New_Beetle_Quick_Reference_Spec_Book.pdf

2006 - 2010

New Beetle

Quick Reference

Specification Book

Volkswagen 2006-2010 New Beetle

Quick Reference Specification Book

Table of Contents

General Information ...................................................... 1

Decimal and Metric Equivalents ...........................................1

Tightening Torque .................................................................2

Warnings and Cautions ........................................................4

Maintenance .........................................................................9

Vehicle Identiication....................................................11

Vehicle Identiication Number (VIN).......................................11

VIN Decoder ..........................................................................11

Type Plate - Location.............................................................14

Vehicle Data Label.................................................................14

Sales Codes ................................................................. 15

Engine Codes .....................................................................15

Transmission Codes ...........................................................15

Vehicle Lifting .............................................................. 15

Lifting Points for Vehicle Hoist ...............................................16

Lifting Points for Floor Jack ...................................................17

Engine Mechanical, Fuel Injection & Ignition – 2.5L

BPR, BRS ..................................................................... 18

General, Technical Data .....................................................18

Engine Number – Location ....................................................18

Engine Data...........................................................................19

Engine – Removing and Installing ......................................20

Engine Installation – Tightening Torques ...............................20

Engine Assembly Mountings – Tightening Torques ...............21

Crankshaft/Cylinder Block ..................................................21

Crankshaft Bearing Caps – Tightening Torques ....................21

Crankshaft/Connecting Rod – Tightening Torques ................21

Parts Attached to Cylinder Block – Tightening Torques .........22

Oil Seal Flanges – Tightening Torques ..................................22

Belt Pulley/Vibration Damper – Tightening Torques ..............22

Flywheel/Sender Wheel – Tightening Torques ......................23

Crankshaft Dimensions .........................................................23

Piston Ring End Gaps ...........................................................23

Piston Ring Side Clearances.................................................23

Piston and Cylinder Dimensions............................................23

New Beetle Quick Reference Speciication Book • July 2010

Cylinder Head and Valvetrain .............................................24

Compression Pressures ........................................................24

Cylinder Head Cover – Tightening Sequence .......................24

Cylinder Head Cover – Tightening Torques ...........................24

Timing Chain for Camshaft Drive – Tightening Torques ........24

Cylinder Head Bolts – Removal Sequence ...........................26

Cylinder Head – Tightening Torques .....................................27

Engine Lubrication..............................................................27

Upper and Lower Oil Pan – Tightening Torques ....................27

Oil Filter Assembly – Tightening Torques...............................27

Lubrication System – Tightening Torques..............................27

Engine Cooling ...................................................................28

Recommended Coolant Mixture Ratios.................................28

Coolant System Body Side – Tightening Torques .................28

Coolant System Engine Side – Tightening Torques ..............28

Fuel Storage and Supply ....................................................29

Fuel Storage and Supply – Tightening Torques –

2.5L BPR .........................................................................29

Fuel Storage and Supply – Tightening Torques –

2.5L BRS .........................................................................30

Fuel Pump – Minimum Delivery Rate – 2.5L BPR.................30

Fuel Pump – Minimum Delivery Rate – 2.5L BRS.................31

Fuel Pump – Speciications ...................................................31

EVAP Canister – Tightening Torques.....................................32

Air Intake and Fuel Injection ...............................................32

Fuel Injection System – Technical Data.................................32

Air Filter Assembly – Tightening Torques...............................32

Intake Manifold – Tightening Torques ....................................32

Fuel Injection – Tightening Torque.........................................33

Exhaust System..................................................................33

Exhaust System – Tightening Torques ..................................33

Secondary Air Injection – Tightening TorquesTightening

Sequence Connection Tube............................................34

Engine Electrical.................................................................34

Battery Charge Condition and Speciic Gravity .....................34

Battery – Tightening Torques .................................................34

Starter – Tightening Torques .................................................35

Generator – Tightening Torques ............................................35

Ignition System ...................................................................35

Ignition Firing Order...............................................................35

Knock Sensors, Camshaft Position Sensor –

Tightening Torques..........................................................35

Spark Plugs – Identiication ...................................................35

