Volkswagen New Beetle Brake System ABS, ABS/EDL 47 Brakes ... · zBrake system, bleeding using US 1116 pressure bleeder zBrake system, bleeding without pressure bleeder zBrake master

FS III front brake caliper, servicing Front brake caliper piston, removing and installing FN 3 front brake calipers , servicing Front caliper piston, removing and installing Rear brake caliper, servicing Pressure leak test Rear brake caliper piston, removing and installing Brake pressure regulator, mounting Brake pressure regulator, checking and adjusting Specifications for load dependent brake pressure regulator Brake system, bleeding Brake system, bleeding using US 1116 pressure bleeder Brake system, bleeding without pressure bleeder Brake master cylinder/brake booster, servicing Vacuum pump for brake booster, removing and installing (vehicles with Diesel engine) Brake master cylinder, removing and installing Brake booster, removing and installing

Volkswagen New Beetle Brake System ABS, ABS/EDL 47 Brakes - Hydraulic Components (Page GR-47)

Volkswagen New Beetle Brake System ABS, ABS/EDL FS III front brake caliper, servicing (Page 47-1)

CAUTION!Before working on the brake system, read CAUTIONS and WARNINGS on pages 45-3 and 45-4 .Notes:

Install all parts in repair kit.New brake calipers are filled with brake fluid and are pre - bled.When assembling, apply thin coat of grease G052 150 A2 to brake cylinders, pistons and seals.

1 - Dust bootDo not damage when inserting piston

2 - Piston

Removing and installing Page 47-2 3 - Brake caliper housing4 - Piston seal

Removing and installing Page 47-2


Front brake caliper piston, removing and installing Special tools and equipment

3409 WedgePiston resetting tool

Removing

- Force piston out of brake caliper housing using compressed air.CAUTION!

Place a piece of wood in the recess to prevent damaging the piston.Use only enough air pressure to force piston out.

WARNING!Always wear safety goggles when working with compressed air.


- Remove piston seal using wedge 3409.CAUTION!When removing, use care to ensure that the cylinder bore is not damaged.Installing- Install new piston seal in caliper.- Lubricate piston and cylinder bore lightly using grease G052 150 A2.

- Install dust boot with outer sealing lip on piston.


- Hold piston in front of caliper and insert inner sealing lip into grove in cylinder using wedge 3409.

- Press piston into brake caliper housing using piston resetting tool.The outer sealing lip of the dust boot must slip into the piston groove.

Volkswagen New Beetle Brake System ABS, ABS/EDL FN 3 front brake calipers , servicing (Page 47-5)

CAUTION!Before working on the brake system, read CAUTIONS and WARNINGS on pages 45-3 and 45-4 Notes:

Install all parts in repair kit.New brake calipers are filled with brake fluid and are pre - bled.When assembling, apply a thin coat of grease G052 150 A2 to brake cylinders, pistons and seals.

1 - Dust cap2 - Bleeder valve

Apply thin coat of brake fluid to threads before installing.3 - Cap

Insert in mounting bushing


4 - Guide pin25 Nm (18 ft lb)

5 - Mounting bushingInsert into brake caliper housing

6 - Brake caliper housing7 - Brake carrier8 - Retaining spring

Insert with both ends in holes in brake caliper housing9 - Piston seal

Removing and installing Page 47-7 10 - Piston

Removing and installing Page 47-7 Apply thin coat of brake fluid to piston before insertingPiston diameter: 54 mm (2.125 in.)

11 - Dust boot


Front caliper piston, removing and installing Special tools and equipment

3409 WedgePiston resetting tool

Removing

- Force piston out of brake caliper housing using compressed air.CAUTION!

Place a piece of wood in the recess to prevent damaging the piston.Use only enough air pressure to force piston out.

WARNING!Always wear safety goggles when working with compressed air.


- Remove seal using wedge 3409.CAUTION!When removing, use care to ensure that the cylinder bore is not damaged.Installing- Install new piston seal in caliper.- Lubricate piston and cylinder bore lightly using grease G052 150 A2.

- Install dust boot with outer sealing lip on piston.


- Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using wedge 3409.

- Press piston into brake caliper housing using piston resetting tool.The outer sealing lip of the dust boot must slip into the piston groove.

Volkswagen New Beetle Brake System ABS, ABS/EDL Rear brake caliper, servicing (Page 47-10)

CAUTION!Before working on the brake system, read CAUTIONS and WARNINGS on pages 45-3 and 45-4 Notes:

Install all parts in repair kit.New brake calipers are filled with brake fluid and pre - bled.Apply a thin coat of grease G052 150 A2 to brake cylinders, pistons and seals.When repairing, be sure to pre - bleed brake calipers (without brake pads) before installing Page 47-16

1 - Self - locking bolt30 Nm (22 ft lb)

Always replaceWhen loosening and tightening, counter - hold on guide pin

2 - Bleeder screwApply thin coat of grease G052 150 A2 to threads before installing


3 - Dust cap4 - Guide pins

Apply thin coat of grease G052 150 A2 before pulling on protective cap5 - Protective cap

Pull onto brake carrier and guide pin6 - Brake carrier with guide pin and protective cap

Replacement part is assembled with sufficient grease on guide pins.If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins.


7 - Dust bootPull outer sealing lip onto piston

8 - Piston with automatic adjustmentRemoving and installing Page 47-13 Apply thin coat of brake fluid to piston before inserting

9 - Piston sealRemoving and installing Page 47-13

10 - Brake caliper housing with parking brake cable leverIf leaking at parking brake cable lever, replace brake caliper housingAfter repairing, pre - bleed caliper housing Page 47-16


Rear brake caliper piston, removing and installing Special tools and equipment

3272 Piston resetting and removal tool3409 WedgeBleeder bottle


Removing

- Remove piston from brake caliper housing by turning knurled wheel counter - clockwise.

Notes:Install special tool 3272 with the collar (arrow) positioned before the piston.If the piston is difficult to move, use a 13 mm wrench on the flats (arrow - A - ).

- Remove seal using wedge 3409.CAUTION!When removing, use care to ensure that the cylinder bore is not damaged.


Installing

- Apply thin coat of brake fluid on piston and piston seal.- Install piston seal in caliper housing.- Place dust boot with outer sealing lip on piston.

- Hold piston in front of caliper housing and install inner sealing lip into grove in cylinder using wedge 3409.


- Screw piston into housing by turning knurled wheel clockwise.Notes:

Install special tool 3272 with the collar (arrow) of the tool seated on the brake caliper.If the piston is difficult to move, use a 13 mm wrench on the flats (arrow - A - ) .If the piston is pushed back with the piston resetting tool or by operating the foot brake, the automatic adjustment in the brake caliper is destroyed.

- Install brake pads.Brake caliper, pre - bleeding

- Open bleeder screw (arrow - A - ) and fill a standard bleeder bottle with brake fluid until bubble - free fluid flows from brake hose connection (arrow - B - ).

- Close bleeder screw.


Pressure leak testSpecial tools and equipment

VAG 1310 A Brake pressure gaugeRequirements

Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) must function properly and not leak.

- Remove bleeder screw at one of the front brake calipers. Connect pressure gauge from VAG 1310 and bleed.

- Apply pressure to brake pedal until gauge indicates pressure of 50 bar (725 psi) and hold for at least 45 seconds.

Pressure must not drop by more than 4 bar (58 psi) during the test- If pressure drops more than specified, replace master cylinder.

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake pressure regulator, mounting (Page 47-18)

1 - Brake pressure regulatorChecking and adjusting Page 47-19

2 - Socket - head bolt21 Nm (15 ft lb)

3 - Bolt21 Nm (15 ft lb)

4 - Nut21 Nm (15 ft lb)

5 - Spring6 - Mounting bracket7 - Bolt

16 Nm (12 ft lb)

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake pressure regulator, checking and adjusting (Page 47-19)

Special tools and equipment

VAG 1310 A Brake pressure gauge

The brake pressure regulator is mounted on a bracket and attached to the rear axle. The regulator is controlled from the rear axle by a spring.Checking function- Depress brake pedal firmly once and release quickly (vehicle on ground).

