Service

Workshop Manual
T-Cross 2019 ➤
Brake system
Edition 02.2019

Service Department. Technical Information

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 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

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 T-Cross 2019 ➤
Brake system - Edition 02.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Overview of fitting locations - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Assembly overview - control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 15
3.3 Separating control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4 Fitting control unit to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Removing and installing speed sensors on front axle G45 / G47 . . . . . . . . . . . . . . . . . . . . 31
4.4 Removing and installing speed sensors on rear axle G44 / G46 . . . . . . . . . . . . . . . . . . . . 32
4.5 Checking ABS sensor ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.5 Removing and installing brake splash plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Removing and installing brake carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.7 Resetting drum brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.8 Removing and installing brake splash plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 Removing and installing handbrake warning switch F9 . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.4 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5 Removing and installing rear brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Contents i
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4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.4 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Assembly overview - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.5 Removing and installing brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.1 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.2 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3 Removing and installing vacuum sender G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.4 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.5 Removing and installing electric vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.4 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

ii Contents
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00 – Technical data
1 Safety information
(VRL012677; Edition 02.2019)
⇒ “1.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1

1.1 Safety precautions when using testers

and measuring instruments during a
road test
Please observe the following if test and measuring equipment is
required during a road test:
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.

1. Safety information 1
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2 Identification
⇒ “2.1 Allocation of PR number - brakes”, page 2

2.1 Allocation of PR number - brakes

⇒ “2.1.1 Front brakes”, page 2
⇒ “2.1.2 Rear brakes”, page 2

2.1.1 Front brakes

The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.

Note

Information on the individual brake that is fitted is currently not

available on the vehicle data sticker.

– For information concerning the installed brake system, see

ELSA/Vehicle-specific notes.
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes -1KU
♦ Arrow 2 - Front brakes -1LJ
The vehicle data sticker can be found in the spare wheel well and
in the service schedule.
The following table explains the PR numbers. The data are im‐
portant for combining the brake caliper/brake disc/brake drum
and brake pads.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
Engine PR no. Front brakes
1.0 l - 70 kW 1ZS FS III (15)
1.0 l - 85 kW
1.6 l - 70 kW TDI

2.1.2 Rear brakes

The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.

Note

Information on the individual brake that is fitted is currently not

available on the vehicle data sticker.

2 Rep. gr.00 - Technical data

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– For information concerning the installed brake system, see

ELSA/Vehicle-specific notes.
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes -1KU
♦ Arrow 2 - Front brakes -1LJ
The vehicle data sticker can be found in the spare wheel well and
in the service schedule.
The following table explains the PR numbers. The data are im‐
portant for combining the brake caliper/brake disc/brake drum
and brake pads.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
Drum brakes
Engine PR no. Rear brakes
1.0 I - 70 kW 1KA TB 228 X 42
1.6 l - 70 kW TDI
Disc brakes
Engine PR no. Rear brakes
1.0 l - 85 kW 1KV / 1KD CI 38 (14)

2. Identification 3
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3 Technical data
⇒ “3.1 Technical data for brakes”, page 4

3.1 Technical data for brakes

⇒ “3.1.1 Brake master cylinder and brake servo”, page 4
⇒ “3.1.2 Front brakes”, page 4
⇒ “3.1.3 Rear brakes”, page 5

3.1.1 Brake master cylinder and brake servo

Brake master cylinder Diameter in mm 22.22
Brake servo (left-hand ∅ in inches 10
drive vehicles)
Brake servo (RHD ve‐ ∅ in inches 7/8
hicles)

3.1.2 Front brakes

Front brake FS III
Item PR no. 1ZS
1 Brake caliper FS III (15)
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc Diam‐ 276
eter in
mm
Brake disc, mm 24
thickness
Brake disc, mm 21
wear limit
4 Brake caliper Diam‐ 57
piston eter in
mm

4 Rep. gr.00 - Technical data

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3.1.3 Rear brakes

Rear brake (drum brake)
Item PR no. 1KA
1 Wheel brake mm 20.64
cylinder
2 Brake lining, mm 42
width
Brake pad, mm 5
thickness
Brake lining, mm 2.5
minimal thick‐
ness
3 Brake drum Diam‐ 228
eter in
mm
Brake drum, Diam‐ 229.8
wear limit eter in
mm

Rear brakes (disc brakes) CI 38 (14)

Item PR no. 1KV / 1KD
1 Brake caliper CI 38 (14)
2 Brake pad, mm 12
thickness
Brake pad, mm 2
wear limit with‐
out backplate
3 Brake disc Diameter in 230
mm
Thickness mm 9
Wear limit mm 7
4 Piston Diameter in 38
mm

3. Technical data 5
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4 Brake test
⇒ “4.1 General information”, page 6
⇒ “4.2 Checking vehicles with front-wheel drive”, page 6

4.1 General information

♦ The drive is provided by the test rig.
♦ For the test, ensure for vehicles with a manual gearbox that
the gear lever is in neutral, and for vehicles with an automatic
gearbox that the selector lever is in »N«.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.

Note

The brake regulation systems do not function when ignition is off.

4.2 Checking vehicles with front-wheel drive

Carry out the brake test on a single-axle roller dynamometer.
The maximum test speed is 6 km/h.
The test beds authorised by Volkswagen fulfil these require‐
ments.

6 Rep. gr.00 - Technical data

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45 – Anti-lock brake system

1 General information
⇒ “1.1 Repair instructions for repair work on ABS”, page 7

1.1 Repair instructions for repair work on

ABS
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Faults in the ABS do not influence the brake system.
The conventional brake system remains functional.
A change in braking behaviour is to be reckoned with.
After the ABS warning lamp comes on, the rear wheels may lock
prematurely during braking.
ABS layout in left-hand drive vehicle:
1 - Hydraulic unit and control unit
2 - Brake servo

1. General information 7
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ABS layout in RHD vehicles:

1 - Brake servo
2 - Hydraulic unit and control unit
The control unit and hydraulic are combined in a single compo‐
nent. They can be separated only when removed. Hydraulic pump
must not be separated from hydraulic unit either.
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using “Guided Fault Finding”.
Perform “Guided Fault Finding” with ⇒ Vehicle diagnostic tester.
♦ With ignition switched off, disconnect battery earth strap.
♦ Before carrying out welding work with an electric welding unit,
see ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 133 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 133 .
♦ During the final road test, ensure that a controlled brake ap‐
plication is performed at least once. Pulsation of the brake
pedal must be noticeable.
♦ Absolute cleanliness is required when working on the anti-lock
brake system. Auxiliary items containing mineral oil, e.g. oils,
greases, etc. must never be used.
♦ Thoroughly clean all unions and adjacent areas before loos‐
ening. Do not use aggressive cleaning agents such as brake
cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover them over.
♦ After separating control unit from hydraulic unit, use transport
protection for contact pins.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately. Sealing plugs must be
used.
♦ Only use lint-free cloths.
♦ Do not remove packaging from replacement parts until imme‐
diately before installation.
♦ Only use genuine packed parts.
♦ Do not work with compressed air if the system is open. Do not
move the vehicle.
♦ During paint application, the control unit may be exposed for
a short period to max. 95°C. For longer periods (approx. 2
hours) it may be exposed to max. 85°C. Ensure that no brake
fluid finds its way into the connectors.

8 Rep. gr.45 - Anti-lock brake system

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2 Overview of fitting locations

⇒ “2.1 Overview of fitting locations - ABS/ESP”, page 9

2.1 Overview of fitting locations - ABS/ESP

1 - ABS control unit - J104-

❑ Location: on hydraulic
unit, on left in engine
compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
The following components are
integrated into the control unit:
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
❑ Removing and installing
⇒ page 15
2 - ABS hydraulic unit - N55-
The hydraulic unit consists of
the components:
❑ ABS return flow pump -
V39-
❑ Brake pressure sender -
G201-
❑ Valve block (contains in‐
let and outlet valves).
❑ Do not separate ABS re‐
turn flow pump - V39-
and valve block
❑ Removing and installing
⇒ page 15
3 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
4 - ESP and TCS warning lamp - K155-
❑ Location: in dash panel insert.
5 - Brake system warning lamp - K118-
❑ Location: in dash panel insert.
6 - Brake light switch - F-
❑ Including brake pedal switch - F47- .
❑ Removing and installing ⇒ page 98
7 - TCS and ESP button - E256-
❑ Fitting location: in dash panel
8 - Diagnostic connection
❑ Location: Driver footwell cover.

2. Overview of fitting locations 9

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9 - Steering angle sender - G85-

❑ Cannot be replaced individually.
❑ In the event of damage to steering angle sender - G85- , steering column must be renewed ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering column; Removing steering column
10 - Front right/left speed sensor -G45- / -G47-
❑ Removing and installing ⇒ page 31
11 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing
12 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing (drum and disc brake) ⇒ page 32
13 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing

10 Rep. gr.45 - Anti-lock brake system

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3 Control unit and hydraulic unit

⇒ “3.1 Assembly overview - control unit and hydraulic unit”, page
11
⇒ “3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 ”, page 15
⇒ “3.3 Separating control unit from hydraulic unit”, page 23
⇒ “3.4 Fitting control unit to hydraulic unit”, page 24
⇒ “3.5 Connecting brake lines to hydraulic unit”, page 26

3.1 Assembly overview - control unit and hy‐

draulic unit
⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 11
⇒ “3.1.2 Assembly overview - control unit and hydraulic unit, right-
hand drive”, page 13

3.1.1 Assembly overview - control unit and hydraulic unit, LHD

1 - ABS control unit - J104-

❑ Removing and installing
ABS hydraulic unit -
N55- with ABS control
unit - J104-
⇒ page 15
2 - ABS hydraulic unit - N55-
❑ Do not separate ABS re‐
turn flow pump - V39-
and valve block
❑ When replacing the hy‐
draulic unit, always seal
the old part with plugs -
1H0 698 311 A- .
❑ Removing and installing
ABS hydraulic unit -
N55- with ABS control
unit - J104-
⇒ page 15
3 - Torx bolt
❑ Tighten new Torx bolts
in three stages in suc‐
cession and in alternate
sequence:
❑ Carefully screw in until
Torx bolts come into
contact with housing
❑ 1st stage: preliminary
tightening torque:
1.5 Nm to 2 Nm (to sup‐
port seal)
❑ 2nd stage: final speci‐
fied torque: 3 Nm
4 - Brake line
❑ ABS hydraulic unit -
N55- to rear right brake
caliper/wheel brake cylinder.

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❑ Marked on hydraulic unit with »RR«
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
5 - Brake line
❑ ABS hydraulic unit - N55- to front left brake caliper.
❑ Marked on hydraulic unit with »FL«
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
6 - Brake line
❑ ABS hydraulic unit - N55- to front right brake caliper.
❑ Marked on hydraulic unit with »FR«
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
7 - Brake line
❑ ABS hydraulic unit - N55- to rear left brake caliper/wheel brake cylinder.
❑ Marked on hydraulic unit with »RL«
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
8 - Brake line
❑ ABS hydraulic unit - N55- to brake master cylinder/secondary piston circuit
❑ Marked on hydraulic unit with »HZ1«
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
9 - Brake line
❑ ABS hydraulic unit - N55- to brake master cylinder/secondary piston circuit
❑ Marked on hydraulic unit with »HZ2«
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
10 - Brake servo
❑ Removing and installing ⇒ “3.3 Removing and installing brake servo”, page 99
11 - Bracket
12 - Torx bolt
❑ 8 Nm
13 - Rubber damper
❑ Qty. 3
14 - Heat shield
Allocation ⇒ Electronic parts catalogue

15 - Hexagon nut
❑ 20 Nm
16 - Bracket
17 - Hexagon nut
❑ 20 Nm

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3.1.2 Assembly overview - control unit and hydraulic unit, right-hand drive

1 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ ∅ 6 mm and union
screw with thread M12 x
1
❑ 14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
2 - Brake line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit
❑ ∅ 6 mm and union
screw with thread M12 x
1
❑ 14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
3 - Brake line
❑ To rear right brake cali‐
per
❑ ∅ 5.25 mm and union
screw with thread M12 x
1
❑ 14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
4 - Brake line
❑ To front left brake cali‐
per
❑ ∅ 5.25 mm and union screw with thread M10 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
5 - Brake line
❑ To front right brake caliper
❑ ∅ 5.25 mm and union screw with thread M12 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
6 - Brake line
❑ To rear left brake caliper
❑ ∅ 5.25 mm and union screw with thread M10 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
7 - ABS hydraulic unit - N55-
❑ ⇒ “3.2.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 , RHD vehicles”, page
19

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8 - Spacer sleeves
9 - Bolt
❑ Qty. 4
❑ 1st stage: preliminary tightening torque: 1.5 Nm to 2 Nm (to support seal)
❑ 2nd stage: final specified torque: 3 Nm
10 - ABS control unit - J104-
❑ ⇒ “3.2.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 , RHD vehicles”, page
19
11 - Bracket
❑ Check for secure seating after installing.
12 - Bolt
❑ Qty. 2
❑ 8 Nm
13 - Rubber damper
❑ Qty. 3
14 - Bracket
15 - Nut
❑ Qty. 2
❑ 20 Nm
16 - Brake servo and brake master cylinder
❑ ⇒ “3.1.2 Assembly overview - brake servo/brake master cylinder, right-hand drive”, page 96
❑ ⇒ “3.3.2 Removing and installing brake servo, RHD”, page 104
❑ ⇒ “3.4.2 Removing and installing brake master cylinder, RHD”, page 109
17 - Brake line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ ∅ 6 mm and union screw with thread M12 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
18 - Brake line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ Properties: ∅ 6 mm and flare nut with M12 x 1 thread
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

14 Rep. gr.45 - Anti-lock brake system

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3.2 Removing and installing ABS control

unit - J104- and ABS hydraulic unit -
N55-
⇒ “3.2.1 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 , LHD vehicles”, page 15
⇒ “3.2.2 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 , RHD vehicles”, page 19

3.2.1 Removing and installing ABS control unit - J104- / ABS hydraulic unit - N55- ,
LHD vehicles

Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1331-

♦ Ring insert tool, open, AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G 1410/7-
♦ Torque wrench - VAS 6854-
♦ Brake pedal depressor - V.A.G 1869/2-
♦ Assembly tool - V.A.G 1410/8-

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Sealing plugs from repair kit 1H0 698 311 A

Fitting location:

The ABS control unit - J104- -1- is bolted to the ABS hydraulic
unit - N55- and is located on the right in the engine compartment.

