BRAKE SYSTEM

Article Text
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

ARTICLE BEGINNING

1990-92 BRAKES
Volkswagen Disc & Drum

1990-92 Passat
1991-92 Cabriolet, Corrado, Fox, Golf, GTI, Jetta, Vanagon

DESCRIPTION

All models are equipped with front disc brakes. Rear brakes
are either disc or drum. Parking brake acts on rear brakes and is
cable-actuated. All models use pressure regulator between front and
rear brake circuits to avoid rear wheel lock-up during hard braking.
A vacuum power-assist servo is used to ease brake pedal
application. A vacuum check valve, located in vacuum supply hose,
prevents vacuum leak off when engine is off.

SERVICING

Manufacturer recommends replacing brake fluid every 2 years.

BLEEDING BRAKE SYSTEM

CAUTION: Ensure fluid level in master cylinder is adequate at all

times during bleeding procedure. Use only DOT 4 brake
fluid. DO NOT use DOT 5 silicone brake fluid.

BLEEDING PROCEDURES

NOTE: Manufacturer recommends bleeding brake system using Pressure

Bleeder (US 1116). If a pressure bleeder is not available,
use standard bleeding procedure.

1) Exhaust vacuum reserve from power unit by depressing brake

pedal several times. On ABS-equipped vehicles, depress brake pedal at
least 20 times to relieve system pressure.
2) On all vehicles, fill master cylinder with clean brake
fluid. If master cylinder was replaced, bleed master cylinder before
bleeding wheel calipers. Connect bleeder hose to appropriate caliper
bleeder valve. See BRAKE LINE BLEEDING SEQUENCE TABLE.

BRAKE LINE BLEEDING SEQUEABLE TABLE

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Application (1) Sequence

Cabriolet, Fox & Vanagon ....................... RR, LR, RF, LF

Corrado ........................... Either Front Caliper First,
Either Rear Caliper First
Golf, GTI, Jetta & Passat
Without ABS .................................. RR, LR, RF, LF
 BRAKE SYSTEM
Article Text (p. 2)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

With ABS .................. LF, RF, Either Rear Caliper First

(1) - On all vehicles, push lever of pressure regulator in

direction of rear axle when bleeding rear brakes.
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3) Submerge other end of hose in clean glass jar partially

filled with clean brake fluid. Pump brake pedal several times, then
hold down. Open bleeder valve. Holding pedal down, close bleeder
valve. Release brake pedal. Repeat procedure until brake fluid shows
no signs of air bubbles. When bleeding rear brakes, push lever of
pressure regulator in direction of rear axle.
4) After bleeding ABS vehicles, turn ignition on. Allow pump
to run until it shuts off. If pump runs longer than 2 minutes, allow
pump to cool for 10 minutes. On all vehicles, ensure master cylinder
reservoir is full.

ADJUSTMENTS

BRAKE PRESSURE REGULATOR

CAUTION: On all models except Vanagon, DO NOT adjust pressure

regulator with brake pedal depressed.

Cabriolet
1) Raise and support vehicle. Attach Pressure Gauges (US
1016) to right front brake caliper and left rear brake cylinder. Bleed
pressure gauge and hoses through valve on gauges.
2) Pump brake pedal several times. Press on brake pedal until
reading on front gauge shows pressure given for 1st reading in BRAKE
PRESSURES TABLE. Hold brake pressure to specification. Rear gauge
reading should be within specification given for 1st reading in BRAKE
PRESSURES TABLE.
3) Increase pressure on brake pedal until reading on front
gauge shows pressure given for 2nd reading in BRAKE PRESSURES TABLE.
Hold brake pressure to specification. Rear gauge reading should be
within specification given for 2nd reading in BRAKE PRESSURES TABLE.
If pressures are within specification, brake pressure regulator is
functioning properly. If pressures are not within specification,
replace pressure regulator. Disconnect gauges and bleed brakes.

