Volkswagen New Beetle. Manual - part 835

Using a press, install triple-rotor star onto shaft stop. Install NEW circlip, ensuring it is seated correctly. 
Install rollers onto triple-rotor star per markings. See Fig. 32 . Slide joint over rollers and hold.  

5. Press specified amount of grease from repair kit, into joint. See TRIPLE ROLLER JOINT (AAR 3300 

i) table under LUBRICATION. Slide joint over rollers and hold. Press specified amount of grease from 
repair set into axle shaft protective boot. Install axle shaft protective boot.  

6. Tighten hose clamp and small clamp with pliers V.A.G. (1275).  

7. Install axle shaft. See FRONT AXLE SHAFT under REMOVAL & INSTALLATION.  

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

SPECIAL TOOLS 

Application 

Ft. Lbs. (N.m) 

Axle Shaft Flange-To-Transmission Bolt 

M8 X 18 

30 (40) 

M8 X 28 

30 (40) 

M8 X 48 

30 (40) 

Axle Shaft Flange-To-Transmission Bolt (Previous) 

M10 X 20 

52 (70) 

M10 X 48 

52 (70) 

Axle Shaft Flange-To-Transmission Bolt (NEW) 

M10 X 23 

52 (70) 

M10 X 52 

52 (70) 

Axle Shaft Wheel Hub 12-Point Nut 

Step 1 

148 (200) 

Step 2 

Loosen 180 Degrees 

Step 3 

Turn Wheel Hub 180 Degrees 

Step 4 

37 (50) 

Step 5 

Turn An Additional 60 Degrees 

Ball Joint-To-Control Arm Bolt 

(1)

Step 1 

15 (20) 

Step 2 

Turn An Additional 90 Degrees 

CV Joint Boot Hose Clamp (Large Diameter) 

(2)

15 (20) 

CV Joint Boot Hose Clamp (Small Diameter) 

(2)

18 (25) 

Pendulum Support-To-Subframe 

18 (25) 

Wheel Bolt 

89 (120) 

(1)

Manufacturer recommends using NEW bolt and nut.

(2)

Torque specification is for use with V.A.G. (1682). See Fig. 24 and Fig. 25 .

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 46 

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Fig. 38: Identifying Special Tools (1 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 47 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 39: Identifying Special Tools (2 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 48 

© 2004 Mitchell Repair Information Company, LLC. 

2003-04 VOLKSWAGEN 

New Beetle 

BUZZERS, RELAYS & TIMERS 

BUZZERS, RELAYS & TIMERS LOCATION 

CIRCUIT PROTECTION DEVICES 

CIRCUIT PROTECTION DEVICES LOCATION 

CONTROL UNITS 

CONTROL UNITS LOCATION 

Component 

Location 

Coolant Fan Control Relay (13) 

On thirteenfold auxiliary relay panel. 

Coolant Preheating Relay (Low Heat Output) 

To left of brake fluid reservoir. 

Daytime Running Lights Changeover Relay (8) 

On thirteenfold auxiliary relay panel. 

Dual Horn Relay 

On relay panel. 

Foglight Relay (1) 

On thirteenfold auxiliary relay panel. 

Fuel Pump Relay (4) 

On relay panel. 

Glow Plug Relay (10) 

On thirteenfold auxiliary relay panel. 

Load Reduction Relay (2) 

On relay panel. 

Motronic Engine Control Module Power 
Supply Relay 

To left of brake fluid reservoir. 

Park/Neutral Position Relay (11) 

On thirteenfold auxiliary relay panel. 

Power Supply (Terminal 30, B+) Relay (12) 

On thirteen fold auxiliary relay panel. 

Radio Speaker Changeover Relay (6) 

On thirteenfold auxiliary relay panel. 

Remote Rear Lid Unlock Motor Relay (2) 

On thirteenfold auxiliary relay panel. 

Secondary Air Injection Pump Relay (1.8L) 

Inside housing, to left of brake fluid 

reservoir. 

Secondary Air Injection Pump Relay (2.0L) 

Inside housing, to left of brake fluid 

reservoir. 

Starter Lock Relay (Clutch Pedal Switch) (3) 

On thirteenfold auxiliary relay panel. 

Wiper/Washer Intermittent Relay (2) (V & VI) 

On relay panel. 

Component 

Location 

Fuse Bracket 

On battery cover. 

Fuse Panel 

Behind left side of dash. 

Relay Panel 

Behind left side of dash. 

Thirteenfold Auxiliary Relay Panel 

Behind left side of dash, integral to relay panel. 

 

2003 Volkswagen New Beetle GLS 

2003-04 VOLKSWAGEN New Beetle

  

 

2003 Volkswagen New Beetle GLS 

2003-04 VOLKSWAGEN New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:04:15 AM

Page 1 

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Wednesday, December 14, 2005 8:04:19 AM

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