NOTICE
Risk of damage to brake lines if bent.
– Never excessively bend the brake lines in the area of the
hydraulic unit.

Removing:
– Read out and note the existing control unit code.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Vehicles with diesel engine:
– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes and
silencers; Removing and installing front exhaust pipe .
– Remove exhaust gas temperature sender 3 - G495- ⇒ Rep.
gr. 26 ; Removing and installing exhaust gas temperature
sender 3 G495 .

Continued for all vehicles:

– Remove heat shield -1- if present. To do this, unscrew nuts
-arrows-.
– Unclip line guide.

16 Rep. gr.45 - Anti-lock brake system

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– Press down retainer catch in direction of -arrow A-.

– Release electrical connector in direction of -arrow B-.
– Pull off connector -1-.

– Mount brake pedal actuator - V.A.G 1869/2- .

– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .

– Connect hose of bleeder bottle -1- to bleeder valve of front left

brake caliper.
– Open bleeder valve.
– Connect bleed hose of bleed bottle to bleed valve of rear left
wheel brake cylinder.
– Open bleeder valve.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left and rear left bleeder valves.
– Do not remove brake pedal depressor - V.A.G 1869/2- .
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
– Ensure no brake fluid gets onto contacts.
– Unclip the brake lines on the bulkhead as far as possible.
– First identify both brake lines from brake master cylinder and
unscrew from hydraulic unit.
– Seal threaded holes immediately using sealing plugs
5Q0 698 311.
– Mark, unscrew and seal threaded holes of remaining brake
lines (brake calipers).
– Fit dust caps of bleeder valves onto brake lines.

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– Pull hydraulic unit together with control unit upwards out of

dampers -arrow-.

Vehicles with diesel engine or 2.0 l petrol engine:

– Unbolt bracket from hydraulic unit -arrows- in vehicle.
– Guide hydraulic unit downwards out of vehicle.
Installing:
Install in reverse order of removal, observing the following:

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If the sealing plugs are removed, brake fluid can escape, and
it can then no longer be guaranteed that the unit is sufficiently
filled and bled.
♦ When installing the hydraulic unit, ensure that the rubber
dampers are not pressed out of bracket.

– Before installing bracket of ABS hydraulic unit - N55- into

bracket, spray rubber dampers with silicone lubricant - D 007
000 A2- .

– Using assembly tool - V.A.G 1410/8- , carefully fit brake lines.

– Bleed brake system ⇒ page 133 .
– Code ABS control unit - J104- using ⇒ Vehicle diagnostic test‐
er in “Guided Fault Finding” mode.
– Code radio.
Specified torques

18 Rep. gr.45 - Anti-lock brake system

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Assembly of special tools for tightening brake lines

Component Specified torque
Nuts for heat shield 20 Nm
♦ ⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 11
♦ Battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly
overview - battery
♦ Front bleeder valves
⇒ “1.1 Assembly overview - front brake caliper”, page 87
♦ Rear bleeder valves
⇒ “2.1 Assembly overview - rear brake caliper”, page 90

3.2.2 Removing and installing ABS control unit - J104- / ABS hydraulic unit - N55- ,
RHD vehicles

Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1331-

♦ Ring insert tool, open, AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G 1410/7-

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♦ Torque wrench - VAS 6854-

♦ Brake pedal depressor - V.A.G 1869/2-
♦ Assembly tool - V.A.G 1410/8-

♦ Engine bung set -

VAS 6122-

Sealing plugs, assembly

part no. 5Q0 698 311
1 - Sealing plug M10
2 - Sealing plug M12

Fitting location of ABS hydraulic unit - N55- and ABS control unit
- J104- in RHD vehicles:
1- Brake servo and brake master cylinder
2- ABS hydraulic unit - N55- and ABS control unit - J104-
Removing:

NOTICE
Risk of damage to brake lines if bent.
– Never excessively bend the brake lines in the area of the
hydraulic unit.

– Locate code of installed control unit and make a note of it.

– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
moving and installing battery .

– Mount brake pedal actuator - VAG 1869/2- .

– Remove noise insulation ⇒ Rep. gr. 66 ; Noise insulation;
Removing and installing noise insulation .

20 Rep. gr.45 - Anti-lock brake system

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– Press down retainer catch in direction of -arrow A-.

– Release bar of electrical connector in direction of -arrow B-.
– Pull off connector -1-.

– Connect hose of bleeder bottle -1- to bleeder valve of front left

brake caliper.
– Open bleed valve.

– Connect hose of bleeder bottle -1- to bleeder valve of rear left

brake caliper.
– Open bleeder valve.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left and rear left bleeder valves.
– Do not remove brake pedal actuator - VAG 1869/2- yet.
– Place sufficiently lint-free cloths under ABS control unit - J104-
and ABS hydraulic unit - N55- .
– Make sure no brake fluid gets onto electrical contacts on ABS
control unit - J104- .

– First, mark the two brake lines -A- and -B- coming from brake
master cylinder.
– Disconnect the two brake master cylinder brake lines -A- and
-B- from ABS hydraulic unit - N55- .
– Immediately seal brake lines and threaded holes with sealing
plugs.
– Mark, disconnect and seal remaining brake lines -1- to -4-.

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– Seal threaded holes of ABS hydraulic unit - N55- -1- using

sealing plugs 5Q0 698 311 -2-.

– Pull off ABS hydraulic unit - N55- -1- together with bracket
-2- in -direction of arrow-.
– The rubber dampers -arrows- will be pulled off the studs of the
bracket -3-.
– Guide hydraulic unit out of vehicle.
Installing:
Install in reverse order of removal, observing the following:

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If the sealing plugs are removed, brake fluid can escape, and
it can then no longer be guaranteed that the unit is sufficiently
filled and bled.
♦ When installing the hydraulic unit, ensure that rubber dampers
are not pressed out of bracket.

– Before installing bracket of ABS hydraulic unit - N55- into

bracket, spray rubber dampers with silicone lubricant - D 007
000 A2- .
– Mount ABS hydraulic unit - N55- on bracket and ensure that it
is seated securely.

– Using assembly tool - V.A.G 1410/8- , carefully fit brake lines.

– Bleed brake system ⇒ page 133 .

22 Rep. gr.45 - Anti-lock brake system

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Tightening sequence of brake lines:

– Start brake line union screws in sequence -4- through -1-.
– Start brake line union screws in sequence -A- to -B-.
– Tighten brake lines in the same sequence.
– Remove brake pedal actuator - VAG 1869/2- .
– Bleed brake system ⇒ page 133 .
– Code control unit -J104- with ⇒ Vehicle diagnostic tester.
To do this, carry out basic setting of steering angle sender - G85- ,
lateral acceleration sender - G200- , longitudinal acceleration
sender - G251- and brake pressure sender - G201- .
Specified torques:
♦ ⇒ “3.1.2 Assembly overview - control unit and hydraulic unit,
right-hand drive”, page 13
♦ ⇒ Rep. gr. 27 ; Battery; Assembly overview - battery
♦ ⇒ Rep. gr. 66 ; Noise insulation; Assembly overview - noise
insulation
♦ Front bleeder valves
⇒ “1.1 Assembly overview - front brakes”, page 34
♦ Rear bleeder valves
⇒ “2.1 Assembly overview - rear brake caliper”, page 90

3.3 Separating control unit from hydraulic

unit
Special tools and workshop equipment required
♦ ESD workplace - VAS 6613-

♦ Torque screwdriver - VAG 1624-

♦ External Torx bit E 6

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• If a control unit is defective, detach the control unit from the

hydraulic unit. Renew only the control unit.
• If the hydraulic unit is defective, the hydraulic unit must be re‐
newed together with the control unit.
• To separate the control unit from the hydraulic unit, the ESP
unit must be removed first.

NOTICE
Risk of damage to hydraulic unit caused by removal of the return
flow pump.
– Never detach the return flow pump from the hydraulic unit.

NOTICE
Risk of damage to control unit caused by static charge and dirt.
– Discharge any static charge: touch an ESD workplace (earth
yourself).
– Protect interior of control unit from moisture and dirt.

This electrostatic charge can cause malfunctions if you touch

electric components.
– Before working on electric components, touch an earthed ob‐
ject, ESD workplace - VAS 6613- . Do not directly touch
connector contacts or electronic components.
– Set down ABS hydraulic unit - N55- together with ABS control
unit - J104- facing upwards on ESD workplace - VAS 6613- .
– Unscrew external Torx head bolts -arrows- from ABS control
unit - J104- and discard.
– Pull ABS control unit - J104- off ABS hydraulic unit - N55-
making sure not to cant the control unit.
– Cover solenoids of ABS control unit - J104- with a lint-free
cloth.
– Check cleanliness of sealing surface of ABS hydraulic unit -
N55- ; clean it with methylated spirits and a lint-free cloth if
necessary.
The sealing surface of the ABS hydraulic unit - N55- may not be
processed with a file, metal scraper, sandpaper or similar.
If the sealing surface of the ABS hydraulic unit - N55- becomes
damaged (e.g. scoring or scratches), renew the ABS hydraulic
unit - N55- together with ABS control unit - J104- .
After separating ABS control unit - J104- and ABS hydraulic unit
- N55- , use transportation protection for contact pins.

3.4 Fitting control unit to hydraulic unit

Special tools and workshop equipment required

24 Rep. gr.45 - Anti-lock brake system

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♦ ESD workplace - VAS 6613-

♦ Torque screwdriver - V.A.G 1624-

♦ External Torx bit E 6

Note

Severe shocks (e.g. dropping, impact) may destroy the control

unit. Control unit must not then be used.

• Clean surfaces before assembling.

– Fit ABS control unit - J104- onto ABS hydraulic unit - N55-
without canting it.

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– Secure ABS hydraulic unit - N55- and ABS control unit - J104-
using the new external Torx head bolts provided. Tighten them
to specified torque in three stages and in diagonal sequence.
The hydraulic unit's threads for securing the control unit must not
be recut.
If the threads are damaged, the hydraulic unit needs to be re‐
newed.
If it is difficult to screw in the bolts by hand or tighten them to
specified torque, renew hydraulic unit.
Specified torque in three stages:
Use new bolts!
Stage 1: position and centre control unit; screw in -
Torx bolts until Torx bolts contact housing
Stage 2: Seat sealing lugs evenly on all sides and 1.5 to
tighten initially. 2 Nm
Stage 3: final torque 3 Nm

Note

Max. 5 repeated bolting processes (hydraulic unit/control unit) are

permissible throughout the entire hydraulic unit's service life.

3.5 Connecting brake lines to hydraulic unit

⇒ “3.5.1 Connecting brake lines to hydraulic unit, LHD”,
page 26
⇒ “3.5.2 Connecting brake lines to hydraulic unit, RHD”,
page 27

3.5.1 Connecting brake lines to hydraulic unit,

LHD
On tandem brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread

26 Rep. gr.45 - Anti-lock brake system

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On hydraulic unit:
1 - Hydraulic unit to rear right brake caliper
- Properties: ∅ 5.25 mm and flare nut with short thread M12 x 1
2 - From hydraulic unit to front left brake caliper
- Properties: ∅ 5.25 mm and flare nut with M10 x 1 thread
3 - From hydraulic unit to front right brake caliper.
- Properties: ∅ 5.25 mm and flare nut with short thread M12 x 1
4 - From hydraulic unit to rear left brake caliper
- Properties: ∅ 5.25 mm and flare nut with M10 x 1 thread
5 - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
6 - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
Specified torques:
♦ ⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 11

3.5.2 Connecting brake lines to hydraulic unit,

RHD
On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
1 - Brake servo and brake master cylinder

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To ABS hydraulic unit - N55- :

1 - Hydraulic unit to rear right brake caliper
- Properties: ∅ 5.25 mm and flare nut with M12 x 1 thread
2 - From hydraulic unit to front left brake caliper
- Properties: ∅ 5.25 mm and flare nut with short thread M10 x 1
3 - From hydraulic unit to front right brake caliper.
- Properties: ∅ 5.25 mm and flare nut with M12 x 1 thread
4 - From hydraulic unit to rear left brake caliper
- Properties: ∅ 5.25 mm and flare nut with short thread M10 x 1
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
Specified torques:
♦ ⇒ “3.1.2 Assembly overview - control unit and hydraulic unit,
right-hand drive”, page 13

28 Rep. gr.45 - Anti-lock brake system

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4 Sensors
⇒ “4.1 Assembly overview - speed sensor on front axle”,
page 29
⇒ “4.2 Assembly overview - speed sensor on rear axle”,
page 30
⇒ “4.3 Removing and installing speed sensors on front axle G45 /
G47 ”, page 31
⇒ “4.4 Removing and installing speed sensors on rear axle G44 /
G46 ”, page 32
⇒ “4.5 Checking ABS sensor ring”, page 32

4.1 Assembly overview - speed sensor on front axle

1 - Wheel hub with wheel bear‐

ing
❑ The ABS sensor ring is
installed in the wheel
hub ⇒ page 30
❑ Removing and installing
⇒ Running gear, axles,
steering; Rep. gr. 40 ;
Wheel bearing; Assem‐
bly overview – wheel
bearing
2 - Wheel bearing housing
3 - Hexagon socket head bolt
❑ 8 Nm
4 - Speed sensor
❑ Before inserting sensor,
clean inner surface of
hole and coat with high-
temperature paste - G
052 112 A3- .
❑ Removing and installing
⇒ page 31

4. Sensors 29
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ABS sensor ring -1-

4.2 Assembly overview - speed sensor on

rear axle
⇒ “4.2.1 Assembly overview - speed sensor on rear axle”,
page 30

4.2.1 Assembly overview - speed sensor on

rear axle
Diagram is valid for vehicles with drum and disc brake.

