Volkswagen New Beetle. Manual - part 1767

 

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Volkswagen New Beetle. Manual - part 1767

 

 

BLEEDING SEQUENCE 

Only use new brake fluid conforming to US standard FMVSS 116, DOT 4. Manufacturer recommends 
replacing brake fluid every 2 years.  

BRAKELINE BLEEDING SEQUENCE 

DISC BRAKES 

Service Specifications 

DISC BRAKE SPECIFICATIONS 

Application 

Sequence 

All Models 

RR, LR, RF, LF 

NOTE:

Manufacturer recommends changing brake fluid every 2 years. 

Application 

In. (mm) 

ABS Speed Sensor-To-Rotor Gap 

Front & Rear 

.003 (.08) 

Front 

Beetle 

FS III Brake Disc 

Disc Diameter 

11.023 (280) 

Original Thickness 

.866 (22) 

Wear Limit 

.748 (19) 

Parallelism & Run-Out 

(1)

FN 3 Brake Disc 

(2)

Disc Diameter 

11.338 (288) 

Original Thickness 

.984 (25) 

Wear Limit 

.866 (22) 

Parallelism & Run-Out 

(1)

Brake Pads 

Original Thickness 

.551 (14) 

Wear Limit (With Pad Backing Plate) 

.276 (7) 

Rear 

Beetle 

Brake Disc 

Disc Diameter 

9.133 (232) 

Original Thickness 

.354 (9) 

Wear Limit 

.276 (7) 

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:54:44 AM

Page 3 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 1: Positioning Front Brake Pads (Arrow Must Point Downwards - FN3 Caliper) 

Brake Pads 

Original Thickness 

.472 (12) 

Wear Limit (With Pad Backing Plate) 

.276 (7) 

(1)

Information is not available from manufacturer.

(2)

FN 3 brake caliper is equipped with a brake pad retaining spring.

NOTE:

Brake pad wear indicator light will come on when front pads are near wear limit. 
Light will go out when new pads are installed. 

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:54:44 AM

Page 4 

© 2004 Mitchell Repair Information Company, LLC. 

Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 2: Retracting Rear Brake Caliper Piston For Pad Installation 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Torque Specifications 

TORQUE SPECIFICATIONS(BRAKES) 

Application 

Ft. Lbs. (N.m) 

Front 

Beetle 

Brake Hose-To-Caliper Banjo Bolt 

FS III (280mm Diameter Disc) 

26 (35) 

FN 3 (288mm Diameter Disc) 

(1)

26 (35) 

Caliper Guide Pins 

21 (28) 

Caliper Mount-to-Steering Knuckle Bolt 

FN 3 (288mm Diameter Disc) 

(1)

92 (125) 

Rear 

Beetle 

Brake Hose-To-Caliper Banjo Bolt 

26 (35) 

Caliper Mount Bolts 

(2)

26 (35) 

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:54:44 AM

Page 5 

© 2004 Mitchell Repair Information Company, LLC. 

CHARGING SYSTEM 

GENERATOR 

Service Specifications 

GENERATOR APPLICATION 

Torque Specifications 

TORQUE SPECIFICATIONS (GENERATOR) 

DRIVE BELTS 

ADJUSTMENT 

DRIVE BELT ROUTING 

Caliper Mount-to-Spindle Bolts 

48 (65) 

Rear Wheel Bearing Hub Nut 

(2)

129 (175) 

Wheel Lug Bolt 

Beetle 

89 (120) 

INCH Lbs. (N.m)

ABS Speed Sensor Mounting Bolt 

Front & Rear 

71 (8) 

(1)

FN 3 caliper is equipped with a brake pad retaining spring.

(2)

Always replace all self-locking bolts.

Application 

Output AMPS 

Beetle 

70, 90 or 120 

Application 

Ft. Lbs. (N.m) 

Generator Mount Bolt 

All Models 

18 (25) 

Generator Belt Pulley Nut 

Without Freewheel 

48 +/- 4 (65 +/- 5) 

With Freewheel 

59 (80) 

Serpentine Belt Tensioner-To-Engine Bolt 

All Models 

18 (25) 

NOTE:

All engines are equipped with automatic belt tensioners. No adjustments are 
necessary. 

 

2003 Volkswagen New Beetle GLS 

2003 SPECIFICATIONS New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:54:44 AM

Page 6 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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