00 - GENERAL, TECHNICAL DATAkankondemuamba.a.k.f.unblog.fr/files/2012/04/brakes1.pdf · neutral position for vehicles equipped with manual transmission. ... Charger/bleeder Unit VAS

BRAKES

Brake System

00 - GENERAL, TECHNICAL DATA

APPLICATION OF PR. NO. FOR BRAKES

Application of PR. No. for brakes

The brake system installed in a vehicle is documented on the vehicle data sticker via the relevant PR number.

Example of a vehicle data sticker

Fig. 1: Example Of Vehicle Data Sticker Courtesy of VOLKSWAGEN UNITED STATES, INC.

In this example, the following brake system is installed in the vehicle:

Arrow 1 - Rear brakes - 1KF

Arrow 2 - Front brakes - 1LC

The vehicle data sticker is located in spare wheel well and in Maintenance booklet.

The following table shows the meaning of the PR numbers. These are important for combination brake caliper/brake disc/brake drum and brake pad.

Front wheel brakes

Engine version PR No. Front brakes3.2L - 162, 177 kW 1LC/1LE Brembo (17")3.6L -206 kW4.2L - 228 kW4.2L -257 kW 1LF Brembo (18")

2006 Volkswagen Touareg

BRAKES Brake System


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Sunday, September 20, 2009 8:55:09 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.

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Country-specific brakes for North America:

Rear brakes (disc brakes)

TECHNICAL DATA

Brake master cylinder and brake booster

Front wheel brakes

FN 3 (16") front wheel brake

5.0L - 230 kW TDI-PD

Engine version PR No. Front brakes4.2L -257 kW 1LE Brembo (17")

Engine version PR No. Rear brakes3.2L - 162, 177 kW 1KF/1KQ Brembo (17")3.6L -206 kW 4.2L - 228 kW 4.2L -257 kW 5.0L - 230 kW TDI-PD

Master brake cylinder Diameter in mm 26,99Brake booster Diameter in

inches9/10-Dual


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Fig. 2: FN 3 (16") Front Wheel Brake Courtesy of VOLKSWAGEN UNITED STATES, INC.

Front brakes, Brembo (17")

Item Pr.- No. 1LB1 Brake caliper FN 3 (16")2 Brake pad, thickness mm 12,53 Brake disc Diameter in mm 308 Brake disc, thickness mm 29,54 Brake caliper, pistons Diameter in mm 60


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Fig. 3: Front Brakes, Brembo (17") - PR No: 1LC Courtesy of VOLKSWAGEN UNITED STATES, INC.

PR No: 1LC

Item Pr.- No. 1LC1 Brake caliper Brembo (17")2 Brake pad, thickness mm 113 Brake disc Diameter in mm 330 Brake disc, thickness mm 324 Brake caliper, pistons Diameter in mm 2 x 34 2 x 36 2 x 38


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Fig. 4: Front Brakes, Brembo (17") - PR No: 1LE Courtesy of VOLKSWAGEN UNITED STATES, INC.

PR No: 1LE

Brembo (18") front wheel brake

Item Pr.- No. 1LE1 Brake caliper Brembo (17")2 Brake pad, thickness mm 113 Brake disc Diameter in mm 330 Brake disc, thickness mm 324 Brake caliper, pistons Diameter in mm 4 x 46


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Fig. 5: Brembo (18") Front Wheel Brake Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rear wheel brakes

Rear wheel brake (disc brake) 16"

Item Pr.- No. 1LF1 Brake caliper Brembo (18")2 Brake pad, thickness mm 113 Brake disc Diameter in mm 350 Brake disc, thickness mm 344 Brake caliper, pistons Diameter in mm 2 x 30 2 x 34 2 x 38


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Fig. 6: FN 3 (16") Front Wheel Brake Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rear brakes (disc brakes 17")

Item Pr.- No. 1KE1 Brake caliper FN 44 (16")2 Brake pad, thickness mm 133 Brake disc Diameter in mm 314 Brake disc, thickness mm 224 Brake caliper, pistons Diameter in mm 44


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Fig. 7: Rear Brakes (Disc Brakes 17") - PR No: 1KF Courtesy of VOLKSWAGEN UNITED STATES, INC.

