Volkswagen New Beetle. Manual - part 821

 

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Volkswagen New Beetle. Manual - part 821

 

 

Fig. 38: Removing & Installing Parking Brake Cables (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 44 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 39: Removing & Installing Parking Brake Cables (3 Of 3) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

PRESSURE SWITCHES 

Removal & Installation 

1. 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.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 45 

© 2004 Mitchell Repair Information Company, LLC. 

2. 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 pressure switch harness connector. Remove pressure switch.  

4. To install, reverse removal procedure. Tighten switch to specification. See TORQUE 

SPECIFICATIONS . Bleed hydraulic system. See BLEEDING BRAKE SYSTEM .  

5. After installation of switches 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.  

REAR DISC BRAKE PADS 

Removal 

1. Raise and support vehicle. Remove rear wheels.  

2. Disconnect parking brake cable from caliper. Remove and discard caliper mounting bolts. See Fig. 3 . 

Remove caliper, and wire aside. DO NOT allow caliper to hang by brake hose. Remove pads and 
retaining springs from caliper support.  

Installation 

1. Use Special Tool (VW 3272) along with Collar (3272/1) or equivalent, to seat caliper piston fully into 

cylinder bore. See Fig. 40 . Seat piston by turning special tool until piston is bottomed out in bore. 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 to finish.  

2. Install brake pads, note positioning of pad to caliper (pin on pad must fit into groove on caliper piston). 

Pull protective foil off outer brake pad backing plate. Position caliper. Secure brake caliper housing with 
NEW self-locking bolts, and tighten to specification. See TORQUE SPECIFICATIONS .  

3. With engine off, depress brake pedal several times to allow pads to move into operating position. Adjust 

parking brake as necessary. See PARKING BRAKE under ADJUSTMENTS.  

4. Install wheels and tighten to specification. See TORQUE SPECIFICATIONS . After installing brake 

pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in 
their normal operating position. Check brake fluid level, and top off as necessary.  

NOTE:

If re-using brake pads, mark them so that they can be installed in their original 
positions to prevent uneven braking. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 46 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 40: Compressing &/Or Removing Rear Brake Caliper Piston 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

VACUUM PUMP (DIESEL MODELS) 

1. Remove wiring harness retainer from vacuum pump. Loosen vacuum hose clamp (arrow A) and remove 

hose from pump. See Fig. 41 . Remove bolts (arrow B) on flange. Remove vacuum pump.  

2. When installing the vacuum pump be sure that the follower engages correctly with the camshaft. Install 

bolts (arrows B) on cylinder head flange. Secure vacuum hose with clamp (arrow A).  

NOTE:

There are no serviceable parts in vacuum pump. If found to be defective 
vacuum pump must be replaced. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 47 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  819  820  821  822   ..