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General body repairs, exterior

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


20,58 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

7.916 KB

255 Sites

Detailed technical data

Immediately readable

This repair manual contains: Body, front, Rear lid, Sliding/tilting sunroof, Convertible top, Electrical/hydraulic top, Windscreen frame, Front bumper, Flush bonded windows, Removing and installing wheel housing liner and Exterior mirror. Show more
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Repair manual New Beetle Cabrio / New Beetle General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Body, front
    1
  • 1.1 Tools
    1
  • 1.2 Assembly overview - lock carrier
    1
  • 1.3 Lock carrier - service position
    3
  • 1.4 Assembly overview - front end
    5
  • 1.5 Assembly overview - front wing
    7
  • 1.6 Replacing anti-friction foil
    8
  • 1.7 Assembly overview - noise insulation
    10
  • 1.8 Removing and installing plenum chamber cover
    14
  • 1.9 Assembly overview - vibration damper, Cabriolet
    15
  • Body - rear
    16
  • 1 Body - rear
    16
  • 1.1 Assembly overview - rear end
    16
  • 1.2 Assembly overview - rear end, Cabriolet
    18
  • 1.3 Assembly overview - rear wing
    20
  • 1.4 Removing and installing diagonal struts
    22
  • Bonnet, rear lid
    24
  • 1 Bonnet
    24
  • 1.1 Assembly overview
    24
  • 1.2 Adjusting rear lid
    25
  • 1.3 Removing and installing Bowden cable
    26
  • 1.4 Removing and installing release lever
    27
  • 1.5 Removing, installing and adjusting bonnet lock
    28
  • 2 Rear lid
    29
  • 2.1 Assembly overview - rear lid
    29
  • 2.2 Assembly overview - rear lid, Cabriolet
    30
  • 2.3 Removing gas strut
    31
  • 2.4 Removing gas strut, Cabriolet
    31
  • 2.5 Releasing gas from gas strut
    32
  • 2.6 Adjusting rear lid
    32
  • 2.7 Adjusting lid, Cabriolet
    34
  • 2.8 Removing and installing lid lock
    34
  • 2.9 Installing and removing lid lock 09.01 ► (USA)
    36
  • 2.10 Removing and installing lid lock, Cabriolet
    37
  • 2.11 Removing and installing motor carrier for remote release of rear lid
    38
  • 2.12 Removing and installing motor carrier for rear lid remote release 09.01 ► (USA)
    39
  • 2.13 Removing and installing retaining plate with motor for remote release of rear lid, Cabriolet
    40
  • 2.14 Removing and installing carrier with microswitch for rear lid, Cabriolet
    42
  • 3 Tank flap unit
    43
  • 3.1 Removing and installing tank flap unit
    43
  • 3.2 Removing and installing fuel tank filler flap release motor
    44
  • Front doors, door components, central locking
    45
  • 1 Front door
    45
  • 1.1 Tools
    45
  • 1.2 Assembly overview - front door
    45
  • 1.3 Assembly overview - front door, Cabriolet
    47
  • 1.4 Removing and installing door
    49
  • 1.5 Removing and installing door, Cabriolet
    52
  • 1.6 Adjusting door
    54
  • 1.7 Assembly overview - door handle and door lock
    55
  • 1.8 Removing and installing lock cylinder housing
    56
  • 1.9 Removing and installing door handle
    57
  • 1.10 Removing and installing door lock
    58
  • 1.11 Removing and installing door lock, Cabriolet
    63
  • 1.12 Removing and installing bearing bracket
    65
  • 1.13 Removing and installing locking knob for release rod
    66
  • 1.14 Door seals, Cabriolet
    67
  • 2 Central locking
    70
  • 2.1 Assembly overview - central locking and convenience system
    70
  • Sunroof
    73
  • 1 Sliding/tilting sunroof
    73
  • 1.1 Tools
    73
  • 1.2 Function
    73
  • 1.3 Assembly overview - sliding/tilting sunroof with glass panel
    73
  • 1.4 Removing and installing sliding/tilting sunroof glass panel
    75
  • 1.5 Adjusting height of sliding/tilting sunroof glass panel
    76
  • 1.6 Adjusting panel seal
    77
  • 1.7 Renewing panel seal
    77
  • 1.8 Removing wind deflector
    77
  • 1.9 Removing sliding headlining
    78
  • 1.10 Removing sliding/tilting sunroof drive
    78
  • 1.11 Adjusting drive for sliding/tilting sunroof (zero position)
    81
  • 1.12 Removing pre-selector control for sliding/tilting sunroof
    82
  • 1.13 Checking parallel running
    82
  • 1.14 Adjusting parallel running
    83
  • 1.15 Removing and installing carrier unit
    83
  • 1.16 Removing coulisse guide
    85
  • 1.17 Cleaning water drain hoses
    86
  • Convertible roof, hardtop, canopy
    89
  • 1 Convertible top
    89
  • 1.1 Safety precautions when working on convertible roof
    89
  • 1.2 Tools
    89
  • 1.3 Assembly overview - electrical/hydraulic convertible roof
    90
  • 1.4 Removing and installing electric/hydraulic convertible roof
    91
  • 1.6 Assembly overview - manual convertible roof
    101
  • 1.7 Removing and installing manual convertible roof
    102
  • 1.8 Removing and installing cover of manual convertible roof
    105
  • 1.9 Removing and installing padding of electric/hydraulic and manual convertible roof
    119
