Volkswagen NEW BEETLE - Repair Manual

61 - 1 Convertible top Safety precautions when working on convertible topOpening convertible top by operating open/close buttonNote:  Observe safet

- Rest of installation is performed in the reverse order of removal. Convertible top cover, electric-/hydraulic convertible top, removing and installi

- Set hydraulic unit with reservoir down vertically in an suitable container and secure it from tipping over. - Open toggle bolt so that hydraulic

- Remove metal tongue - 3 - from pump housing (metal tongue will be damaged if left in pump housing). Metal tongue - 3 - is no longer required. Ins

- Position motor - 1 - with new pump wheel onto hydraulic pump - 5 - and install with new bolts - 2 - (bolts - 2 - are micro-encapsulated, tightening

installing Sealing ring  Always replace Sealing ring is contained in repair set Hydraulic Pump Oil reservoir, removing and installingRemovi

catch escaping oil while doing so. - Remove Torx bolts - 1 - and carefully pull off oil reservoir. Installing - Coat O-ring - 3 - with hydraulic oil

- Hydraulic system, filling and bleeding 61-2, Hydraulic system, filling and bleeding . Hydraulic cylinder, assembly overviewHydraulic cylinder R

 2x Convertible Top Open Position Switch  Installed only on right side Screwdriver Ball head Cap Securing clip Piston rod Hydraulic c

- Loosen toggle bolt on hydraulic pump so that any present residual pressure can vent from the system. - Open cap - 12 - of Convertible Top Open Posi

- Installation is performed in the reverse order of removal. Note :  When installing, check for damages and proper seating of O-rings on hydraulic l

- Remove left and right luggage compartment trim. Repair Manual, Body Interior, Repair Group 70, Luggage compartment trim, removing and install

- Turn handle - 10 - 90 o and loosen roof edge trim - 13 - . - Pull front roof frame seal off roof frame -arrow-. Convertible top

- Remove retaining clip - 1 - and remove hydraulic hoses from hydraulic cylinder. - Guide hydraulic hoses through water tray.Installing Note:  When

61 - 3 Manual convertible topManual convertible top, assembly overviewRight damper  Removing 61-2, Hydraulic cylinder, removing and installing

 Supplied as replacement part  Allocation Parts catalog Convertible Top Control Module J256  On 13-pin secondary relay carrier above relay c

installing Locking washer Bracket Pin Bolt  18 1.8 Nm 2x Screwdriver Ball head Ball socket Shock absorber, removing and installin

- Pry ball socket - 8 - off ball head - 7 - using screwdriver - 6 - . - Close convertible top manually. - Remove bolts - 5 - (2x, 18 Nm). Installing

61 - 4 Windshield frame Windshield frame, electric-/hydraulic and manual convertible top, assembly overview Roof crossmember Retaining track for

/hydraulic and manual convertible top, removing and installing Removing - Open convertible top. - Remove seal - 1 - from retaining rail. Note :  Ens

- Remove mounting bolt for convertible top cover - arrow - . - Pull clamping strip out of front roof edge channel - arrow - . - Pull convertible

- Unhook cable with ball -1 - . - Remove C-pillar roof frame gaskets off side convertible top frame. First remove inner edge, then pull in - dir

- Drill out pop rivet on frame - arrow - and remove using drift and hammer. Note:  Observe routing and position of fabric and cable. - Drill

cable. - Pull tension cable downward in - direction of arrow -. - Close convertible top but do not lock.- Fold convertible top cover rearward. -

- Pull piping - 2 - out of rear window channel - 1 - - arrows - . - Remove bolts - 3 - (12x, 10 Nm) and nut - 4 - (10 Nm) from body - 1 - . - Re

- Carefully drill out pop rivet - 4 - from retaining clip - 5 - . - Remove securing clip - 3 - from ball socket -2-. - Pull hinge - 6 - out of bal

following notes:- Install convertible top headliner in rear window channel, starting from lower center upward leading to the sides. It is recomm

beginning from center. - Secure ends of zip fastener using staple gun VAS 6148 (3 to 5 mm from end of zip fastener). Make sure staple is closed