PR No: 1KF

Item Pr.- No. 1KF1 Brake caliper Brembo (17")2 Brake pad, thickness mm 113 Brake disc Diameter in mm 330 Brake disc, thickness mm 284 Brake caliper, pistons Diameter in mm 2 x 28 2 x 30


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Fig. 8: Rear Brakes (Disc Brakes 17") - PR No: 1KQ Courtesy of VOLKSWAGEN UNITED STATES, INC.

PR No: 1KQ

Parking brake (drum brake) 16"

Item Pr.- No. 1KQ1 Brake caliper Brembo (17")2 Brake pad, thickness mm 113 Brake disc Diameter in mm 330 Brake disc, thickness mm 284 Brake caliper, pistons Diameter in mm 2 x 44


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Fig. 9: Parking Brake (Drum Brake) 16" Courtesy of VOLKSWAGEN UNITED STATES, INC.

Parking brake (drum brake) 17"

Item 1 Parking brake drum Diameter in mm 1852 Parking brake pad, width mm 30 Parking brake pad, total

thicknessmm 5.5


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Fig. 10: Parking Brake (Drum Brake) 17"Courtesy of VOLKSWAGEN UNITED STATES, INC.

BRAKE TEST

General information

The wheels are driven by the test stand.

When testing, place selector lever in driving position N for vehicles with automatic transmission and in neutral position for vehicles equipped with manual transmission.

Follow instructions issued by manufacturer of brake test equipment.

Test

Brake test must be performed on a regulated brake test stand driven in opposite directions.

Moving in opposite directions means: The rollers on the brake test stand turn forward on the one side and backward on the other side.

Regulated means: The speed of the test stand rollers must be regulated in such a way as to avoid any speed difference during the brake test.

That prevents the braking force from being transmitted to the drivetrain.

The wheel that is turning forward is measured during the test, which makes two brake tests per axle necessary.

Test speed must not exceed 6 km/h.

The Volkswagen approved test stand meets these requirements.

45 - ANTI-LOCK BRAKE SYSTEM

GENERAL NOTES ON ANTI-LOCK BRAKING SYSTEM (ABS)

For ABS Mark 25, the following version is installed in the vehicle:

Item 1 Parking brake drum Diameter in mm 2102 Parking brake pad, width mm 30 Parking brake pad, total

thicknessmm 5,5

NOTE: Electronic brake control systems are inoperative when the ignition is switched off.


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ABS/EDL/ASR with electronic stabilization program (ABS/EDL/ASR/ESP)

The ABS brake system is divided diagonally (two circuits). The vacuum brake servo unit boosts the brakes pneumatically.

ABS system malfunctions influence the brake system including boost assist. Changes in braking behavior should be checked. When the ABS warning lamp is lit up, the wheels may lock during braking!

Vehicles with ABS Mark 25 do not have a mechanical brake pressure regulator. A specially coordinated software program in the control module determines brake pressure allocation at the rear axle.

Fig. 11: Identifying Control Module, Hydraulic Unit And Hydraulic Pump Courtesy of VOLKSWAGEN UNITED STATES, INC.

Control module - 1 - and hydraulic unit - 2 - comprise a single unit. Separation can only be performed when removed from vehicle. The hydraulic pump - 3 - must not be separated from the hydraulic unit.

New control modules via the replacement parts service are not coded. Modules must be coded following installation.

Code control module using: VAS 5051 via "Guided fault finding" function.

Fig. 12: ABS Layout In Left-Hand Drive Vehicle


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Courtesy of VOLKSWAGEN UNITED STATES, INC.

ABS layout in left-hand drive vehicle.

