Running gear
- Running gear, axles, steering
- Technical data
- Front suspension, drive shafts
- Electrical/electronic components and locations
- Torque settings for front axle
- Repairing front suspension
- Overview - front axle
- I - Assembly overview: subframe, anti-roll bar and suspension link
- Checking swivel joint
- Removing and installing swivel joint
- Removing and installing suspension link
- Renewing bonded rubber bush for suspension link
- Removing and installing subframe
- Renewing bonded rubber bushes in subframe
- Repairing threads in longitudinal member
- II - Assembly overview: wheel bearing
- Removing and installing front wheel bearing with wheel bearing housing installed
- III - Assembly overview: coil spring strut
- Removing and installing suspension strut
- Repairing front coil spring suspension strut
- Repairing drive shafts
- Overview - drive shafts
- Removing and installing constant velocity joint shaft and triple roller joint shaft AAR 2000 and AAR 2900
- Removing and installing triple roller joint drive shaft AAR 3300i
- I - Repairing front drive shaft with constant velocity joint
- Removing, checking and installing outer constant velocity joint
- Removing, checking and installing inner constant velocity joint
- II - Repairing front drive shaft with triple roller joint AAR 2000
- Dismantling and assembling triple roller joint
- IV - Repairing front drive shaft with triple roller joint AAR 2900
- Dismantling and assembling triple roller joint AAR 2900
- IV - Repairing drive shaft with triple roller joint AAR 3300i
- Dismantling and assembling triple roller joint AAR 3300i
- Rear suspension, drive shaft
- Rear axle in unladen position
- Torque settings for rear axle
- Repairing rear axle
- Repairing wheel bearing
- Wheels, tyres. axle align
- Specified torque for wheel bolts
- Protecting wheel centring seat against corrosion
- Wheels, tyres
- Wheel alignment
- Wheel alignment|General
- Test prerequisites:
- Test preparations
- Vehicle data sticker
- Wheel alignment specifications
- Adjusting camber at front wheels
- Adjusting camber on rear axle
- Adjusting toe setting on rear axle (front-wheel drive vehicles)
- Adjusting front axle toe
- Checking left and right-hand wheel lock
- Steering
- Connecting VAS 5051 A and selecting functions
- Torque settings for steering system
- Steering column
- Removing and installing steering column
- Checking steering column for damage
- Removing and installing steering lock housing
- Assembly overview - steering column cross member for New Beetle saloon
- Assembly overview - steering column cross member for New Beetle Cabriolet
- Steering column variations
- Removing and installing locking cable for ignition with key removal lock
- Checking ignition key removal lock
- Repairing power steering
- Removing and installing power steering box
- Assembly overview - power steering box (LHD)
- Assembly overview - power steering box (RHD)
- Removing and installing track rod
- Revised track rod ball joints
- Revised track rods
- Checking play, tightness and bellows of track rod ball joints
- Determining centre position of steering rack
- Adjusting steering box
- Bottom-mounted vane pump
- Top-mounted vane pump
- Top-mounted vane pump (vehicles with 2.5 l 5-cylinder engine)
- Vane pump, reservoir, hydraulic lines (vehicles with 1.4 l engine)
- Vane pump, reservoir, hydraulic lines (vehicles with 1.6 l, 1.8 l, 2.0 l or TDI engine)
- Assembly overview
- Installing reservoir
- Securing pressure line and suction hose on vehicles with 1.6 l engine
- Securing pressure line and suction hose on vehicles with TDI engine and air conditioner
- Securing pressure line and suction hose on vehicles with 2.0 l or TDI engine with no air conditioner and vehicles with 1.8 l tur
- Securing pressure line and suction hose on vehicles with 2.0 l engine with air conditioner and vehicles with 1.8 l turbo engine
- Securing pressure line and suction hose on vehicles with TDI unit injector engine
- Assembly overview
- Vane pump, reservoir, hydraulic lines (vehicles with 2.3 l V5 engine)
- Vane pump, reservoir, hydraulic lines (vehicles with 2.5 l 5-cyl. engine)
- Securing pressure line on manual and automatic gearboxes
- Securing pressure line on 5-speed manual gearbox 02T
- Securing pressure line on 5-speed manual gearbox 02J
