Volkswagen New Beetle. Manual - part 819

 

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Volkswagen New Beetle. Manual - part 819

 

 

Fig. 33: Removing & Installing Center Console Models Built May 2003 & Up (1 Of 3) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:18 AM

Page 36 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 34: Removing & Installing Center Console Models Built May 2003 & Up (2 Of 3) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:18 AM

Page 37 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 35: Removing & Installing Center Console Models Built May 2003 & Up (3 Of 3) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

ELECTRIC VACUUM PUMP 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:18 AM

Page 38 

© 2004 Mitchell Repair Information Company, LLC. 

1. Locate electric vacuum pump on subframe in front of steering box, left side. See Fig. 8 . Unscrew hex 

bolt securing guard plate. Unscrew bolts on bracket for vacuum pump.  

2. Disconnect vacuum hose (arrow) from vacuum pump. Disconnect electric vacuum pump harness 

connector. Remove pump.  

3. To remove bracket (arrow), unscrew nut (2) from bolt (1). Remove bolt (4) and detach bracket. To 

disassemble bracket further, remove bolts (3). Installation is reverse of removal procedure.  

FRONT DISC BRAKE PADS 

Removal (FS III) 

1. Raise and support vehicle. Remove front wheels. Remove guide pin protective caps. See Fig. 1 . 

Disconnect brake pad wear indicator harness connector.  

2. Remove both guide pins from brake caliper. Remove brake caliper housing and secure with wire so that 

the weight of the brake caliper does not stress or damage brake hose. Remove brake pads from front 
brake caliper housing.  

Installation (FS III) 

1. Before inserting new brake pads, press piston back into the cylinder with piston resetting tool. Brake pad 

with black three finger clip is to be used on the outer side of brake caliper housing.  

2. Install brake caliper housing with brake pads on wheel bearing housing, lower part of brake caliper 

housing first. Brake caliper housing lug must be behind the wheel bearing housing guide. Secure brake 
caliper housing to brake carrier with both guide pins and tighten to specification. See TORQUE 
SPECIFICATIONS 
.  

3. Connect brake pad wear indicator harness connector. After brake pad change firmly depress brake pedal 

several times with vehicle stationary, so that the brake pads are properly seated in their normal operating 
position. Check brake fluid level.  

Removal (FN3) 

1. Raise and support vehicle. Remove front wheels. Remove guide pin protective caps. See Fig. 2 . Pry 

brake pad retaining spring out from brake caliper housing with a screwdriver and remove. Disconnect 
brake pad wear indicator harness connector.  

2. Remove both guide pins from brake caliper. Remove brake caliper housing and secure with wire so that 

the weight of the brake caliper does not stress or damage brake hose. Remove brake pads from brake 
caliper housing.  

NOTE:

To identify brake system equipped on vehicle, see BRAKE SYSTEM 
IDENTIFICATION table under IDENTIFICATION. 

NOTE:

Before pressing the piston back, draw off brake fluid from the reservoir with a 
bleeder bottle. Otherwise if reservoir has been topped off, fluid will overflow 
and cause damage. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:18 AM

Page 39 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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