  • 1.11 Assembly overview - convertible roof headliner, tensioning system ► 11.03
    132
  • 1.12 Removing and installing convertible roof liner tensioning system ► 11.03
    134
  • 1.13 Assembly overview - convertible roof headliner, tensioning system 12.03 ►
    139
  • 1.14 Removing and installing convertible roof headliner tensioning system 12.03 ►
    141
  • 1.16 Removing and installing front convertible roof catch
    148
  • 1.18 Assembly overview - rear locking mechanism for manual convertible roof
    150
  • 2 Electrical/hydraulic top
    151
  • 2.1 Assembly overview
    151
  • 2.2 Filling and bleeding the hydraulic system
    151
  • 2.3 Removing and installing hydraulic pump
    153
  • 2.4 Assembly overview - impeller for hydraulic pump
    154
  • 2.5 Removing and installing impeller for hydraulic pump
    154
  • 2.6 Assembly overview - oil reservoir
    158
  • 2.7 Removing and installing oil reservoir
    158
  • 2.8 Assembly overview - hydraulic cylinder
    161
  • 2.9 Removing and installing the hydraulic cylinder
    161
  • 2.10 Removing and installing hydraulic hoses
    163
  • 3 Manually operated convertible roof
    166
  • 3.1 Assembly overview - manual convertible roof
    166
  • 3.2 Assembly overview - dampers
    167
  • 3.3 Removing and installing dampers
    167
  • 4 Windscreen frame
    169
  • Bumpers
    171
  • 1 Front bumper
    171
  • 1.1 Assembly overview
    171
  • 2 Rear bumper
    173
  • 2.1 Assembly overview
    173
  • Glazing
    175
  • 1 Flush bonded windows
    175
  • 1.1 Tools
    175
  • 1.2 Materials
    177
  • 1.3 Assembly overview - windscreen
    177
  • 1.4 Removing windscreen
    178
  • 1.5 Removing windscreen, Cabriolet
    180
  • 1.6 Installing windscreen
    181
  • 1.7 Removing and installing rain sensor
    181
  • 1.8 Assembly overview - side window
    182
  • 1.9 Removing undamaged side window
    183
  • 1.10 Removing broken side window
    184
  • 1.11 Installing side window
    184
  • 1.12 Assembly overview - rear window
    184
  • 1.13 Removing undamaged rear window
    185
  • 1.14 Removing broken rear window
    187
  • 1.15 Installing rear window
    187
  • 1.16 Preparing old undamaged window for glazing
    187
  • 1.17 Preparing new window for glazing
    188
  • 1.18 Preparing body flange for glazing
    188
  • 1.19 Installation instructions
    189
  • 1.20 Minimum curing period
    189
  • 1.21 Touching up paint damage
    189
  • 1.22 Cleaning off excess adhesive sealing material
    190
  • 2 Door windows
    191
  • 2.1 Tools
    191
  • 2.2 Assembly overview- front door window
    191
  • 2.3 Removing front door window
    192
  • 2.4 Adjusting door window
    193
  • 2.5 Removing and installing assembly carrier
    193
  • 2.6 Renewing window regulators
    197
  • 2.7 Assembly overview - front door window, Cabriolet
    199
  • 2.8 Removing and installing front door window, Cabriolet
    200
  • 2.9 Adjusting front door window, Cabriolet
    201
  • 2.10 Removing and installing assembly carrier, Cabriolet
    204
  • 2.11 Removing and installing front window regulators, Cabriolet
    205
  • 2.12 Renewing window regulator, Cabriolet
    207
  • 2.14 Overcoming resistance with excess force limitation
    213
  • 3 Side window, Cabriolet
    214
  • 3.1 Assembly overview - side windows
    214
  • 3.2 Removing and installing side window
    214
  • 3.3 Adjusting side window
    216
  • 3.4 Removing and installing carrier plate
    220
  • 3.5 Renewing window regulators
    220
  • 3.6 Removing and installing window regulator motor
    222
  • Exterior equipment
    223
  • 1 Removing and installing wheel housing liner
    223
  • 1.1 Front wheel housing liner
    223
  • 1.2 Rear wheel housing liner
    224
  • 2 Exterior mirror
    227
  • 2.1 Tools
    227
  • 2.2 Removing and installing mirror glass
    227
  • 2.3 Removing and installing mirror housing
    228
  • 2.4 Removing and installing turn signal bulb
    229
  • 2.5 Removing and installing rear view mirror
    230
  • 3 Roof mouldings
    235
  • 3.1 Roof moulding
    235
  • 4 Protective strips
    236
  • 4.1 Renewing protective strips
    236
  • 4.2 Replacing sill panel strips, Cabriolet
    237
  • 4.3 Removing and installing convertible roof frame protective strip, Cabriolet
    238
  • 5 Rear spoiler
    241
  • 5.1 Assembly overview
    241
  • 5.2 Function
    241
  • 5.3 Raising and lowering the rear spoiler “manually”
    242
  • 5.4 Removing and installing rear spoiler drive
    242
  • 5.5 Removing and installing rear spoiler assembly
    243
  • 5.6 Checking and adjusting parallel running
    245
  • 5.7 Removing and installing cable lower guide tubes
    246
  • 5.8 Lubricate rear spoiler rods
    247
  • 6 Windbreak
    248
  • 6.1 Removing and installing windbreak mounting
    248
  • 6.2 Removing and installing rear windbreak mounting
    248
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)
Suitable car types 1Y7, 9C1
Category Reparaturanleitung

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