- Securing pressure line on 5-speed manual gearbox 0A4
- Securing pressure line on 6-speed manual gearbox 02M
- Securing pressure line on automatic gearbox 01M
- Assembly overview - vane pump with hydraulic lines (vehicles with automatic gearbox 09G)
- Assembly overview - vane pump with hydraulic lines (vehicles with dual clutch gearbox 02E)
- Bleeding steering system, checking for leaks and checking fluid level
- Body
- General body repairs, exterior
- Body front
- Body - front
- Body - front|Tools
- Lock carrier - Assembly overview
- Lock carrier - service position
- Front part - Assembly overview
- Front wing - assembly overview
- Replacing anti-scratch film
- Noise insulation - assembly overview
- Removing and installing plenum chamber cover
- Vibration damper (Cabriolet) - Assembly overview
- Body, front
- Tools
- Assembly overview - lock carrier
- Lock carrier - service position
- Assembly overview - front end
- Assembly overview - front wing
- Replacing anti-friction foil
- Assembly overview - noise insulation
- Removing and installing plenum chamber cover
- Assembly overview - vibration damper (cabriolet)
- Body - front
- Body, rear
- Bonnet, flaps, cab, central locking
- Bonnet, flaps, cab, central locking|Bonnet
- Rear lid
- Rear lid - Assembly overview
- Rear lid (Cabriolet) - Assembly overview
- Removing gas strut
- Removing gas-filled strut (cabriolet)
- Releasing gas from gas strut
- Adjusting lid
- Adjusting lid (cabriolet)
- Removing and installing lid lock
- Installing and removing lid lock 09.01 (USA)
- Removing and installing lid lock (cabriolet)
- Removing and installing rear lid remote release motor carrier
- Removing and installing rear lid remote release motor carrier 09.01 (USA)
- Removing and installing retaining plate for rear lid remote release motor (Cabriolet)
- Removing and installing carrier with microswitch for rear lid (cabriolet)
- Tank flap unit
- Front door, central locking
- Front door
- Front door|Tools
- Front door - assembly overview
- Front door (Cabriolet) - Assembly overview
- Removing and installing door
- Removing and installing door (cabriolet)
- Adjusting door
- Door handle and door lock - Assembly overview
- Removing and installing lock cylinder housing
- Removing and installing door handle
- Removing and installing door lock
- Removing and installing door lock (cabriolet)
- Removing and installing mounting plate
- Removing and installing locking knob for release rod
- Door seals (cabriolet)
- Central locking
- Front door
- Sliding roof
- Sliding/tilting sunroof
- Sliding/tilting sunroof|Tools
- Functional check
- Sliding/tilting roof with glass panel - Assembly overview
- Removing and installing sliding/tilting sunroof glass panel
- Adjusting height of sliding/tilting sunroof glass panel
- Adjusting panel seal
- Renewing panel seal
- Removing wind deflector
- Removing sliding headlining
- Removing drive for sliding/tilting sunroof
- Adjusting drive for sliding/tilting sunroof (zero (0) position)
- Removing pre-selector control for sliding/tilting sunroof
- Checking parallel running
- Adjusting parallel running
- Removing and installing carrier unit
- Removing coulisse (guide plate)
- Cleaning water drain hoses
- Sliding/tilting sunroof
- Convertible top/hard top/canopy
- Convertible roof
- Safety precautions when working on convertible roof
- Convertible roof|Tools
- Electrohydraulic convertible roof - Assembly overview
- Removing and installing electrohydraulic convertible roof
- Removing and installing electrohydraulic convertible roof fabric
- Manually operated convertible roof - Assembly overview
- Removing and installing manually operated convertible roof
- Removing and installing cover for manually operated convertible roof
- Removing and installing padding material for electrohydraulic and manual operation convertible roof
- Removing and installing liner for electrohydraulic and manually operated convertible roof
- Roof liner tensioning system 11.03 - Assembly overview
- Removing and installing roof liner tensioning system 11.03
- Roof liner tensioning system 12.03 - Assembly overview
- Removing and installing roof liner tensioning system 12.03
- Roof front latch for electrohydraulic and manually operated convertible roof - Assembly overview
- Removing and installing roof front latch