Corrado, Golf, GTI, Jetta & Passat

1) Depress brake pedal once firmly. Release brake pedal
quickly, watching for regulator lever to move when pedal is released.
If regulator lever does not move when pedal is released quickly,
replace regulator. If regulator lever moved, go to next step.
2) Ensure vehicle fuel tank is full, luggage compartment is
empty and a driver is in driver seat. Raise and support vehicle. Using
Pressure Gauges (US 1016), attach one gauge to right rear brake
cylinder or caliper. If vehicle is ABS-equipped, go to next step. If
vehicle is not ABS-equipped, go to step 4).
3) Using Distributor (tee) (803 611 755) and an additional 8"
 BRAKE SYSTEM
Article Text (p. 3)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

(203 mm) of brake line, connect one gauge in front of pressure

regulator. Bleed pressure gauge and hoses through valve on gauges.
Lower vehicle. Bounce rear of vehicle several times. Go to step 5).
4) Attach Pressure Gauges (US 1016) to left front brake
caliper. Bleed pressure gauge and hoses through valve on gauges. Lower
vehicle. Bounce rear of vehicle several times.
5) Pump brake pedal several times. Press on brake pedal until
reading on front gauge shows pressure given for 1st reading in BRAKE
PRESSURES TABLE. Hold brake pressure to specification. Rear gauge
reading should be within specification given for 1st reading in BRAKE
PRESSURES TABLE.
6) Increase pressure on brake pedal until reading on front
gauge shows pressure given for 2nd reading in BRAKE PRESSURES TABLE.
Hold brake pressure to specification. Rear gauge reading should be
within specification given for 2nd reading in BRAKE PRESSURES TABLE.
If pressures are within specification, brake pressure regulator is
functioning properly. If pressures are not within specification, go to
next step.
7) If pressure is too high, decrease spring pressure on
regulator. If pressure is too low, increase spring pressure on
regulator. If adjusting spring pressure on regulator does not bring
pressures within specification, replace pressure regulator. Disconnect
gauges, and bleed brakes.

Fox
1) Depress brake pedal once firmly. Release brake pedal
quickly, watching for regulator lever to move when pedal is released.
If regulator lever does not move when pedal is released quickly,
replace regulator. If regulator lever moved, go to next step.
2) Raise and support vehicle. Using Spring Compressors (VW
5340), compress rear suspension until measured distance between center
of wheel and edge of fender lip is approximately 15" (381 mm).
Compress both sides of rear suspension at the same time.
3) Attach Pressure Gauges (US 1016) to left front brake
caliper and right rear brake cylinder. Bleed pressure gauge and hoses
through valve on gauges. Pump brake pedal several times. Press on
brake pedal until reading on front gauge shows pressure given for 1st
reading in BRAKE PRESSURES TABLE. Hold brake pressure to
specification. Rear gauge reading should be within specification given
for 1st reading in BRAKE PRESSURES TABLE.
4) Increase pressure on brake pedal until reading on front
gauge shows pressure given for 2nd reading in BRAKE PRESSURES TABLE.
Hold brake pressure to specification. Rear gauge reading should be
within specification given for 2nd reading in BRAKE PRESSURES TABLE.
If pressures are within specification, brake pressure regulator is
functioning properly. If pressures are not within specification, go to
next step.
5) If pressure is too high, decrease spring pressure on
regulator. If pressure is too low, increase spring pressure on
regulator. If adjusting spring pressure on regulator does not bring
pressures within specification, replace pressure regulator. Disconnect
gauges, and bleed brakes.
 BRAKE SYSTEM
Article Text (p. 4)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

Vanagon
1) Raise and support vehicle. Attach Pressure Gauges (US
1016) to left front brake caliper and right rear brake cylinder. Bleed
pressure gauge and hoses through valve on gauges.
2) Pump brake pedal several times. Remove nuts holding
pressure regulator. Press on brake pedal until reading on both gauges
is 725 psi (51 kg/cmý).
3) Tilt regulator forward 30 degrees. DO NOT damage brake
lines when tilting regulator. Increase pressure on brake pedal until
reading on gauge connected to front caliper reads 1450 psi (102
kg/cmý).
4) With regulator tilted forward 30 degrees and gauge for
front caliper reading 1450 psi (102 kg/cmý), reading on gauge
connected to rear brake cylinder must be 798-943 psi (56-66 kg/cmý).
If reading is not within specified range, replace pressure regulator.
Disconnect gauges and bleed brakes. When installing pressure
regulator, ensure bolt heads face in forward (driving) direction.