New Beetle Quick Reference Speciication Book • July 2010

Manual Transmission .................................................. 36

General, Technical Data .....................................................36

0A4 Manual Transmission Speciications ..............................36

Manual Transmission – Installing .......................................36

Clutch – Tightening Torques ..................................................36

0A4 Manual Transmission – Tightening Torques ...................37

Automatic Transmission............................................. 39

General, Technical Data .....................................................39

09G Automatic Transmission Speciications..........................39

09G Automatic Transmission Planetary Gearbox and

Final Drive Capacities .....................................................41

Automatic Transmission – Installing ...................................41

09G Automatic Transmission –Tightening Torques ...............41

09G Automatic Transmission Automatic Transmission

Fluid (ATF) Cooler – Tightening Torque ..........................42

Suspension, Wheels, Brakes, Steering ..................... 43

Wheel Bolts – Tightening Torques ......................................43

Front Suspension and Drive Axles .....................................43

Subframe – Tightening Torques.............................................43

Control Arm – Tightening Torques .........................................43

Pendulum Support – Tightening Torques ..............................43

Stabilizer Bar – Tightening Torques .......................................44

Wheel Bearing Housing – Tightening Torques ......................44

Suspension Strut – Tightening Torques .................................44

Drive Axle – Tightening Torques ............................................44

Left Front Level Control Sensor G78 – Tightening Torques ..45

Rear Suspension ................................................................45

Rear Axle – Tightening Torques.............................................45

Shock Absorbers – Tightening Torques .................................45

Left Rear Level Control Sensor G76 – Tightening Torques ...45

Wheel Alignment.................................................................46

Wheel Bolts – Tightening Torque ...........................................46

Steering Wheel – Tightening Torque .....................................46

Wheel Alignment – Suspension Identiication........................46

Wheel Alignment – Requirements and work procedure

for all vehicles .................................................................47

Wheel Alignment Data – Front Suspension...........................48

Wheel Alignment Data – Rear Suspension ...........................49

Front Axle Camber and Toe Adjusting (Overall) –

Tightening Torques..........................................................50

Front Axle Toe Adjusting (Individual) –Tightening Torque ......50

Rear Axle Toe Adjusting – Tightening Torque ........................50

New Beetle Quick Reference Speciication Book • July 2010

iii

Brake System with Anti-lock Braking System (ABS) ..........50

Brake System – Identiication ................................................51

Front Brake System – Technical Data ...................................51

Rear Brake System – Technical data.....................................52

Hydraulic Brake System – Tightening Torques ......................52

Brake System Vacuum Pump –Tightening Torques ..............53

Brake Pressure Regulator – Tightening Torques ...................53

Front Axle Brakes FN3 – Tightening Torques ........................54

Rear Axle Brakes – Tightening Torques ................................54

Parking Brake – Tightening Torque .......................................54

Brake Pedal – Tightening Torques.........................................54

Steering ..............................................................................54

Steering Column – Tightening Torques .................................55

Crossmember for Steering Column –Tightening Torques......55

Steering Gear – Tightening Torques ......................................55

Power Steering Pump – Tightening Torques .........................55

09G Transmission Pressurized Power Steering Line to

Transmission – Tightening Torques.................................56

0A4 Transmission Pressurized Power Steering Line to

Transmission – Tightening Torques.................................56

Body.............................................................................. 57

Body Dimensions................................................................57

Front Dimensions ..................................................................57

Center Dimensions ................................................................60

Body Rear..............................................................................62

Body Panel Gaps................................................................65

Front Dimensions ..................................................................65

Rear Dimensions ...................................................................66

Body Exterior ......................................................................67

Front – Tightening Torques ....................................................67

Rear – Tightening Torques ....................................................67

Hood – Tightening Torques....................................................67

Rear Lid – Tightening Torques...............................................67

Front Doors – Tightening Torques .........................................68

Sunroof – Tightening Torques................................................68

Body Interior .......................................................................68

Front Seat Belts – Tightening Torques ..................................68

Back Seat Belts – Tightening Torques ...................................69

Airbag System – Tightening Torques .....................................69

Front Seats – Tightening Torques..........................................69

Back Seats – Tightening Torques ..........................................69

New Beetle Quick Reference Speciication Book • July 2010

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