How to Replace the Throttle Body in a VW Beetle

Written by ehow cars editor
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Volkswagen introduced the New Beetle in 1998. Consumers with fond memories of the "VW Bugs" of their youth flocked to Volkswagen dealers in what would kick of a "retro-futurist design craze" that has not lagged since. Available as a hatchback or as a convertible, the front-wheel drive New Beetle is based on the Golf platform of the previous generation. Despite better options in both the new and used car markets, the New Beetle continues to attract a steady stream of followers.

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Things you need

  • Mechanic's toolset, including a full socket set, wrenches and screwdrivers
  • Torque wrench
  • Clean shop cloths
  • Replacement gasket

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    Remove the Throttle Body

  1. 1

    Make sure the engine and all components are completely cool. Disconnect the battery ground. Then isolate it to avoid accidental contact with the terminal while installing the throttle body.

  2. 2

    Remove the engine cover fasteners and take off the engine cover. Take out the air intake duct and then take the cover off the air filter. Disengage the electrical connector from the throttle control assembly.

  3. 3

    Label the hoses on the throttle body to their respective fittings. Disconnect all the hoses. Take the accelerator cable from the throttle body on vehicles with the 2.0L engine.

  4. 4

    Remove the throttle body fasteners and lift the throttle body off the manifold. Drape a clean shop cloth over the opening to prevent debris from falling into the engine.

  5. 5

    Pull the gasket and dispose of it. Clean the mating surfaces of all traces of dirt, old gasket material and carbon deposits.

    Install the Throttle Body

  1. 1

    Install a new gasket on the throttle body. Finger-tighten the bolts and then torque them to 84 inch pounds.

  2. 2

    Attach the accelerator cable to throttle body on the 2.0L engine. Connect all vacuum hoses to the throttle body. Be sure to remove the labels or tags.

  3. 3

    Reconnect the remaining components in the order of their removal. Position the engine cover over the engine and tighten the retaining screws.

  4. 4

    Connect the battery ground to the terminal and tighten the bolt. Start the engine, check for leaks and make the necessary adjustments.

Tips and warnings

  • Never smoke or expose an open flame of any kind to the area near fuel-related engine parts.
  • Take care not to damage the throttle body or gasket mating surfaces. Do not use harsh solvents or sharp tool to clean them.

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