BRAKE PRESSURES TABLE

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Front Gauge Rear Gauge
Application psi (kg/cmý) psi (kg/cmý)

Cabriolet
1st Reading ......... 797 (56) ............ 565-623 (40-44)
2nd Reading ........ 1450 (102) ........... 739-826 (52-58)
Corrado
1st Reading ......... 725 (51) ............ 391-478 (28-34)
2nd Reading ........ 1450 (102) ........... 696-783 (49-55)
Fox
Coupe & Sedan
1st Reading ........ 725 (51) ............ 537-609 (38-43)
2nd Reading ....... 1450 (102) ........... 725-958 (51-67)
Wagon
1st Reading ........ 725 (51) ............ 392-479 (28-34)
2nd Reading ....... 1450 (102) ........... 754-841 (53-59)
Golf & Jetta
1st Reading ......... 725 (51) ........ (1) 450-479 (32-34)
2nd Reading ........ 1450 (102) ....... (2) 812-914 (57-64)
GTI & Jetta GLi
1st Reading ......... 725 (51) ........ (1) 450-479 (32-34)
2nd Reading ........ 1450 (102) ....... (2) 754-783 (53-55)
Passat
1st Reading ......... 725 (51) ............ 435-522 (31-37)
2nd Reading ........ 1450 (102) ........... 739-826 (52-58)
Vanagon
1st Reading ......... 725 (51) ...................... .....
2nd Reading ........ 1450 (102) ........... 798-943 (56-66)

(1) - On vehicles equipped with ABS, rear gauge 1st reading is

493-595 psi (35-42 kg/cmý).
 BRAKE SYSTEM
Article Text (p. 5)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

(2) - On vehicles equipped with ABS, rear gauge 2nd reading is

812-914 psi (57-64 kg/cmý).
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MASTER CYLINDER PUSH ROD

NOTE: Push rod is not adjustable on models not listed.

Cabriolet
Loosen lock nut on push rod. Turn clevis until distance
between booster mounting flange and center of clevis hole is 8.11"
(206 mm). Tighten lock nut.

NOTE: On Vanagon, adjust push rod before installing in vehicle.

Vanagon
Loosen lock nut on push rod. Turn clevis until distance
between booster mounting flange and center of clevis eye is 4.40" (112
mm). Tighten lock nut.

STOPLIGHT SWITCH

NOTE: Stoplight switches mounted on master cylinder are

nonadjustable.

Adjustable stoplight switch is located above brake pedal.

Loosen lock nut. Turn switch until distance between brake pedal arm
and first thread on switch body is .20-.24" (5-6 mm). Tighten lock
nut. See Fig. 1.

Fig. 1: Adjusting Stoplight Switch

Courtesy of Volkswagen United States, Inc.

PARKING BRAKE

Cabriolet & Fox

Raise and support vehicle. Apply brake pedal once firmly. On
Fox, remove heat deflector plate from under vehicle to access parking
brake cable adjustment. On all vehicles, pull parking brake handle up
2 notches. Loosen locking nuts, at parking brake lever. Tighten
 BRAKE SYSTEM
Article Text (p. 6)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

adjusting nuts until respective rear wheel is locked. Release parking

brake. Ensure rear wheels rotate freely. Tighten lock nuts.

Corrado, GTI, Jetta GLi & Passat (Rear Disc)

1) Raise and support vehicle. Disengage parking brake. Loosen
locking nuts at parking brake lever. Tighten adjusting nuts until
levers on calipers just move off stops. Measure gap between stop and
lever. See Fig. 2.
2) Maximum clearance between parking brake lever (on caliper)
and stop is .060" (1.5 mm). Apply and release parking brake. Ensure
rear wheels rotate freely. Tighten lock nuts.