NOTES FOR REPAIR WORK ON ABS

Notes for repair work on ABS

Before performing repairs to the ABS, determine the cause of the malfunction via "Guided Fault Finding".

"Guided Fault Finding" is performed using Vehicle Diagnosis, Testing and Information System VAS 5051.

Before working on the ABS, disconnect the battery ground (GND) strap. Note radio code (for vehicles equipped with coded anti theft radio), determine if necessary.

Before welding with an electric welding tool reference welding information in.

When working with brake fluid, observe relevant safety precautions and notes --> Bleeding braking system.

After finishing any work that required opening the brake system, bleed the brake system using the Brake Charger/bleeder Unit VAS 5234 or Brake Pedal Actuator VAG 1869/2, --> Bleeding braking system.

During final road test, carry out at least one ABS controlled braking operation (appropriate pulsations must be felt at brake pedal).

Absolute cleanliness is required when working on the anti-lock brake system, it is not permitted to use any products which contain mineral oil, such as oils, greases etc.

Thoroughly clean all unions and the adjacent areas before loosening. Do not use aggressive cleaning agents such as brake cleaner, fuel, thinners or similar chemicals.

Place parts that have been removed on a clean surface and cover.

Carefully cover over opened components or seal, if repairs are not carried out immediately. (Use Plugs 1 H0 698 311 A )

Only use lint-free cloths.

Unpack replacement parts only immediately prior to installation.

Only use genuine packed parts.

Do not work with compressed air and do not move vehicle while the system is open.

Make sure that no brake fluid enters electrical connections.

When painting, electronic control module can be exposed to a maximum temperature of. 95 °C only briefly, and to a maximum of 85 °C for longer periods (approx. 2 hours).

CONNECTING VAS 5051 AND SELECTING FUNCTIONS

Connecting VAS 5051 and selecting functions


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Special tools, testers and auxiliary items required

Fig. 13: VAS 5051 Vehicle Diagnosis, Testing and Information System Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicle Diagnosis, Testing and Information System VAS 5051 Vehicle diagnosis, testing and information system

Diagnostic cable VAS 5051/1 or VAS 5051/3

Fig. 14: Identifying Diagnostic Cable VAS 5051/1 Connector Or VAS 5051/3 To Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect Diagnostic Cable VAS 5051/1 connector or VAS 5051/3 to Data Link Connector (DLC) - arrow-.

CAUTION: Test equipment must always be secured on the rear seat during a road test.

These devices may be operated only by a passenger during a test drive.


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Fig. 15: Identifying Volkswagen Tester VAS 5051, On Switch Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch on tester - arrow -.

The tester is operational when it displays a picture of a car.

Switch on ignition.

Select Guided Fault Finding on screen.

Select the following, one after another:

Brand

Type

Model year

Version

Engine code

Confirm the entered data.

Wait until tester has checked all control modules installed in the vehicle.

Press the Go to button and select the "Function/component selection" function.

Select on display "Running gear"

Select on display "Brake system"

Select "01-On Board Diagnostic (OBD) capable system..." indicated on display.

Select on display "Anti-lock brake system...".

Select on display "Function".

Now, all possible functions of Anti-lock Brake System (ABS) installed in vehicle are displayed.

Select the desired function on display.


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ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLATION LOCATIONS

Electrical/electronic components and installation locations

Fig. 16: Electrical/Electronic Components And Installation Locations Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - ABS Hydraulic Unit N55

Component location: In plenum chamber, right side

The hydraulic unit consists of the components:

ABS Hydraulic Pump V64

Valve block (contains the in/outlet valves)

The ABS Hydraulic Pump V64 and valve block must not be separated from one another


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2 - ABS Control Module (w/EDL) J104

Component location: At hydraulic unit on right side of plenum chamber.

Do not disconnect electrical connector before successfully completing On Board Diagnostic (OBD). Switch the ignition off before disconnecting the electrical connector.

