www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2014 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You



Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI 101

TDI 101 Got a simple/basic TDI question? Are you a newbie (new to the forums). Feel free to post your question here.

Reply
 
Thread Tools
Old July 13th, 2009, 23:20   #1
weirdajs
Veteran Member
 
weirdajs's Avatar
 
Join Date: May 2008
Location: Junction city,KS
Default How to replace a battery in New Beetle

How to replace a battery in New Beetle
First off I don't have a picture of taking your top battery cover off.

Tools you need are 1/4 Ratchet or 1/4 Air Ratchet,1/4 Extension,10mm, and a 13mm. Tools not shown are a set of Hex wrenches/Allen wrenches and Flat tip Screwdriver.
First you need to take off your battery top cover. To do that squeeze the latch and then you should be able to lift the cover off. If not carefully use a Screwdriver to pry it without breaking the plastic cover. Now mine didn't have the top cover because it is broke off.

Next now loosen the 10mm Negative battery terminal nut. This located on the right side of the battery. Cause this you are not sparking with your tools. This also being safe
SEE THE PICTURE ABOVE FOR MORE HELP

Ok on the Positive terminal is two different nuts you need to loosen. One 10mm nut holds the terminal and other is for the fusebox. I loosen both because it was easier to move the Positive cable. This makes it easier for later on. Use your 1/4 Ratchet with your Extension and 10mm Socket to loosen both nuts. There is a washer behind the 10mm nut be careful. Don't lose it along with the bolt behind the terminal. Now wiggle it instill you pull the Positive cable off and out your away.
SEE THE PICTURE ABOVE FOR MORE HELP

You might have to pry gently with your Screwdriver to loosen your terminals. Both
Positive and Negative terminal ends To do that is get underneath and pry. Or pry between the terminal end where the bolt was.
SEE THE PICTURE ABOVE FOR MORE HELP

The Power Steering Reservoir is in your way. First undo the plastic cable clamps next to the battery box. Next where you see Power Steering Reservoir to the left underneath the Air Injection hose is a Hex bolt. Shown above in the picture This holds the Positive cable with a plate attached to it. Take your Hex/Allen wrench should be 3/16 wrench to loosing the bolt. That holds the Power Steering Reservoir and Positive cable plate together. Once you have the bolt loose. Now pull up on the Power Steering Reservoir to free the Positive cable plate.
SEE THE PICTURE ABOVE FOR MORE HELP

After you have loosen the Positive cable and Power Steering Reservoir. Now push the cable under the Power Steering hose and Air Injection hose. So it is completely out the way.
SEE THE PICTURE ABOVE FOR MORE HELP

Behind the battery box is a plastic clip that holds the fuse box wires together. Just pull up and out to remove the plastic clip. This makes it easier to move the fuse box around.
SEE THE PICTURE ABOVE FOR MORE HELP



You need now to remove the two plastic battery box pieces. First remove the first piece by pulling it apart at the seems. Secondly there might be a battery clamp holding the battery in place. Take your 13mm then and remove the bolt holding the battery in place. Push the Power Steering Reservoir away a little. Battery needs to be tipped by raising bottom of Positive side. Then lift pull towards your left to get out the battery. Removed the second plastic piece.
SEE THE PICTURES ABOVE FOR MORE HELP
__________________
no gnis I trap eht s'ereH nognilK sa llew sa tpircSavaJ ni tneulf m'I no gnirb uoy ziuq aivirt yna eca ll'I gnop gnip fo emag a ni ttub ruoy kcik erus nac I gnos emeht etiruovaf ym si "syaD yppaH" nug gniredlos a tog I tub tag a tog t'nia I

Last edited by weirdajs; July 20th, 2009 at 19:42.
weirdajs is offline   Reply With Quote
Old July 13th, 2009, 23:22   #2
weirdajs
Veteran Member
 
weirdajs's Avatar
 
Join Date: May 2008
Location: Junction city,KS
Default





After you have the battery out take off the heat shield cover. And then replace it on the new battery.
SEE THE PICTURES ABOVE FOR MORE HELP



The battery plastic piece next to the fender well you removed, earlier put back in place. To put the battery back again, you need to lift and tip on the Positive side. By doing this you should be able to slide it back in again. Now attached your other plastic piece to the other one.
SEE THE PICTURE ABOVE FOR MORE HELP



Find you plastic piece that goes behind the battery box. Reattach it so it is holding the fuse box cables.
SEE THE PICTURE ABOVE FOR MORE HELP



Re-fish the Positive cable under the Air Injection hose and Power Steering hose. Before you bolt up your Power Steering Reservoir, you have line up the Positive cable plate first. Lining up Positive cable plate is easy. You just have to make sure the Power Steering Reservoir fit in the Positive cable plate hole.
SEE THE PICTURE ABOVE FOR MORE HELP



I am going to show a little trick before bolting back your Power Steering Reservoir. Take a piece of masking tape and wrap it around your Hex/Allen wrench with the bolt. This makes it easier bolting up the Power Steering Reservoir. Then tear off the tape and finishing tightening the bolt.
SEE THE PICTURE ABOVE FOR MORE HELP





Re-clamp your Positive cable to plastic clamp on the battery box. Attach the Positive cable back to the Positive terminal. Not the Negative terminal Reattach Positive cable from the fuse box. Or you could first reattach the Negative cable. Take the Negative cable and attach back to the Negative terminal.
SEE THE PICTURES ABOVE FOR MORE HELP