Fig. 2: Adjusting Rear Disc Parking Brake

Courtesy of Volkswagen United States, Inc.

Golf, GTI & Jetta (Rear Drum)

Raise and support vehicle. Apply brake pedal once firmly.
Pull parking brake handle up 4 notches. Loosen locking nuts, at
parking brake lever. Tighten adjusting nuts until respective rear
wheel can just be rotated by hand. Release parking brake. Ensure rear
wheels rotate freely. Tighten lock nuts.

NOTE: On Vanagon, check rear brake adjustment before adjusting

parking brake.

Vanagon
1) Raise and support vehicle. Release parking brake. Tighten
self-locking adjusting nut until there is no play at brake components.
Check for play by pulling on cable housings. Apply and release parking
brake several times.
2) Check adjustment by pulling parking brake handle up 2-4
notches. Rear wheels should be too tight to turn by hand. Release
parking brake. Rear wheels should rotate freely.

WHEEL BEARINGS

NOTE: FWD front wheel bearings and rear wheel bearings on Vanagon,
 BRAKE SYSTEM
Article Text (p. 7)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

also called hub or axle bearings, are sealed units with

1-piece outer race. Bearings are not adjustable.

NOTE: Front wheel bearings, also called hub or axle bearings, are
sealed units with 1-piece outer race. Bearings are not
adjustable

Rear Wheel Bearings (Except Vanagon)

Tighten adjusting nut snugly while turning drum or rotor.
Back off and retighten nut until thrust washer can just be moved with
screwdriver. Install locking cap and new cotter key. Install dust cap.

Front Wheel Bearings (Vanagon)

Tighten adjusting nut snugly while turning rotor. Back off
and retighten nut slowly until thrust washer can just be moved with
screwdriver under finger pressure. After adjustment, peen flange of
NEW hub nut into spindle axle shaft recess.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal (Cabriolet, Fox, Golf, GTI & Jetta)

Raise and support vehicle. Remove front wheels. Remove
retaining spring at top and bottom of caliper. Remove caliper mounting
bolts. Push caliper assembly upward and swing out from bottom. Hang
caliper aside with wire. Siphon small amount of brake fluid from
reservoir. Remove pads and retaining springs from caliper support.
Replace pads that exceed wear limit. Wear limit of pads is .28" (7.0
mm), including backing plate. See Fig. 3, 4 or 5.

Fig. 3: Identifying Front Caliper Components (Typical)

Courtesy of Volkswagen United States, Inc.
 BRAKE SYSTEM
Article Text (p. 8)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

Fig. 4: Identifying Front Disc Brake Components (Fox)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Identifying Front Disc Brake Components (Except Fox)

Courtesy of Volkswagen United States, Inc.

Installation
1) Seat caliper piston fully into cylinder bore. Attach
retaining springs to caliper support. Install inner pad first and then
install outer pad.
2) Install caliper assembly into caliper support. DO NOT
force caliper any further than necessary to start Allen head mounting
bolts. Excessive force could distort springs, which could cause noises
 BRAKE SYSTEM
Article Text (p. 9)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

during braking. Depress brake pedal several times to allow pads to

move into operating position. Ensure master cylinder reservoir fluid
level is full.

Removal (Corrado, Passat & Vanagon)

Raise and support vehicle. Remove front wheels. Hold lower
guide pin using an open end wrench. Remove lower caliper mounting
bolt. Push caliper assembly upward and swing out from bottom. Siphon
small amount of brake fluid from reservoir. Remove pads and retaining
springs from caliper support. Replace pads exceeding wear limit. Wear
limit of pads is .28" (7.0 mm), including backing plate. See Fig. 3 or
5.

Installation
Seat caliper piston fully into cylinder bore. Install inner
pad and then outer pad. Swing caliper assembly down. Hold lower guide
pin using an open end wrench. Install lower caliper mounting bolt.
Depress brake pedal several times to allow pads to move into operating
position. Ensure master cylinder reservoir fluid level is full.