1 - Wheel hub with wheel bear‐

ing
❑ ABS sensor ring is in‐
stalled in wheel bearing
⇒ page 31 .
❑ Removing and installing
⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Wheel bearing, trailing
arm
2 - Stub axle
3 - Speed sensor
❑ Before inserting sensor,
clean inner surface of
hole and coat with high-
temperature paste - G
052 112 A3- .
❑ Removing and installing
⇒ page 32
4 - Hexagon socket head bolt
❑ 8 Nm

30 Rep. gr.45 - Anti-lock brake system

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ABS sensor ring -1-

4.3 Removing and installing speed sensors

on front axle -G45- / -G47-
Special tools and workshop equipment required
♦ Torque wrench 2-10 Nm - VAG 1783-

Removing:
– Raise vehicle on lift.
– Disconnect electrical connector -2- from speed sender .
– Unscrew bolt -1- from wheel bearing housing.
– Pull speed sensor out of wheel bearing housing.
Installing:
Install in reverse order of removal, observing the following:
– Clean inside surface of hole before inserting speed sensor .
Coat speed sensor all-round with high-temperature paste - G
052 112 A3- .
– Move steering to full left and right lock. When doing so, check
speed sensor wire for freedom of movement.
Specified torques
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page
29

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4.4 Removing and installing speed sensors

on rear axle -G44- / -G46-
⇒ “4.4.1 Removing and installing speed sensors on rear axle
G44 / G46 ”, page 32

4.4.1 Removing and installing speed sensors

on rear axle -G44- / -G46-
Special tools and workshop equipment required
♦ Torque wrench 2-10 Nm - VAG 1783-

Removing:
– Raise vehicle on lift.
– Disconnect electrical connector -2- from speed sender .
Diagram shows a disc brake. Allocation for drum brake is identi‐
cal.
– Unscrew bolt -1- from stub axle.
– Pull speed sensor out of stub axle.
Installing:
Install in reverse order of removal, observing the following:
– Clean inside surface of hole before inserting speed sensor .
Coat speed sensor all-round with high-temperature paste - G
052 112 A3- .
Specified torques
♦ ⇒ “4.2.1 Assembly overview - speed sensor on rear axle”,
page 30

4.5 Checking ABS sensor ring

Special tools and workshop equipment required
♦ Sensor gauge - T10473-

32 Rep. gr.45 - Anti-lock brake system

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Procedure
• Wheel bearing unit is removed.
– Using sensor gauge - T10473- , check ABS sensor ring -2- all
around, as shown in illustration.
1 - Wheel bearing unit
2 - Seal with integrated ABS sensor ring

Test pattern for ABS sensor ring:

A - ABS sensor ring is OK
B - ABS sensor ring is defective

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46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brakes”, page 34
⇒ “1.2 Removing and installing brake pads/linings”, page 36
⇒ “1.3 Removing and installing brake caliper”, page 39
⇒ “1.4 Removing and installing brake disc”, page 43
⇒ “1.5 Removing and installing brake splash plate”, page 44

1.1 Assembly overview - front brakes

⇒ “1.1.1 Assembly overview – front brake, FS III front brake”, page
34

1.1.1 Assembly overview – front brake, FS III front brake

Note

♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Fit brake pedal actuator - V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose
(release pressure in system).

34 Rep. gr.46 - Brakes - mechanism

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1 - Brake disc
❑ Internally ventilated
❑ Wear limit ⇒ page 4
❑ Always renew on both
sides of an axle.
❑ Removing and installing
⇒ page 43
❑ Never remove brake
discs from wheel hub by
force. If necessary use
penetrating fluid, be‐
cause otherwise brake
discs can be damaged.
2 - Torx bolt
❑ 4.5 Nm
3 - Brake pads
❑ Thickness 14 mm not in‐
cluding backplate
❑ Wear limit: 2 mm ex‐
cluding backing plate.
❑ Check thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake pads/linings:
Checking thickness
❑ Always renew on both
sides of an axle.
❑ Removing and installing
⇒ page 36
4 - Brake caliper
❑ Do not disconnect brake
hose when changing

1. Front brakes 35
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pads.
❑ Removing and installing
⇒ page 39
❑ Repairing ⇒ page 87
5 - Guide pin
❑ 30 Nm
6 - Cap
7 - Clamping sleeve
❑ Not present: brake caliper has limit stop instead
8 - Brake hose with banjo union and banjo bolt
❑ 35 Nm
9 - Wheel hub with wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 40 ; Wheel bearing; Assembly over‐
view – wheel bearing
10 - Torx bolts
❑ 12 Nm
11 - Splash plate
12 - Wheel bearing housing
❑ With integrated brake carrier.
❑ Lightly grease guide surfaces with lithium grease - G 052 150 A2- .
13 - Speed sensor
❑ Before inserting sensor, clean inner surface of hole and coat with high-temperature paste - G 052 112
A3- .
14 - Hexagon socket head bolt
❑ 8 Nm

1.2 Removing and installing brake pads/lin‐

ings
⇒ “1.2.1 Removing and installing brake pads, FS III front brake”,
page 36

1.2.1 Removing and installing brake pads, FS

III front brake
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

36 Rep. gr.46 - Brakes - mechanism

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♦ Piston resetting appliance - T10145-

♦ Lithium grease - G 052150 A2-

Removing
– Remove wheels.
– Remove protective caps -arrows-.

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– Unscrew and remove both guide pins -arrows- from brake cal‐
iper -1-.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Mark brake pads or linings when removing if they are to be
reused. Fit in same position when installing, or braking will be
uneven.
– Take brake pads out of brake caliper.
Cleaning:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

– Thoroughly clean contact surfaces for brake pads on brake

carrier and remove any corrosion.
– Clean brake caliper.
– Use only methylated spirits for cleaning the brake caliper.
Installing
– Before pressing pistons back, draw off some brake fluid from
reservoir with a bleeder bottle. Otherwise, particularly if res‐
ervoir has been topped up, fluid will overflow and cause dam‐
age.
– Lightly grease guide surface on brake carrier with lithium
grease - G 052150 A2- .

– Push back piston into brake caliper -2- using piston resetting
tool - T10145- -1-.

– Insert inner brake pad with retaining spring -1- in piston and
outer brake pad with retaining spring -2- in brake caliper.
1- Inner brake pad with large 3-finger clip -1- (silver in colour)
and lettering “Kolbenseite” (German for “piston side”) on
backplate.
2- Outer brake pad with small 3-finger clip -2- (coloured black).

38 Rep. gr.46 - Brakes - mechanism

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– Position brake caliper -2- with brake pads -3- on bottom

-arrow A- of brake carrier -1- first.
• Pin -arrow B- of brake caliper -1- must be positioned behind
backplate guide -1-!

– Bolt brake caliper -1- with both guide pins -arrows- to back‐
plate.

– Insert both cover caps -arrows-.

– Install wheels.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques
♦ ⇒ “1.1.1 Assembly overview – front brake, FS III front brake”,
page 34
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .

1.3 Removing and installing brake caliper

⇒ “1.3.1 Removing and installing brake caliper, FS III front brake”,
page 39

1.3.1 Removing and installing brake caliper,

FS III front brake
Special tools and workshop equipment required

1. Front brakes 39
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♦ Torque wrench - V.A.G 1331-

♦ Brake pedal depressor - V.A.G 1869/2-

Removing

Note

This procedure is only relevant when replacing or repairing the

brake caliper.

– Remove wheels.
– Connect bleed bottle bleeder hose -1- to bleeder valve of
brake caliper.
– Open bleeder valve.

40 Rep. gr.46 - Brakes - mechanism

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– Apply brake pedal depressor - V.A.G 1869/2- .

– Close bleed valve and remove bleed bottle.

– Unscrew -2- brake hose -1-.

– Remove protective caps -arrows-.

– Unscrew and remove both guide pins -arrows- from brake cal‐
iper -1-.
– Pull brake caliper off brake carrier.
– Take brake pads out of brake caliper.
Installing
– Installing brake pads ⇒ page 36 .

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– Position brake caliper -2- with brake pads -3- on bottom

-arrow A- of brake carrier -1- first.
• Pin -arrow B- of brake caliper -1- must be positioned behind
backplate guide -1-!

– Bolt brake caliper -1- with both guide pins -arrows- to back‐
plate.

– Insert both cover caps -arrows-.

– Screw -2- brake hose -1- onto brake caliper.

– Remove brake pedal depressor - V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Install wheels.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques
♦ ⇒ “1.1.1 Assembly overview – front brake, FS III front brake”,
page 34
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .

42 Rep. gr.46 - Brakes - mechanism

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1.4 Removing and installing brake disc

⇒ “1.4.1 Removing and installing brake disc, FS III front brake”,
page 43

1.4.1 Removing and installing brake disc, FS

III front brake
Special tools and workshop equipment required
♦ Torque wrench 2-10 Nm - VAG 1783-

Removing:
– Remove wheels.
– Remove brake pads ⇒ page 36 .
– Unscrew bolt -arrow- for brake disc -1-.
– Remove brake disc -1- from wheel hub.
Installing:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

– Thoroughly clean contact surfaces of brake disc and wheel

bearing.
– Do not cant brake disc when placing on wheel hub.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques:
♦ ⇒ “1.1 Assembly overview - front brakes”, page 34
♦ ⇒ Rep. gr. 44 ; Wheels and tyres; Tightening torques of wheel
bolts

1. Front brakes 43
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1.5 Removing and installing brake splash

plate
⇒ “1.5.1 Removing and installing splash plate, FS III front brake”,
page 44

1.5.1 Removing and installing splash plate,

FS III front brake
Removing:
– Remove brake disc ⇒ page 43 .
– Remove bolts -arrows- for splash plate -1-.
– Remove splash plate -1- from wheel hub.
Installing:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

– Clean wheel hub and cover plate.

– Place splash plate on wheel hub.

– Install bolts -arrows-.

Specified torques:
♦ ⇒ “1.1.1 Assembly overview – front brake, FS III front brake”,
page 34

44 Rep. gr.46 - Brakes - mechanism

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2 Rear brakes
⇒ “2.1 Assembly overview - rear brakes”, page 45
⇒ “2.2 Removing and installing brake pads/linings”, page 50
⇒ “2.3 Removing and installing brake caliper”, page 53
⇒ “2.4 Removing and installing brake carrier”, page 55
⇒ “2.5 Removing and installing brake disc”, page 57
⇒ “2.6 Removing and installing brake shoes”, page 58
⇒ “2.7 Resetting drum brakes”, page 65
⇒ “2.8 Removing and installing brake splash plate”, page 66

2.1 Assembly overview - rear brakes

⇒ “2.1.1 Assembly overview – rear brake, drum brake”,
page 45
⇒ “2.1.2 Assembly overview - brake shoes:”, page 47
⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 48

2.1.1 Assembly overview – rear brake, drum brake

Note

♦ After renewing the wheel brake cylinder, brake carrier and brake shoes, depress the brake pedal 15 times
forcefully with the vehicle stationary. This process ensures that brake shoes are properly seated in their
normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Before removing a wheel brake cylinder, brake carrier or disconnecting a brake line from the wheel brake
cylinder, fit brake pedal depressor - V.A.G 1869/2- (release pressure in system).

2. Rear brakes 45
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1 - Axle beam
2 - Hexagon socket head bolt
❑ 8 Nm
3 - Speed sensor
❑ Before inserting sensor,
clean inner surface of
hole and coat with high-
temperature paste -
G 052 112 A3 - .
4 - Brake line
❑ 14 Nm
5 - Stub axle
6 - Parking brake cable
❑ Adjusting parking brake
⇒ page 71
7 - Hexagon bolt
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Rear axle
8 - Torx bolt
❑ 4 Nm
9 - Brake drum
❑ Wear limit ⇒ page 5
❑ Reset brake before re‐
moving brake drum
⇒ page 65
❑ Clean carefully and
check for wear, dam‐
age, dimensional accu‐
racy and flawless brake
surface.
10 - Cap
❑ Pressing off and driving in ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
11 - Bolt
❑ Renew after removing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
12 - Wheel hub with wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
13 - Brake backplate with brake shoes
❑ Minimal thickness of brake lining: 2.5 mm.
❑ Check thickness ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings: Checking thickness
❑ Reset brake before removing brake drum ⇒ page 65

46 Rep. gr.46 - Brakes - mechanism

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2.1.2 Assembly overview - brake shoes:

1 - Plug
❑ Remove to check thick‐
ness of brake shoes
2 - Roll pin
3 - Bolt
❑ 10 Nm
4 - Bleeder valve
❑ 10 Nm
5 - Protective cap
❑ Fit onto bleeder valve.
6 - Brake carrier
7 - Wheel brake cylinder
❑ Check for leaks
⇒ page 48
8 - Automatic adjuster
❑ With adjusting screw
❑ Fitting position
⇒ page 48
❑ Grease contact surfa‐
ces with lubricating
paste - G 000 650-
9 - Brake shoe with lever for
parking brake
❑ Removing and installing
⇒ page 58
❑ Adjusting parking brake
⇒ page 71
❑ Always replace both
sides of axle
10 - Retaining clip
❑ For locking brake shoe
❑ Fitting position ⇒ page 48
11 - Lower return spring
12 - Upper return spring
13 - Brake shoe
❑ Removing and installing ⇒ page 58
❑ Check brake pad thickness ⇒ Maintenance ; Booklet KJ1
❑ Always replace both sides of axle

2. Rear brakes 47
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Checking wheel brake cylinder for leaks

– Lift off dust boot with removal wedge - 3409- .
– If brake fluid is found in the dust boot, renew wheel brake cyl‐
inder.
Ensure the dust boot is not damaged when lifting off.

Installation position of automatic adjuster

1 - Automatic adjuster with thermal clip
2 - Parking brake lever
3 - Brake shoe

NOTICE
Thermal clip - bi-metallic strip must point towards brake drum.

Installation position of retaining clip

Closed side of retaining clip must point towards wheel hub.

2.1.3 Assembly overview – rear brake, disc brake

Note

♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Fit brake pedal actuator - V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose
(release pressure in system).
♦ Note the different versions of the rear brake. Observe the disc brake CI 38 and PC 38 HRA.

