volkswagen new beetle -...

ABS Module Removal & Installation Instructions ModuleMaster Support: 208-892-0764 www.modulemaster.co Volkswagen New Beetle 1998-2002 The New Beetle uses either the Kelsey Hayes Mark20 or Mark60. One of the main differences is the Mark20 uses two electrical connectors while the Mark60 uses a single wider connector. The Mark20 is repairable, but the Mark60 is not. Removal Procedure 1. Identify your ABS hydraulic unit. It is a block of aluminum with attached pump motor and multiple brake lines connected to it (see diagram, right). Since the ABS module is mounted to the bottom of the hydraulic unit, the ABS assembly must be removed as a unit. Before you start, make sure your controller uses two electrical connectors. If it only has one, we cannot rebuild your module. 2. Remove plastic cover from the area around the ABS modulator (if any). 3. Depress brake pedal and keep down using a brake pedal depressor or equivalent. 4. Remove connector for air mass sensor. Unscrew bolts on air filter housing and place housing to the left side. 5. Place absorbent towel under the hydraulic unit in order to collect brake fluid. 6. Unscrew brake lines from brake master cylinder to hydraulic unit (arrows), and plug the holes to protect against dirt . 7. Tie up disconnected brake lines with wire, so that brake line ends are higher than brake fluid level in reservoir. Make sure that no brake fluid enters the control module housing as this can lead to contact corrosion and result in system failure. 8. Label and remove remaining brake lines. 9. Remove both controller connectors (press tab and pull straight off). 10. Unscrew bracket bolts and remove the ABS 2002 VW New Beetle

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ABS Module Removal & Installation Instructions ModuleMasterSupport: 208-892-0764www.modulemaster.co

Volkswagen New Beetle

1998-2002

The New Beetle uses either the Kelsey Hayes Mark20 or Mark60. One of the main differences is the Mark20 uses two electrical connectors while the Mark60 uses a single wider connector. The Mark20 is repairable, but the Mark60 is not.

Removal Procedure 1. Identify your ABS hydraulic unit. It is a block of

aluminum with attached pump motor and multiple brake lines connected to it (see diagram, right). Since the ABS module is mounted to the bottom of the hydraulic unit, the ABS assembly must be removed as a unit. Before you start, make sure your controller uses two electrical connectors. If it only has one, we cannot rebuild your module.

2. Remove plastic cover from the area around the ABS modulator (if any).

3. Depress brake pedal and keep down using a brake pedal depressor or equivalent.

4. Remove connector for air mass sensor. Unscrew bolts on air filter housing and place housing to the left side.

5. Place absorbent towel under the hydraulic unit in order to collect brake fluid.

6. Unscrew brake lines from brake master cylinder to hydraulic unit (arrows), and plug the holes to protect against dirt .

7. Tie up disconnected brake lines with wire, so that brake line ends are higher than brake fluid level in reservoir. Make sure that no brake fluid enters the control module housing as this can lead to contact corrosion and result in system failure.

8. Label and remove remaining brake lines.9. Remove both controller connectors (press tab

and pull straight off).10.Unscrew bracket bolts and remove the ABS

2002 VW New Beetle

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