, Body-Interior, Repair Group 70 Door trim, removing and installing
- Disconnect all connectors - arrows - .
- Route wire connector with adhesive strip (otherwise it catches easily in door) or push
out with tool VAS 1978 (contact from connector housing.
- Remove screws - 1 - and remove triangular trim - 2 - from, the back - arrow - .
Volkswagen New Beetle
Body - Exterior
Rear view mirror (Page 66-8)
- Remove screws - 1 - and remove outside mirror - 2 - from door hinge - 3 - . Torque:
bolts - 1 - = 10 Nm (89 in. lb)
Notes:
Cover bolts are accessible after opening the door.
Electrical wires are routed through door opening.
Reinstall in reverse sequence.
- Ensure the electrical wire in the window channel is routed correctly, otherwise the
window can catch on the wire when opening and closing.
- Check function
Volkswagen New Beetle
Body - Exterior
Roof mouldings, removing and installing (Page 66-9)
1 - Roof moulding
With cover strip -4-.
Do not bend roof moulding.
- Starting at windshield, carefully pry off with soft plastic wedge.
- Place roof moulding on rear end of roof channel and press in from rear to front stop.
2 - Rear window
3 - Windsheild
4 - Cover strip
Installing:
Insert cover strip into pocket of roof moulding onto stop. Then press into roof
channel.
5 - Sealing lip
Component part of pre-coating
Volkswagen New Beetle
Body - Exterior
Rear spoiler (Page 66-10)
Spoiler on rear lid
Assembly overview
1 - Spoiler
2 - Spoiler hinge assembly
3 - Rear lid
4 - Motor bracket
5 - Guide tube for cables
6 - Motor
7 - Torx screw
8.0 1 Nm
8 - Torx screw
2.5 0.5 Nm
9 - Torx screw
6.0 0.6 Nm
10 - Rubber stop
Volkswagen New Beetle
Body - Exterior
Rear spoiler (Page 66-11)
Removing upper and lower trim
- Remove rear lid lower trim.
Repair Manual, Body-Interior, Repair Group 70
- Remove rear lid upper trim.
Repair Manual, Body-Interior, Repair Group 70
Removing motor
-
Remove screw -1Open the metallic strap -2- that fixes motor -3Remove screws -4Remove motor -3-
Installing
- In reverse order to removal
Volkswagen New Beetle
Body - Exterior
Rear spoiler (Page 66-12)
Guide tube and motor bracket, removing
- Remove the clip -3- from both sides, located on rear lid upper corners.
- Remove screws -2- from bracket -1-.
- Release guide tube from the 7 retaining clips -arrows-.
Installing
- In reverse order to removal.
Volkswagen New Beetle
Body - Exterior
Rear spoiler (Page 66-13)
Rear spoiler, removing
- Remove the clip -3- from both sides, located on rear lid upper corners.
- In reverse order to removal
Torque 6.0 0.6 Nm
- Remove the grommet -5- carefully.
- Remove the spoiler hinge assembly -1- from rear lid -2-.
WARNING!
When removing the spoiler hinge assembly -1- make sure not to damage the seals.
- Remove rubber stop -4- (if necessary).
Installing
- In reverse order to removal.
Volkswagen New Beetle
Body - Exterior
Rear spoiler (Page 66-14)
Rear spoiler, adjusting
When installing the rear spoiler all gaps must be verified -see figureThe gaps are adjusted by loosening the screw -3- that the fix the spoiler hinge assembly
on both sides -1page 66-13
CAUTION!
The spoiler hinge assembly can now be moved in all directions.
Note:
The maximum opening of the spoiler is about 17 and it closes in 5 steps.
Volkswagen New Beetle
Body - Exterior
Protective strips (Page 66-15)
Sill panel strips, replacing
1 - Sill panel protective strip
Self-adhesive
Removing:
- Heat sill panel protective strip with a hot air blower before removing.
Installing:
- Clean exterior panels with silicone remover and then rub dry.
- fit protective foil -3-.
- Insert grommet -2- into hole in sill.
- Pull off protective paper, align sill panel protective strip with guide pin and bond
(press on using force). Working temperature approx. 20 C.
Volkswagen New Beetle
Body - Exterior
Protective strips (Page 66-16)
2 - Grommet
3 - Sill panel protective foil
Self-adhesive
Installing:
- Clean exterior panels with petrol and afterwards treat with silicone remover and then
rub dry.
- Pull off narrow section of protective foil and align at indentation -4-.
- Bond sill panel protective foil along the reference edge -arrow-.
- Pull of remaining protective paper and bond sill panel protective foil on complete.
4 - Indentation
First indentation is used as reference point to position the sill panel protective foil -35 - Door
6 - Door inner seal
Pull off to fit sill panel protective foil.
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