48 Rep. gr.46 - Brakes - mechanism

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1 - Axle beam
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Rear axle
2 - Bolt
❑ 8 Nm
3 - Speed sensor
❑ Assembly overview
⇒ page 30
4 - Handbrake cable
❑ Adjusting parking brake
⇒ page 72
❑ Removing and installing
⇒ page 73
❑ Allocation ⇒ Electronic
Parts Catalogue “ETKA”
5 - Bolt
❑
❑ 30 Nm +30°
6 - Brake hose
❑ With banjo bolt and
seals
❑ Do not disconnect brake
hose when changing
pads.
❑ Specified torque of ban‐
jo bolt to brake caliper:
38 Nm
❑ Allocation ⇒ Electronic
Parts Catalogue “ETKA”
7 - Stub axle
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Rear axle
8 - Hexagon bolt
❑ Self-locking
❑ Renew after removal
❑ 35 Nm
9 - Brake caliper
❑ Repairing ⇒ page 90
❑ Removing and installing ⇒ page 50
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
10 - Brake pads
❑ Thickness ⇒ page 5
❑ Wear limit ⇒ page 5
❑ Check thickness ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings: Checking thickness
❑ Always replace both sides of axle
❑ Removing and installing ⇒ page 50
11 - Brake carrier
❑ With guide pins and protective cap.
❑ Replacement part is supplied assembled with sufficient grease on guide pins
❑ If protective cap or guide pins are damaged, install set of repair components. Use grease sachet from
repair kit.

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❑ Assembly overview ⇒ page 90
❑ Removing and installing ⇒ page 55
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
12 - Brake disc
❑ Thickness ⇒ page 5
❑ Wear limit ⇒ page 5
❑ Removing and installing ⇒ page 57
❑ Check thickness ⇒ Maintenance ; Booklet ; Checking condition of discs and thickness of pads at front
and rear
❑ When worn, renew on both sides of axle.
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
13 - Bolt
❑ 4 Nm
14 - Dust cap
❑ Renew after removal
❑ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing, trailing arm; Assembly overview - wheel
bearing
15 - Bolt
❑ Renew after removing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
16 - Wheel hub with wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
❑ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing, trailing arm; Assembly overview - wheel
bearing
17 - Splash plate
❑ Removing and installing ⇒ page 66
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
18 - Bolt
❑ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle

2.2 Removing and installing brake pads/lin‐

ings
⇒ “2.2.1 Removing and installing brake pads/linings, CI 38 disc
brake ”, page 50

2.2.1 Removing and installing brake pads/lin‐

ings, CI 38 disc brake
Special tools and workshop equipment required
♦ Piston compressing tool - T10165-

50 Rep. gr.46 - Brakes - mechanism

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♦ Torque wrench - V.A.G 1331-

Removing
– Remove wheels.
– Push lever -2- in direction of -arrow-. Unhook parking brake
cable -1- from lever.
– Press together two retaining tabs -arrows- and remove parking
brake cable from brake caliper carrier.

– Unscrew bolts -arrows-. Counterhold on guide pins -1, 2- to do

this.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.

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– Remove brake pads -2- from brake carrier -1-.

– Mark brake pads when removing if they are to be reused. Fit
in same position when installing, or braking will be uneven.
Cleaning:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

– Thoroughly clean contact surface for brake pads on backplate

and remove corrosion.
– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive residue and grease.
– Use only methylated spirits for cleaning the brake caliper.
Installing

Note

Before pressing piston back, draw off some brake fluid from res‐
ervoir with a bleeder bottle, for example. Otherwise, particularly if
reservoir has been topped up, fluid will overflow and cause dam‐
age.

– Position piston compressing tool - T10165- so that collar rests

on plate - T10165/1- .
– Use plate - T10165/1- for assistance when screwing in.
– Screw in piston by turning thumb wheel on piston compressing
tool - T10165- clockwise. Do not damage protective cap.
♦ If piston moves sluggishly, an open-jaw spanner (AF 13) can
be used on the flats designed for the wrench -arrow A-.
– Make sure that protective caps are not damaged and are seat‐
ed correctly.
– Make sure that guide pins are free to move.

– Thoroughly clean contact surfaces -arrows- of brake pads.

52 Rep. gr.46 - Brakes - mechanism

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– Pull protective foil off brake pad backplate.

– Insert brake pads -2- into brake carrier -1-.

– Tighten new bolts -arrows- for brake caliper. Counterhold on

guide pins -1, 2- when doing this.
♦ Repair kit includes 4 self-locking hexagon bolts which must
always be installed.

– Push parking brake cable into bracket on brake caliper until

both locking lugs -arrows- engage.
– Push lever -2- in direction of -arrow-. Attach parking brake ca‐
ble -1- to lever.
– Install wheels.
– Check parking brake adjustment ⇒ page 71 .

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 48
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .

2.3 Removing and installing brake caliper

⇒ “2.3.1 Removing and installing brake caliper, CI 38 disc brake”,
page 53

2.3.1 Removing and installing brake caliper,

CI 38 disc brake
Special tools and workshop equipment required

2. Rear brakes 53
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♦ Torque wrench - V.A.G 1331-

♦ Brake pedal depressor - V.A.G 1869/2-

♦ Plugs - 1H0 698 311 A-

Removing
This procedure is only relevant when replacing or repairing the
brake caliper.
– Remove wheels.
– Push lever -2- in direction of -arrow-. Unhook parking brake
cable -1- from lever.
– Press together two retaining tabs -arrows-. Then pull parking
brake cable out of retainer on brake caliper.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close bleeder valve and remove bleed bottle.

54 Rep. gr.46 - Brakes - mechanism

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– Unscrew brake hose from brake caliper.

– Unscrew bolts -arrows-. Counterhold on guide pins -1, 2- to do
this.
– Immediately seal brake line and threaded hole with sealing
plugs.
– Unscrew both securing bolts from brake caliper, counter hold‐
ing on guide pin.
– Remove brake caliper from brake carrier.
Installing
– Installing brake pads ⇒ page 50 .
– Secure brake caliper to brake carrier with new self-locking
bolts.
– Screw brake line to brake caliper.
– Bleed brake system ⇒ page 133 .

– Push handbrake cable -1- into bracket on brake caliper until

both locking lugs -arrows- engage.
– Push lever in direction of -arrow-. Attach handbrake cable
-1- to lever -2-.
– Check parking brake adjustment ⇒ page 71 .
– Install wheels.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 48
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .

2.4 Removing and installing brake carrier

2. Rear brakes 55
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Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-
♦ Piston compressing tool - T10165-
Removing:
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
Do not open hydraulic system of brakes in order to remove!
– Remove wheels.
– Remove brake pads ⇒ page 50 .
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.

56 Rep. gr.46 - Brakes - mechanism

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– Remove bolts -arrows- for brake carrier -1-.

– Remove backplate -1-.
Cleaning:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

Use only methylated spirits for cleaning the brake system.

Installing:
Install in reverse order. The following should be observed:
– Thoroughly clean contact surfaces for brake pads on brake
carrier and remove any corrosion.
If existing brake pads are to be re-used, re-install the marked
brake pads at the same position.
– Secure brake caliper with new self-locking bolts ⇒ Electronic
parts catalogue “ETKA” .
– Install wheel and tighten.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 48
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Specified torques for wheel bolts

2.5 Removing and installing brake disc

Special tools and workshop equipment required
♦ Torque wrench 6-50 Nm - VAG 1331-

Removing:
– Remove brake pads ⇒ page 50 .

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– Remove backplate ⇒ page 55 .

– Unscrew bolt -arrow- for brake disc -1-.
– Remove brake disc -1-.
– Never remove brake discs from wheel hub by force. If neces‐
sary use penetrating fluid, because otherwise brake discs can
be damaged.
– Thoroughly clean contact surface on wheel hub to remove any
corrosion.
Installing:
Install in reverse order of removal, observing the following:
– Place brake disc on wheel hub.

– Screw in bolt -arrow- for brake disc -1- and tighten.

– Install brake carrier ⇒ page 55 .
– Installing brake pads ⇒ page 50 .

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques:
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 48
♦ ⇒ Rep. gr. 44 ; Wheels and tyres; Tightening torques of wheel
bolts

2.6 Removing and installing brake shoes

Special tools and workshop equipment required
♦ Hook - 3438-

58 Rep. gr.46 - Brakes - mechanism

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♦ Assembly tool - T30114-

♦ Pliers - T30115A-

♦ Drum brake tool - T20215-

Removing:
– Reset drum brake ⇒ page 65 .
– Remove brake drum ⇒ page 45 .
– Remove wheel hub with wheel bearing assembly ⇒ Running
gear, axles, steering; Rep. gr. 42 ; Rear axle .
– Move parking brake lever -A- back into working position with
hook - 3438- .

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– Remove retaining clips -1- using assembly tool - T30114- -2-,

pressing from behind against pin when doing so.

– Lever off brake shoe with parking brake lever -1- in direction
of -arrow A- from lower support -2- with aid of water pump
pliers -4-.
– Place brake shoe -1- in front of lower support -2- in direction
of -arrow B-.
– Unhook lower return spring -3-.

– Remove other retaining clip -1- using assembly tool - T30114-

-2-, pressing from behind against pin when doing so.

– Press together both brake shoes -1 and 2- at bottom in direc‐

tion of -arrow A-.
– Carefully pull down both brake shoes -1 and 2-. When doing
this, do not damage wheel brake cylinder, rubber boot and
automatic adjuster.

60 Rep. gr.46 - Brakes - mechanism

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– Unhook parking brake cable -1- from parking brake lever -2-.

– Lever out upper return spring -1- from brake shoe without
parking brake lever -3- using a screwdriver -2-.

Note

Check all components for damage and replace if necessary.

Cleaning:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

Note

– Use only methylated spirits for cleaning the brake system.

Installing

– Grease contact surfaces -arrows- with lubricating paste - G

000 650- .

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– Attach parking brake cable -1- to parking brake lever -2-.

– Mount brake shoe with parking brake lever -1- using assembly
tool - T30114- -3-.

– Fit retaining clip -2-.

– Insert upper return spring -1- in both brake shoes -2 and 3-.
– Place brake shoe without parking brake lever -3- on wheel
brake cylinder -4- as shown in diagram. Then lever around in
direction of -arrow- and place in front of lower support -5-.

– Attach bottom spring -1-. Lever brake shoe -3- into lower sup‐
port -4- using pipe wrench -2-.

62 Rep. gr.46 - Brakes - mechanism

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– Insert roll pin and retaining clip -1- with assembly tool -
T30114- -2-.

– Observe correct position of clips -2 and 4- and springs

-1 and 3-.
Installing automatic adjuster

Note

♦ Note that the automatic adjuster has a fine mechanism.

♦ Avoid impacts.
♦ Do not deform components.
♦ No adjustment on gear wheel.
♦ Any damage will have a negative effect on the function of the
automatic adjuster and the brake. Even the smallest indenta‐
tions, chips and deformations can impair the automatic ad‐
juster significantly, which will result in a shorter service life of
the equipment.

To ensure that the brake functions optimally, pre-adjustment of

the automatic adjuster is required. The automatic adjuster must
be free to rotate and it should be possible to install it without ap‐
plying force.
The “rough setting” is achieved by screwing the bolt onto the
thread -arrow A-.
For the “fine setting”, keep the regulator under pressure
-arrows B- and then perform “fine adjustment”.

Note

♦ Manual adjustment of the automatic adjuster must be carried

out in order to attain the requisite diameter at the brake shoes.
♦ Should the diameter be too small, there is a chance that the
upper spring will have too little tension to guarantee the setting
function.
♦ If manual adjustment is not be carried out fully or at all, there
is a risk of premature wear of the brake shoes, the automatic
adjuster falling down or major damage.

– Screw automatic adjuster in or out (rough setting) in such a

way that it sits between both brake shoes with slight pretension
so that readjustment is activated.

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– Spread brake shoes with fitting pliers - T30115A- .

– Position automatic adjuster on brake shoe with parking brake
lever first in direction of -arrow A-.
– Place lever of automatic adjuster in recess of both brake shoes
-arrow B-.
– Observe installation position: short lugs point towards brake
carrier and threaded side points towards parking brake lever
⇒ page 48 .
– Clean centre seat of wheel hub of brake drum. Then treat with
corrosion protection - AKR 322 000- .
– Clean centre hole of brake drum. Then treat with corrosion
protection - AKR 322 000- .

Note

Do not allow the corrosion protection - AKR 322 000- to enter the
wheel bolt threads.

– Install wheel hub with wheel bearing assembly ⇒ Running

gear, axles, steering; Rep. gr. 42 ; Rear axle .

Note

♦ The drum brake tool - T20215- has holes with and without
thread.
♦ The threaded holes are for storing the bolts.
♦ The through holes are for securing the tool on the wheel hub.

– Secure drum brake tool - T20215- -1- on wheel hub using bolts
-3- supplied.

64 Rep. gr.46 - Brakes - mechanism

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– Spread brake shoes with fitting pliers - T30115A- repeatedly

-arrows- until adjustment on automatic adjuster is no longer
visible or audible.
– Remove drum brake tool - T20215- .
– Install brake drum.

Note

If the brake drum is to be re-used, remove any corrosion and take

account of the maximum permissible wear diameter.

– Depress brake hard at least 15 times.

– Adjusting parking brake ⇒ page 71 .
– Mount wheel.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques:
♦ ⇒ “2.1.1 Assembly overview – rear brake, drum brake”,
page 45
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .

2.7 Resetting drum brakes

Vehicles with front centre armrest
– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .

2. Rear brakes 65
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Continued for all vehicles

– Loosen adjustment nut -1- until parking brake cable -2- can be
pulled out of compensator.
– Remove wheels.

– Push parking brake lever -1- through threaded hole of wheel

bolt backwards as far as possible with a screwdriver until park‐
ing brake lever slips behind brake shoe.
Brake shoes are detensioned in this way.

2.8 Removing and installing brake splash

plate
Special tools and workshop equipment required
♦ Torque wrench 6-50 Nm - VAG 1331-

Removing:
– Loosen wheel bolts.
– Raise vehicle on lift.
– Remove wheel.
– Remove backplate ⇒ page 55 .
– Remove brake disc ⇒ page 57 .

66 Rep. gr.46 - Brakes - mechanism

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– Remove wheel bearing unit ⇒ Running gear, axles, steering;

Rep. gr. 42 ; Suspension link wheel bearing; Assembly over‐
view - wheel bearings .
– Remove bolts -arrows- for splash plate -1-.
– Remove splash plate -1- together with stub axle.
Cleaning:

WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.

Use only methylated spirits for cleaning the brake system.

Installing:
Install in reverse order. The following should be observed:
If existing brake pads are to be re-used, re-install the marked
brake pads at the same position.

NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.