- Roof rear locking device for electrohydraulic convertible roof - Assembly overview
- Roof rear locking device for manually operated convertible roof - Assembly overview
- Convertible top
- Safety precautions when working on convertible roof
- Convertible top|Tools
- Assembly overview - electrical/hydraulic convertible roof
- Removing and installing electric/hydraulic convertible roof
- Removing and installing convertible roof cover, electric/hydraulic convertible roof
- Assembly overview - manual convertible roof
- Removing and installing manual convertible roof
- Removing and installing cover of manual convertible roof
- Removing and installing padding of electric/hydraulic and manual convertible roof
- Removing and installing convertible roof headliner of electric/hydraulic and manual convertible roof
- Assembly overview - convertible roof headliner, tensioning system ? 11.03
- Removing and installing convertible roof liner tensioning system ? 11.03
- Assembly overview - convertible roof headliner, tensioning system 12.03 ?
- Removing and installing convertible roof headliner tensioning system 12.03 ?
- Assembly overview - front locking mechanism for electric/hydraulic and manual convertible roof
- Removing and installing front convertible roof catch
- Assembly overview - rear locking mechanism for electrical/hydraulic convertible roof
- Assembly overview - rear locking mechanism for manual convertible roof
- Electrohydraulic roof
- Assembly overview
- Filling and bleeding the hydraulic system
- Removing and installing hydraulic pump
- Impeller for hydraulic pump - Assembly overview
- Removing and installing impeller for hydraulic pump
- Oil reservoir - Assembly overview
- Removing and installing oil reservoir
- Hydraulic cylinder - Assembly overview
- Removing and installing the hydraulic cylinder
- Removing and installing hydraulic hoses
- Electrical/hydraulic top
- Assembly overview
- Filling and bleeding the hydraulic system
- Removing and installing hydraulic pump
- Assembly overview - impeller for hydraulic pump
- Removing and installing impeller for hydraulic pump
- Assembly overview - oil reservoir
- Removing and installing oil reservoir
- Assembly overview - hydraulic cylinder
- Removing and installing the hydraulic cylinder
- Removing and installing hydraulic hoses
- Manually operated convertible roof
- Windscreen frame
- Convertible roof
- Bumper
- Glazing/window mechanism
- Flush bonded windows
- Flush bonded windows|Tools
- Materials
- Windscreen - Assembly overview
- Removing windscreen
- Removing windscreen (cabriolet)
- Installing windscreen
- Removing and installing rain sensor
- Side window - Assembly overview
- Removing undamaged side window
- Removing broken side window
- Installing side window
- Rear window - assembly overview
- Removing undamaged rear window
- Removing broken rear window
- Installing rear window
- Preparing old undamaged window for glazing
- Preparing new window for glazing
- Preparing body flange for glazing
- Fitting instructions
- Curing time
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- Door windows
- Door windows|Tools
- Front door window - assembly overview
- Removing front door window
- Adjusting door window
- Removing and installing assembly carrier
- Front door window - Assembly overview (cabriolet)
- Removing and installing front door window (cabriolet)
- Adjusting front door window (cabriolet)
- Removing and installing assembly carrier (cabriolet)
- Removing and installing window regulator (Cabriolet)
- Electric window regulator with convenience function (automatic opening and closing) and force limitation mechanism
- Overriding resistance with excess force limitation (EFL)
- Side window (cabriolet)
- Flush bonded windows
- Exterior equipment
- Removing and installing wheel housing liner
- Exterior mirror
- Roof mouldings
- Protective strips
- Rear spoiler
- Windbreak
- Body front
- General body repairs, interior
- Interior equipment
- Interior mirror
- Compartments, covers and trims
- Assembly overview - centre console ? 01.01
- Removing and installing centre console ? 01.01
- Removing and installing drink holder or ashtray in centre console ? 01.01
- Assembly overview - centre console 02.01 ? 04.03
- Removing and installing centre console 02.01 ? 04.03
- Removing rear ashtray from centre console 02.01 ? 04.03
- Removing drink holder 02.01 ?
