Volkswagen New Beetle. Manual - part 2566

 

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Volkswagen New Beetle. Manual - part 2566

 

 

TRANSMISSION REFILL CAPACITIES 

BATTERY DISCONNECT PRECAUTIONS 

Do not loosen or remove ground strap from body. Disconnect terminal from battery only.  

Once battery has been connected, check operation of radio, clock and convenience electronics. Completely open 
and close all power windows.  

ECM 

If connector is disconnected from ECM or battery is disconnected, all adaptation values in control module are 
erased. DTC memory content will remain intact however. If engine is started after this, a rough, uneven idle can 
result. In this case, engine must be allowed to run at idle for a few minutes or a longer road test must be 
performed until adaptation procedure has been completed.  

ADJUSTMENTS 

BRAKE LIGHT SWITCH 

For servicing purposes, they will be referred to as "old style" and "new style". It is important to identify which 
style of switch is installed, prior to servicing, as each requires specific removal and installation (replacement) 
procedures. See Fig. 3 .  

"Old style" switch is identified by a large (approximately 10 mm) plunger tip button, and a square plunger shaft. 
"New style" switch is identified by a small (approximately 4 mm) plunger tip without a button, and round 
plunger shaft. "Old style" switches can be removed and reinstalled/adjusted. "New style" switch must NOT be 
reused after removal. Always replace.  

Should a brake light switch require replacement, only a specific "new style" switch is available (supersedes all 
previous part number versions). This switch requires critical procedures be followed, prior to and during 

Application 

Qts. (L) 

02M (5 & 6 Speed) 

2.4 (2.3) 

CAUTION: Turn ignition switch to OFF position. Before disconnecting negative 

battery terminal, obtain anti-theft radio security code. Disconnect negative 
battery terminal. After reconnecting battery, re-code and check operation 
of anti-theft radio. 

NOTE:

Vehicles with On Board Diagnostics (OBD) II must have readiness code for 
Electronic Control Module (ECM) re-generated after battery has been 
disconnected. See appropriate SELF-DIAGNOSTICS article in ENGINE 
PERFORMANCE. 

NOTE:

Two different styles of brake light switch were used in production. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:27 AM

Page 4 

© 2004 Mitchell Repair Information Company, LLC. 

installation.  

Fig. 3: Identifying "New Style" & "Old Style" Brake Switches 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Brake Light Switch (Old Style) 

1. Remove driver's lower instrument panel cover. Disconnect brake light switch harness connector. Turn 

switch counterclockwise 90 degrees. Pull switch out from retainer mounting hole. See Fig. 4 .  

2. Pull plunger out completely. Depress and hold brake pedal in down position. Note orientation of retainer 

tabs on switch, and carefully insert switch into retainer mounting hole. Secure switch, by turning 
clockwise 90 degrees. Slowly release brake pedal to stop. This will automatically adjust switch plunger 
travel. Connect brake light switch harness connector. Check function of brake light switch. 

NOTE:

The following applies only to an existing, functional "old style" switch that is 
removed, reinstalled/adjusted. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:27 AM

Page 5 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 4: Removing Brake Light Switch (Old Style) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Brake Light Switch (New Style) 

1. Remove driver's lower instrument panel cover. Disconnect brake light switch harness connector. Turn 

switch counterclockwise 45 degrees. Pull switch out from retainer mounting hole. Pull plunger 
completely out (arrow). See Fig. 5 .  

CAUTION: "New style" switches have an internal switch mechanism that will be 

damaged if not installed and adjusted accordingly. DO NOT depress 
switch plunger or otherwise rotate retaining collar of switch prior to 
installation. Brake pedal must be held in Up position (not depressed) 
during switch installation. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:27 AM

Page 6 

© 2004 Mitchell Repair Information Company, LLC. 

2.  

Hold brake pedal in Up position (against stop). Note orientation of retainer tabs (1 and 2) on switch. 
Carefully insert switch into retainer mounting hold. Push switch in and seat fully into opening (pressing 
plunger against brake pedal to adjust). Once seated, secure switch by turning clockwise 45 degrees. This 
action turns plunger shoe into correct orientation to make electrical contacts in switch operate, as well as 
locks in plunger adjustment against brake pedal. Connect brake switch connector. Check function of 
brake light switch.  

Fig. 5: Adjusting Brake Light Switch (New Style) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

SELECTOR MECHANISM 

CAUTION: When installing, switch must be rotated until it is fully locked and 

electrical connector is in horizontal position. Inspect to ensure 
internal stop pin on retaining collar is fully seated against outer shell. 

NOTE:

To ensure correct gear selector adjustment, moving parts of selector 
mechanism and transmission elements must be in proper condition. Selector 
mechanism must move freely. See Fig. 6 . Transmission, clutch and clutch 
mechanism must also be in proper condition. Transmission is in Neutral 
position. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:27 AM

Page 7 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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