Brake pressure regulator must move


Checking and adjustingRequirements

vehicle emptied of all cargo and passengersdriver (approx. 75 kg [165 lb]) in driver's seatfull fuel tankfull windshield washer / headlight washer reservoirspare tire in place

- Lift vehicle and connect pressure gauges to left front and right rear calipers.- Bleed both gauges.- Lower vehicle and bounce rear of vehicle several times.- Depress brake pedal to obtain specified pressure at front axle, then read pressure at

rear axle.- Compare reading with specifications and adjust if necessary.

Page 47-21


Specifications for load dependent brake pressure regulator


Brake pressure regulator, adjusting Pressure test result for rear axle too high:- Release tension on regulator spring.Pressure test result for rear axle too low:- Increase tension on regulator spring.Notes:Do not adjust with the brake pedal depressed. Use the following work sequence:- Read pressure- Release brake pedal.- Adjust spring.- Depress brake pedal again.- Read pressure and if necessary, readjust.- Remove pressure gauges and bleed brake system.

Page 47-23

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake system, bleeding (Page 47-23)

(Vehicles with ABS and ABS/EDL)Changing brake fluid: Repair Manual, Maintenance WARNING!Brake fluid is poisonous.CAUTION!

Brake fluid must not contact painted parts.Brake fluid absorbs moisture from the air and must therefore be replaced every two years. Use only new, unused and approved brake fluid that complies with MVSS 116 DOT 4.Do not use silicone - based brake fluid (DOT 5). Even the smallest traces can cause severe corrosion in the brake system.

If one or two chambers in the brake fluid reservoir are completely empty (e.g. leaks in braking system) bleed the hydraulic unit with the VAG 1551 Scan Tool in "basic setting" function.

Repair Manual, ABS, ABS/EDL On Board Diagnostic (OBD) CAUTION!Do not exceed filling pressure of 1 bar (14.5 psi) when filling brake fluid using pressure bleeder US 1116. The brake system will not be completely bled if excessive pressure is used.


Brake system, bleeding using US 1116 pressure bleeder

Special tools and equipment US 1116 Brake filling and bleeding unit

- Connect brake filling and bleeding unit.- Open bleeder screws in specified sequence and bleed calipers.Notes:On vehicles with a brake pressure regulator press the regulator lever toward the rear when bleeding rear brakes.Bleeding sequence1- Right rear caliper/wheel cylinder2- Left rear caliper/wheel cylinder3- Right front caliper4- Left front caliper- Road test vehicle and, under controlled conditions, brake firmly enough to activate

ABS at least once.


Brake system, bleeding without pressure bleeder- Connect hose from bleeder bottle to brake at each wheel using sequence from

previous page.- Pump brake pedal several times and then hold pedal down.- Open bleeder screw.- Close bleeder screw.CAUTION!The brake fluid level in the reservoir must not fall below the MIN mark during bleeding.- Release brake pedal.- Repeat operation until brake fluid flows without air bubbles.Brake fluid, changing

Repair Manual, Maintenance

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake master cylinder/brake booster, servicing (Page 47-26)

CAUTION!Before working on the brake system, read CAUTIONS and WARNINGS on pages 45-3 and 45-4 Notes:Master cylinder and brake booster can be replaced separately.1 - Brake Booster

With gasoline engines vacuum is taken from the intake manifoldWith Diesel engines a vacuum pump provides the required vacuumFunctional check:

- With engine off, depress brake pedal firmly several times (to exhaust vacuum in unit).

- Depress brake pedal with average foot pressure, hold and start engine. If brake booster is working properly, pedal will give slightly under foot (boost becomes effective).


If booster is not functioning replace complete brake boosterCheck valve (in vacuum hose) Page 47-30 , Functional checkSeparating booster from brake pedal Page 46-50 Removing and installing Page 47-33

2 - Cap3 - Brake fluid reservoir4 - Sealing plug

Moisten with brake fluid and press into reservoir5 - Retainer pin

Install through brake master cylinder

6 - Brake master cylinderCannot be repaired. If faulty, replace as complete unit

7 - Self - locking nut20 Nm (15 ft lb)Always replace


8 - Heat shieldOnly for vehicles with 110 Kw engine


10 - SealAlways replace

11 - Sealing plug12 - Vacuum hose- Insert into brake booster

13 - GasketFor brake booster


15 - BootMust be seated correctly or may cause air noise.


