Volkswagen New Beetle. Manual - part 823

 

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Volkswagen New Beetle. Manual - part 823

 

 

and damage. Replace defective parts as necessary.  

Reassembly 

1. Use all parts supplied in repair kit. Apply a thin coat of assembly lubricant G 052 150 A2 to piston and 

seal before inserting. Fit piston seal into cylinder. Slide dust seal onto piston. Slowly insert piston into 
bore. On self-adjusting rear calipers, use Special Tool (VW 3272) along with Collar (3272/1) or 
equivalent, to help screw piston into housing by turning knurled wheel clockwise. If piston is pushed 
back with a piston resetting tool or by operating foot brake automatic adjustment in the brake caliper is 
destroyed.  

2. Seat inner lip of dust seal in groove on cylinder housing. Open bleed screw and push piston into bore as 

far as possible. Fit outer lip of dust seal into piston groove.  

MASTER CYLINDER 

Manufacturer does not recommend overhaul of master cylinder, but recommends replacement if failure occurs. 
See MASTER CYLINDER under REMOVAL & INSTALLATION.  

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

Application 

Ft. Lbs. (N.m) 

Front 

FS III 

Brake Hose-To-Caliper Banjo Bolt 

26 (35) 

Caliper Guide Pins 

21 (28) 

FN 3 

Brake Hose-To-Caliper Banjo Bolt 

26 (35) 

Caliper Guide Pins 

21 (28) 

Caliper-To-Steering Knuckle Bolts 

92 (125) 

Rear 

C38 

Brake Hose-To-Caliper Banjo Bolt 

28 (38) 

Caliper-To-Carrier Self-Locking Bolts 

(1)

26 (35) 

Caliper Carrier-To-Spindle Bolts 

48 (65) 

Brake Pressure Switch 

18 (25) 

Brake Booster-To-Bulkhead Self-Locking Nuts 

(1)

15 (20) 

Brake Pedal Assembly Pivot Bolt & Nut 

15 (20) 

Brake Pressure Regulator Spring Retaining Bolts 

15 (20) 

Electric Vacuum Pump-To-Subframe Bolts 

15 (20) 

Master Cylinder Mounting Nuts 

(1)

15 (20) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

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Wednesday, December 14, 2005 7:59:19 AM

Page 52 

© 2004 Mitchell Repair Information Company, LLC. 

DISC BRAKE SPECIFICATIONS 

DISC BRAKE SPECIFICATIONS 

Wheel Lug Bolt 

89 (120) 

(1)

Always replace all self-locking bolts.

Application 

In. (mm) 

Front 

FS III (1.9L TDI & 2.0L) 

Disc Diameter 

11.02 (280) 

Original Thickness 

.866 (22) 

Wear Limit 

(2)

.748 (19) 

Caliper Piston Diameter 

2.13 (54) 

Lateral Runout & Parallelism 

(1)

FN 3 (1.8L) 

Disc Diameter 

11.338 (288) 

Original Thickness 

.984 (25) 

Wear Limit 

(2)

.866 (22) 

Caliper Piston Diameter 

2.13 (54) 

Lateral Runout & Parallelism 

(1)

Brake Pads 

Original Thickness 

.551 (14) 

Wear Limit (With Pad Backing Plate) 

.276 (7) 

Rear 

C38 (All Engines, Solid Disc) 

Disc Diameter 

9.133 (232) 

Original Thickness 

.354 (9) 

Wear Limit 

(2)

.276 (7) 

Caliper Piston Diameter 

1.496 (38) 

Lateral Runout & Parallelism 

(1)

C38 (All Engines, Vented Disc) 

Disc Diameter 

10.079 (256) 

Original Thickness 

.866 (22) 

Wear Limit 

(2)

.787 (20) 

Lateral Runout & Parallelism 

(1)

Brake Pads 

Original Thickness 

.472 (12) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:19 AM

Page 53 

© 2004 Mitchell Repair Information Company, LLC. 

Wear Limit (With Pad Backing Plate) 

.276 (7) 

(1)

Information is not available from manufacturer.

(2)

When worn, always replace brake discs on both sides of an axle.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:19 AM

Page 54 

© 2004 Mitchell Repair Information Company, LLC. 

1998-04 DRIVE AXLES 

Axle Shafts - New Beetle 

IDENTIFICATION 

AXLE SHAFTS 

Volkswagen New Beetle may be equipped with one of four different front axle shafts. See Fig. 1 -Fig. 4 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:12 AM

Page 1 

© 2004 Mitchell Repair Information Company, LLC. 

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:17 AM

Page 1 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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