Special tools, testers and auxiliary items required  Closing Pliers VAS 6138  Staple Gun VAS 6148  Replacement staples VAS 6148/1  Pop Rive

- Before installing roof edge strip into roof edge channel, align marking (strip) - 1 - of convertible top cover with center line of hole - 2 - of

Convertible top frame  Convertible top, removing 61-1, Manual convertible top, removing and installing Convertible top cover  Replace 61-1, M

Convertible top headliner  Replace 61-1, Convertible top headliner, electric-/hydraulic and manual convertible top, removing and installing Bolt

- Open convertible top latch to remove pressure from convertible top. Note:  Illustration shows convertible top lock in its correct functional po

- Remove bolt - arrow - - Clean bolt heads and apply 2 drops of thread hardener.- Install bolts and tighten to the following tightening torque:T

- Open retaining clips - 2 - from tension cable - 1 - using screwdriver. Retaining clips remain clipped at same position. Note:  To ease installa

- Disconnect harness connector - 1 - for rear window on left and right. - Guide connection wiring for heated rear window into interior and unclip

- Check sealing cord - 1 - on convertible top retaining frame, replace if necessary. - Place convertible top in convertible top box (second mech

Manual convertible top, cover, removing and installingNote:  Protect vehicle from paint damage by using suitable protective covers and fabric reinf

- Remove mounting bolt for convertible top cover - arrow - . - Pull convertible top cover of sealing piping out of side roof edge sealing channe

Convertible top frame  Convertible top, removing 61-1, Electric-/hydraulic convertible top, removing and installing Convertible top cover  Re

- Unhook cable with ball -1 - . - Remove C-pillar roof frame gasket in - direction of arrow - . - Pull piping out of C-pillar channel in - dir

- If present, pull insert piping - 2 - off water guide -1-. - Pull headliner - 2 - from convertible top fabric retaining frame - 1 - out in - di

- Drill out pop rivet on inner C-pillar - arrow - and remove using drift and hammer. - Pull tension cable downward in - direction of arrow -.

- Pull piping - 2 - out of rear window channel - 1 - - arrow - . - Remove three mounting bolts on both sides on molding seal of rear upholstery

- Remove bolts - 3 - (10 Nm) and nut - 4 - (10 Nm) from body - 1 - . - Remove convertible top retaining frame - 2 - from body - 1 - . Sealing ba

- Remove mounting bolt from roof edge -arrow-. - Remove sealing piping of padding out of roof edge - 1 - , bow 1 - 2 - , bow 2 - 3 - in - dire

- Pull out convertible top to side in - direction of arrow - . Note:  To ease installation, observe assignment of each sealing piping of converti

- To ease work sequence, insert convertible top cover/hinge - 1 - into ball socket - 2 - in - direction of arrow - . Note:  Do not secure secur

- Using a plastic hammer, press attachment of detail-pad roof edge strip with convertible top cover into roof edge channel in - direction of arr

- Secure tightening belt - 1 - to bow 2 - 2 - . To ease this work step, first thread mounting bolt - 3 - onto tightening belt - 1 - and onto hea

 Replace 61-1, Padding, electric-/hydraulic convertible top and manual convertible top, removing and installing Nut 10 Nm Bolt  12x 10 Nm

- Bolt on tension cable at rear. - Hook ball into front roof frame. - Adhere padding onto C-pillar using double-sided adhesive tape - arrow -

frame, replace if necessary. - Remove Fitting Bracket V.A.G 1887 from convertible top fabric retaining frame and body. - Position convertible to

- Connect harness connector - 1 - . - Press piping into rear window channel -arrow-. - Press in convertible top headliner - 2 - on convertible t

- Using screwdriver, guide long tension strap - 1 - through securing strip of convertible top padding - 2 - and pull out. To do so, place screwd

- Insert piping into C-pillar channel in - direction of arrow - . Note:  Piping must be flush with upper C-pillar edge. - Press clamping stri

- Install front roof frame seal - arrow A - and C-pillar - arrow B - . - Install roof edge trim 61-1, Convertible top front latch, electric-/hydra

