Volkswagen New Beetle Body - Exterior 50 Body - Front (Page GR-50)

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Reginald Wade
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1 50 Body - Front (Page GR-50) Body, front Front end, Assembly overview Front fender, assembly overview Lock carrier, removing and installing Lock carrier, service position Noise insulation, assembly overview Plenum close out panel, removing and installing Tools Transparent foil protection for front fenders

2 Body, front (Page 50-1) Tools Special tools and auxiliary items required 3411 Guide rods

3 Body, front (Page 50-2) Lock carrier, removing and installing 1 - Lock carrier with attachments Removing: - Remove front panel Page Disconnect bowden cable on lock and disconnect electrical connections. - Remove bolts and and bumper support Unbolt radiator and condenser from lock carrier. - Secure radiator and condenser in engine compartment. Note: Do not hang condenser from wires

4 Do not damage wires - Remove bolts Remove lock carrier with connecting panel and lock.

5 Body, front (Page 50-3) Installing: - Align lock carrier to long members and secure. - Adjust headlights. 2 - Bolt Qty. 4 6 Nm (53 in. lb) For radiator support 3 - Bolt Qty Nm (22 ft lb)

6 4 - Bolt Qty. 4 9 Nm (80 in. lb) 5 - Bumper carrier With impact absorber 6 - Pop rivet Qty Insulation Bonded with Butyl adhesive cord AKL

7 Body, front (Page 50-4) 8 - Connecting panel Fastened to lock carrier with blind rivets. 9 - Blind rivet nut Qty Hood lock Removing and installing Page Bolt 20 Nm (15 ft lb) 12 - Hex bolt (self-locking) 12 Nm (9 ft lb)

8 When reusing: clean bolt threads with a wire brush and nut threads with thread chaser; coat bolt with locking fluid D A Radiator and condenser 14 - Radiator

9 Body, front (Page 50-5) Lock carrier, service position - Remove front bumper Page Disconnect bowden cable on lock. - Remove one bolt on each long member and screw special tool 3411 onto right and left long member. - Remove bolts and (left and right) and pull lock carrier with special tool 3411 forward.

10 Body, front (Page 50-6) Front end, Assembly overview Note: Fenders and bumper cover can only be removed together as an assembly. 1 - Front end Removing: - Remove wheel house inner fender Page Remove wheel house bolts -2-, -3-, and Disconnect connectors for turn signals, fog lights and temperature sensor Remove nuts Remove spreader clips -10-

11 - Remove screws -4- and Pull front end, left and right, outward from threaded bolt; and with two technicians pull forward from vehicle.

12 Body, front (Page 50-7) Installing: - Before installing front end, check anti-abrasive film at contact surfaces; replace if necessary Page 50-11, item When installing the front end, ensure the cushion fits correctly on the upper long members on both sides. 2 - Bolt With nut 6 Nm (53 in. lb) 3 - Combi bolt 6 Nm (53 in. lb) 4 - Bolt

13 Quantity Nm (53 9 in. lb) Install with locking compound D A2

14 Body, front (Page 50-8) 5 - Insulation 6 - Hex nut 6 1 Nm (53 9 in. lb) 7 - Bolt 7.5 Nm (66 in. lb) Qty. 4 Install with locking compound D A2 8 - Bolt With nut 6 Nm (53 in. lb)

15 9 - Exterior temperature sensor 10 - Spreader clip Qty. 3 To remove: Press spreader pin through clip

16 Body, front (Page 50-9) Front fender, assembly overview Note: The front fenders are both components of the front end, and are removed as an assembly Page Fender Removing: - Remove front end Page 50-6, bolts -4- and -7- Installing: - Before fastening fender, install a zinc intermediate piece AKL to each bolt position contact area. 2 - Bolt Install with locking compound D A2 3 - Clip

17 Body, front (Page 50-10) 4 - Bolt Install with locking compound D A2 Qty Nm (40 9 in. lb) 5 - Reinforcement With holes 6 - Reinforcement With weld nuts 7 - Bolt Install with locking compound D A2 Qty Nm (40 9 in. lb) 8 - Front bumper cover 9 - Reinforcement With holes

18 Body, front (Page 50-11) 10 - Reinforcement With welded nuts 11 - Abrasion protection Check condition, replace if necessary 12 - Pop rivet Qty Bracket Bolted to front of long member 14 - Bolt Qty Nm (53 9 in. lb) 15 - Close - out panel Riveted to fender