Vacuum pump for brake booster, removing and installing (vehicles with Diesel engine)Removing- Remove retainer for wiring harness from vacuum pump.

- Loosen vacuum hose clamp (arrow - A - ) and remove hose from pump.- Remove bolts (arrow - B - ) on flange.- Remove vacuum pump.Notes:Vacuum pump cannot be repaired.


Installing

Notes:When installing vacuum pump be sure that follower engages correctly with camshaft.- Install bolts (arrows - B - ) on cylinder head flange and secure vacuum hose with

clamp (arrow - A - ).

- Check function of check valve - A - .Air must pass through in direction of arrow.Valve must stay closed (no air passes through) in opposite direction.

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake master cylinder, removing and installing (Page 47-31)

Special tools and equipment 3094 Hose clamps or equivalent

CAUTION!Before working on the brake system, read the CAUTIONS and WARNINGS on pages 45-3 and 45-4 .Removing- Spread sufficient lint - free cloths in area of plenum chamber, and on engine and

transmission to catch any escaping brake fluid.WARNING!

Brake fluid is poisonous.To draw off brake fluid from the reservoir, use a bleeder bottle which is used only for brake fluid. Never siphon brake fluid by mouth.

- Using bleeder bottle, draw off as much brake fluid as possible from brake fluid reservoir .

- Clamp clutch master cylinder supply hose with clamp 3094 or equivalent.- Remove clutch master cylinder supply hose from reservoir.

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake master cylinder, removing and installing (Page 47-32)

- Disconnect brake fluid level sensor wiring connector.- Disconnect brake lines on brake master cylinder and seal with plugs from repair kit,

Part No. 1H0 698 311 A.- Remove nuts securing brake master cylinder to brake booster.- Carefully remove brake master cylinder from brake booster.Installing- Install master cylinder in reverse order of removal.Notes:

When connecting brake master cylinder and brake booster be sure that the push rod is correctly located in the master cylinder.After installing, bleed brakes Page 47-23 and clutch Repair Manual, Manual Transmission 02J , Repair Group 30.

Volkswagen New Beetle Brake System ABS, ABS/EDL Brake booster, removing and installing (Page 47-33)

Special tools and equipment

3094 Hose clamps or equivalentCAUTION!Before working on the brake system, read the CAUTIONS and WARNINGS on pages 45-3 and 45-4 .Removing- Obtain radio code on vehicles with coded radio.- Disconnect battery.Vehicles with manual transmission- Clamp clutch master cylinder supply hose with special tool 3094 or equivalent.- Remove clutch master cylinder supply hose from reservoir.All vehicles- Remove ABS control module and hydraulic unit Page 45-12 .- Disconnect vacuum hose from brake booster.


Vehicles with Diesel TDI engine- Remove wiring harness retainer from vacuum pump.All vehicles- Remove trim below instrument panel.

- Remove bolts - 1 - .- Remove cover - A - .Vehicles with manual transmission

- Remove connecting plate between clutch and brake pedals.All vehicles- Remove brake light switch - 1 - .- Separate brake pedal from brake booster Page 46-50 .


- Remove nuts (arrows).- Guide brake booster with brake master cylinder out forward to remove.InstallingInstall brake master cylinder with brake booster in reverse order of removal.- Adjust brake light switch.

Repair Manual, ABS, ABS/EDL On Board Diagnostic (OBD), Repair Group 01- After installing, bleed brakes Page 47-23 and clutch Repair Manual, Manual

Transmission 02J, Repair Group 30.

Documents

Volkswagen New Beetle Brake System ABS, ABS/EDL 47 Brakes ... · zBrake system, bleeding using US 1116 pressure bleeder zBrake system, bleeding without pressure bleeder zBrake master