Specified torques:
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 45
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing,
trailing arm
♦ ⇒ Wheels and Tyres Guide; Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts

2. Rear brakes 67
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3 Parking brake
⇒ “3.1 Assembly overview - parking brake”, page 68
⇒ “3.2 Removing and installing handbrake lever”, page 69
⇒ “3.3 Removing and installing handbrake warning switch F9 ”,
page 70
⇒ “3.4 Adjusting parking brake”, page 71
⇒ “3.5 Removing and installing rear brake cable”, page 73

3.1 Assembly overview - parking brake

1 - Push-button
❑ Pulling off ⇒ page 69
❑ Will be destroyed when
pulling off; must be re‐
newed
❑ Push onto handbrake
lever push rod and en‐
sure both locking lugs
are engaged by pulling
slightly.
2 - Handbrake lever trim
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 68 ;
Compartments/covers;
Removing and installing
handbrake lever trim
3 - Bolt
❑ Qty. 2
❑ Renew after removal
❑ 20 Nm +90°
4 - Compensator
5 - Adjustment nut
❑ Adjusting parking brake:
❑ Vehicles with drum
brakes ⇒ page 71 .
❑ Vehicles with disc
brakes ⇒ page 72 .
6 - Rubber grommet
7 - Right guide tube
8 - Left guide tube
9 - Parking brake cables
❑ Removing and installing (drum brakes) ⇒ page 73
❑ Removing and installing (disc brakes) ⇒ page 76
10 - Bolt
❑ 23 Nm
11 - Spacer plate
12 - Handbrake warning switch - F9-
❑ ⇒ “3.3 Removing and installing handbrake warning switch F9 ”, page 70

68 Rep. gr.46 - Brakes - mechanism

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13 - Parking brake lever

❑ ⇒ “3.2 Removing and installing handbrake lever”, page 69

Removing push button

Note

When pulling off, the push-button is damaged beyond repair and

must be replaced.

3.2 Removing and installing handbrake lev‐

er
Removing:
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; centre console .
– Separate connector -A- of handbrake warning switch - F9-
-B-.
– Unclip retaining tabs -arrows- of handbrake warning switch -
F9- -B- and remove.

– Loosen adjustment nut -1- until parking brake cable -2- can be
pulled out of compensator.

3. Parking brake 69
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– Unscrew bolts -arrows- and remove parking brake lever.

Installation
Install in reverse order of removal, observing the following:

– Insert parking brake lever and tighten bolts -arrows- to speci‐

fied torque.

– Insert parking brake cable -2- in compensator and tension with

adjustment nut -1-.
– Adjusting parking brake ⇒ page 71 .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console .
Specified torques:
♦ ⇒ “3.1 Assembly overview - parking brake”, page 68
♦ ⇒ General body repairs, exterior; Rep. gr. 68 ; Centre console

3.3 Removing and installing handbrake

warning switch - F9-
Removing:
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; centre console .
– Move driver seat forwards.

70 Rep. gr.46 - Brakes - mechanism

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– Separate connector -A- of handbrake warning switch - F9-

-B-.
– Unclip retaining tabs -arrows- of handbrake warning switch -
F9- -B- and remove.
Installing:
Install in reverse order.

3.4 Adjusting parking brake

⇒ “3.4.1 Adjusting handbrake, drum brakes”, page 71
⇒ “3.4.2 Adjusting handbrake, disc brakes”, page 72

3.4.1 Adjusting handbrake, drum brakes

A new adjustment is only necessary when the parking brake ca‐
bles, brake carrier or brake pads are renewed.
Vehicles with front centre armrest
– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .
Continued for all vehicles
• Foot brake must be functional and bled.
• The parking brake cables are routed without tension and at‐
tached to the lever in the drum brake.
• Parking brake lever is in rest position.
– Depress brake hard at least 15 times.

3. Parking brake 71
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– Pretension parking brake cables -2- with adjustment nut -1-

just until handbrake lever returns to rest position on its own
(see note below).

Note

Pull handbrake lever from rest position to just before it engages

in first tooth. Then, release handbrake lever. The handbrake lever
must return to rest position on its own.

– Pull and release parking brake lever three times.

– Pull parking brake lever over 3 notches.
– Tighten adjustment nut -1- until both wheels cannot be turned
by hand.
– Release parking brake and check that both wheels turn freely.
If required turn adjustment nuts back slightly.
– The handbrake lever must return to rest position on its own.

Note

Adjustment nut -1- must be screwed at least 3 mm beyond end

of pull rod.

– Install parts of centre console ⇒ General body repairs, interior;

Rep. gr. 68 ; Centre console .
Due to the automatic rear wheel brake adjustment, there is no
requirement to adjust the parking brake after making new/initial
adjustment.

3.4.2 Adjusting handbrake, disc brakes

Note

A new adjustment is only necessary after renewing, handbrake

cables, brake calipers and brake discs.

Adjusting:
Vehicles with front centre armrest
– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .
Continued for all vehicles
– Raise vehicle on lift.
– Depress brake pedal forcefully at least 3 times.
Below the first notch, the handbrake lever must return to its re‐
leased position.
• Handbrake lever in rest position.
– Apply parking brake once firmly.
– Release parking brake.

72 Rep. gr.46 - Brakes - mechanism

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– Adjust handbrake by means of adjustment nut -arrow-.

– Set parking brake tightly and release 3 times.

– Tighten adjusting nut enough so that levers -1- on brake cali‐

pers lift off stops -2-.
– The total distance -a- between lever -1- and stops -2- on left
and right brake calipers must be ≤ 1.5 mm.
– Check that both wheels turn freely.
Due to the automatic rear wheel brake adjustment, there is no
requirement to adjust the parking brake after making new/initial
adjustment.

3.5 Removing and installing rear brake ca‐

ble
⇒ “3.5.1 Removing and installing rear handbrake cable, drum
brakes”, page 73
⇒ “3.5.2 Removing and installing rear handbrake cable, disc
brakes”, page 76

3.5.1 Removing and installing rear handbrake

cable, drum brakes
Removing:
Special tools and workshop equipment required
♦ Torque wrench 6-50 Nm - VAG 1331-

Vehicles with front centre armrest

– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .

3. Parking brake 73
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Continued for all vehicles

– Release parking brake.
– Loosen adjustment nut -1- until parking brake cable -2- can be
detached from compensator.
– Raise vehicle on lift.
– Remove wheel.
– Remove brake drum ⇒ page 45 .
– Remove brake shoes ⇒ page 58 .

– Disengage parking brake cable with parking brake lever from

brake shoe.
– Pull parking brake cable out of brake carrier.

– Pull out handbrake cable -2- from its attachment points on rear
axle -1-.

74 Rep. gr.46 - Brakes - mechanism

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– Release attachment -3- of parking brake cable -1-.

– Pull out handbrake cable -1- in direction of -arrow- from guide
tube -2-.
Installing:

– Insert handbrake cable -1- in direction of -arrow- into guide

tube -2-.
– Install attachment -3- of parking brake cable -1-.

– Push parking brake cable into brake carrier.

– Engage parking brake cable with parking brake lever from
brake shoe.
– Install brake shoes ⇒ page 58 .
– Install brake drum ⇒ page 45 .

– Engage handbrake cable -2- in its attachment points on rear

axle -1-.

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– Attach handbrake cable -2- in compensator.

– Pretension handbrake cable with adjustment nut -1-.
– Install wheels.
– Adjusting parking brake ⇒ page 71 .
– Secure underbody panel.
– Install parts of centre console ⇒ General body repairs, interior;
Rep. gr. 68 ; Centre console .
Specified torques
♦ ⇒ “2.1.1 Assembly overview – rear brake, drum brake”,
page 45
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .

3.5.2 Removing and installing rear handbrake

cable, disc brakes
Special tools and workshop equipment required
♦ Torque wrench 6-50 Nm - VAG 1331-

Removing:
Vehicles with front centre armrest
– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .
Continued for all vehicles
– Release parking brake.

76 Rep. gr.46 - Brakes - mechanism

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– Loosen adjustment nut -1- until parking brake cable -2- can be
detached from compensator.
– Raise vehicle on lift.

– Push parking brake lever -2- in direction of -arrow-. Unhook

parking brake cable -1- from lever when doing this.
– Press together two retaining tabs -arrows- and remove parking
brake cable from brake caliper carrier.

– Pull out handbrake cable -2- from its attachment points on rear
axle -1-.

– Release attachment -3- of parking brake cable -1-.

– Pull out handbrake cable -1- in direction of -arrow- from guide
tube -2-.
Installing:

3. Parking brake 77
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– Insert handbrake cable -1- in direction of -arrow- into guide

tube -2-.
– Install attachment -3- of parking brake cable -1-.

– Push parking brake cable into bracket on brake caliper until

both locking lugs -arrows- engage.
– Push parking brake lever -2- in direction of -arrow-. Attach
parking brake cable -1- to lever when doing this.

– Engage handbrake cable -2- in its attachment points on rear

axle -1-.

– Attach handbrake cable -2- in compensator.

– Pretension handbrake cable with adjustment nut -1-.
– Adjusting parking brake ⇒ page 71 .
– Secure underbody panel.
– Install parts of centre console ⇒ General body repairs, interior;
Rep. gr. 68 ; Centre console .

78 Rep. gr.46 - Brakes - mechanism

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4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 79
⇒ “4.2 Separating brake pedal from brake servo”, page 82
⇒ “4.3 Connecting brake pedal to brake servo”, page 83
⇒ “4.4 Removing and installing mounting bracket”, page 83
⇒ “4.5 Removing and installing brake pedal”, page 85

4.1 Assembly overview - brake pedal

⇒ “4.1.1 Assembly overview - brake pedal, left-hand drive”, page
79
⇒ “4.1.2 Assembly overview - brake pedal, right-hand drive”, page
81

4.1.1 Assembly overview - brake pedal, left-hand drive

Note

♦ The handbrake pedal travel must not be restricted by additional floor coverings.
♦ Do not lubricate or grease the pivot pin. The pivot pin must remain dry.

4. Brake pedal 79
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1 - Hexagon nut
❑ Self-locking
❑ Renew after removal
❑ 20 Nm
❑ Bolting sequence
⇒ page 80
2 - Pivot pin
❑ Cannot be removed
3 - Mounting bracket
❑ Removing and installing
⇒ page 83
4 - Bearing bush
5 - Brake pedal
❑ Separating brake pedal
from brake servo
⇒ page 82
❑ Connect brake pedal to
brake servo
⇒ page 83
❑ Removing and installing
⇒ page 85
6 - Cap
7 - Bearing shell
8 - Support
❑ For ball head of brake
servo push rod
9 - Clamping washer

Bolting sequence:

80 Rep. gr.46 - Brakes - mechanism

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4.1.2 Assembly overview - brake pedal, right-hand drive

Note

♦ The handbrake pedal travel must not be restricted by additional floor coverings.
♦ Do not lubricate or grease the pivot pin. The pivot pin must remain dry.

1 - Brake servo
❑ Assembly overview
⇒ page 96
❑ Removing and installing
⇒ page 104
2 - Mounting bracket
❑ Removing and installing
⇒ page 84
3 - Nut
❑ 20 Nm
❑ Tightening sequence
⇒ page 82
4 - Nut
❑ To secure brake servo
❑ Qty. 2
❑ 25 Nm
5 - Nut
❑ Cannot be removed
6 - Bearing bush
❑ Cannot be removed
7 - Brake pedal
❑ Cannot be removed
8 - Cover
9 - Bearing shell
❑ For ball head of brake
servo plunger rod.
10 - Support
❑ For ball head of brake
servo plunger rod.
11 - Pivot pin
❑ Cannot be removed
12 - Bearing bush
❑ Cannot be removed
13 - Bearing bush

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Tightening sequence:
– Tighten nuts in specified sequence -1- to -5-.

4.2 Separating brake pedal from brake ser‐

vo
Special tools and workshop equipment required
♦ Release tool - T10159B- for left-hand drive vehicles

♦ Release tool - T10242- for right-hand drive vehicles

82 Rep. gr.46 - Brakes - mechanism

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– First press brake pedal -1- in direction of brake servo and hold.
1 - Brake pedal
2 - Push bar
3 - Retaining lugs
4 - Mounting bracket
A - Release tool - T10159B- for left-hand drive vehicles and re‐
lease tool - T10242- for right-hand drive vehicles
– Insert release tool -A-, and pull it towards driver seat. Coun‐
terhold on brake pedal -1- while doing so. Pedal must not move
towards driver seat when doing this. This action will press re‐
taining lugs -3- of mounting off ball head of plunger rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool - T10159B- and brake pedal together towards
driver seat. While doing so, the brake pedal will be pulled off
the ball head of the plunger rod.
Specified torque
♦ Footwell cover on driver side ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers

4.3 Connecting brake pedal to brake servo

– Hold ball head of push rod in front of mounting and push brake
pedal in direction of brake servo, so that the ball head clicks
into place.
– Check engagement by pulling briefly on brake pedal.

4.4 Removing and installing mounting

bracket
⇒ “4.4.1 Removing and installing mounting bracket, left-hand
drive”, page 83
⇒ “4.4.2 Removing and installing mounting bracket, RHD”,
page 84

4.4.1 Removing and installing mounting

bracket, left-hand drive
Removing:
– Remove footwell vent ⇒ Heater, air conditioning system; Rep.
gr. 80 ; Air duct; Removing and installing footwell vent on
driver side .
– Remove crash bar ⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel cross member .
– Separate brake pedal from brake servo ⇒ page 82 .
– Remove bottom steering column trim ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers .

4. Brake pedal 83
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– Disconnect electrical connector -1-. To separate electrical

connector, turn retaining bracket and pull off connector.
– Release fasteners -arrows- and remove data bus diagnostic
interface - J533- -3- downwards from mounting -2-.
– Pull connector off accelerator position sender.

– Unscrew nuts from mounting bracket -1, 2, 3, 4 and 5-.

– Remove the mounting bracket.
Installing

Note

Ensure when inserting mounting bracket that cable of accelerator

pedal position sender is free and not trapped.

– Start all nuts -1, 2, 3, 4 and 5- on studs and screw on lightly.