3 - Brake Pressure Sensor 1 G201

Component location: At brake master cylinder.

Removing and installing --> Brake Pressure Sensor 1 G201 , removing and installing

4 - Brake Booster Pressure Sensor G294

Only installed on vehicles with gasoline engine and automatic transmission

Component location: In vacuum hose to brake booster

Removing and installing --> Brake Booster Pressure Sensor G294 , removing and installing

5 - Brake System Vacuum Pump V192

Only installed on vehicles with gasoline engine and automatic transmission

Component location: In engine compartment, front right

Removing and installing --> Brake System Vacuum Pump V192 , removing and installing

6 - ASR/ESP Control Lamp K155

Component location: In the instrument cluster

Function: --> Malfunction indication via indicator lamps for level control system

7 - ABS Warning Lamp K47



8 - Brake System Warning Lamp K118



9 - ASR/ESP Button E256

Component location: in center console


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10 - ESP-Sensor Unit G419

Component location: Beneath center console

Combined Transverse Acceleration Sensor G200, Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251

Combined in one housing

Observe installation instructions --> ESP Sensor Unit G419 , removing and installing

11 - Steering Angle Sensor G85

Component location: On steering column between steering wheel and steering column switch

Observe installation instructions --> Steering Angle Sensor G85 , removing and installing

12 - Data Link Connector (DLC)

Component location: cover in driver footwell

Diagnostic connection

13 - Brake Light Switch F and Brake Pedal Switch F47

Removing and installing --> Brake Light Switch F and Brake Pedal Switch F47 , removing and installing

Vehicle from calendar week 48/06 do not have a brake light switch

14 - Right Front ABS Wheel Speed Sensor G45/Left Front ABS Wheel Speed Sensor G47

Replacing --> Speed sensor on front axle, removing and installing

15 - Wheel bearing/hub unit

The ABS sensor ring is installed in the wheel bearing

16 - Right Rear ABS Wheel Speed Sensor G44/Left Rear ABS Wheel Speed Sensor G46

Replacing --> Speed sensor on rear axle, removing and installing



Diagnostic connection


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Fig. 17: Diagnostic Connection Courtesy of VOLKSWAGEN UNITED STATES, INC.

MALFUNCTION INDICATION VIA INDICATOR LAMPS FOR LEVEL CONTROL SYSTEM

Malfunction indication via indicator lamps for level control system

Fig. 18: Level Control System Warning Lamps Courtesy of VOLKSWAGEN UNITED STATES, INC.

Warning lamps

ABS Warning Lamp K47

Item Designation1 ASR/ESP Control Lamp K1552 Brake Pad Wear Indicator Lamp K323 ABS Warning Lamp K474 Brake System Warning Lamp K118


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If ABS Warning Lamp K47 - 3 - does not go out after the ignition is switched on and the test sequence is complete, it could be caused by the following errors:

a - Voltage supply is below 10 Volt

b - There is a malfunction in the ABS

The ABS system remains switched off during an ABS malfunction - b - , but the traditional brake system remains fully functional.

c - Since the last time the vehicle was started there was a temporary speed sensor malfunction.

In this case the ABS Warning Lamp K47 will go out after the engine is restarted and the vehicle speed exceeds 2.75 km/h.

d - The connection from instrument cluster to ABS Control Module (w/EDL) J104 is interrupted. --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

e - ABS Warning Lamp K47 is faulty

Fig. 20: Level Control System Warning Lamps


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ABS Warning Lamp K47 and Brake System Warning Lamp K118

If ABS Warning Lamp K47 - 3 - goes out but Brake System Warning Lamp K118 - 4 - lights up, the malfunctions causes may be:

a - The brake fluid level is too low.

Three warning tones are audible after switching on the ignition.

b - There is a malfunction in the wiring to Brake System Warning Lamp K118 --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.

If ABS Warning Lamp K47 - 3 - and Brake System Warning Lamp K118 - 4 - lights up, ABS system is malfunctioning. A change in braking behavior should be checked.