- Assembly overview - centre console 05.03 ? and Cabriolet
- Removing and installing centre console 05.03 ? and Cabriolet
- Removing rear ashtray from centre console 05.03 ? and Cabriolet
- Removing and installing armrest padding 05.03 ? and Cabriolet
- Removing trim under centre of dash panel
- Removing glove compartment
- Removing and installing glove compartment lock cylinder
- Removing and installing glove compartment lid
- Removing footwell cover (driver side)
- Removing trim under steering column
- Removing spectacles compartment
- Removing front centre armrest
- Removing and installing armrest clip
- Removing sun visor
- Removing sun visor (Cabriolet)
- Removing plenum chamber inner cover
- Removing and installing centre console stowage net (Mexico)
- Removing and installing trim of steering wheel clip
- Grab handles
- Sill mouldings
- Passenger protection
- Seat belts
- Seat belts - checking
- Automatic roll-over protection (Cabriolet)
- Safety precautions and notes for working on automatic roll-over protection
- Assembly overview - automatic roll-over protection
- Removing and installing automatic roll-over protection
- Lowering automatic roll-over protection
- Lowering roll-over protection (Cabriolet roof closed)
- Removing and installing impact carrier
- Passenger protection|Airbag
- Passenger protection|Tools
- Detailed overview - airbag
- Component overview (Cabriolet)
- Safety precautions and notes when working on airbag
- Renewing airbag units following an accident
- Assembly overview - driver airbag unit
- Removing and installing driver airbag unit
- Assembly overview - front passenger airbag unit
- Removing and installing front passenger airbag unit
- Assembly overview - steering wheel
- Removing and installing steering wheel
- Removing and installing return spring with slip ring
- Removing and installing airbag control unitJ234
- Assembly overview - side airbag for driver/front passenger side
- Removing and installing side airbag on driver/front passenger side
- Assembly overview - side airbag on driver/front passenger side, from 05.03
- Removing and installing side airbag for driver/front passenger side, from 05.03
- Assembly overview - side airbag sensor for driver/front passenger side
- Removing and installing side airbag sensor for driver/front passenger side
- Assembly overview - side airbag sensor for driver/front passenger side, from 05.03
- Removing and installing side airbag sensor for driver/front passenger side, from 05.03 (in lower part of B-pillar)
- Assembly overview - side airbag sensor for driver/front passenger side (Cabriolet)
- Removing and installing side airbag sensor for driver/front passenger side (Cabriolet)
- Assembly overview - driver airbag crash sensorG283 and front passenger airbag crash sensorG284
- Removing and installing driver airbag crash sensorG283 and front passenger airbag crash sensorG284
- Removing and installing front passenger airbag deactivation switchE224, 05.03 >
- Removing and installing front passenger airbag deactivation switchE224 (Cabriolet)
- Assembly overview - underside of Passive Occupant Detection System (PODS), (USA)
- Assembly overview - upper side of Passive Occupant Detection System (PODS), (USA)
- Removing and installing Passive Occupant Detection System (PODS), (USA)
- Trim, noise insulation
- dash panel
- Door trim
- Door trim|Tools
- Assembly overview - front door trim
- Removing and installing front door trim
- Assembly overview - front door trim (Cabriolet)
- Removing and installing front door trim (Cabriolet)
- Repairing door trim
- Assembly overview - door trim
- Removing and installing upper part (shoulder) of door trim
- Assembly overview - door trim (Cabriolet)
- Removing and installing upper part (shoulder) of door trim (Cabriolet)
- Pillar and side trims
- Assembly overview - upper A-pillar trim
- Removing and installing upper A-pillar trim
- Removing and installing lower A-pillar trim