- Remove C-pillar padding securing bolts from convertible top retaining frame and pull out sealing piping -arrow-. - Guide connection wire for h

- Remove piping from roof edge. - Open convertible top half way. - Remove convertible top headliner as far as rear bow 61-1, Convertible top h

- Remove rubber cable securing bolt from bow 2 - arrow - . Warning! For safety reasons, keep tension on rubber cable when removing bolt.- Fold pa

bow 3 for convertible top frame tension cable.- Guide connection wire for heated rear window and hinge through padding. - Guide rubber cable through h

motors must not be disconnected from vehicle electrical system on vehicles with electric-/hydraulic convertible top.  Position side trim panels i

- Remove roof edge trim 61-1, Convertible top front latch, electric-/hydraulic and manual convertible top - assembly overview . - Remove bolts

- Pull insert profile - 1 - of dart out of bow molding seal. - Pull darts between bow 3 and retaining frame.- Remove molding seal -1 - from bo

- Pull convertible top cover piping out of C-pillar channel in - direction of arrow - . - Loosen bonding - 1 - from C-pillar. - Drill out pop

- Open convertible top completely. - Drill out pop rivet for lower tension cable retainer -1-. - Close convertible top. - Pull convertible top h

- Remove rubber cable bolt for headliner from convertible top frame. Warning! For safety reasons, keep tension on rubber cable when removing bo

- Pull slide - 1 - downward out of guide. Installing Note:  In order to install headliner to rear window correctly, these steps must be strictl

- It is recommended to use plastic hammer in order to insert spoiler piping correctly. - Insert rivets on both sides of spoiler piping -arrow-.

- Attach headliner to third fixation - arrow -. - Attach headliner to fourth fixation - arrow -. - Install tension cables (convertible top headl

- Install securing bolt. - Install roof edge trim. - Install tension cable - arrow - on both sides of convertible top frame. - Convertible top

circle - - Open convertible top cover to install headliner at rear window and leave a space of approx. 10 cm between convertible top latch and c

 If convertible top handle does not return to rest position designated after opening or closing convertible top: - Check torque of handle attac

- Install upper and lower center parts of headliner. Starting at top, press headliner against rear window.Note:  If headliner cannot be inserte

Note:  Distance between staples is not relevant. - If necessary, insert convertible top cover - 1 - into convertible top retaining rail - 2 -

removal.Headliner tensioning system, assembly overview 11.03 Vehicles 12.03 61-1, Headliner tensioning system, assembly overview 12.03. Conver

Convertible top headliner  Replace 61-1, Convertible top headliner, electric-/hydraulic and manual convertible top, removing and installing Gui

 Inserted in upper cable track guide with cable shoe ( Item - 10 - ) Upper cable track guide with eyelet  Tied to guide rail headliner ( Item

 Each side of vehicle has a headliner tensioning system, consisting of a guide, guide rail headliner (with tied cables, cable shoes, cable track gu

- Remove two pop rivets - 1 - from frame and loosen cable shoes. Note:  Observe installation position of cable shoes. If necessary, use drift

- Untie both cables - 1 - from guide rail headliner and pull out of deflector (center), out of deflector eyelet (bottom) and out of deflector (t

- Remove securing bolt at roof edge and pull out tension strap with reinforcement plate in - direction of arrow -. Installing - Tie an approx. 92

- Guide lower cable - 1 - through deflector (center) - 2 - and then through deflector eyelet - 3 -. - Guide upper cable through upper deflector

- If present, pull insert piping - 2 - off water guide -1-. - Pull insert piping - 2 - from top at convertible top fabric retaining frame - 1 -

- Secure guide rail headliner - 1 - to reinforcement plate - 2 - . To do so, carefully press securing clips - 3 - together using pliers. Observe c

- Insert guide - 1 - into frame - 2 - and secure two lower points - 3 - using pop rivets. - Bring upper cable - 2 - behind cross rail - 1 - and ov

- Guide upper cable - 1 - with sliding cable shoe - 2 - to inclined frame - 3 - . - Rivet sliding cable eyelet - 2 - (flat side of eyelet to frame

