Volkswagen New Beetle. Manual - part 746

SAFETY PRECAUTIONS 

Changing brake fluid: see BRAKE FLUID, CHANGING . 

If one or two chambers in the brake fluid reservoir are completely empty (e.g. leaks in braking system) bleed 
the hydraulic unit with the VAG 1551 or VAS 5051 Scan Tool in "basic setting" function. 

See  

ABS & ABS/EDL TROUBLESHOOTING FLOW CHART V.A.G 1551 SCAN TOOL / TESTER VAS 
5051 

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When driving or riding in an airbag-equipped vehicle, NEVER hold 
the scan tool or other test equipment in your hands or lap while in 
motion. Objects between you and the airbag increase the risk of 
injury in an accident.  

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During a test drive in an airbag-equipped vehicle, test equipment 
must always be fastened to and operated from the rear seat by a 
second technician.  

WARNING:

Brake fluid is poisonous.

CAUTION:

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Brake fluid must not contact painted parts.  

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Brake fluid absorbs moisture from the air and must therefore be 
replaced every two years. Use only new, unused and approved brake 
fluid that complies with MVSS 116 DOT 4.  

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Do not use silicone-based brake fluid (DOT 5). Even the smallest 
traces can cause severe corrosion in the brake system.  

CAUTION: Do not exceed filling pressure of 1 bar (14.5 psi) when filling brake fluid 

using VAS 5234. The brake system will not be completely bled if excessive 
pressure is used.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

Fig. 4: ABS & ABS/EDL Troubleshooting Flow Chart V.A.G 1551 Scan Tool / Tester VAS 5051 (1 Of 2)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Fig. 5: ABS & ABS/EDL Troubleshooting Flow Chart V.A.G 1551 Scan Tool / Tester VAS 5051 (2 Of 2)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLATION LOCATIONS 

1. ABS hydraulic unit -N55- 

The hydraulic unit consists of the following components: 

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ABS hydraulic pump -V64-

1

 ) 

 

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Valve block (contains the inlet and outlet valves)  

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ABS hydraulic pump -V64- and valve block must not be separated from one another. See ANTI-
LOCK BRAKE SYSTEM .  

NOTE:

The following list refers to items in Fig. 6 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

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When changing hydraulic unit, always seal old part with plugs from repair set Part No. 1H0 698 
311 A  

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Multi-pin harness connector terminal assignment, see MULTI-PIN HARNESS CONNECTOR 
WITH TERMINAL ASSIGNMENT 

2. ABS control module -J104- 

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Checked by On Board Diagnostic (OBD)  

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Located on hydraulic unit in left side of engine compartment  

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Removing and installing 

See ABS CONTROL MODULE AND HYDRAULIC UNIT, REMOVING AND 
INSTALLING . 

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Checking multi-pin harness connector to control module, see MULTI-PIN HARNESS 
CONNECTOR WITH TERMINAL ASSIGNMENT  

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Before disconnecting harness connector: 

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Check DTC memory.  

„

Switch ignition off before separating harness connector.  

3. ABS/EDL hydraulic unit -N55- 

The hydraulic unit consists of the components: 

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ABS hydraulic pump -V64-

1

 ) 

 

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Valve block (contains the inlet and outlet valves)  

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ABS hydraulic pump -V64- and valve block must not be separated from one another.  

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When changing hydraulic unit, always seal old part with plugs from repair kit Part No. 1H0 698 
311 A  

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Multi-pin harness connector terminal assignment, see MULTI-PIN HARNESS CONNECTOR 
WITH TERMINAL ASSIGNMENT 

4. ABS/EDL and ABS/EDL/ASR control module -J104- 

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Checked by On Board Diagnostic (OBD)  

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Located on hydraulic unit in left side of engine compartment  

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Checking multi-pin harness connector to control module, see MULTI-PIN HARNESS 
CONNECTOR WITH TERMINAL ASSIGNMENT

CAUTION: Part numbers are listed here for reference only. Always check 

with your Parts department for the latest information.

CAUTION: Part numbers are listed here for reference only. Always check 

with your Parts department for the latest information.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle

  

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Before disconnecting harness connector: 

„

Check DTC memory.  

„

Switch ignition off before separating harness connector.  

5. Brake light switch -F- 

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Open in rest position  

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Adjusting, see BRAKE LIGHT SWITCH, ADJUSTING  

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Can be checked via Read Measuring Value Block, see READ MEASURING VALUE BLOCK 
(FUNCTION 08)  

6. Data Link Connector (DLC) 

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Installation position: Current model (DLC) location is left of steering column, under the instrument 
panel. Early production is at the center console below heating/air conditioning controls.  

7. ASR/ESP Control Lamp -K155- (only for vehicles with ASR) 

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Location: In instrument cluster  

8. Warning light for brake system -K118- 

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Location: in instrument cluster  

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Function, see PARKING BRAKE INDICATOR LIGHT -K14-/WARNING LIGHT FOR 
BRAKE SYSTEM -K118-  

9. ABS warning light -K47- 

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Location: in instrument cluster  

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Function, see WARNING LIGHTS  

10. ABS wheel speed sensors -G45-/-G47- (front) 

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Checked by On Board Diagnostic (OBD)  

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Before inserting sensor clean inner surface of sensor mounting and coat with lubricating paste G 
000 650  

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When connecting wheel speed sensor wire make sure it is not twisted in wheelhousing  

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Securing bolt tightening torque: 10 N.m (7 ft lb)  

11. Wheel hub with wheel speed sensors rotor (front) 

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Removing and installing 

See SUSPENSION - FRONT (GOLF/JETTA/GTI FROM LATE 1999 PRODUCTION) . 

12. ABS wheel speed sensor -G44-/-G46- (rear) 

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Checked by On Board Diagnostic (OBD)  

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Installing, see item 10  

13. Wheel hub with wheel speed sensor rotor (rear) 

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Removing and installing 

See SUSPENSION - FRONT (GOLF/JETTA/GTI FROM LATE 1999 PRODUCTION) .

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES On Board Diagnostic (OBD) - New Beetle