- Assembly overview - B-pillar trim
- Removing and installing B-pillar trim
- Assembly overview - C-pillar trim
- Removing and installing C-pillar trim
- Assembly overview - side trim
- Removing and installing side trim
- Pillar and side trims (Cabriolet)
- Assembly overview - A-pillar upper trim
- Removing and installing upper A-pillar trim
- Assembly overview - side trim
- Removing and installing side trim
- Assembly overview - side panel trim on Cabriolets with motorised folding roof, with large roof flaps and flap control motor
- Repairing side panel
- Assembly overview - flap module
- Removing and installing push rod
- Removing and installing large roof flap
- Removing and installing Bowden cable
- Removing and installing small roof flap
- Removing and installing flap positioning motor
- Removing and installing lever
- Removing and installing large and small trim
- Removing large cover
- Installing
- Removing smaller trim
- Installing
- Adjusting large and small trim
- Assembly overview - Cabriolets with manually operated folding roof and motorised folding roof with no large roof flaps and flap
- Repairing side panel
- Assembly overview - flap module
- Removing and installing Bowden cable
- Removing
- Installing
- Removing and installing small roof flap
- Removing
- Installing
- Removing and installing flap positioning motor
- Removing
- Installing
- Removing and installing small trim
- Adjusting small trim
- Removing and installing roll-over protection
- Removing and installing rear shelf
- Assembly overview water strip
- Removing and installing water strip
- Luggage compartment trims
- Assembly overview - luggage compartment side trim on left
- Assembly overview - luggage compartment side trim on right
- Removing and installing luggage compartment side trim on left or right
- Assembly overview - load sill cover
- Removing and installing load sill cover
- Assembly overview - luggage compartment trim on left (Cabriolet)
- Assembly overview - luggage compartment trim on right (Cabriolet)
- Removing and installing luggage compartment side trim on left or right (Cabriolet)
- Removing and installing luggage compartment side trim (Cabriolet)
- Assembly overview - load sill cover (Cabriolet)
- Removing and installing load sill cover (Cabriolet)
- Assembly overview - rear bulkhead trim (Cabriolet)
- Removing and installing rear bulkhead trim (Cabriolet)
- Tailgate/boot lid trim
- Assembly overview - rear lid upper trim
- Removing and installing rear lid upper trim
- Assembly overview - rear lid lower trim
- Removing and installing rear lid lower trim
- Assembly overview - rear lid lower trim
- Removing and installing rear lid lower trim
- Assembly overview - luggage compartment lid trim (Cabriolet)
- Removing and installing luggage compartment lid trim (Cabriolet)
- Assembly overview - luggage compartment lid trim (Cabriolet for USA)
- Removing and installing luggage compartment lid trim (Cabriolet for USA)
- Roof trims
- Roof trims|Tools
- Removing and installing moulded headliner
- Assembly overview - inner and outer trim for roof cross member (Cabriolet)
- Removing and installing inner and outer trim for roof cross member (Cabriolet)
- Assembly overview - roof cross member seal and retaining rail (Cabriolet)
- Removing and installing roof cross member seal and retaining rail (Cabriolet)
- Seat frames
- Front seats
- Front seats|Tools
- Removing and installing front seat
- Assembly overview - front backrest
- Removing and installing front backrest
- Removing and installing head restraint guides
- Assembly overview - seat height adjuster element
- Removing and installing seat height adjustment element
- Assembly overview - fire extinguisher bracket (front passenger side)
- Removing and installing fire extinguisher bracket on front passenger side
- Assembly overview - backrest frame ? 04.03 and (Cabriolet)
- Assembly overview - backrest frame 05.03 ?
