Volkswagen New Beetle. Manual - part 658

See ON BOARD DIAGNOSTIC (OBD), INITIATING .

Fig. 2: Identifying Hydraulic Part And Control Module - ITT Mark 20 IE 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

DIFFERENCES BETWEEN ABS ITT MARK 20 IE AND ABS/EDL ITT MARK 20 IE 

I. I - ABS - ITT Mark 20 IE 

Dimension a = 100 mm (3.9 in.) 

II. II - ABS/EDL - ITT Mark 20 IE 

Dimension a = 130 mm (5.1 in.) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Anti-Lock Brake System - New Beetle

  

Fig. 3: Identifying Dimension ABS ITT Mark 20 IE and ABS/EDL ITT Mark 20 IE 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

SAFETY PRECAUTIONS 

WARNING:

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Brake fluid is poisonous. 

CAUTION:

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Before working on ABS or ABS/EDL system, obtain the radio code 
before disconnecting battery ground strap.  

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Brake fluid must not contact painted parts.  

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Brake fluid absorbs moisture from the air and must be replaced every 
two years. Use only new, and unused approved brake fluid that 
complies with MVSS 116 DOT4.  

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Do not use silicone-based brake fluid (DOT 5). Even the smallest 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Anti-Lock Brake System - New Beetle

  

HYDRAULIC UNIT, BRAKE BOOSTER/MASTER CYLINDER, OVERVIEW, 
VEHICLES UP TO 09.00 

traces can cause severe corrosion in the brake system.  

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Before doing any electric welding on the car, disconnect the ABS 
control module.  

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After work that requires opening the brake hydraulic system, bleed 
the system after completion of the repairs.  

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During the final road test make at least one controlled brake test 
where the brake pedal is felt to pulsate (ABS operation).  

CAUTION:

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Absolute cleanliness is required when working on the ABS or 
ABS/EDL system. Do not use any products that contain mineral oil 
such as oil, greases, etc.  

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Thoroughly clean all connections and the area immediately around 
them before loosening. Do not use aggressive cleaning agents such 
as brake cleaner, gasoline or thinners.  

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Place removed parts on a clean surface and cover them. Only use 
clean plastic covering or paper. Do not use rags that may contain 
lint.  

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Carefully seal or cover opened components if repairs cannot be 
completed right away.  

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After separating the control module from the hydraulic unit, use the 
transportation protection for the valve dome.  

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Only install replacement parts from original packaging. Only remove 
the parts from the package immediately before installation.  

CAUTION:

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Do not work with compressed air nearby whenever the hydraulic 
system is open. Do not move the vehicle with the hydraulic system 
open.  

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Be very careful not to let any brake fluid enter any wiring harness 
connectors.  

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Do not re-use fasteners that are worn or deformed from normal use.  

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Some fasteners are designed to be used only once and are unreliable 
and may fail if used a second time. This includes but is not limited to 
nuts, bolts, washers, clamps, circlips and cotter pins. Always follow 
the recommendations in this manual. Replace these fasteners with 
new parts where indicated and any other time it is deemed necessary 
by inspection.  

CAUTION: Before working on the brake system, read CAUTIONS and WARNINGS in 

SAFETY PRECAUTIONS .

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Anti-Lock Brake System - New Beetle

  

1. Brake booster 

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On gasoline engines vacuum is taken from the intake manifold.  

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Diesel engines have a vacuum pump to create the required vacuum. 

Functional check: 

„

With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in 
the unit).  

„

Depress brake pedal with average foot pressure, hold and start engine. If brake booster is 
working properly, the pedal will be felt to give slightly under foot (booster assistance 
becomes effective).  

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If pedal does not give, replace brake booster.  

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Check valve (in vacuum hose) 

Functional check. See VACUUM CHECK VALVE . 

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Separating from brake pedal. See BRAKE BOOSTER .  

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Removing and installing. See BRAKE BOOSTER .  

2. Cap  

3. Brake fluid reservoir  

4. Sealing plug 

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Moisten with brake fluid and press into reservoir  

5. Retainer pin 

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Insert through brake master cylinder  

6. Brake master cylinder 

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Cannot be repaired. If faulty, replace as complete unit  

7. Self-locking nut 

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20 N.m (15 ft. lb)  

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Always replace  

8. Bolt 

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9 N.m (80 in. lb)  

9. Cap nut 

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9 N.m (80 in. lb)  

10. ABS/EDL hydraulic unit  

NOTE:

Complete master cylinders and brake boosters can be replaced separately.

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Anti-Lock Brake System - New Beetle