Volkswagen New Beetle Body - Exterior

Volkswagen New Beetle Body - Exterior 55 Hood, Lids (Page GR-55)

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Hood, removing and installing Bowden cable, removing and installing Front gas strut, removing Hood lock, removing and installing Hood, adjusting Release lever, removing and installing Trunk lid, assembly overview Lock cylinder carrier, removing and installing (power) Rear gas strut, removing Rear lid lock, removing and installing Releasing gas from strut Trunk lid stop, adjusting Fuel tank filler door, removing and installing Fuel fill door actuator, removing and installing

Volkswagen New Beetle Body - Exterior Hood, removing and installing (Page 55-1)

1 - Hood Removing: - Remove hoses for windshield washer system and washer jets. - Take out bolts - 9 - and remove hood. - Disconnect gas strut -3- from hood page 55-3 . Adjusting Page 55-4 2 - Cushion 3 - Hood support To M.Y. 1998 From M.Y. 1999

page 55-3

4 - Clip 5 - Plenum seal Pushed onto flange


6 - Clip 7 - Seal 8 - Hinge 9 - Bolt 23 Nm (17 ft lb) 10 - Hose - windshield washer Removing Repair Manual, Electrical Equipment , Repair Group 92 11 - Rubber stop Adjust hood height to fenders using rubber stop.


Front gas strut, removing From M.Y. 1999 with front gas strut - Support lid.

- Lift retaining clip -2- with a screwdriver and pull gas strut off ball stud -1-. Note: If gas strut is to be reused, retaining clip -2- must not be taken out of ball socket completely, otherwise retaining clip will be damaged. 1- Ball stud, 21 Nm 2- Retaining clip 3- Gas strut


Hood, adjusting Hood can be aligned between fenders by moving hinges within the slotted holes. By adjusting rubber stops - 11 - ( Page 55-2 ), the hood can be adjusted for height relative to the fender. After installation or adjusting, treat hinges and bolts with corrosion protection.


Bowden cable, removing and installing

1 - Bowden cable Removing: - Remove acuator lever Page 55-7 and remove Bowden cable from clip at lock and engine compartment - Remove lower A pillar trim Repair Manual, Body-Interior, Repair Group 70 - Tie string (approx. 1 m - 3 ft) to cable at hood release and pull cable out at lever end. Installing: - Using the same string, pull new cable into place.


2 - Grommet Qty. 2 3 - Spreader nut 4 - Release lever Removing and installing

Page 55-7

5 - Self-tapping screw 6 - Lever bracket Cable attached 7 - Bowden cable clip 8 - Hood lock Removing and installing

Page 55-8


Release lever, removing and installing

Removing 1 - Trim 2 - Release lever Removing: - Pull release lever -1- approx. 2 cm (0.8 in.) - Insert small screwdriver into gap between release lever - 1 - and clip - 2 - . - Release release lever again and unclip clip from release lever (clip falls behind trim). Installing: - Push clip - 2 - completely into release lever.

- Press release lever onto bracket. - Check function. 3 - Clip


Hood lock, removing and installing

1 - Hood lock Adjust within slotted holes Removing: - Press clevis arms of release lever - 3 - apart with the aid of a screwdriver - 5 - and remove release lever. - Remove screws - 7 - . - Release bowden cable - 8 - and separate micro switch connection (only vehicles with anti - theft alarm) - 9 - . 2 - Connecting panel Fastened to lock carrier with blind rivets

Page 50-4, item 8.


3 - Release lever 4 - Clip 5 - Screwdriver (assembly aid) 6 - Clip 7 - Hex bolt (self-locking) 12 Nm (9 ft lb) When reusing: clean bolt threads with a wire brush and nut threads with thread cleaning tap; coat bolt with locking fluid D 185 400 A 2. 8 - Bowden cable 9 - Micro switch

Volkswagen New Beetle Body - Exterior Trunk lid, assembly overview (Page 55-10)

1 - Trunk lid Adjusting

Page 55-14

2 - Bolt 20 Nm (15 ft lb) 3 - Hinge Adjusting

Page 55-14

4 - Bolt 8 Nm (71 in. lb) 5 - Nut 8 Nm (71 in. lb) 6 - Gasket 7 - Bolt 23 Nm (17 ft lb)


8 - Lock plate Adjusting - within oversized holes 9 - Bolt 10 Nm (89 in. lb) 10 - Adjustment buffer Adjusting Page 55-14 11 - Ball stud 21 Nm (15 ft lb) 12 - Gas - filled strut Removing and installing Page 55-12 Releasing gas Page 55-13 13 - Bolt 10 Nm (89 in. lb) 14 - Rubber cushion


Rear gas strut, removing

Trunk lid, support. - Lift retaining clip - 2 - with a screwdriver and pull gas strut off ball stud - 1 - . Note: If gas strut is to be reused, retaining clip - 2 - must not be taken out of ball socket completely, otherwise retaining clip will be damaged. 1- Ball stud, 15 Nm (11 ft lb) 2- Retaining clip 3- Gas strut


Releasing gas from strut

- Clamp gas-filled strut in vice in area x = 50 mm. WARNING! Clamp only within this area, otherwise danger of accident! - Saw through cylinder of gas-filled strut within first third of cylinder's overall length using piston rod end of cylinder as reference point. Note: Protective goggles must be worn when sawing. Cover area of saw cut with a cloth. Dispose of oil properly.


