Volkswagen New Beetle

Body -- Collision
00 General Technical Data (Page GR-00)

z Technical Data
z Vehicle identification
z Safety instructions
z Body foam insulation
z Galvanized body parts
z Body panel gaps
z Body, front
z Body, rear
z Body dimensions
z Body, front
z Body, center
z Body, rear
z Floor, front
z Floor, center
z Floor, rear
Volkswagen New Beetle
Body -- Collision
Technical Data (Page 00-1)

Vehicle identification number

The vehicle Identification number (chassis number) is stamped on the right side under the
engine compartment rear bulk head. View it through the window in the plenum chamber
cover.
Vehicle information label

The vehicle information label is located on the front long member - arrow - above the
horns.
Note:
Lift the vehicle on a hoist and use a mirror -1- to see the label -arrow-.
Volkswagen New Beetle
Body -- Collision
Technical Data (Page 00-2)

Information label contains:

a- PKN (7 digits), example: 1719016
b- Color, example: B7B7
c- Commercial code: 1C13L4
d- Destination: X9A
Vehicle data sticker

The vehicle data sticker is located in spare tire wheel well.

Volkswagen New Beetle
Body -- Collision
Safety instructions (Page 00-3)

- Always use an air extraction system when performing welding and grinding work.
- Never perform welding and grinding simultaneously in the same area.
- Clean the work area regularly.
- Clean the air extraction system at regular intervals.
- Observe all general shop safety rules such as eye, ear, and chemical protection.
Volkswagen New Beetle
Body -- Collision
Body foam insulation (Page 00-4)

The 1998 Beetle has various body cavities that are foam treated.
Foam locations are described in the individual repair instructions.
Foam insulation is a pre - formed synthetic material that reduces noise transfer to the
interior.
The parts catalog shows insulation on illustration 863 - 20.
The pre - formed foam parts are installed during body assembly, they expand during
drying time in the paint shop oven at approx.180 C (388 F) after priming.
As these temperatures cannot be achieved under normal workshop conditions, proceed
as follows:
Prerequisites
- Before continuing with this procedure, ensure the replacement part is correctly
prepared.
- Remove excess foam material.
- Repaint, apply two coats (wet on wet) of glass/paint primer D009 200 02 if
necessary, flash - off time - approx.10 min.
Replacing insulation
- Apply sealing cord AKD 497 010 04 R10 around circumference of insulation.
Volkswagen New Beetle
Body -- Collision
Body foam insulation (Page 00-5)

- Install insulation.
- Attach new part (e.g. A pillar) and position new part by pressing gently in insulation
area and weld in place.
- Do not SG weld 15 mm (0.59 in.) either side of insulation.
- Re - under coat repaired area after painting vehicle, as required.
Volkswagen New Beetle
Body -- Collision
Galvanized body parts (Page 00-6)

The vehicle consists of body panels galvanized on both sides!

Before performing body repairs observe the following information:
General notes; Body repairs, General body repairs; Work sequences; Galvanized
body parts.
Volkswagen New Beetle
Body -- Collision
Body panel gaps (Page 00-7)

Body, front

The 3371 adjustment gauge is used to check or adjust gaps.

A - 0.5 mm (0.019 in.)
G - 3.5 mm (0.137 in.)
H - 4.0 mm (0.157 in.)
I - 3.5 mm (0.137 in.)
K - 5.0 mm (0.196 in.)
L - 5.5 mm (0.216 in.)
Volkswagen New Beetle
Body -- Collision
Body panel gaps (Page 00-8)

Body, rear

A - 0.5 mm (0.019 in.)

H - 4.0 mm (0.157 in.)
K - 5.0 mm (0.196 in.)
M - 6.0 mm (0.236 in.)
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-9)

Body, front

Dimension between suspension struts

Dimension between long members.
CAUTION!
Dimensions only given for checking purposes. The straightening fixture dictates
final figure.
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-10)

Dimension between fender supports under windshield

Dimension between fender supports
CAUTION!
Dimensions only given for checking purposes. The straightening fixture dictates
final figure.
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-11)

Windshield opening, diagonal dimension

Windshield center, from plenum to roof dimension
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-12)

Body, center

Door Opening
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-13)

Dimension between A - pillars

Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-14)

Dimension between B - pillars

Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-15)

Body, rear

Hatch opening, height dimension

Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-16)

Hatch opening, width dimension

Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-17)

Dimension between long members

CAUTION!
Dimensions only given for checking purposes. The straightening fixture dictates
final figure.
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-18)

Floor, front

CAUTION!
Dimensions only given for checking purposes. The straightening fixture dictates
final figure.
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-19)

Floor, center

CAUTION!
Dimensions only given for checking purposes. The straightening fixture dictates
final figure.
Volkswagen New Beetle
Body -- Collision
Body dimensions (Page 00-20)

Floor, rear

CAUTION!
Dimensions only given for checking purposes. The straightening fixture dictates
final figure.