FRONT & REAR BRAKE CALIPER

Removal & Installation

Raise and support vehicle. Remove wheels. Disconnect brake
line from caliper, and plug openings. Bend back locking tabs (if
equipped) on mounting bolts. If removing rear brake calipers,
disconnect parking brake cables. On all calipers, remove caliper
mounting bolts. See Fig. 3 or 8. Remove caliper assembly from wheel
bearing housing. To install, reverse removal procedure. Use new lock
plates (if equipped) and mounting bolts. Bleed hydraulic brake system.
See BLEEDING PROCEDURES under BLEEDING BRAKE SYSTEM.

FRONT & REAR BRAKE ROTOR

Removal (Except Vanagon)

Raise and support vehicle. Remove wheels. Remove caliper and
suspend from frame with wire. Remove countersunk screw that holds
rotor to hub. Pull rotor off hub.

Removal (Vanagon)
Raise and support vehicle. Remove wheels. Remove caliper,
leaving hose connected. Suspend caliper from frame with wire. Remove
grease cap. Loosen peen nut. Remove thrust washer and outer wheel
bearing. Pull hub and rotor from spindle.

Installation (All Models)

To install, reverse removal procedure. Adjust wheel bearings
(if necessary). See WHEEL BEARINGS under ADJUSTMENTS.

REAR DISC BRAKE PADS

Removal (Corrado & Passat)

 BRAKE SYSTEM
Article Text (p. 10)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

Raise and support vehicle. Remove rear wheels. Disconnect

parking brake cable from caliper. Remove caliper mounting bolts.
Remove caliper and hang aside. Siphon small amount of brake fluid from
reservoir. Remove pads and retaining springs from caliper support.
Replace pads that exceed wear limit. Wear limit of pads is .28" (7.0
mm), including backing plate.

Installation
Seat caliper piston fully into cylinder bore. Install inner
pad first and then install outer pad. Position caliper. Install
caliper mounting bolts. Depress brake pedal several times to allow
pads to move into operating position. Ensure master cylinder reservoir
fluid level is full.

CAUTION: On GTI and Jetta GLi, DO NOT depress brake pedal with
engine running to reset automatic adjuster. High pressure
created by booster could jam automatic adjustment piston
causing premature pad wear and/or damage to automatic
adjuster.

Removal (GTI & Jetta GLi)

Raise and support vehicle. Remove rear wheels. Disconnect
parking brake cable from caliper. Remove upper caliper mounting bolt.
Swing caliper down on lower mounting bolt. Remove brake pads from
carrier. Wear limit is .276" (7.0 mm), including backing plate.

Installation
Place brake pads in carrier. Using Allen wrench, push piston
into caliper while turning it clockwise. Swing caliper into position.
Install new self-locking upper mounting bolt. Reconnect parking brake
cable, and check parking brake adjustment. With engine off, depress
brake pedal approximately 40 times to reset automatic adjuster.

REAR BRAKE DRUM

CAUTION: ALWAYS loosen or tighten castellated axle nuts with wheels

on ground.

Removal (Cabriolet, Golf, GTI & Jetta)

Raise and support vehicle. Remove one wheel bolt. Using
screwdriver inserted through wheel bolt hole, push adjusting wedge up
against stop. Remove grease cap, cotter pin, nut lock and nut. Remove
thrust washer and outer bearing. Remove drum with inner bearing and
grease seal.

Installation
To install, reverse removal procedure. Adjust wheel bearings
(if necessary). See WHEEL BEARINGS under ADJUSTMENTS. Apply brake
pedal firmly several times to set self-adjusting mechanism.

Removal (Fox)
Raise and support vehicle. Remove heat deflector plate from
 BRAKE SYSTEM
Article Text (p. 11)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

under vehicle to access parking brake cable adjustment. Disconnect

parking brake cable (at adjustment point). Remove dust cap and cotter
pin. Loosen axle nut. Raise and support vehicle. Remove wheels. Pull
off brake drum.

Installation
To install, reverse removal procedure. Adjust wheel bearings
(if necessary). See WHEEL BEARINGS under ADJUSTMENTS.

