Volkswagen New Beetle. Manual - part 815

 

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Volkswagen New Beetle. Manual - part 815

 

 

Fig. 17: Vacuum Pump Electrical Test Steps No. 1 & 2 (Models From 06/2002) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 18: Vacuum Pump Electrical Test Step No. 3 (Models From 06/2002) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 19: Vacuum Pump Electrical Test Step No. 4 (Models From 06/2002) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 20 

© 2004 Mitchell Repair Information Company, LLC. 

SERVICING 

Manufacturer recommends replacing brake fluid every 2 years. After replacing brake fluid, bleed brake system. 
See BLEEDING BRAKE SYSTEM .  

REMOVAL & INSTALLATION 

BRAKE BOOSTER 

Removal 

1. Obtain radio code. Disconnect negative battery cable. Clamp and remove clutch master cylinder supply 

hose. Remove ABS control module and hydraulic unit. See REMOVAL & INSTALLATION in 
appropriate ANTI-LOCK BRAKE SYSTEM article. Disconnect brake lines to master cylinder. 
Disconnect vacuum hose from brake booster.  

2. On vehicles equipped with 1.9L TDI engine, remove retainer for wiring harness from vacuum pump.  

3. On all models, remove harness connector from retainer (2). See Fig. 20 . Disconnect in-line harness 

connector (1).  

4. Remove lower instrument panel trim. Remove bolts (1) and remove cover "A". See Fig. 21 . On vehicles 

equipped with manual transmission, remove connecting plate between clutch and brake pedals. Remove 
brake light switch. See appropriate procedure under BRAKELIGHT SWITCH 

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. 

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

painted surface, wipe it off immediately and wash with water. 

CAUTION: When battery is disconnected, vehicle computer and memory systems 

may lose memory data. Driveability problems may exist until adaptation 
systems have completed a relearn cycle. See COMPUTER RELEARN 
PROCEDURES article in GENERAL INFORMATION before disconnecting 
battery. 

NOTE:

Before disconnecting battery, on vehicles equipped with coded anti-theft radio, 
note radio code, obtain if necessary. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 21 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 20: Locating In-Line Harness Connector 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 22 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 21: Removing Lower Instrument Panel Trim 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. Remove brake pedal from brake booster by first pressing brake pedal in direction of brake booster and 

hold. Insert special tool T 10006 and pull in direction of driver's seat, when doing this counter-hold on 
brake pedal (at this moment the pedal must not be allowed to move backward). See Fig. 22 . Mounting 
retaining tabs will be pressed off the ball head of the push rod. For ease of illustration separating the 
brake pedal from the brake booster is shown with the pedal cluster removed.  

6. Remove brake booster-to-firewall nuts. Guide brake booster with brake master cylinder forward to 

remove.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 23 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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