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

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Irma Garrett
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1 53 Body - Rear (Page GR-53) Body, rear Rear end, assembly overview Rear fender, assembly overview Transparent foil protection for rear fenders

2 Body, rear (Page 53-1) Rear end, assembly overview Note: The rear fender and the bumper cover (together called the "rear end") can only be removed together as a single unit. 1 - Rear Removing: - Remove wheel house liners Page 66-2 (on right side). - Remove tail light cluster Repair Manual, Electrical Equipment, Repair Group 94 - Remove fuel tank door Page (on right side). - Remove bolts -2-, -7- and -8-.

3 Body, rear (Page 53-2) - Remove nuts Remove bolt -3- and Pull rear end on left and right-hand side outward off the threaded studs and carry away to rear with the aid of a second technician. Installing: - Before setting rear end in place, check condition of anti-abrasive film on contact surfaces; replace if necessary. 2 - Bolt 6 Nm Insert with locking fluid D A2 3 - Bolt 7.5 Nm Qty. 4 Insert with locking fluid D A2

4 Body, rear (Page 53-3) 4 - Anti-abrasive film 5 - Captive weld nuts 6 - Bolt 7.5 Nm Qty. 28 Install with locking compound D A2 7 - Bolt 1.2 Nm Qty Bolt Qty Nm Install with locking compound D A2 9 - Spring nut Qty. 2

5 Body, rear (Page 53-4) Rear fender, assembly overview Note: The rear fender and the bumper cover (together called the "rear end") can only be removed together as a single unit page Fender Removing: - Remove wheel house liner (left only) Page Remove tail light cluster Repair Manual, Electrical Equipment, Repair Group 94 - Remove fuel tank door Page (right only). - Remove rear end Page Remove screw and nut Remove bolts -3- and -6- and take off fender.

6 Body, rear (Page 53-5) Installing: - Before setting rear end in place, check condition of anti-abrasive filt -12- on contact surfaces; replace if necessary. 2 - Bolt 6 1 Nm (53 9 in. lb) Install with locking compound D A2 3 - Bolt 6 1 Nm (53 9 in. lb) Install with locking compound D A2 4 - Reinforcement With holes 5 - Bumper cover, rear Removing Page 63-4

7 Body, rear (Page 53-6) 6 - Bolt 6 1 Nm (53 9 in. lb) Install with locking compound D A2 7 - Reinforcement With holes 8 - Reinforcement With weld nuts 9 - Bolt 6 1 Nm (53 9 in. lb) Qty. 14 Install with locking compound D 10 - Reinforcement With weld nuts 11 - Bracket Bolted to front of long member 12 - Abrasion protection

8 Body, rear (Page 53-7) 13 - Captive weld nut 14 - Bracket Bolted to front of long member 15 - Clip 16 - Bolt Install with locking compound D A2

9 Transparent foil protection for rear fenders (Page 53-8) 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.

10 Transparent foil protection for rear fenders (Page 53-9) 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-. Note: In order to increase thickness and strength of foil, two must be used on each side (one over the other).

11 Transparent foil protection for rear fenders (Page 53-10) - 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 53-11, application procedure.

12 Transparent foil protection for rear fenders (Page 53-11) 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 bubles 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.

13 Transparent foil protection for rear fenders (Page 53-12) 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.

14 Transparent foil protection for rear fenders (Page 53-13) - 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.

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