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Volkswagen New Beetle: Body, front

50 - 1

Volkswagen New Beetle


Body, front
Tools

Special tools, testers and auxiliary items required

Support Tool 3411

Lock carrier, assembly overview


Body, front

Lock carrier

Removing:

- Remove front part 50-


1, Front part, assembly
overview .

- Disengage hood release


cable at lock and
disconnect electrical
harness connectors.

- Remove bolts Item - 3


- and Item - 4 - and
remove bumper carrier
Item - 5 - .

- Unscrew radiator and


condenser from lock
carrier.

- Secure radiator and


condenser in engine
compartment.

Note :

Do not disengage condenser at lines.

Condenser lines must not be kinked.

- Remove bolts Item - 11


- .

- Remove lock carrier with


connecting plate and lock.

Installing:

- Center lock carrier at


longmembers.

- Adjust headlights anew.

Bolt

4x

6 Nm

For radiator mounting


Body, front

Bolt

4x

6x (USA)

30 Nm

Bolt

4x

9 Nm

Bumper carrier

With insulation

Pop rivet

4x

Insulation

Bonded using butyl adhesive


sealing cord AKL 450 005
05

Connecting plate

Secured to lock carrier using


pop rivet

Internally threaded pop rivet

2x

Lid lock

Removing and installing


55-1, Hood lock, removing,
installing and adjusting

Bolt

20 Nm

Self-locking hex bolt

12 Nm

When reusing: Clean bolt


Body, front

thread using wire brush and


nut thread using tap, coat
bolt with locking compound
D 185 400 A2

Radiator and condenser

Radiator mounting

Impact absorber (USA)

Nut (USA)

Bolt (USA)

Lock carrier, service position

- Remove front part 50-1, Front part, assembly


overview .

- Disengage hood release cable at lock.

- Remove one bolt each - 2 - from longmembers and bolt


in Support Tool 3411 at right and left longmembers for
this.
Body, front

- Remove bolts - 1 - and - 3 - at left and right and pull


lock carrier toward front in area of Support Tool 3411 .

Front part, assembly overview

Note :

Overview describes removal and installation of front


part for vehicles 06.05. Removal and installation
applies to vehicles 07.05 , except slight changes.

Front fender and front bumper cover can only be


removed together from vehicle as so-called front
part.

It is necessary that tightening sequence of bolts - 4 -


is observed to ensure surface alignment and joint.

Front part must be installed free of stress.

Front part
Body, front

Removing:

- Remove headlight

Repair Manual, Electrical Equipment,


Repair Group 94,

- Remove wheelhousing
liners 66-1, Front wheel
housing liner .

- Remove bolts from


wheelhousings Item - 2 -
, Item - 3 - and Item -
8-

- Disconnect harness
connectors for turn signals
and fog lights.

- Disconnect hose
connector in vehicles with
headlight washer system

Repair Manual, Electrical equipment,


Repair Group 92, Headlight washer
system

- Remove nuts Item - 6 -


.

- Remove expanding clips


Item - 9 - .

- Remove bolts Item - 4


- and Item - 7 - .

- Pull left and right front


part outward off threaded
pins and remove forward
from vehicle with two
mechanics.

Installing:

- Before reattaching front


part, adhere anti-friction foil
Item - 11 - on contact
areas, or check condition
of old anti-friction foil.

- When installing front part,


ensure proper seating of
Body, front

insulation Item - 5 - on
both sides of longmember
and make sure it engages
properly on headlight
bracket.

Bolt

With nut

6 Nm

Combination bolt

6 Nm

Bolt

18x

7.5 Nm

Insert with locking fluid D


185 400 A2

Note tightening sequence

Insulation

Hex nut

6 Nm

Bolt

7.5 Nm

4x

Insert with locking fluid D


185 400 A2

Bolt

2x

Insert with locking fluid D


185 400 A2

Expanding clip

3x

To remove, press spreader


Body, front

pin through

Face plate

Front spoiler

Ventilation grid

Front fender, assembly overview

Note :

Overview describes removal and installation of front


fender for vehicles 06.05. Removal and
installation applies to vehicles 07.05 , except
slight changes.

Fenders are part of front part and are removed


together 50-1, Front part, assembly overview .

Observe tightening sequence of bolts - 2 - , - 4 - , -


7 - to ensure surface alignment and joint.
Body, front

Fender

Removing:

- Remove headlight

Repair Manual, Electrical Equipment,


Repair Group 94,

- Remove front part 50-


1, Front part, assembly
overview .