ASR/ESP Control Lamp K155

If the ASR/ESP Control Lamp K155 - 1 - does not turn off after the ignition is switched on and the test sequence is completed, the malfunction may be:

There is a malfunction present which only affects the ASR/ESP. The ABS/EDL and EBD safety systems are still completely functional --> check DTC memory.

a - Short circuit to B+ in the ASR/ESP button.

b - A short circuit to ground in ASR/ESP Control Lamp K155 activation.

CAUTION: After ABS Warning Lamp K47 and Brake System Warning Lamp K118 light up, rear wheels may lock prematurely when braking.


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c - The connection from instrument cluster to contact 31 of ABS Control Module (w/EDL) J104 is interrupted.

d - ASR/ESP was switched off by the ASR/ESP Button E256.

If the ASR/ESP Control Lamp K155 blinks while driving, the ASR or ESP system is in regulating mode.


If the ASR/ESP Control Lamp K155 - 1 - did not light up during self-test, the following malfunction is present:

a - ASR/ESP Control Lamp K155 is faulty --> perform electrical test

ABS Warning Lamp K47 and ASR/ESP Control Lamp K155

If the ABS warning light K47 - 3 - and the ASR/ESP control lamp K155 - 1 - do not turn off after the ignition is switched on and the test sequence is completed, the malfunction may be:

a - The voltage supply for the ABS system is below 10 volts and the vehicle speed is less than 12 km/h --> Perform electrical test.

b - A short circuit to positive in ASR/ESP Control Lamp K155 activation.

- Short circuit to B+ in ASR/ESP Button E256.


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ABS Warning Lamp K47 , Brake System Warning Lamp K118 and ASR/ESP Control Lamp K155

If ABS Warning Lamp K47 - 3 - , ASR/ESP Control Lamp K155 , - 1 - and Brake System Warning Lamp K118 - 4 - do not go out, malfunction causes may be:

a - The voltage supply for the ABS system is below 10 volts and the vehicle speed is less than 12 km/h --> Perform electrical test.

b - There is a malfunction in the hydraulic control module; ABS system is therefore not operating.

A change in braking behavior should be checked. The rear wheels can lock up when braking!

c - There was a dynamic wheel speed sensor malfunction during the last driving period.

In this case, the warning lamps automatically switch off after a new vehicle start once a speed of 2.75 km/h is exceeded. This requires that the malfunction does not occur again after the repair work and new test are performed.



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Brake System Warning Lamp K118

If the Brake System Warning Lamp K118 - 4 - does not go out after switching the ignition on, the malfunction may be:

a - Foot operated parking brake is engaged.

- Switch for Brake System Warning Lamp K118 is malfunctioning or incorrectly adjusted.

- There is a malfunction in the wire routing --> Perform electrical test.

The parking brake switch also informs the ABS Control Module (w/EDL) J104 whether the parking brake is set or not. When the parking brake pedal is set, the ESP control is negatively influenced.


Brake Pad Wear Indicator Lamp K32

If Brake Pad Wear Indicator Lamp K32 - 2 - does not switch off 3 seconds after the ignition is switched on or if it lights up when vehicle is driven, it could be caused by the following malfunctions:

a - The brake pads are worn.

Check front and rear axle brake pads/linings. Replace worn brake pads/linings.

b - There is a malfunction in the wire routing. --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

HYDRAULIC UNIT, BRAKE BOOSTER/MASTER BRAKE CYLINDER - ASSEMBLY OVERVIEW

Hydraulic unit, brake booster/master brake cylinder - assembly overview


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Fig. 26: Hydraulic Unit, Brake Booster/Master Brake Cylinder - Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - ABS Control Module (w/EDL) J104

