Volkswagen New Beetle. Manual - part 822

 

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Volkswagen New Beetle. Manual - part 822

 

 

Fig. 41: Removing & Installing Vacuum Pump (Diesel Models) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

OVERHAUL 

BRAKE BOOSTER 

Manufacturer does not recommend overhaul of brake booster, but recommends replacement if failure occurs. 
See BRAKE BOOSTER under REMOVAL & INSTALLATION.  

BRAKE CALIPER 

NOTE:

Black staining from piston seal wear may show on caliper bore walls and 
piston. This staining is normal. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 48 

© 2004 Mitchell Repair Information Company, LLC. 

Disassembly 

Remove brake caliper. See FRONT & REAR BRAKE CALIPER under REMOVAL & INSTALLATION. 
Remove caliper from vehicle. Remove pads, and clean exterior surfaces. On front calipers, use a block of wood 
between piston and housing to prevent damage to piston. On self-adjusting rear calipers, use Special Tool (VW 
3272) along with Collar (3272/1) or equivalent, to help remove piston from housing by turning knurled wheel 
counterclockwise. Remove dust seal. Remove piston seal without damaging bore or groove. Use following 
illustrations to aid in overhaul. See Fig. 42 -Fig. 44 .  

Fig. 42: Exploded View Of FS III Caliper (Front Axle) 
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 49 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 43: Exploded View OF FN3 Caliper (Front Axle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:19 AM

Page 50 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 44: Exploded View Of Self-Adjusting Rear Brake Caliper 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Cleaning & Inspection 

Use alcohol or brake cleaning fluid to clean hydraulic chambers. Check cylinder bore and piston for corrosion 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:19 AM

Page 51 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  820  821  822  823   ..