- Remove bolts Item - 7


- and Item - 4 - .

Installing:

- Before reattaching front


part, adhere anti-friction foil
Item - 11 - on contact
areas, or check condition
of old anti-friction foil.

Bolt

Insert with locking fluid D


185 400 A2

Note tightening sequence

Clip

Bolt

Insert with locking fluid D


185 400 A2

3x

6 Nm

Note tightening sequence

Base plate

Base plate

With welded captive nuts

Bolt
Body, front

Insert locking fluid D 185 400


A2

2x

6 Nm

Note tightening sequence

Front bumper cover

Base plate

With holes

Base plate

With welded captive nuts

Anti-friction foil

Check condition, replace if


necessary

Pop rivet

19x

Bracket (convertible)

Bolted to outside of
sidemember

Bracket

Bolted to outside of
sidemember

Bolt

2x

6 Nm

Sealing part

Riveted into fender

Anti-friction foil, replacing


Body, front

Materials:

Transparent anti-friction foil (left/right)

1C0 807 907 A/908 A


1C0 821 713 B/714 B
1C0 853 843 /844 A
1C0 853 387 A/ 388 A
1C0 821 711 B/ 712 B

Note:

Preparation for adhering of anti-friction foil 50-1,


General application notes , General application
notes.

Front hood anti-friction foil

- Adhere protective foil - 6 - under release lever to avoid


scratches when opening. ( 867 807 637 )

Rear lid anti-friction foil

- Attach anti-friction foil - 7 - as depicted in illustration


( 1HM 837 997 ).

Rubber buffer of rear lid must seat exactly in center of anti-


friction foil - 7 - .

Front sill anti-friction foil


Body, front

- Adhere anti-friction foil to front sill.

- Adhere anti-friction foil so that strip projects 5 mm from


edge of fender to sill.

Rear sill anti-friction foil

Adhere anti-friction foil to rear sill.


Body, front

- Adhere anti-friction foil so that strip projects 5 mm from


edge of fender to sill.

General application notes

- Mix a solution of 25 % isopropyl alcohol and 75 % water,


do not use soap or soap solution.

- Clean and dry front and rear bumpers.

- Remove further material using adhesive removal solution


D 200 000 10 .

- Do not work anti-friction foil under 15 C ambient


temperature.

- Remove foil from wax paper, do not touch adhesive.

- Moisten adhesive on foil with alcohol/water solution

- Use soft plastic wedge to attach foil, then remove


seeping fluid.

- Check whether foil is attached correctly. There may be


no air bubbles and/or wrinkles.

- Dry with clean soft cloth

Procedure for removing foil

- Heat foil edge using heat air gun.

- Remove foil starting from head edge while continuing to


heat remainder at the same time.

Noise insulation panel, assembly overview

Note:

Depending on vehicle equipment, slight changes are


possible.

Vehicles with gasoline engine


Body

Noise insulation

For gasoline engines

Bolted and connected in


front area of lock carrier

Lower part bolted to side


parts

Bolt

2x

Bolt

Qty. 10

Clamping washer

4x
Body, front

Vehicles with Diesel engine

Noise insulation

For Diesel engines

Bolted and connected in


front area of lock carrier

Bolt

2x

Bolt

4x

Clamping washer

4x

Vehicles with gasoline engine (convertible)


Body, front

Note:

- Arrow - points in direction of travel.

Noise insulation

Bolted and connected in


front area of lock carrier

V-belt guard

Right support

Bolt

4x

Bolt

8x

Bolt

4x
Body, front

Speed nut

8x

Engine screening

Left support

Bolt

2x

Plenum chamber cover, removing and installing

Plenum chamber sealing part

Removing:

- Remove windshield wiper

Repair Manual, Electrical Equipment,


Body, front

Repair Group 92,

- Pull rubber seal off edge


of plenum chamber cover.

- Remove components
from plenum chamber
cover if necessary.

- Remove bolt Item - 4 -


, nut Item - 3 - and
brace Item - 5 - .

- Remove bolts Item - 2


- .

- Remove outer plenum


chamber cover.

Bolt

Nut

Combination bolt

Brace

Counterbalance weight, assembly overview (convertible)


Body, front

Bulkhead carrier

Bolt

4x

Balance weight

Removing:

- Remove plenum chamber


cover 50-1, Plenum
chamber cover, removing
and installing .

- Remove nut - 4 - .

Nut

4x

5 Nm
Body, front

Balance weight

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