Volkswagen New Beetle. Manual - part 820

 

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Volkswagen New Beetle. Manual - part 820

 

 

Installation (FN3) 

1. Before inserting new brake pads, press piston back into the cylinder with piston resetting tool. 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. When installed arrow on brake pad 
backplate must point downward. Ensure this pads are installed correctly. See Fig. 36 .  

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. Check brake fluid level. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 40 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 36: Identifying Brake Pad Installation Position (FN3) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

FRONT & REAR BRAKE CALIPER 

Removal & Installation 

1. Raise and support vehicle. Remove wheels. Disconnect brakeline from caliper, and plug openings. 

Disconnect parking brake cables.  

2. On all calipers, remove caliper mounting bolts. Remove caliper assembly from wheel bearing housing. To 

install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE 
SPECIFICATIONS 
. Bleed hydraulic brake system. See BLEEDING PROCEDURES under 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 41 

© 2004 Mitchell Repair Information Company, LLC. 

BLEEDING BRAKE SYSTEM.  

FRONT & REAR BRAKE ROTOR 

Removal & Installation 

1. Raise and support vehicle. Remove wheels. Remove brake caliper. See FRONT & REAR BRAKE 

CALIPER . Secure caliper with wire so that the weight of the brake caliper does not stress or damage 
brake hose.  

2. On rear brakes, remove brake caliper carrier.  

3. On front and rear, remove countersunk screw that holds rotor to hub. Pull rotor off hub. To install, reverse 

removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .  

MASTER CYLINDER 

Removal 

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

hose. Remove intake hose and harness connector from mass air flow sensor. Remove air cleaner 
complete. On vehicles equipped with a 2.0L or 1.8L engines, remove protective housing for relays from 
cable channel.  

2. To catch leaking brake fluid, place sufficient lint free cloths in area of plenum chamber, engine and 

transmission. Install bleeder hose and bleeder bottle to the front left brake caliper bleeder screw and open 
bleeder screw. Operate brake pedal until sufficient amount of brake fluid has been pumped out for the 
brake fluid level in the brake fluid reservoir to sink below the clutch master cylinder supply hose (if 
equipped). Close front left bleeder screw.  

3. Disconnect brake fluid level warning indicator sensor harness connector. Disconnect brake pressure 

sender harness connectors.  

4. Disconnect brake lines on brake master cylinder. Seal brake lines and threaded holes with plugs from 

repair kit Part No. 1H0 698 311 A, or equivalent. Remove brake master cylinder nuts. Carefully remove 
brake master cylinder from brake booster unit.  

Installation 

1. To install, reverse removal procedure. Always use NEW "O" ring between master cylinder and brake 

booster. When installing the brake master cylinder and brake booster unit together, make sure that the 
push rod is correctly located in the brake master cylinder.  

2. Apply slight pressure to the brake pedal to move the push rod towards brake master cylinder; this makes 

it easier to guide brake master cylinder onto the push rod. Tighten fasteners to specification. See 
TORQUE SPECIFICATIONS .  

3. Bleed hydraulic system. See BLEEDING BRAKE SYSTEM . After installing master cylinder, a zero 

compensation of brake pressure sender 1 and brake pressure sensor 2 must be performed in addition to 
basic settings on vehicles with ABS/EDL/ASR/ESP. See FUNCTION 04 - BASIC SETTING in 
appropriate ANTI-LOCK BRAKE SYSTEM & TRACTION CONTROL article.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

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© 2004 Mitchell Repair Information Company, LLC. 

PARKING BRAKE CABLES 

Use following illustrations to aid in removal and installation of parking brake lever and cables. See Fig. 37 -Fig. 
39
 .  

Fig. 37: Removing & Installing Parking Brake Cables (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 43 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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