– Tighten nuts -1, 2, 3, 4 and 5- to specified torque.
– Fit electrical connector from accelerator pedal position sender.
– Connect brake pedal to brake servo ⇒ page 83 .
– Install data bus diagnostic interface - J533- ⇒ Rep. gr. 97 ;
Control units; Overview of fitting locations - control units .
– Install bottom steering column trim ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers .
– Install crash bar ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel cross member .
– Install vent in footwell under steering column ⇒ Heater, air
conditioning system; Rep. gr. 87 ; Air duct; Removing and
installing footwell vent on driver side .
Specified torques
♦ ⇒ “4.1.1 Assembly overview - brake pedal, left-hand drive”,
page 79

4.4.2 Removing and installing mounting

bracket, RHD
Removing:
– Remove footwell vent on driver side ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air duct; Removing and installing footwell
vent on driver side .

84 Rep. gr.46 - Brakes - mechanism

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– Remove accelerator pedal module - GX2- ⇒ Fuel supply sys‐

tem - petrol engines; Rep. gr. 20 ; Accelerator; Removing and
installing accelerator pedal module GX2 .
– Separate brake pedal from brake servo ⇒ page 82 .
– Remove nuts -arrows- from mounting bracket -1-.

– Secure brake servo -1- against falling.

– Guide out mounting bracket between steering column and
dash panel and remove. Tilt and turn mounting bracket ac‐
cordingly when doing so.
Installing:
Install in reverse order of removal, observing the following:
– Connect brake pedal to brake servo ⇒ page 83 .
Specified torques:
♦ ⇒ “4.1.2 Assembly overview - brake pedal, right-hand drive”,
page 81
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air duct; Assembly
overview - air duct and air distribution in passenger compart‐
ment .

4.5 Removing and installing brake pedal

⇒ “4.5.1 Removing and installing brake pedal, left-hand drive ve‐
hicles”, page 85

4.5.1 Removing and installing brake pedal,

left-hand drive vehicles
Removing:
– Separate brake pedal from brake servo ⇒ page 82 .
– Disconnect securing plate -2- from pivot pin -1-.
– Pull out pivot pin in direction of -arrow- from bracket.
– Remove brake pedal from mounting bracket.
Installing:
– Push pivot pin from right to left through pedal bracket and
brake pedal.

Note

Use a new clamping washer.

4. Brake pedal 85
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– Mount securing plate -2- on pivot pin -1-.

– Connect brake pedal to brake servo ⇒ page 83 .
Specified torques:
♦ ⇒ “4.1.1 Assembly overview - brake pedal, left-hand drive”,
page 79

86 Rep. gr.46 - Brakes - mechanism

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47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - front brake caliper”, page 87
⇒ “1.2 Removing and installing brake caliper piston”, page 88

1.1 Assembly overview - front brake caliper

⇒ “1.1.1 Assembly overview - front brake caliper, FS III front
brake”, page 87

1.1.1 Assembly overview - front brake caliper, FS III front brake

♦ Install complete repair kit when servicing.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of lithium grease - G 052 150 A2- to brake
cylinder, piston and seal.

1 - Dust cap
❑ Fit onto bleed valve
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of lithium
grease - G 052 150 A2-
to thread
❑ 10 Nm
3 - Bearing bush
❑ Insert into brake caliper.
4 - Guide pin
❑ 30 Nm
5 - Caps
❑ Insert into mounting
bush.
6 - Brake caliper
7 - Seal
❑ Removing and installing
⇒ page 88
8 - Piston
❑ Removing and installing
⇒ page 88
9 - Seal
❑ Removing and installing
⇒ page 88

1. Front brake caliper 87

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1.2 Removing and installing brake caliper

piston
Special tools and workshop equipment required
♦ Removal wedge - 3409-

♦ Piston resetting appliance - T10145-

Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston:

– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
Installing
Install in reverse order of removal, observing the following:
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Insert seal in brake caliper.

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– Place protective cap with outer sealing lip on piston.

– Insert inner sealing lip into groove in cylinder using wedge

3409.
When doing this, hold piston in front of brake caliper.

– Press piston into brake caliper using piston resetting appli‐

ance.
The outer sealing lip of the protective cap will then lock in the
groove of the piston.

1. Front brake caliper 89

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2 Rear brake caliper

⇒ “2.1 Assembly overview - rear brake caliper”, page 90
⇒ “2.2 Removing and installing brake caliper piston”, page 91

2.1 Assembly overview - rear brake caliper

⇒ “2.1.1 Assembly overview - rear brake caliper, CI 38 disc brake”,
page 90

2.1.1 Assembly overview - rear brake caliper, CI 38 disc brake

♦ Install complete repair kit when servicing.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply thin coat of lithium grease - G 052 150 A2- to brake
cylinder, piston and seal.
♦ In the event of repairs, it is essential to appropriately pre-bleed
brake calipers (without brake pads) before installing them in
the vehicle ⇒ page 93 .

1 - Hexagon bolt
❑ Self-locking
❑ When loosening and
tightening, counter hold
on guide pin.
❑ Renew after removal
❑ 35 Nm
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of lithium
grease - G 052 150 A2-
to thread
❑ 10 Nm
3 - Dust cap
4 - Guide pin
❑ Grease before fitting
protective cap.
5 - Protective cap
❑ Fit onto brake carrier
and guide pin.
6 - Brake carrier
❑ With guide pins and pro‐
tective cap.
❑ Replacement part is
supplied assembled
with sufficient grease on
guide pins
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate

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guide pins.
7 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
8 - Piston
❑ With automatic adjusting mechanism
❑ Removing and installing ⇒ page 91
9 - Seal
❑ Removing and installing ⇒ page 91
10 - Brake caliper
❑ With handbrake cable lever
❑ If there is a leak at handbrake cable lever, renew brake caliper.
❑ Following repair work, pre-bleed brake caliper ⇒ page 93 .

2.2 Removing and installing brake caliper

piston
⇒ “2.2.1 Removing and installing brake caliper piston”,
page 91
⇒ “2.2.2 Pre-bleeding brake caliper”, page 93

2.2.1 Removing and installing brake caliper

piston
Special tools and workshop equipment required
♦ Removal wedge - 3409-

♦ Piston compressing tool - T10165-

♦ Bleeder bottle

2. Rear brake caliper 91

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Removing
– Turn piston anti-clockwise out of brake caliper using piston
compressing tool - T10165- .
♦ If piston moves sluggishly, an open-jaw spanner (AF 13) can
be used on the flats designed for the wrench -arrow A-.

– Remove seal using removal wedge - 3409- .

Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of lithium grease - G 052 150 A2- to piston and
seal before installing.

– Place protective cap with outer sealing lip on piston.

– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper.
– Mount piston resetting appliance - T10165- on piston of brake
caliper.

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– To screw in piston, use plate - T10165/1- .

Note

Apply resetting and removal tool so that collar of tool is resting on

brake caliper.

– Install piston in brake caliper by turning thrust piece in clock‐

wise direction.

2.2.2 Pre-bleeding brake caliper

– Open bleeder valve -arrow A- and, using a commercially avail‐
able bleeder bottle, fill with brake fluid until bubble-free brake
fluid flows from threaded hole of brake hose connection
-arrow B-. Close bleeder valve.
Position brake caliper as illustrated to pre-bleed.

2. Rear brake caliper 93

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3 Brake servo and brake master cylin‐

der
⇒ “3.1 Assembly overview - brake servo/brake master cylinder”,
page 94
⇒ “3.2 Removing and installing brake light switch”, page 98
⇒ “3.3 Removing and installing brake servo”, page 99
⇒ “3.4 Removing and installing brake master cylinder”,
page 106
⇒ “3.5 Removing and installing brake fluid reservoir”, page 112

3.1 Assembly overview - brake servo/brake

master cylinder
⇒ “3.1.1 Assembly overview - brake servo/brake master cylinder,
left-hand drive vehicles”, page 94
⇒ “3.1.2 Assembly overview - brake servo/brake master cylinder,
right-hand drive”, page 96

3.1.1 Assembly overview - brake servo/brake master cylinder, left-hand drive ve‐
hicles
Complete brake master cylinders and brake servos can be re‐
newed independently of each other.

94 Rep. gr.47 - Brakes - hydraulics

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1 - Hexagon nut
❑ Self-locking
❑ Renew after removal
❑ 23 Nm
2 - Heat shield
❑ Equipment version
3 - Brake master cylinder
❑ Cannot be repaired. If
faulty, renew complete.
❑ Removing and installing
⇒ page 106
4 - Brake line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit
❑ 14 Nm
5 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ 14 Nm
6 - Torx bolt
❑ 8 Nm
7 - Brake light switch - F-
❑ Including brake pedal
switch - F47- .
❑ Removing and installing
⇒ page 98
8 - Warning contact for brake
fluid level - F34-
9 - Brake fluid reservoir
10 - Pin
11 - Cap
12 - Vacuum hose
❑ With non-return valve
❑ Checking non-return valve ⇒ page 120 .
❑ With vacuum sender - G608- on some petrol engines
❑ Removing and installing vacuum sender - G608- ⇒ page 121
13 - Plug
14 - Plug
❑ Moisten with brake fluid and press into brake master cylinder.
15 - Brake servo
❑ Functional check:
– Depress brake pedal forcefully several times with engine switched off. Vacuum in unit is dissipated as a
result.

– Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the brake pedal will now give perceptibly under foot (servo assistance becomes activated).
❑ If faulty renew complete
❑ Checking ⇒ page 121

3. Brake servo and brake master cylinder 95

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❑ Non-return valve (in vacuum hose) functional check ⇒ page 120 .
❑ Separating from brake pedal ⇒ page 82
❑ Removing and installing ⇒ page 99
16 - Seal
❑ For brake servo
17 - Hexagon nut, self-locking
❑ Self-locking
❑ Renew after removal
❑ 20 Nm
18 - Seal
❑ Renew after removal

3.1.2 Assembly overview - brake servo/brake master cylinder, right-hand drive

1 - Cap
2 - Brake fluid reservoir
❑ With brake fluid level
warning contact - F34-
3 - Brake servo
❑ Removing and installing
⇒ page 104
❑ Functional check:
– Depress brake pedal
forcefully several times
with engine switched
off. Vacuum in unit is
dissipated as a result.

– Now depress brake

pedal with average foot
pressure, hold and start
engine. If the servo unit
is working properly, the
brake pedal will now
give perceptibly under
foot (servo assistance
becomes activated).
❑ Checking brake servo
vacuum system
⇒ page 121
❑ If faulty renew complete
4 - Seal
❑ Vacuum hose for brake
servo
5 - Vacuum line
6 - Seal
❑ Renew after removing
❑ Bonded (only when orig‐
inally assembled at factory)
❑ Remove adhesive residue
❑ The adhesive bond at the bulkhead/brake servo does not have to be renewed.

96 Rep. gr.47 - Brakes - hydraulics

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7 - Nut
❑ Qty. 2
❑ 20 Nm
8 - Seal
❑ Renew if damaged
❑ Ensure that seals are correctly seated
❑ Between brake master cylinder and brake servo
9 - Brake master cylinder
❑ ⇒ “3.4.2 Removing and installing brake master cylinder, RHD”, page 109
❑ When attaching brake master cylinder to brake servo, make sure plunger rod is properly positioned in
brake master cylinder.
❑ Complete brake master cylinders and brake servo can be renewed individually
10 - Brake light switch - F-
❑ ⇒ “3.2.2 Removing and installing brake light switch, right-hand drive”, page 99
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ 8 Nm
13 - Heat shield
❑ On brake fluid reservoir.
14 - Heat shield
❑ For brake servo
15 - Nut
❑ Renew after removing
❑ Qty. 2
❑ Self-locking
❑ 23 Nm
16 - Brake line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ 14 Nm
17 - Plug
❑ Renew if damaged
❑ Ensure that seals are correctly seated
❑ Moisten sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder
❑ Between brake master cylinder and brake fluid reservoir
18 - Brake line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ 14 Nm
19 - Spreader rivet
❑ For securing brake fluid reservoir

3. Brake servo and brake master cylinder 97

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3.2 Removing and installing brake light

switch
⇒ “3.2.1 Removing and installing brake light switch, LHD”,
page 98
⇒ “3.2.2 Removing and installing brake light switch, right-hand
drive”, page 99

3.2.1 Removing and installing brake light

switch, LHD
Removing
– Separate electrical connector -2-.
– Unscrew bolt -3-.
– Pull off brake light switch - - -1- from bottom of brake master
cylinder.

Installation
Install in reverse order of removal, observing the following:
– Make sure that brake light switch - F- -1- seats properly against
edge -arrow- of brake master cylinder.
Specified torques
♦ ⇒ “3.1.1 Assembly overview - brake servo/brake master cyl‐
inder, left-hand drive vehicles”, page 94

98 Rep. gr.47 - Brakes - hydraulics

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3.2.2 Removing and installing brake light

switch, right-hand drive
– Release and pull off connector -2- from brake light switch - F-
-1-.
– Remove bolt -3-.
– Unscrew brake light switch - F- from brake master cylinder.
Installing:
Install in reverse order of removal, observing the following:
– Make sure that brake light switch - F- -1- is inserted properly
in guide -4- of brake master cylinder.
Specified torques:
♦ ⇒ “3.1.2 Assembly overview - brake servo/brake master cyl‐
inder, right-hand drive”, page 96

3.3 Removing and installing brake servo

⇒ “3.3.1 Removing and installing brake servo, LHD”, page 99
⇒ “3.3.2 Removing and installing brake servo, RHD”, page 104

3.3.1 Removing and installing brake servo,

LHD

Note

If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 121 .

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment - VAS 5234-

3. Brake servo and brake master cylinder 99

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♦ Torque wrench - V.A.G 1331-

♦ Sealing tool - T10249-

♦ Hot air blower, e.g. hot air blower - VAS 1978/14A-

Removing
Vehicles with battery in engine compartment:
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery
tray; Removing and installing battery tray .
Vehicles with battery in luggage compartment:
– Remove jump-start terminal ⇒ Electrical system; Rep. gr. 27 ;
Jump-start terminal; Removing and installing jump-start ter‐
minal .
Continued for all vehicles:
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Lay out sufficient lint free clothes in area of engine and gear‐
box.

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Vehicles with manual gearbox:

– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal supply hose -2- with sealing tool - T10249- -1-, and tie it
up.
Continued for all vehicles:

– Pull off connector of brake fluid level warning contact - F34-

-3- from vacuum sender - G608- -2- (if fitted) and from brake
light switch - F- -1-.
– Dissipate vacuum in brake servo by depressing brake pedal
several times.