Trunk lid stop, adjusting Note: The trunk lid is adjusted correctly, when the mating lines are even and flush all round when closed. Vehicle must be standing on its wheels when performing adjustments. - Shut lines/gaps: Repair Manual, Body-Collision, Repair Group 00 ; Body gaps/shuts lines; Trunk lid - After completing installation or adjustments, apply corrosion protection to hinges and bolts. Adjusting trunk lid hinge - Install hinge without trunk lid.

With locked hinge, set screw - 1 - must contact stop - 2 - without pressure. - Hinge pre - tension, turn setscrew - 1 - 1.5 - 3 mm (0.05 - 0.15 in.) both sides.


Rear lid, adjusting Rear lid hinge and lock plate as well as the tailgate lock have been adjusted. - Install rubber grommet on hood, both sides.

- Install adjustable mount - 1 - in channel loosely, to aid adjustment. - Slide mount - 1 - in top position - arrow - . - Close trunk lid completely and open again.

- Slide mount - 1 - up in channel on both sides by dimension - a - = 1...2 mm (0.039 0.078 in.). Tightening torque: 10 Nm (89 in. lb) Lid must close without much force and in locked position not have any up or down movement. When unlocking, the lid will pop up slightly due to pre - tension.


Rear lid lock, removing and installing

1 - Lock cylinder carrier With lock cylinder, micro-switch and fold-away handle The lock cylinder can only be removed with the carrier. Removing and installing Page 55-19 . 2 - VW emblem Upper part for access to handle and lock cylinder swivels Assemble with carrier - 1 Removing: 3 - Water drain channel (rubber) Push fit on drain connection on carrier -1-.

CAUTION! Ensure the rubber drain channel is routed correctly, otherwise water will drain onto the lock and into the trunk.


4 - Trunk lid 5 - Lock Removing: Repair Manual, Body-Interior, Repair Group 70 - Disconnect connector on lock. - Unclip operating rod - 9 - , unscrew bolts -6- and remove lock from trunk lid. 6 - Bolt 23 Nm (17 ft lb) 7 - Lock plate Adjusting - within slotted holes Removing: - Remove lock carrier trim Repair Manual, Body-Interior, Repair Group 70 Lock carrier trim, removing and installing - Remove screws - 8 - .


8 - Bolt 23 Nm (17 ft lb) 9 - Operating rod 10 - Bolt 5 Nm (44 in. lb)


Lock cylinder carrier, removing and installing (power lock) Removing - Remove trunk lid trim. Repair Manual, Body-Interior, Repair Group 70 Lock carrier trim.

- Separate connectors - arrows - . - Unclip operating rod - 1 - for lock carrier. - Release wire from clip - 2 - .

- Remove screws - 1 - and remove electrical wire support panel - 2 - .


- Remove bolts - 1 - and loosen tie wrap - 3 - of water drain channel - 4 -. - Pull lock cylinder carrier - 1 - off trunk lid and then from outer hand grip. Installing Reassemble in reverse sequence. - Replace tie wrap for water drain channel and clips to fasten wire harness.

Volkswagen New Beetle Body - Exterior Fuel tank filler door, removing and installing (Page 55-21)

Removing from right rear fender - Remove tail light Repair Manual, Electrical Equipment , Repair Group 94; Tail light , removing. - Remove filler cap. Secured with strap from M.Y. 2000 - Pull ring - 1 - (behind the sealing lip) out of rubber cup - 2 - . - Remove screw - 2 - .

- Lift fuel tank filler door - 1 - rear and remove from the back with attachment strap -2-. Installing Reassemble in reverse sequence.

Volkswagen New Beetle Body - Exterior Fuel tank filler door, removing and installing (Page 55-22)

Fuel filler door actuator, removing and installing The actuator for the fuel fill door release is located on a bracket on the right wheelhouse Removing - Remove luggage compartment trim, right side Repair Manual, Body-Interior, Repair Group 70 rear compartment trim, removing and installing

- Remove connector - 1 - from motor - 2 - . - Disconnect cable at bracket - arrow - . - Remove screws - 3 - , remove motor from bracket and disconnect cable at motor. Installing Reassemble in reverse sequence. - Check function.