Removal (Vanagon)
Remove dust cap and cotter pin. Loosen castellated nut. Raise
and support vehicle. Remove wheels. Release parking brake at
equalizer, and back off adjuster. Remove drum retaining screws. Attach
a puller and remove drum. Ensure drum can rotate freely during
removal.

Installation
To install, reverse removal procedure. Drum retaining screws
must be tight. Tighten castellated axle nut to 253 ft. lbs. (345 N.m).
Adjust parking brake, and depress brake pedal several times to set
self-adjusting mechanism.

REAR BRAKE SHOES

Removal (Cabriolet, Fox, Golf, GTI & Jetta)

1) Remove brake drum. See REAR BRAKE DRUM under REMOVAL &
INSTALLATION. After removing drum, remove retainer clips, hold-down
springs and anchor pins. Remove lower return spring. Disconnect
parking brake cable from lever. See Fig. 6.

Fig. 6: Identifying Rear Brake Components (Except Vanagon)

Courtesy of Volkswagen United States, Inc.

2) Disconnect adjusting wedge spring and upper return spring.

 BRAKE SYSTEM
Article Text (p. 12)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

Remove brake shoes together with push rod and tensioning spring. Place
push rod and shoes in vise. Remove tension spring. Separate shoes from
push rod.

Installation
To install, reverse removal procedure. Ensure that lug on
adjusting wedge faces backing plate. Adjust wheel bearings (if
necessary). See WHEEL BEARINGS under ADJUSTMENTS. Apply brake firmly
to set self-adjusting mechanism.

Removal (Vanagon)
1) Remove brake drum. See REAR BRAKE DRUM under REMOVAL &
INSTALLATION. After removing drum, remove retainer clips, hold-down
springs and anchor pins. Disconnect parking brake cable from lever on
brake shoe. Disconnect lower return and adjuster springs. Pull brake
shoes out of lower support. See Fig. 7.

Fig. 7: Identifying Rear Brake Components (Vanagon)

Courtesy of Volkswagen United States, Inc.

2) Disconnect both upper return springs. Remove both brake

shoes from backing plate together with adjuster lever. Ensure both
pistons remain in wheel cylinder. Separate brake shoes from adjuster
lever. Remove parking brake lever from rear brake shoe.

Installation
1) To install, reverse removal procedure. Adjust brake shoes
so distance from lining surface on leading shoe to lining surface on
trailing shoe is 9.87" (250.7 mm).
2) Adjust parking brake at equalizer. There should be no free
play between parking brake lever on brake shoe and adjusting rod.
Install brake drum. Depress brake pedal several times to set self-
adjusting mechanism.

MASTER CYLINDER
 BRAKE SYSTEM
Article Text (p. 13)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

Removal (Except Vanagon)

1) Drain master cylinder reservoir. Remove cover plate (if
equipped). Disconnect brake lines and wiring at master cylinder.
2) On models without power assist servo, disconnect brake
push rod at brake pedal. On models equipped with power assist servo,
remove master cylinder from servo. Be careful to keep any spacers used
on attaching bolts for proper installation.

Installation
To install, reverse removal procedure. Always use new "O"
ring between master cylinder and power assist servo. Bleed hydraulic
system.

Removal (Vanagon)
1) Remove instrument panel. Drain master cylinder reservoir.
Disconnect brake lines and wiring at master cylinder. Disconnect
vacuum lines at power assist servo. Remove pedal and bracket assembly.
2) Disconnect brake push rod from brake pedal. Remove power
assist servo and master cylinder assembly together from pedal bracket.
Remove master cylinder from power assist servo.

Installation
To install, reverse removal procedure. Install new "O" ring
between master cylinder and power assist servo. Adjust brake push rod
length. See MASTER CYLINDER PUSH ROD under ADJUSTMENTS in this
article. Bleed hydraulic system.

VACUUM POWER ASSIST SERVO

NOTE: Not all vehicles have all components.

Removal (Except Vanagon)

Remove master cylinder from power assist servo. Disconnect
brake push rod from brake pedal. Disconnect vacuum hose from servo.
Remove servo from vehicle.

