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 FRAMERADIATOR SUPPORTLOCATIONS

2003 Volkswagen New Beetle (1C1) L4-2.0L (AVH)

Radiator Support: Locations

2003 Volkswagen New Beetle (1C1) L4-2.0L (AVH)SECTION Locations

Lock carrier, assembly overview

1. Lock carrier with attachments
Removing:
Remove front part, refer to Front End, Assembly Overview Front End, Assembly Overview
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.