- Removing and installing cable for adjusting seat longitudinally
- Removing and installing lumbar support frame 05.03 ?
- Removing and installing backrest release cable 05.03 ?
- Rear seats
- Removing and installing rear bench seat (one-piece)
- Removing and installing backrest (one-piece)
- Assembly overview - backrest locking device (one-piece backrest)
- Removing and installing backrest locking device (one-piece backrest)
- Removing and installing rear bench seat (two-piece)
- Removing and installing backrest (two-piece)
- Assembly overview - backrest locking device (two-piece backrest)
- Removing and installing right backrest locking device (two-piece backrest)
- Assembly overview - left backrest locking device (two-piece backrest)
- Removing and installing left backrest locking device (two-piece (split) backrest)
- Removing and installing rear bench seat (Cabriolet)
- Removing and installing backrest (Cabriolet)
- Assembly overview - through-loading aperture (Cabriolet)
- Removing and installing through loading aperture (Cabriolet)
- Front seats
- Seat padding, covers
- Front seat cover and padding
- Rear seat cover and padding
- Rear seat cover and padding|Tools
- Assembly overview - cover and padding for bench seat
- Removing and installing cover and padding for rear bench seat
- Assembly overview - cover and padding for seat backrest (one-piece or right-hand side)
- Removing and installing cover and padding for seat backrest (one-piece or right-hand side)
- Assembly overview - cover and padding for left backrest
- Removing and installing cover and padding for left seat backrest
- Assembly overview - cover and padding for backrest (Cabriolet)
- Removing and installing cover and padding for seat backrest (Cabriolet)
- Assembly overview - cover and padding for bench seat (Cabriolet)
- Removing and installing cover and padding for bench seat (Cabriolet)
- Interior equipment
- General body repairs, exterior
- Heating, ventilation, air conditioning system
- Heating, air conditioning
- Heating
- Repairing heating system
- Passenger compartment heating - assembly overview
- Removing and installing fresh air blower V2 and fresh air blower series resistor with overheating fuses N24
- Removing and installing intermediate piece and intermediate piece, defrost
- Removing connecting piece
- Removing and installing dust and pollen filter
- Removing vents
- Defroster channel
- Removing and installing controls for heated and fresh air
- Checking ventilation
- Removing and installing heater unit
- Removing and installing heat exchanger
- Dismantling and assembling heater unit
- Dismantling and assembling heated air and fresh air controls
- Installing and adjusting cables
- Repairing heating system
- Aux. heater/heater booster
- Air conditioner
- Notes on repair work to vehicles with air conditioning and on handling refrigerant
- Air conditioning system with manual controls
- Air conditioning and heating - passenger compartment
- Air conditioning and heating system - Engine compartment
- Removing and installing air conditioner compressor
- Removing and installing refrigerant lines from air conditioner compressor
- Repairing Sanden air conditioning system magnetic clutch N25
- Checking water drain valve
- Ancillary bracket for air conditioner compressor
- Repair work on the refrigerant circuit which can only be carried out by suitable workshops with properly trained mechanics (spec
- Repairing components in refrigerant circuit
- Removing evacuating and charging valve, low-pressure side
- Removing evacuation and charging valve, high-pressure side
- High-pressure safety valve on air conditioner compressor
- Receiver with dryer
- Expansion valve
- Checking air conditioning system pressure switch F129
- Checking high pressure sensor G65
- Removing and installing condenser
- Dismantling and assembling air conditioning unit
- Dismantling and assembling evaporator housing
- Capacities
- Refrigerant R134a
- Refrigerant oil
- Oil distribution
- Heating
- Heating, air conditioning