– Pull out vacuum hose -1- from brake servo -2-.

– Disconnect brake lines from brake master cylinder and seal
holes using sealing plugs - 1H0 698 311 A- .
– Fit dust caps of bleeder valves onto brake lines.
Vehicles with dual clutch gearbox:
– Remove selector cable and cable support bracket from gear‐
box ⇒ Rep. gr. 34 ; Selector mechanism; Assembly overview
- selector mechanism .

Vehicles with manual gearbox:

– Disconnect gear selector cable and gate selector cable from
gearbox selector lever ⇒ Rep. gr. 34 ; Selector mechanism;
Assembly overview – selector mechanism .

3. Brake servo and brake master cylinder 101

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– Unbolt cable support bracket from gearbox, and lay it to one

side together with cables ⇒ Rep. gr. 34 ; Selector mechanism;
Assembly overview – selector mechanism .
Continued for all vehicles:
– Separate brake pedal from brake servo ⇒ page 82 .

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– Unscrew 2 nuts for brake servo -3 and 4- on mounting bracket.

– Pull brake servo off bulkhead, applying force to separate bon‐
ded joint.
– Carefully remove brake servo from the vehicle.
– If brake servo sticks in holes, loosen both remaining nuts on
mounting bracket.
– Unbolt brake master cylinder from brake servo.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
Installing

Note

♦ The brake servo is given the additional bonded joint only dur‐
ing factory assembly.
♦ The adhesive bond between the brake servo and the bulkhead
does not need to be renewed, but the seal does.

– Remove adhesive residue from brake servo and plenum

chamber bulkhead.
– To do so, apply gentle heat from hot air blower to the adhesive
residue and pull it off.
– Thoroughly clean surfaces.
Install in reverse order of removal, observing the following:
– Renew brake servo seal ⇒ Item 16 (page 96) .
– Carefully insert brake servo and tighten nuts.
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
– When joining brake master cylinder to brake servo, make sure
seal ⇒ Item 18 (page 96) is properly seated.
– Coat sealing plugs with brake fluid before pressing brake fluid
reservoir into brake master cylinder.
– Connect brake pedal to brake servo ⇒ page 83 .
– Bleed brake system ⇒ page 133 .
Specified torques
♦ ⇒ “3.1.1 Assembly overview - brake servo/brake master cyl‐
inder, left-hand drive vehicles”, page 94
♦ ⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 11
♦ Selector mechanism ⇒ Rep. gr. 34 ; Selector mechanism;
Assembly overview - selector mechanism .
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
♦ ⇒ Electrical system; Rep. gr. 27 ; Jump start connection; As‐
sembly overview - jump start connection

3. Brake servo and brake master cylinder 103

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3.3.2 Removing and installing brake servo,

RHD

Note

If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 121 .

Special tools and workshop equipment required

♦ Engine support - T10533-

Fitting location of brake servo in RHD vehicles:

1 - Brake servo and brake master cylinder
2 - ABS hydraulic unit - N55- and ABS control unit - J104-
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– If fitted, remove engine cover panel ⇒ Rep. gr. 10 ; Engine
cover panel; Removing and installing engine cover panel .

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Vehicles with petrol engine:

– Release and pull off electrical connector -1- on oil level and oil
temperature sender - G266- .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Removing and installing pendulum support .
– Remove catalytic converter ⇒ Rep. gr. 26 ; Emission control;
Removing and installing catalytic converter .
– Remove exhaust system bracket from engine ⇒ Rep. gr. 26 ;
Emission control; Assembly overview - emission control .
Vehicles with seat heating:
– Remove coolant pipes on bulkhead ⇒ Auxiliary heater, sup‐
plementary heating system; Rep. gr. 82 ; Coolant circuit with
auxiliary heater/supplementary heating system .
Vehicles with dual clutch gearbox:
– Remove selector lever cable from gearbox ⇒ ; Rep. gr. 34 ;
Selector mechanism; Removing and installing selector lever
cable .
– Release and pull off connector for mechatronic unit for dual
clutch gearbox - J743- ⇒ Rep. gr. 34 ; Mechatronic unit .
– Detach wiring harness from front of gearbox and push up‐
wards.
Vehicles with manual gearbox:
– Disconnect gear selector cable and gate selector cable from
gearbox. Then unbolt cable support bracket and lay it to one
side, together with cables ⇒ Rep. gr. 34 ; Selector mecha‐
nism .

Continued for all vehicles:

– Position engine support - T10533- as shown.
– Engine support - T10533/2- is positioned on flat bolt connect‐
ing point of engine support - T10533/1- .
– Screw in original bolt of pendulum support -2- in front threaded
hole of pendulum support.
– Screw an M8 × 40 mm bolt -1- fitted with a washer -2- into left
threaded hole in noise insulation.
– Tighten bolts by hand.
– Push engine and gearbox with engine support - T10533- as
far forwards as possible.
– Ensure that electrical connection from starter does not contact
battery tray.
Vehicles with diesel engine:
– Remove emission control module ⇒ Rep. gr. 26 ; Emission
control; Removing and installing emission control module .

3. Brake servo and brake master cylinder 105

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Continued for all vehicles:

– Release vacuum in brake servo by depressing brake pedal
several times.
– Pull vacuum line -1- out of brake servo -2-.
– Remove brake master cylinder ⇒ page 109 .
– Detach brake servo from brake pedal ⇒ page 82 .

– Unscrew nuts -3- and -4-.

– Pull brake servo off plenum chamber bulkhead.
– Remove brake servo downwards.
– Carefully remove brake servo from the vehicle.
Installing:
Install in reverse order of removal, observing the following:
– Thoroughly clean sealing surfaces.
– Renew brake servo seal ⇒ Item 6 (page 96) .
– Carefully insert brake servo and tighten nuts.
– Connect brake pedal to brake servo ⇒ page 83 .
– If present, ensure that thermal boot is mounted on vacuum
line.
– Install brake master cylinder ⇒ page 109 .
Specified torques:
♦ ⇒ “3.1.2 Assembly overview - brake servo/brake master cyl‐
inder, right-hand drive”, page 96
♦ ⇒ “3.1.2 Assembly overview - control unit and hydraulic unit,
right-hand drive”, page 13
♦ Coolant expansion tank ⇒ Rep. gr. 19 ; Radiator/radiator fan;
Assembly overview – radiator/radiator fan
♦ Engine mounting and pendulum support ⇒ Rep. gr. 10 ; As‐
sembly mountings; Assembly overview - assembly mountings

3.4 Removing and installing brake master

cylinder
⇒ “3.4.1 Removing and installing brake master cylinder, left-hand
drive”, page 106
⇒ “3.4.2 Removing and installing brake master cylinder, RHD”,
page 109

3.4.1 Removing and installing brake master

cylinder, left-hand drive
Special tools and workshop equipment required

106 Rep. gr.47 - Brakes - hydraulics

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♦ Brake filling and bleeding equipment - VAS 5234-

♦ Torque wrench - V.A.G 1331-

Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery
tray; Removing and installing battery tray .
Continued for all vehicles:
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Lay out sufficient lint free clothes in area of engine and gear‐
box.
Manual gearbox:
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal supply hose -2- with sealing tool - T10249- -1-, and tie it
up.
Continued for all vehicles

3. Brake servo and brake master cylinder 107

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– Pull off electrical connectors from brake fluid level warning

contact - F34- -2- and from brake light switch - F- -1-.

– Unscrew stud -1- and pull brake fluid reservoir -2- out of seal‐
ing plugs.
– Lever cable retainer off pin.
– Unscrew brake lines from brake master cylinder -1- and seal
holes using sealing plugs - 1H0 698 311 A- .
– Fit dust caps of bleeder valves onto brake lines.

– Unscrew nuts -2- from brake master cylinder.

– Remove heat shield, if fitted.
– Carefully take brake master cylinder out of brake servo.
– Remove brake light switch - F- .
Installing
– Install in reverse order.
Observe the following important points when installing:
– Renew oil seal between brake master cylinder and brake ser‐
vo.
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
– Bleed brake system ⇒ page 133 .
Specified torques
♦ ⇒ “3.1.1 Assembly overview - brake servo/brake master cyl‐
inder, left-hand drive vehicles”, page 94
♦ ⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 11

108 Rep. gr.47 - Brakes - hydraulics

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3.4.2 Removing and installing brake master

cylinder, RHD
Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1331-

♦ Brake pedal depres‐

sor - V.A.G 1869/2-

♦ Brake filling and

bleeding equipment -
VAS 5234-

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♦ Sealing plug repair kit

- 1H0 698 311 A-

♦ Engine bung set -

VAS 6122-

♦ Socket T30 - T10405-

♦ Torque wrench -
V.A.G 1410-

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♦ Ring spanner insert

set AF 11 - V.A.G
1331/2-
Sealing plugs, assembly
part no. 5Q0 698 311
1 - Sealing plug M10
2 - Sealing plug M12

Fitting location of brake master cylinder in RHD vehicles:

1 - Brake servo and brake master cylinder
2 - ABS hydraulic unit - N55- and ABS control unit - J104-

Removing:
– Release connector -2- and pull off brake light switch - F- -1-.
– Remove brake fluid reservoir ⇒ page 114 .

– Unscrew brake lines -2- from brake master cylinder -1-.

– Seal brake lines with sealing plugs from repair kit Part
No. 1H0 698 311 A.
– Remove nuts -arrows-.
– Remove heat shield -3-.
– Carefully remove brake master cylinder from brake servo.
Installing:
Install in reverse order. Observe the following when doing this:
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
– When assembling brake master cylinder with brake servo,
make sure seal is properly seated ⇒ Item 8 (page 97) .
– Carefully fit brake lines.
– Install brake fluid reservoir ⇒ page 114 .
Vehicles without manual gearbox:
– Bleed brake system ⇒ page 133 .

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Vehicles with manual gearbox:

– Check seals -2- for damage and renew if necessary.
– Make sure that seals -2- engage correctly in supply hose -1-.
– Connect supply hose -1-.
– Bleed brake system ⇒ page 133 .
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism;
Bleeding clutch mechanism .
Specified torques:
♦ ⇒ “3.1.2 Assembly overview - brake servo/brake master cyl‐
inder, right-hand drive”, page 96
♦ ⇒ “3.5.2 Connecting brake lines to hydraulic unit, RHD”, page
27
♦ Front bleeder valves
⇒ “1.1 Assembly overview - front brake caliper”, page 87
♦ Rear bleeder valves
⇒ “2.1 Assembly overview - rear brake caliper”, page 90

3.5 Removing and installing brake fluid res‐

ervoir
⇒ “3.5.1 Removing and installing brake fluid reservoir, left-hand
drive vehicles”, page 112
⇒ “3.5.2 Removing and installing brake fluid reservoir, right-hand
drive vehicles”, page 114

3.5.1 Removing and installing brake fluid res‐

ervoir, left-hand drive vehicles
Special tools and workshop equipment required
♦ Sealing tool - T10249-

♦ Brake filling and bleeding equipment - VAS 5234-

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Removing:
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234-
and adapter - VAS 5234/1- .
– As protection against escaping brake fluid, place a number of
lint-free cloths in area beneath brake master cylinder.
Vehicles with manual gearbox
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .

– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch sender cylinder -3- with sealing
tool - T10249- -1-.
– Tie return hose -2- in place above.
Continued for all vehicles

– Separate electrical connector from brake fluid level warning

contact - -F34-- -2-.

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– Unscrew stud -1- and pull brake fluid reservoir -2- out of seal‐
ing plugs.

NOTICE
Push brake line slightly to one side.

Installing:
Install in reverse order of removal, observing the following:
– Lightly lubricate seals with brake fluid before installing brake
fluid reservoir.
– Fit brake fluid reservoir.

CAUTION
Make sure that the brake fluid reservoir engages in the retainers
and is seated securely.

– Bleed brake system ⇒ page 133 .

Vehicles with manual gearbox
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism;
Bleeding clutch mechanism .

CAUTION
Before initial road test, ensure that brakes work correctly.

Specified torques:
• ⇒ “3 Brake servo and brake master cylinder”, page 94
• ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery

3.5.2 Removing and installing brake fluid res‐

ervoir, right-hand drive vehicles
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment - VAS 5234-

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♦ Engine bung set - VAS 6122-

♦ Socket T30 - T10405-

♦ Torque wrench - VAS 6854-

♦ Ratchet insert 1/4" - VAS 6234-

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Fitting location of brake master cylinder in RHD vehicles:

1 - Brake servo and brake master cylinder
2 - ABS hydraulic unit - N55- and ABS control unit - J104-
Removing:

– Place sufficient lint-free cloths in area of engine.

– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .

– If present, remove thermal boot -1-.

– To do so, remove clamping washer -2- from bulkhead.
– Detach wiring harness and remove bracket -3-.
– Release press stud -4- and open thermal boot at brake line.

Vehicles with manual gearbox:

– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal supply hose with suitable plug from engine bung set -
VAS 6122- -1- or hose clamps up to 25 mm - 3094- .
– Raise and tie return hose -2- in place.

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Continued for all vehicles:

– Remove heat shield -1- if present.
– Also unscrew screw -3- with Torx screwdriver bit T30 -
T10405- .
– Pull heat shield -1- upwards out of retainers -arrows- on brake
fluid reservoir -2-.

– Release electrical connector -2- for brake fluid level warning

contact - F34- and pull it off brake fluid reservoir -1-.

– Pull out spreader rivet -3- in -direction of arrow-.

– Pull brake fluid reservoir -1- upwards off brake master cylinder
-2-
– If necessary, unscrew front brake line on brake master cylinder
⇒ Item 16 (page 97) .
– If fitted, press refrigerant lines upwards slightly.
– Seal openings using a suitable plug from engine bung set -
VAS 6122- .
Installing:
Install in reverse order of removal, observing the following:
– Ensure that plugs are seated correctly in brake master cylinder
⇒ Item 17 (page 97) .
– Moisten sealing plugs ⇒ Item 17 (page 97) with brake fluid
before pressing brake fluid reservoir into brake master cylin‐
der.
– Spreader rivet can be pushed in from other side.
Vehicles without manual gearbox:
– Bleed brake system ⇒ page 133 .

