Beruflich Dokumente
Kultur Dokumente
Body - Exterior
50 Body - Front (Page GR-50)
z Body, front
z Front end, Assembly overview
z Front fender, assembly overview
z Lock carrier, removing and installing
z Lock carrier, service position
z Noise insulation, assembly overview
z Plenum close out panel, removing and installing
z Tools
z Transparent foil protection for front fenders
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-1)
Tools
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. 4
30 Nm (22 ft lb)
4 - Bolt
Qty. 4
9 Nm (80 in. lb)
5 - Bumper carrier
With impact absorber
6 - Pop rivet
Qty. 4
7 - Insulation
Bonded with Butyl adhesive cord AKL 450 005 05
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-4)
8 - Connecting panel
Fastened to lock carrier with blind rivets.
9 - Blind rivet nut
Qty. 2
10 - Hood lock
Removing and installing Page 55-8
11 - Bolt
20 Nm (15 ft lb)
12 - Hex bolt (self-locking)
12 Nm (9 ft lb)
When reusing: clean bolt threads with a wire brush and nut threads with thread
chaser; coat bolt with locking fluid D 185 400 A 2.
13 - Radiator and condenser
14 - Radiator
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-5)
Note:
Fenders and bumper cover can only be removed together as an assembly.
1 - Front end
Removing:
- Remove wheel house inner fender Page 66-1.
- Remove wheel house bolts -2-, -3-, and -8-.
- Disconnect connectors for turn signals, fog lights and temperature sensor -9-.
- Remove nuts -6-.
- Remove spreader clips -10-
- Remove screws -4- and -7-.
- Pull front end, left and right, outward from threaded bolt; and with two technicians
pull forward from vehicle.
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-7)
Installing:
- Before installing front end, check anti-abrasive film at contact surfaces; replace if
necessary Page 50-11, item 11.
- When installing the front end, ensure the cushion - 5 - 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
Quantity 18
6 1 Nm (53 9 in. lb)
Install with locking compound D 185 400 A2
Volkswagen New Beetle
Body - Exterior
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 185 400 A2
8 - Bolt
With nut
6 Nm (53 in. lb)
9 - Exterior temperature sensor
10 - Spreader clip
Qty. 3
To remove: Press spreader pin through clip
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-9)
Note:
The front fenders are both components of the front end, and are removed as an assembly
Page 50-6.
1 - Fender
Removing:
- Remove front end Page 50-6, bolts -4- and -7-
Installing:
- Before fastening fender, install a zinc intermediate piece AKL 381 035 50 to each
bolt position contact area.
2 - Bolt
Install with locking compound D 185 400 A2
3 - Clip
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-10)
4 - Bolt
Install with locking compound D 185 400 A2
Qty. 3
4.5 1 Nm (40 9 in. lb)
5 - Reinforcement
With holes
6 - Reinforcement
With weld nuts
7 - Bolt
Install with locking compound D 185 400 A2
Qty. 2
4.5 1 Nm (40 9 in. lb)
8 - Front bumper cover
9 - Reinforcement
With holes
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-11)
10 - Reinforcement
With welded nuts
11 - Abrasion protection
Check condition, replace if necessary
12 - Pop rivet
Qty. 20
13 - Bracket
Bolted to front of long member
14 - Bolt
Qty. 2
6 1 Nm (53 9 in. lb)
15 - Close - out panel
Riveted to fender
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-12)
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. 2
3 - Bolt
Qty. 4
4 - Lock washer
Qty. 4
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-13)
1 - Noise insulation
Bolted to lock carrier
2 - Bolt
Qty. 10
3 - Bolt
Qty. 2
4 - Lock washer
Qty. 4
Volkswagen New Beetle
Body - Exterior
Body, front (Page 50-14)
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 1C0 807 907 A/908 A
2.- p/n 1C0 821 713 B/714 B
3.- p/n 1C0 853 843 / 844 A
4.- p/n 1C0 853 387 A/ 388 A
5.- p/n 1C0 821 711 B/712 B
CAUTION!
Transparent foil protection must be applied at 15 - 30 C (60 - 90 F) on clean
dry surface.
Volkswagen New Beetle
Body - Exterior
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 867 807 637)
Sticker -6- must be installed under release lever to avoid nail scratches while opening.
(p/n 867 807 637)
- 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.
Volkswagen New Beetle
Body - Exterior
Transparent foil protection for front fenders (Page 50-18)
- 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
Transparent foil protection for front fenders (Page 50-20)
- 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.