Also Mods sorry I don't know where to post it Just trying to help that's all.
__________________
no gnis I trap eht s'ereH nognilK sa llew sa tpircSavaJ ni tneulf m'I no gnirb uoy ziuq aivirt yna eca ll'I gnop gnip fo emag a ni ttub ruoy kcik erus nac I gnos emeht etiruovaf ym si "syaD yppaH" nug gniredlos a tog I tub tag a tog t'nia I

Last edited by weirdajs; July 20th, 2009 at 19:40.
weirdajs is offline   Reply With Quote
Old July 14th, 2009, 10:44   #3
lkchris
Veteran Member
 
Join Date: Apr 2008
Location: Albuquerque, NM, USA
Default

Just did mine and had no problem just removing positive cable from battery terminal, i.e. no need to disconnect from fuse box. (This is way "official" procedures specify.)

In any event, you shouldn't recommend working on postive until negative cable is removed from battery first. (You got reassembly correct). Reason obviously is that if your wrench touches something else it's meaningless working on the negative and when subsequently working on postitive, it's safe, too, as negative is removed and there're no sparks left.

You should note--as Bentley manual does--that tipping of battery (raising inside end) is required for removal/installation. It's not coming out straight up.
__________________
Kent Christensen
Albuquerque
'03 New Beetle TDI, '07 E320 Bluetec, '07 GL320CDI
lkchris is offline   Reply With Quote
Old July 14th, 2009, 11:12   #4
weirdajs
Veteran Member
 
weirdajs's Avatar
 
Join Date: May 2008
Location: Junction city,KS
Default

Quote:
Originally Posted by lkchris
Just did mine and had no problem just removing positive cable from battery terminal, i.e. no need to disconnect from fuse box. (This is way "official" procedures specify.)

In any event, you shouldn't recommend working on postive until negative cable is removed from battery first. (You got reassembly correct). Reason obviously is that if your wrench touches something else it's meaningless working on the negative and when subsequently working on postitive, it's safe, too, as negative is removed and there're no sparks left.

You should note--as Bentley manual does--that tipping of battery (raising inside end) is required for removal/installation. It's not coming out straight up.
You are right and true. It was after midnight when I finished typing up this guide. I don't mind constructive criticism from people. I might re-edit this guide some more.
__________________
no gnis I trap eht s'ereH nognilK sa llew sa tpircSavaJ ni tneulf m'I no gnirb uoy ziuq aivirt yna eca ll'I gnop gnip fo emag a ni ttub ruoy kcik erus nac I gnos emeht etiruovaf ym si "syaD yppaH" nug gniredlos a tog I tub tag a tog t'nia I
weirdajs is offline   Reply With Quote
Old July 20th, 2009, 19:46   #5
weirdajs
Veteran Member
 
weirdajs's Avatar
 
Join Date: May 2008
Location: Junction city,KS
Default

Ok tdiclub I revise my guide a little. lkchris is right about working on the Negative side first. What was I thinking when I typed up it. Sorry I didn't take more pictures. I wanted it done.
__________________
no gnis I trap eht s'ereH nognilK sa llew sa tpircSavaJ ni tneulf m'I no gnirb uoy ziuq aivirt yna eca ll'I gnop gnip fo emag a ni ttub ruoy kcik erus nac I gnos emeht etiruovaf ym si "syaD yppaH" nug gniredlos a tog I tub tag a tog t'nia I
weirdajs is offline   Reply With Quote
Old April 29th, 2010, 05:46   #6
joel12mi
Newbie
 
Join Date: Mar 2010
Location: WV
TDI(s): new beetle
Default

I finally got the battery out but did break the 2 sided plastic battery box\cover. Broke off the tab right behind the headlight.

This was a pain to say the least. It is very tight working space.
joel12mi is offline   Reply With Quote
Old July 22nd, 2011, 17:12   #7
spyderhead
Veteran Member
 
Join Date: Mar 2005
Location: Jackson, Mississippi
Default Question on battery install

Just read the above thread; wish I had changed the battery myself. I wanted a better battery - Interstate - and had an old friend who owns a Firestone dealership change the battery. He broke the wrap-around shield in two spots (both pieces) putting the battery back in. As a result, the power steering reservoir does not fit right, and the piece that goes across the top to hold the fuse box is broken (fuse box slides into this piece). He thought it was not a big deal; I think it might be.
Has anyone ever had VW replace the battery shield pieces and - if so - what did it cost? As it is now, my fuse box is just sitting atop the new battery (can move when driving) and my power steering reservoir is not very secure.
Any/all advice/suggestions are appreciated.
spyderhead is offline   Reply With Quote
Old October 25th, 2013, 13:00   #8
Cha2ga
Veteran Member
 
Cha2ga's Avatar
 
Join Date: Jun 2013
Location: Liberty, SC
Fuel Economy: 46
Default

I know this is an old thread; however, thanks to the OP! I just bought an 000-915-105-DG from my dealer for 119.83. It is listed as 12V 72Ah 380A DIN 640A EN/SAE. I'll go home an follow this DIY after work!
Cha2ga is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 2 (0 members and 2 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 14:53.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2014
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2013, All Rights Reserved
Page generated in 0.17122 seconds with 11 queries
[Output: 89.55 Kb. compressed to 77.29 Kb. by saving 12.26 Kb. (13.70%)]