Volkswagen New Beetle. Manual - part 816

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  814  815  816  817   ..

 

 

Volkswagen New Beetle. Manual - part 816

 

 

Fig. 22: Disconnecting Brake Pedal From Booster 
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 24 

© 2004 Mitchell Repair Information Company, LLC. 

Installation 

Before installing master cylinder, clean residual brake fluid from brake booster. Ensure push rod is properly 
centered in master cylinder. To install, reverse removal procedure. Hold push rod ball head in front of mounting 
and push brake pedal in direction of brake booster until the ball head engages audibly. Tighten fasteners to 
specification. See TORQUE SPECIFICATIONS . Adjust brake light switch. See BRAKELIGHT SWITCH 
under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM .  

BRAKELIGHT SWITCH 

Before removing brakelight switch, identify which one of 2 possible switch types is installed. "Old style" switch 
is identified by large approximately 10 mm plunger tip button, and square plunger shaft. "New style" switch is 
identified by small approximately 4 mm plunger tip without button, and round plunger shaft.  

Brakelight Switch (Old Style) 

1. Remove driver's side lower instrument panel cover. Brakelight switch is located on bracket above brake 

pedal. Disconnect brake light switch harness connector. See Fig. 23 . Turn brakelight switch 90° 
counterclockwise, and guide switch from bracket.  

2. To install, pull switch plunger out to stop. Depress and hold brake pedal in down position. Guide switch 

into opening and turn 90° clockwise. Slowly release brake pedal to stop. This automatically adjusts 
switch plunger travel. Verify proper function of brake lights. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 25 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 23: Removing, Installing & Adjusting Brake Light Switch (Old Style) 
Courtesy of AUDI OF AMERICA, INC. 

Brakelight Switch (New Style) 

1. Remove driver's side lower instrument panel cover. Brakelight switch is located on bracket above brake 

pedal. Disconnect brake light switch harness connector. Turn brakelight switch 45° counterclockwise, and 
guide switch from bracket. Dispose of switch accordingly. "New style" switches must NOT be reused 
after removal. Always replace.  

2. "New style" switches have an internal switch mechanism that will be damaged if not installed and 

adjusted according to the following procedure. DO NOT depress switch plunger or otherwise rotate the 
retaining collar of the switch prior to installation. Brake pedal must be held in the up position (not 
depressed) during switch installation. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 26 

© 2004 Mitchell Repair Information Company, LLC. 

3. Pull out plunger completely (arrow). See Fig. 24 . Hold brake pedal in up position (against stop). Note 

orientation of retainer tabs on switch and carefully insert switch into retainer mounting hole.  

4. Push switch in and seat fully into opening (pressing plunger against brake pedal to adjust). Once seated, 

secure switch by turning clockwise 45°. This action turns the plunger shoe into the correct orientation to 
make electrical contacts in switch operate, as well as locks in the plunger adjustment against the brake 
pedal. Switch must be rotated until it is fully locked and harness connector is in horizontal position. 
Inspect to ensure internal stop pin on retaining collar is fully seated against outer shell. Reconnect 
brakelight switch harness connector. Verify proper function of brake lights.  

Fig. 24: Identifying Brake Light Switch (New Style) 
Courtesy of AUDI OF AMERICA, INC. 

CENTER CONSOLE 

Models Built Up To January 2001 

Use following illustrations to aid in removing and installing center console. For models built up to January 
2001, see Fig. 25 -Fig. 28 .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 27 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  814  815  816  817   ..