Brake And Clutch System, Brake Fluid, Changing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Oils containing minerals damage seals and rubber grommets on brake systems.
Brake fluid is poisonous. Do not let brake fluid come in contact with the paint.
Brake fluid is hygroscopic, which means that it absorbs moisture from the air. Always store brake fluid in air-tight containers.
Wash off any spilled brake fluid with plenty of water.
Follow all disposal regulations.

CAUTION:

Use only Brake Fluid VW 501 14B 000 750 in this vehicle.

Special tools and workshop equipment required

Brake Charger/Bleeder Unit VAS 5234

Fig 1: Brake Charger/Bleeder Unit VAS 5234
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Wrench - Brake Bleeder Set VAS 5519

Fig 2: Identifying Brake Bleeder Socket VAS 5519
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Brake Bleeding Tool Set VAS 6564

Fig 3: Identifying Brake Bleeder Tool Set VAS 6564
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Extract the brake fluid.

NOTE:

Do not remove the strainer inside the brake fluid reservoir.

After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the screen).

-- Remove the cap -1- from the brake fluid reservoir.

Fig 4: Identifying Brake Fluid Reservoir Cap -1-

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-- Use the hose from the Brake Charger/Bleeder Unit VAS 5234 to extract as much brake fluid as possible.

Fig 5: Identifying Hose From Brake Charger/Bleeding Unit VAS 5234

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WARNING:

Do not use extracted brake fluid again!

Bleeding the brake system

-- Attach the adapter -1- to the brake fluid reservoir.

Fig 6: Identifying Screw Adapter -1-

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Pay attention to the operating instructions. Refer to Operating instructions for VAS 5234.

-- Set the correct pressure using a Brake Charger/Bleeding Unit VAS 5234. Refer to Special Tools

-- Connect the hose from the Brake Charger/Bleeder Unit VAS 5234 to the adapter -1-.

NOTE:

Use a suitable bleed hose. It must seat tightly on the bleed valve so that no air can get into the brake system.

-- Remove the cap -1- from the bleed valve on the left front brake caliper.

Fig 7: Identifying Bleeder Screw Cap -1-

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-- Connect the collector bottle bleed hose -1- to the left front bleed valve. Open the bleed valve and let the corresponding amount of brake fluid (see table) flow out. Close the bleed valve. Torque, refer to Special Tools

Fig 8: Identifying Collector Bottle Bleeder Hose -1-

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-- Install the cap on the left front brake caliper bleed valve.

Repeat the same procedure on the right front side of the vehicle.

-- Remove both rear wheels to access the bleed valve if necessary.

-- Remove the cap -1- on the left rear brake caliper bleed valve.

Fig 9: Identifying Vent Screw Cap

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-- Connect the collector bottle bleed hose -1- to the left rear bleed valve.

Fig 10: Identifying Collector Bottle Bleeder Hose

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-- Open the bleed valve and let the corresponding amount of brake fluid (see table) flow out. Close the bleed valve. Torque, refer to Special Tools

-- Install the cap on the left rear brake caliper bleed valve.

-- Repeat the same procedure on the right rear side of the vehicle.

Bleeding the clutch slave cylinder

NOTE:

Only on vehicles with a manual transmission.

Remove the air filter housing, if necessary.

Procedure:

-- Refer to [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Description and Operation [For engine(s) CVCA] Description and Operation → Diesel Direct Injection → Air Filter Assembly Overview

-- Refer to [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Description and Operation [For engine(s) CVCA] Description and Operation → Injection System → Air Filter, Removing and Installing.

-- Attach the bleed hose to the bleed valve -arrow- on the clutch slave cylinder -1-.

Fig 11: Identifying Clutch Slave Cylinder -1-

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-- Open the valve and drain approximately 50 ml brake fluid.

-- Close the value and press the clutch pedal quickly 10 to 15 times.

-- Open the valve again and drain approximately 50 ml brake fluid.

-- Close the valve.

-- Remove the bleed hose and press the clutch pedal several times.

-- Install the air filter housing in reverse order of removal.

Sequence/Brake Fluid Quantity

Sequence Bleed Valves:	Amount of brake fluid, which must flow out of the bleed valves:
Brake caliper
left front	0.20 liter
right front	0.20 liter
Brake wheel cylinder/brake caliper
Left rear	0.30 liter
Right rear	0.30 liter
Clutch slave cylinder	0.15 liter

Automatic Transmission Total Capacity: Approximately 1.00 Liters

Manual Transmission Total Quantity: Approximately 1.15 liters

-- Move filler lever on Brake Charger/Bleeding Unit VAS 5234 to "B" (see operating instructions).

-- Remove the filler hose from the adapter.

-- Remove the adapter from the brake fluid reservoir.

-- Check the brake fluid level and fill if necessary. It must be between -1- and -2-.

Fig 12: Identifying Brake Fluid Level Marks On Reservoir

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-- Install the brake fluid reservoir cap -1-.

Fig 13: Identifying Brake Fluid Reservoir Cap -1-

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-- Install the rear wheel if necessary. Refer to WHEEL BOLTS, TIGHTENING TO TIGHTENING SPECIFICATION .

-- Perform a function test during the test drive.