Volkswagen New Beetle. Manual - part 662

 

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Volkswagen New Beetle. Manual - part 662

 

 

Installing 

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Using new bolts, install control module to hydraulic unit. Do not tighten more than max. 4 N.m (35 in. 

Fig. 14: Pulling Control Module Straight Up To Remove 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

CAUTION:

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Only remove sealing plugs on the new hydraulic unit just before 
installing the corresponding brake line.  

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If the sealing plugs are removed too early, brake fluid can escape. It 
can no longer be guaranteed that the unit is sufficiently filled or 
adequately bled.  

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When assembling the control module and hydraulic unit, be sure that 
the hydraulic unit valve dome is not tilted against the control module 
solenoid valves.  

 

2003 Volkswagen New Beetle GLS 

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

  

lb).  

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Re-connect electrical connector for hydraulic pump motor.  

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Install ABS unit to bracket.  

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After tightening brake lines, tighten hydraulic unit.  

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Continue installation in reverse order of removal.  

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Bleed brake system. See BLEEDING BRAKE SYSTEM .  

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Enter radio code.  

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Code control module  

See CODE CONTROL MODULE (FUNCTION 07) . 

Tightening torques: 

Control module to hydraulic unit : max. 4 N.m (35 in. lb) 

Hydraulic unit bolt to bracket : 8 N.m (71 in. lb) 

Nut for brake master cylinder to brake booster : 20 N.m (15 ft. lb) 

Brake lines to ABS unit: 

Thread M10 x 1 : 15 N.m (11 ft. lb) 

Thread M12 x 1 : 15 N.m (11 ft. lb) 

Nut to body : 20 N.m (15 ft. lb) 

Cap nut to body : 20 N.m (15 ft. lb) 

ABS SYSTEM COMPONENTS FOR FRONT AXLE, REMOVING AND 
INSTALLING 

NOTE:

Hand-tighten bolts to make attaching individual brake lines easier.

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

SAFETY PRECAUTIONS 
.

NOTE:

Removing and installing ABS system parts is identical for FS III and FN 3 brake 
calipers.

NOTE:

The following list refers to items in Fig. 15 .

 

2003 Volkswagen New Beetle GLS 

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

  

1. ABS wheel speed sensor 

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Before inserting sensor, clean hole and coat with grease, Part No. G 000 650  

2. Wheel bearing housing  

3. Socket-head bolt 

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8 N.m (71 in. lb)  

4. Splash shield  

5. Bolt 

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10 N.m (7 ft. lb)  

6. Wheel bearing 

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Replace each time after removing  

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Removing and installing 

See WHEEL BEARING (WHEEL BEARING HOUSING INSTALLED IN VEHICLE) . 

7. Phillips screw  

8. Brake disc  

9. Wheel hub with ABS wheel speed sensor rotor 

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Removing and installing 

See WHEEL BEARING (WHEEL BEARING HOUSING INSTALLED IN VEHICLE) . 

10. Circlip  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 15: Identifying ABS System Components For Front Axle 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ABS WHEEL SPEED SENSOR FOR FRONT AXLE, REMOVING AND INSTALLING 

Removing 

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Raise vehicle.  

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Disconnect connector for wheel speed sensor and speed sensor wiring -1-.  

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Remove bolt -2- from wheel bearing housing.  

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Remove ABS wheel speed sensor from wheel bearing housing.  

Installing 

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Before inserting wheel speed sensor, clean hole and coat speed sensor with grease, Part No. G 000 650. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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