Volkswagen New Beetle. Manual - part 812

 

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Volkswagen New Beetle. Manual - part 812

 

 

Gasoline models with automatic transmissions may be equipped with an auxiliary electric vacuum pump. 
Vacuum pump supplies vacuum to brake booster ensuring adequate vacuum for proper vacuum assist. Vacuum 
pump is activated by a signal from ABS control module, and is located under master cylinder. Vacuum sensor 
located in vacuum line to brake booster sends signal to ABS control module indicating vacuum level.  

On models equipped with diesel engines, a vacuum pump for brake booster is mounted to rear of cylinder head. 
Vacuum pump supplies vacuum to brake booster ensuring adequate vacuum for proper vacuum assist.  

SWITCHES 

Brakelight Switch 

Two different styles of brake light switch were used in production. For servicing purposes they will be referred 
to here 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. On diesel and gasoline 
models with cruise control, Brake Switch "F" and Brake Pedal Switch (cruise control/DFI) "F47" are integrated. 
Only "old style" switches can be removed, then reinstalled and adjusted. "New style" switches must NOT be 
reused after removal, and must be replaced.  

Brake Pressure Sensors 

Brake Pressure Sensor 1 and Brake Pressure Sensor 2 located on brake master cylinder send brake pressure 
information to ABS control module.  

BRAKE ASSIST 

Vehicles manufactured from 02/2002 are equipped with brake assist. When brake pedal is depressed, 
mechanical brake assist is activated. Brake pedal can now be partially released and pressed again with less 
force. It is not possible to repair the brake assist, the complete brake booster must be replaced.  

BLEEDING BRAKE SYSTEM 

BLEEDING PROCEDURES 

WARNING:

Use only DOT 4 brake fluid from a sealed container. DO NOT mix brake 
fluid with any other type. 

CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on 

painted surface, wipe it off immediately and clean with alcohol. 

WARNING:

Use only DOT 4 brake fluid from a sealed container. DO NOT mix brake 
fluid with any other type. 

CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 8 

© 2004 Mitchell Repair Information Company, LLC. 

Standard Procedure 

1. To identify ABS application, see ABS IDENTIFICATION under IDENTIFICATION.  

2. Ensure brake master cylinder reservoir is full. Connect hose to brake caliper bleed screw and insert other 

end of hose in a clear container 1/4 full of clean brake fluid. Bleed brake calipers in following sequence: 

Vehicles Equipped With Mark 20 ABS - 

z

Right Rear Caliper  

z

Left Rear Caliper  

z

Right Front Caliper  

z

Left Front Caliper  

Vehicles Equipped With Mark 60 ABS - 

z

Left Front Caliper  

z

Right Front Caliper  

z

Left Rear Caliper  

z

Right Rear Caliper  

3. About 1/2 pt. (200 cc) of brake fluid is expelled from each wheel when bleeding entire system. Top off 

fluid level in reservoir to MAX mark and close reservoir cap. Before driving vehicle, depress brake pedal 
several times to ensure brakes are working correctly.  

With Brake Filler & Bleeder Unit 

1. To identify ABS application, see ABS IDENTIFICATION under IDENTIFICATION.  

2. Connect pressure bleeder (VAS 5234) or equivalent, to master cylinder reservoir. Connect hose to brake 

caliper bleed screw and insert other end of hose in a clear container 1/4 full of clean brake fluid. Bleed air 
from brake system in following order: 

Vehicles Equipped With Mark 20 ABS -

painted surface, wipe it off immediately and clean with soap and water. 

NOTE:

Brake fluid should be replaced every 2 years regardless of elapsed mileage. 

NOTE:

When using a brake system filling and bleeding appliance (such as VAS 5234) 
to replenish the brake fluid, make sure that filling pressure does not exceed 15 
psi (1 bar). If the filling pressure exceeds 15 psi (1 bar), a hydraulically 
controlled change-over valve (which is required for the Electronic Differential 
Lock function) prevents unrestricted flushing of the EDL-related parts of the 
hydraulic unit. If this is the case, it may not be possible to bleed the system 
properly. For this reason the pressure must be reduced to 15 psi (1 bar) on the 
brake filler and bleeding unit. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 9 

© 2004 Mitchell Repair Information Company, LLC. 

z

Right Rear Caliper  

z

Left Rear Caliper  

z

Right Front Caliper  

z

Left Front Caliper  

Vehicles Equipped With Mark 60 ABS - 

z

Left Front Caliper  

z

Right Front Caliper  

z

Left Rear Caliper  

z

Right Rear Caliper  

3. About 1/2 pt. (200 cc) of brake fluid is expelled from each wheel when bleeding entire system. Top off 

fluid level in reservoir to MAX mark and close reservoir cap. Before driving vehicle, depress brake pedal 
several times to ensure brakes are working correctly.  

When Master Cylinder Reservoir Is Empty 

1. Bleed brake system as outlined in WITH BRAKE FILLER & BLEEDER UNIT . When brake fluid is 

free from air bubbles, go to next step.  

2.  

Turn ignition off. Connect VAS 5051 scan tool or equivalent to Data Link Connector (DLC). DLC is 
located under dash to left of steering wheel. See Fig. 6 . From VEHICLE SELF-DIAGNOSTIC menu, 
select 03 - BRAKE ELECTRONICS. Press "Q" button to confirm input, and go to next step.  

3. On scan tool, press "0" and "4" to select 04 - BASIC SETTING. Press "Q" button to confirm input. Press 

"0", "0" and "1" to enter DISPLAY GROUP 001. Press "Q" button to confirm input, and go to next step.  

4. Press and hold brake pedal with substantial foot pressure. Pedal drops, hydraulic pump starts up, pedal 

returns. When scan tool displays RELEASE PEDAL; FR/FL BLEED SCREWS OPEN, release pedal, 
and open front bleeder screws. On scan tool, press UP button or "0", "0" and "2" to advance to Display 
Group 002, and go to next step.  

5. Wait 10 seconds. Hydraulic pump should start up and run briefly. When scan tool displays PRESS 

PEDAL 10X; BLEED SCREWS CLOSED, press pedal 10 times, close front bleeder screws. On scan 
tool, press UP button or "0", "0" and "3" to advance to Display Group 003, and go to next step.  

6. Press and hold brake pedal in position. Repeat bleeding procedure as specified in steps 4 and 5 for rear 

brakes. On scan tool, press UP button several times to advance to the next display groups until display 
group 17 is indicated, and go to next step.  

7. When scan tool displays PARTIAL BLEEDING OVER, press BACK arrow button to exit diagnostic 

NOTE:

System must first be pre-bled when one chamber in the brake fluid reservoir is 
completely empty. 

NOTE:

For more information on connection and operation of VAS scan tool, see 
appropriate ANTI-LOCK - TEVES MK 20 (WITH TCS/EDL/ESP) or ANTI-
LOCK - TEVES MK 60 (WITH TCS/EDL/ESP) article in BRAKES. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 10 

© 2004 Mitchell Repair Information Company, LLC. 

function 04 - BASIC SETTING. From scan tool menu, select diagnostic function 06 - END OUTPUT. 
Press "Q" button to confirm input, and disconnect scan tool.  

8. Bleed brakes using standard bleeding procedure. See STANDARD PROCEDURE .  

Fig. 6: Locating Data Link Connector 
Courtesy of AUDI OF AMERICA, INC. 

ADJUSTMENTS 

BRAKE LIGHT SWITCH 

NOTE:

For brakelight switch adjustment, see BRAKELIGHT SWITCH under REMOVAL 
& INSTALLATION. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 11 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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