Volkswagen New Beetle. Manual - part 844

 

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Volkswagen New Beetle. Manual - part 844

 

 

With battery installed, and ignition switched off, check voltage between battery terminals with voltmeter. If no 
load voltage is 12.5 volts, or higher, battery is okay. If no load voltage is lower than 12.5, recharge battery, and 
repeat procedure. If battery voltage is still less than 12.5 after charging battery, replace battery. See BATTERY 
under REMOVAL & INSTALLATION.  

BENCH TESTING 

BRUSHES 

Remove voltage regulator from back of generator. Ensure brushes are longer than .20" (5 mm). If necessary, 
install new brushes. DO NOT allow solder to run into strands of brush leads. See Fig. 3 and Fig. 4 .  

VOLTAGE REGULATOR BRUSH SPECIFICATIONS 

Application 

In. (mm) 

New 

0.5 (12) 

Wear Limit 

0.2 (5) 

Tolerance 

0.04 (1) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 6 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 3: Checking Generator Brushes (Models Up To May 1999) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 7 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 4: Checking Brushes (Models From June 1999 & On) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

REMOVAL & INSTALLATION 

WARNING:

Vehicles are equipped with air bag supplemental restraint system. Before 
attempting any repairs involving steering column, instrument panel or 
related components, see SERVICE PRECAUTIONS and DISABLING & 
ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT 
SYSTEMS article. 

CAUTION: When battery is disconnected, vehicle computer and memory systems 

may lose memory data. Driveability problems may exist until computer 
systems have completed a relearn cycle. See COMPUTER RELEARN 
PROCEDURES article in GENERAL INFORMATION before disconnecting 
battery. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 8 

© 2004 Mitchell Repair Information Company, LLC. 

BATTERY 

Removal & Installation (Convertible From Aug 2002 & Sedan From Dec 2002) 

1. Disconnect battery. Press retainer clips (arrows), and pull upward to remove battery shield. See Fig. 5 . 

Remove bolt (1) and battery hold-down (2). See Fig. 6 .  

2.  

Remove power steering fluid reservoir retaining clip bolt (1). See Fig. 7 . Remove clip holder. Remove 
bolt (2) attaching air cleaner-to-battery platform.  

3.  

Carefully slide battery to left, and lift from battery tray. Remove plastic retainer clip (1). See Fig. 8 . 
Gently press down and sideways (arrow), and remove battery shield. If necessary, remove bolts (1) to 
remove battery carrier. See Fig. 9 .  

4. To install, only use batteries with a 10.5 mm battery foot strip. Install battery so lug of battery carrier 

(arrow) engages in battery groove (1). See Fig. 10 . Ensure battery can not move left or right when in 
position.  

5.  

On batteries with hose for central venting, ensure venting hose is not kinked. Only then can battery vent 
freely. On batteries without hose for central venting, ensure opening on upper side of battery cover is not 
blocked.  

6. To complete installation, reverse removal procedure. Install battery hold-down and bolt (2). See Fig. 6 . 

Tighten bolt to specification. See TORQUE SPECIFICATIONS . Tighten power steering fluid 
reservoir retaining clip bolt and air cleaner-to-battery platform to specification. See TORQUE 
SPECIFICATIONS 
.  

CAUTION: After installing battery, check to ensure battery is seated securely. If 

battery is not secured properly, the following will result: 

z

Shortened battery service life due to vibration damage.  

z

Battery cell and plate damage.  

z

Electrolyte leakage due to battery case damage.  

z

Poor collision safety.  

NOTE:

DO NOT disconnect power steering hoses from reservoir. 

CAUTION: Ensure power steering fluid reservoir, air cleaner or other 

components are not damaged upon removal of battery. Carefully 
move reservoir, air cleaner and other components away from battery 
area as necessary for clearance. 

NOTE:

The battery is correctly installed when the center groove in the battery foot 
strip aligns with threaded hole in the battery carrier (arrows). See Fig. 11 . 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CHARGING SYSTEMS Generators & Regulators - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:02:43 AM

Page 9 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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