Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLKSWAGEN2003NEW BEETLE (1C1) L4-2.0L (AVH)REPAIR AND DIAGNOSISBODY AND FRAMELOCATIONSLOCK CARRIER, ASSEMBLY OVERVIEW
2003 Volkswagen New Beetle (1C1) L4-2.0L (AVH)
Lock Carrier, Assembly Overview
2003 Volkswagen New Beetle (1C1) L4-2.0L (AVH)SECTION Lock Carrier, Assembly Overview
Lock carrier, assembly overview
1. Lock carrier with attachments
Removing:
Remove front part, refer to Front End, Assembly Overview [1][2]Procedures
Unhook Bowden cable at lock and disconnect electrical connectors.
Unbolt radiator and condenser from lock carrier.
Secure radiator and condenser in engine compartment.
Note: Do not hang condenser up on its lines. Do not kink condenser lines.
Remove lock carrier with connecting plate and lock.
Installing:
Align lock carrier within enlongated holes.
Adjust headlights.
2. Bolt
Qty. 4
6 Nm
For radiator mounting
3. Bolt
Qty. 4
Qty. 6 (USA)
30 Nm
4. Bolt
Qty. 4
9 Nm
5. Bumper carrier
With insulation
6. Pop rivet
Qty. 4
7. Insulation
Bonded with Butyl adhesive cord AKL 450 005 05.
8. Union plate
Secured to lock carrier with pop rivets
9. Pop rivet nut
Qty. 2
10. Tailgate lock
11. Bolt
20 Nm
12. Hexagon bolt (self-locking)
12 Nm
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 mounting
15. Impact damper (USA)
16. Nut (USA)
17. Bolt (USA)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.