- Pull cable secured to eyelet out until eyelet is reached - arrow - . - Install strap eyelet. - Untie cable from eyelet.- Open and, if necessary, c

Convertible top cover Convertible top frame Convertible top headliner Retaining plate with cables  Secured to reinforcement plate with retain

Lower deflector eyelet  Secured to frame with rivet Upper deflector  Secured to frame with rivet Sliding cable with eyelet  Secured to fram

Inserted in weaving guide Item - 11 - Headliner tensioning system, removing and installing 12.03 Vehicles 11.03 61-1, Headliner tensioning sy

- Remove two rivets - 1 - and loosen guide - 2 - from frame - 3 - and weaving guide - 4 - . Note:  Replace guide if scratched, damaged or plastic

 Observe installation position of weaving guides - 2 - at lower cable end. If necessary, use drift to drive out. - To remove retaining plate

- Push securing clips - 1 -inward toward headliner. - Remove roof edge trim 61-1, Convertible top front latch, electric-/hydraulic and manual

Luggage compartment trim; removing and installing luggage compartment side trim (Convertible) - Disconnect harness connector - 1 - for rear wind

insert retaining plate into headliner.  Observe original mounting position of retaining plate. - Press securing clips - 1 - of retaining pl

- Guide upper cable - 1 - through upper deflector - 2 - and then through headliner handle - 3 - in - direction of arrow - . - Insert both cables

securing clips - 3 - using pliers while doing so. Make sure that securing clips are seated correctly in mounting holes of retaining plate with cab

- and eyelets - 2 - are installed on outer side of convertible top frame.  Observe original position of eyelets. - Guide upper cable - 2 - be

Cable may be damaged when riveted into lower bore. Place flat side of both cable eyelets onto frame, otherwise there is risk of malfunction.

Repair Manual, Body Interior, Repair Group 70, Convertible top front latch, electric-/hydraulic and manual convertible top - assembly overviewLin

Circlip Bolt  10 Nm Pin Bolt Handle  Removing: Clip Clip Roof edge trim  Removing: - Remove socket head bolt from side.- Uncl

Roof crossmember Bolt Micro switch Plate Convertible top lock  Removing: - Remove roof crossmember trim Repair Manual, Body Interior,

 Installing: Bolt  10 Nm . - Installation is the reverse order of removal.Note:  Convertible top can be adjusted via elongated holes in conve

Convertible top latch Removing:  Installing: - Remove side trim. Repair Manual, Body Interior, Repair Group 70, - Open convertible top.- Dis

- Remove bolt - 4 - . Note:  Do not loosen base plate mounting bolts - 1 - and - 3 - under any circumstance, otherwise basic settings of converti

Washer  7x Bolt  10 Nm  7x Cable for emergency release Adjusting motor Harness connector Micro switch (convertible top closed) 

Convertible top latch Removing: Installing: - Remove side trim Repair Manual, Body Interior, Repair Group 70, - Open convertible top.- Rem

Washer  6x Bolt 10 Nm  6x - When convertible top has engaged, tighten bolts Item - 3 - . - Then perform function test.Convertible top

61 - 2 Electric/hydraulic convertible top Assembly overview Right hydraulic cylinder  Removing 61-2, Hydraulic cylinder, removing and installing

removing and installing Convertible Top Control Module j256  In luggage compartment, right rear  Further information Electrical Wiring Diagram

Switch E137  Located in center console Hydraulic system, filling and bleedingWhen hydraulic pump is overloaded, a thermo fuse interrupts circuit an

- Unscrew oil filler plug - 1 - . - Oil for convertible top hydraulics: G 002 00 . - Top off hydraulic oil only until oil level is between "M

- With convertible top open, oil level must be located between "Min" and "Max" marking - 2 - , correct if necessary. - Tighten o

- Carefully pull hydraulic lines - 3 - out of openings. - Remove hex nut - 4 - (5 Nm). Installing Installation is performed in the reverse order of r

Motor for hydraulic pump Removing and installing 61-2, Hydraulic pump, removing and installing Torx bolts  Always replace 5 Nm Pump wheel