19 Body, front (Page 50-12) Noise insulation, assembly overview Note: Minor deviations may be possible depending on vehicle equipment. Gas engine vehicles 1 - Noise insulation assembly Bolted to lock carrier Bottom panel bolted to side panel 2 - Bolt Qty Bolt

20 Qty Lock washer Qty. 4

21 Body, front (Page 50-13) Diesel engine vehicles 1 - Noise insulation Bolted to lock carrier 2 - Bolt Qty Bolt Qty Lock washer Qty. 4

22 Body, front (Page 50-14) Plenum close - out panel, removing and installing 1 - Plenum close - out panel Removing: - Remove plenum closeout panel (outer). - Remove seal from edge of closeout panel. - If necessary, disassemble components from closeout panel - Remove bolt and nut then remove brace Remove close - out panel Bolt 3 - Hex nut, 70 Nm (52 ft lb)

23 4 - Combi bolt 5 - Brace

24 Transparent foil protection for front fenders (Page 50-15) Beginning with production, a new transparent foil protection is being installed on front and rear fenders Materials: Transparent foil protection (left/right) 1.- p/n 1C A/908 A 2.- p/n 1C B/714 B 3.- p/n 1C / 844 A 4.- p/n 1C A/ 388 A 5.- p/n 1C B/712 B CAUTION! Transparent foil protection must be applied at C (60-90 F) on clean dry surface.

25 Transparent foil protection for front fenders (Page 50-16) Sticker -6- must be installed under release lever to avoid nail scratches while opening. (p/n ) - Locate sticker -7- as shown in illustration. (p/n 1HM ) - Verify rear lid rubber stop rests against center of sticker -7-. CAUTION! Note: In order to increase thickness and strength of foil, two must be used on each side (one over the other).

26 Transparent foil protection for front fenders (Page 50-17) Sticker -6- must be installed under release lever to avoid nail scratches while opening. (p/n ) - Front foil protection (left/right) must be applied before mounting front fender, as shown in illustration. Rear foil protection (left/right) must be applied before mounting rear fender, as shown in illustration. Note: If film protection falls off Page 50-18, application procedure.

27 Transparent foil protection for front fenders (Page 50-18) Application procedure (general) - Prepare a solution, 25% isopropylic alcohol and 75% water; do not use soap or detergents. - Clean and dry the front and rear fenders. - Remove foil from waxed paper and do not touch adhesive. - Wet adhesive area on foil with alcohol/water solution. - Use a soft plastic guide to set foil in place and remove excessive residue. - Verify proper foil placement, to avoid air bubbles and/or wrinkles. - Dry with a clean soft cloth. Procedure for removing foil protection - Heat any corner of foil with a heat gun. - Remove foil starting with corner you heated, pull foil slowly, while applying heat. It is very important to pull foil slowly for ease or removal and to avoid paint damage. If adhesive residue remaines, use 3M Citrus Base Cleaner for final cleaning.

28 Transparent foil protection for front fenders (Page 50-19) Transparent film protection, removing and installing - Remove front wheel house liner. Removing and installing, Page Remove nuts Remove bracket Bolted to front of long member - Carefully pull fender out and remove rocker panel transparent protection. - Apply rear foil protection (left/right) before mounting rear fender, as shown in illustration. Note: Transparent protection must be placed exactly as before. New film protection must protrude 5 mm from fender.

29 Transparent foil protection for front fenders (Page 50-20) - Remove front wheel house liner. Removing and installing Page Remove screws Remove bracket -1-. Bolted to front of long member - Carefully pull fender out and remove rocker panel transparent protection. - Apply rear foil protection (left/right) before mounting rear fender, as shown in illustration. Note: Transparent protection must be placed exactly as before. New film protection must protrude 5 mm from fender.

Volkswagen New Beetle Body - Exterior 53 Body - Rear (Page GR-53)

Volkswagen New Beetle Body - Exterior 53 Body - Rear (Page GR-53) 53 Body - Rear (Page GR-53) Body, rear Rear end, assembly overview Rear fender, assembly overview Transparent foil protection for rear fenders Body, rear (Page 53-1) Rear end, assembly overview Note: The