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Vehicles with manual gearbox:

– Check seals -2- for damage and renew if necessary.
– Make sure that seals -2- engage correctly in supply hose -1-.
– Connect supply hose -1-.
– Bleed brake system ⇒ page 133 .
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism;
Bleeding clutch mechanism .
Specified torques:
♦ ⇒ “3.1.2 Assembly overview - brake servo/brake master cyl‐
inder, right-hand drive”, page 96

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4 Vacuum system
⇒ “4.1 Assembly overview - vacuum pump”, page 119
⇒ “4.2 Checking non-return valve”, page 120
⇒ “4.3 Removing and installing vacuum sender G608 ”,
page 121
⇒ “4.4 Checking vacuum system”, page 121

4.1 Assembly overview - vacuum pump

⇒ “4.1.1 Assembly overview – vacuum pump, mechanical vacuum
pump”, page 119
⇒ “4.1.2 Assembly overview - vacuum pump for brakes V192 ”,
page 119

4.1.1 Assembly overview – vacuum pump,

mechanical vacuum pump
– Vacuum pump is located together with oil pump in sump ⇒
Rep. gr. 17 ; Sump/oil pump; Assembly overview - sump/oil
pump .

4.1.2 Assembly overview - vacuum pump for brakes - V192-

Only on some of the vehicles with petrol engine.
Vacuum pump for brakes - V192- is located on front right-hand
side in engine compartment on engine support.
No provision is made for repairs to vacuum pump for brakes -
V192- . If a fault is found, the vacuum pump for brakes - V192-
must be renewed.

4. Vacuum system 119

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1 - Bracket
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Secure to engine
mounting
❑ 20 Nm
2 - Vacuum pump for brakes -
V192-
❑ ⇒ “4.5.1 Removing and
installing electric vac‐
uum pump, vehicles
with 1.0 l petrol engine”,
page 126
3 - Bracket
4 - Rubber damper
❑ Ensure it is properly
seated
❑ Observe installation po‐
sition: washer points
downwards
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm

4.2 Checking non-return valve

Installation position of non-return valve -1- in the vacuum hose
can vary depending on model.
♦ Air must pass through non-return valve -1- in direction of ar‐
row.
♦ Non-return valve must remain closed in opposite direction.
Observe correct installation position!

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4.3 Removing and installing vacuum sender

- G608-

Note

The vacuum sender - G608- is only installed in selected petrol

engines.

Removing
– Disconnect connector -3- from vacuum sender - G608- -1-.
– Unclip vacuum sender - G608- -1- from vacuum line -2-.
Installing
Install in reverse order. The following should be observed:

Note

♦ Make sure to check the seal for damage before installing the
vacuum sender - G608- .
♦ If the seal is damaged, the vacuum sender must be renewed.

4.4 Checking vacuum system

⇒ “4.4.1 Connecting vacuum gauge for brake servo VAS 6721 ”,
page 122
⇒ “4.4.2 Checking vacuum generation”, page 122
⇒ “4.4.3 Checking for leaks”, page 123
⇒ “4.4.4 Vacuum generation with manual vacuum pump VAS
6213 ”, page 125
The following test instructions are intended to help find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or a so-called »hard brake pedal«.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if included)
Measuring results will be influenced by the geographical location.
The higher the location is above sea level, the lower the air pres‐
sure will be.
Take note of the following test requirements:
♦ Inspect all vacuum hoses for damage (e.g. cracks or marten
bite) and to ensure that they are correctly and firmly attached
♦ Ensure cleanliness when working on vacuum system
♦ Before starting work, clean engine compartment if necessary

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4.4.1 Connecting vacuum gauge for brake

servo - VAS 6721-
Special tools and workshop equipment required
♦ Vacuum gauge for brake servo - VAS 6721-

– Pull vacuum hose out of brake servo.

– Depress brake pedal several times to facilitate easier removal
of vacuum hose.
– Place brake servo vacuum gauge - VAS 6721- between them
-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Shut- In direction of vacuum hose, non-return valve and,
off if fitted, vacuum pump
valve
B Shut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-

C Shut- In direction of brake servo

off
valve

– Connect hose -A- from brake servo tester - VAS 6721- to vac‐
uum hose.
– Press adapter -C- into brake servo.

4.4.2 Checking vacuum generation

Special tools and workshop equipment required

122 Rep. gr.47 - Brakes - hydraulics

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♦ Vacuum gauge for brake servo - VAS 6721-

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar
♦ and decreases steeply as the altitude increases (approx.
100 mbar/1,000 m altitude).
♦ Local and time fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Check all vacuum hoses for damage (e.g. cracks or marten

bite), and check that they are correctly and firmly attached.
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 122 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine > 60°C, press accelerator briefly - engine
speed above 2000 rpm.
– Read indicated measured value.
Normally, the vacuum that is generated lies between 600 and
950 mbar.
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213- ⇒ page 125 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

4.4.3 Checking for leaks

Special tools and workshop equipment required

4. Vacuum system 123

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♦ Vacuum gauge for brake servo - VAS 6721-

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar
♦ and decreases steeply as the altitude increases (approx.
100 mbar/1,000 m altitude).
♦ Local and time fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Check all vacuum hoses for damage (e.g. cracks or marten

bite), and check that they are correctly and firmly attached.
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 122 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine > 60°C, press accelerator briefly - engine
speed above 2000 rpm.
Normally, the vacuum that is generated lies between 600 and
950 mbar.

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– Open cut-off valve -C- to evacuate brake servo.

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
In the case of a greater vacuum decrease, check the following
components:
1- Brake servo
2- non-return valve, vacuum hoses with push-on connections
and vacuum pump/intake manifold
If there are large leaks, the vacuum decreases steeply within a
few seconds.
Vacuum check in vicinity of brake servo:

– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake manifold:

– Once vacuum has been generated, close shut-off valve -C- to

check vacuum system from brake servo vacuum gauge - VAS
6721- to intake manifold or to vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

4.4.4 Vacuum generation with manual vac‐

uum pump - VAS 6213-
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump - VAS 6213- in certain cases.
– To do this, connect manual vacuum pump - VAS 6213- to vac‐
uum hose from connection -B- on brake servo vacuum gauge
- VAS 6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump - VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge - VAS 6721- .
– Then, carry out the corresponding checks.

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4.5 Removing and installing electric vacuum

pump
⇒ “4.5.1 Removing and installing electric vacuum pump, vehicles
with 1.0 l petrol engine”, page 126

4.5.1 Removing and installing electric vacuum

pump, vehicles with 1.0 l petrol engine
Removing:
– Pull off vacuum hose -1- and connector -2- from vacuum pump
for brakes - V192- -A-.

– Loosen and unscrew bolts -1- and -2-.

– Remove bracket with brake vacuum pump - V192- .
– Release and remove both clips on vacuum pump.
– Pull out vacuum pump for brakes - V192- upwards from brack‐
et.
Installing:
– Insert vacuum pump in bracket.

Note

Make sure that vacuum pump is properly seated in bracket. Vac‐

uum connection must point in the direction of travel.

– Engage vacuum pump in bracket with both clips.

– Insert bracket with vacuum pump in vehicle.

– Tighten bolts -1- and -2-.

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– Attach vacuum hose -1- to vacuum pump for brakes - V192- .

– Attach connector -2-.
Specified torques
Component Specified torque
Bolts for securing vacuum pump to 20 Nm
engine support

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5 Brake lines
⇒ “5.1 Repairing brake lines”, page 128

5.1 Repairing brake lines

The flanging tool for brake lines - VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this enables partial brake line sec‐
tions to be renewed at less expense.
The use of flanging tool - V.A.G. 1356- is not permitted due to the
coating and the diameter of the black brake lines.

Note

♦ Brake pipes may only be bent up to max. 90°.

♦ Otherwise they will become kinked or deformed.
♦ This will result in the cross-section of the lines to be changed
in a manner which is not permitted.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle; merely clean with methylated spirits.

Special tools and workshop equipment required

♦ Flanging tool for brake lines - VAS 6056-

♦ Brake filling and bleeding equipment - VAS 5234-

List of individual tools:

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1 - Flanging tool - VAS 6056/1-

❑ Flanging tool - VAS
6056/1- contains flang‐
ing jaws - VAS 6056/6-
2 - Pipe cutter - VAS 6056/2-
3 - Brake line scraper - VAS
6056/3-
❑ Grub screws (in shaft
and at side) are adjus‐
ted and must not be
tampered with!
4 - Set of grips with plastic jaws
- VAS 6056/4-
5 - Pipe bending tool - VAS
6056/5-
6 - Special wrench, 6 mm
7 - Flanging jaws - VAS
6056/7-

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5.1.1 Assembly overview - flanging tool

1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws.
2 - Fastening for handle
❑ Must be unbolted to ac‐
cess securing bolt for
upper part
3 - Securing bolt
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ For centring and holding
flanging jaws
❑ Allen head bolt, 2 mm
5 - Flanging jaws
❑ Various.
❑ Assembly instructions
⇒ page 130 .

Flanging jaw assembly instructions:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (light) for green brake lines

Note

♦ Arrow on rounded side of flanging jaws must point to edge of

housing.
♦ Straight side of flanging jaws must be installed to spindle, as
flanging head is not otherwise formed correctly.

5.1.2 Work instructions

– Unbolt respective brake line from brake caliper or wheel brake
cylinder.
– Catch escaping brake fluid and dispose of it as per regulations.

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– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) using pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.

– Clamp brake line in set of grips -4- so that approx. 50 mm

project from plastic jaws.
– Clamp scraper -3- into a drill and place it onto brake line.
– Scrape off coating from brake line using a drill at slow speed,
applying light pressure against brake line.
Length of scraping is determined by stop in scraper.
– Pull scraper off brake line and remove scrapings.

– Remove set of grips and slide union bolt -D- onto brake line.

– Slide brake line -B- up to stop -A- in flanging tool.

Note

Brake line must be positioned against stop when the hexagon

socket head bolts are tightened, or the flange will not be formed
correctly.

– Clamp brake line in flanging tool.

– Push brake line towards front until it can no longer be moved.
– Fold up stop -A-.
– Tighten hexagon socket head bolts diagonally using angle
screw driver -C-.

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– Turn spindle as far as stop in flanging tool.

– Turn spindle back again.
– Unscrew hexagon socket head bolts in diagonal sequence.
– Remove brake line from flanging tool, then clean and inspect
brake line and flange.
Briefly flush the section of brake line remaining in the vehicle:
– Connect brake filling and bleeding unit - VAS 5234- , connect
bleeder bottle hose to brake line flange and allow brake filling
and bleeding unit - VAS 5234- to run briefly until a little brake
fluid has run through.
– Blow out the new brake line to be inserted with compressed
air.

– Join brake lines with the connector -E-.

– Install brake line.
– Bleed brake system ⇒ page 133 .

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6 Hydraulic system
⇒ “6.1 General notes on brake fluid”, page 133
⇒ “6.2 Bleeding hydraulic system following standard procedure”,
page 133
⇒ “6.3 Subsequent bleeding of hydraulic system”, page 134
⇒ “6.4 Leakage test”, page 136

6.1 General notes on brake fluid

⇒ “6.1.1 General notes on brake fluid”, page 133
⇒ “6.1.2 Changing brake fluid”, page 133

6.1.1 General notes on brake fluid

Note

♦ Only use new brake fluid conforming to VW standard

(VW 501 14).
♦ Brake fluid is poisonous. In addition, due to its corrosive effect
brake fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air. Always store brake fluid in air tight con‐
tainers.
♦ Wash away any spilt brake fluid using plenty of water.

6.1.2 Changing brake fluid

⇒ Maintenance ; Booklet ; Brake and clutch system: changing
brake fluid

6.2 Bleeding hydraulic system following

standard procedure

Note

♦ Bleeding the hydraulic system using brake filling and bleeding

equipment - VAS 5234- is described.
♦ A pre-pressure of 2 bar is required for bleeding the ABS hy‐
draulic unit - N55- .

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment - VAS 5234-

6. Hydraulic system 133

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♦ Tool set for brake bleeding - VAS 6564-

♦ Insert tool - VAS 6564/9-

Perform the following steps:

Note

Adhere strictly to work sequence when bleeding brake system.

– Connect brake filling and bleeding equipment - VAS 5234- .

– Open bleeder valves in specified order and bleed wheel brake
cylinders/brake calipers.
1- Front left brake caliper
2- Front right brake caliper
3- Rear left wheel brake cylinder/ brake caliper
4- Rear right wheel brake cylinder/ brake caliper
Use suitable bleeder hose.
Breather hose must sit tightly on bleeder valve so that no air can
enter brake system.
– Leave bleeder valve of each brake caliper open with bleeder
hose fitted until brake fluid discharges free of air bubbles.

6.3 Subsequent bleeding of hydraulic sys‐

tem
Special tools and workshop equipment required

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♦ Brake filling and bleeding equipment - VAS 5234-

♦ Tool set for brake bleeding - VAS 6564-

♦ Insert tool - VAS 6564/9-

Re-bleeding is carried out if:

♦ brake pedal travel is too long or so-called »soft brake pedal«
Subsequent bleeding requires the assistance of a second me‐
chanic.
– Connect brake filling and bleeding equipment - VAS 5234- .
– Depress brake pedal firmly and hold.
– Open bleeder valve on wheel brake cylinder/brake caliper.
– Fully depress brake pedal.
– Close bleed valve with pedal held down.
– Release brake pedal slowly.
Bleeding sequence must be carried out 5 times per brake caliper:
Bleeding sequence:
1- Front left brake caliper
2- Front right brake caliper

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3- Rear left wheel brake cylinder/ brake caliper

4- Rear right wheel brake cylinder/ brake caliper
After bleeding, a road test must be carried out, during which at
least one ABS intervention must be triggered.

6.4 Leakage test

Special tools and workshop equipment required
♦ Tester for brake pressure regulator - V.A.G 1310 A-
♦ Adapter M10 - V.A.G 1310/6-

Prerequisites for testing:

• Brake system functioning and without leaks.
Checking
– Remove bleeder valve at one of front brake calipers.
– Connect brake system tester - V.A.G 1310 A- with corre‐
sponding adapter and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
during the test period of 45 seconds. Renew brake master
cylinder if drop in pressure exceeds specification.

Specified torques
♦ ⇒ “1.1.1 Assembly overview - front brake caliper, FS III front
brake”, page 87

136 Rep. gr.47 - Brakes - hydraulics

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