Removal (Vanagon)
Remove instrument panel. Remove servo and master cylinder as
an assembly. Separate master cylinder from servo.
Installation (All Models)
To install, reverse removal procedure. Before attaching brake
push rod to brake pedal, check and adjust push rod length. See MASTER
CYLINDER PUSH ROD under ADJUSTMENTS. Always replace damping ring,
washer, filter and "O" ring (as equipped). Slots in damping washer and
filter must be offset 180 degrees (if equipped). Complete
installation, and bleed hydraulic system. See Fig. 9.

OVERHAUL

NOTE: Black staining from piston seal wear may show on caliper
bore walls and piston. This staining is normal. DO NOT
 BRAKE SYSTEM
Article Text (p. 14)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

disassemble power assist servo as parts are not available.

Fig. 8: Identifying Caliper Components (Typical)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Power Assist Master Cylinder Components

Courtesy of Volkswagen United States, Inc.
 BRAKE SYSTEM
Article Text (p. 15)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

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Application Ft. Lbs. (N.m)

Caliper Mounting Bolts (1)

Cabriolet ........................................... 29 (39)
Corrado, Passat & Vanagon ........................... 26 (35)
Fox ................................................. 30 (41)
Golf, GTI & Jetta
Front .............................................. 18 (25)
Rear ............................................... 26 (35)
Pad Carrier Mounting Bolt
Cabriolet ........................................... 52 (70)
Corrado & Passat
Front ............................................. 92 (125)
Rear ............................................... 48 (65)
Vanagon ........................................... 200 (271)
Fox, Golf, GTI & Jetta .............................. 48 (65)
Rear Axle Nut
Vanagon ........................................... 369 (500)
Rear Backing Plate-To-Flange Bolt
Except Vanagon ...................................... 44 (60)
Vanagon ............................................. 47 (64)
Rear Brake Shoe Support Bolt
Vanagon ............................................. 48 (65)
Wheel Lug Nut
Except Vanagon ..................................... 81 (110)
Vanagon ........................................... 123 (167)

INCH Lbs. (N.m)

Wheel Cylinder Bolt

Except Vanagon ....................................... 80 (9)
Vanagon ............................................ 177 (20)

(1) - Always replace all self-locking bolts.

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DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS TABLE (1)

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Application In. (mm)

Front
Cabriolet
Original Thickness ............................... .787 (20)
Wear Limit ....................................... .709 (18)
Corrado
Disc Diameter .................................. 11.02 (280)
 BRAKE SYSTEM
Article Text (p. 16)
1991 Volkswagen Vanagon
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Saturday, March 18, 2000 09:02PM

Original Thickness ............................... .866 (22)

Wear Limit ....................................... .787 (20)
Fox
Disc Diameter ................................... 9.41 (239)
Original Thickness ............................... .472 (12)
Wear Limit ....................................... .394 (10)
Golf, GTI, Jetta & Passat
Solid
Original Thickness ............................. .472 (12)
Wear Limit ..................................... .394 (10)
Vented
Disc Diameter ............................... 10.079 (256)
Original Thickness ............................. .787 (20)
Wear Limit ..................................... .709 (18)
Vanagon
Disc Diameter .................................. 10.16 (258)
Original Thickness ............................... .591 (15)
Wear Limit ....................................... .512 (13)
Rear
Original Thickness ................................ .394 (10)
Wear Limit ......................................... .315 (8)

(1) - Lateral runout is .002" (.05 mm)

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DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS TABLE

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Application In. (mm)

Except Vanagon
Drum Diameter ................................... 7.087 (180)
Maximum Drum Refinish Diameter ................ 7.106 (180.5)
Wear Limit ...................................... 7.126 (181)
Vanagon
Drum Diameter ................................... 9.921 (252)
Maximum Drum Refinish Diameter .............. (1) 9.961 (253)
Wear Limit .................................... 9.980 (253.5)

(1) - Use oversize linings after turning drum .020" (.50 mm) or
more.
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END OF ARTICLE