2 - ABS Hydraulic Unit N55

3 - Brake line

Master brake cylinder/primary piston circuit to hydraulic control unit

Identification at hydraulic unit - DK -

4 - Brake line

Master brake cylinder/secondary piston circuit to hydraulic unit

Identification at hydraulic unit - SK -


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5 - Brake line

Via intermediate piece toward rear left brake caliper

Marked on hydraulic unit with - HL -

6 - Brake line

Via intermediate piece toward front right brake caliper

Marked on hydraulic unit with - VR -

7 - Brake line

To left front brake caliper

Marked on hydraulic unit with - VL -

8 - Brake line

Via intermediate piece toward rear right brake caliper

Marked on hydraulic unit with - HR -

9 - Intermediate piece

10 - Bracket

11 - Flange bolt, 5 Nm

12 - Bolt, 8 Nm

13 - Buffer

14 - Gasket

For brake booster

15 - Tandem brake booster

On gasoline engines, vacuum is supplied from intake manifold.

Vehicles with gasoline engine and automatic transmission are equipped with a brake system vacuum pump.

On Diesel engines, a vacuum pump is installed for vacuum creation.

Functional check:

With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool).

Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).


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Replace as a unit in the event of malfunction (previously, check all vacuum lines).

Removing and installing --> Brake booster, removing and installing

16 - Sealing ring

17 - Brake Booster Membrane Position Sensor G420

Removing and installing --> Brake Booster Membrane Position Sensor G420 , removing and installing

18 - Snap ring

19 - Seal

Connection for vacuum hose

20 - Vacuum hose

To brake booster

21 - Sealing ring

22 - Self-locking nut, 25 Nm

Always replace after removal



24 - Bracket

25 - Master brake cylinder

Cannot be serviced. Replace as complete unit if malfunctioning.

Removing and installing --> Brake master cylinder, removing and installing

26 - Seals

Moisten with brake fluid and press into brake fluid reservoir

27 - Brake fluid reservoir

28 - Master Cylinder cap

29 - Torx bolts, 4 Nm


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Connection of brake lines from master brake cylinder to hydraulic unit

Fig. 27: Connection Of Brake Lines From Master Brake Cylinder To Hydraulic Unit (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Hydraulic unit to primary piston circuit of master brake cylinder

- Identification at hydraulic unit - DK -

B - Hydraulic unit to master cylinder secondary piston circuit

- Identification at hydraulic unit - SK -

1 - Hydraulic unit to front left brake caliper

- Marked on hydraulic unit with - VL -

2 - Hydraulic via intermediate unit to front right brake caliper

- Marked on hydraulic unit with - VR -

3 - Hydraulic via intermediate unit to rear right brake caliper

- Marked on hydraulic unit with - HR -

4 - Hydraulic via intermediate unit to rear left brake caliper

- Marked on hydraulic unit with - HL -


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Fig. 28: Connection Of Brake Lines From Master Brake Cylinder To Hydraulic Unit (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.

ABS hydraulic control unit, removing and installing


Fig. 29: Torque Wrench V.A.G 1410 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque Wrench VAG 1410


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Fig. 30: Brake Pedal Depressor V.A.G 1869/2Courtesy of VOLKSWAGEN UNITED STATES, INC.

Brake Pedal Actuator VAG 1869/2

Sealing Plug Repair Set 1H0 698 311A

Fig. 31: Sealing Plug Repair Set, Part No. 1H0 698 311 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

After separating the control module from the hydraulic unit, always install transport protection on the hydraulic unit for the valve domes.

Warranties will not be granted for hydraulic units without transport protection.

1 - Transport protection for valve domes (foam)

2 - Sealing plug M 10

3 - Sealing plug M 12

Component location:

The control module is bolted to the hydraulic unit and is located to the right in the plenum chamber.

CAUTION: Do not bend brake lines near the hydraulic unit!


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Control module and hydraulic unit, removing

Note or request radio code on vehicles with coded radio if necessary.

Disconnect battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Remove plenum chamber cover --> 64 - GLASS, WINDOWS .

Remove engine control module.

Remove the ground cable from the body, located behind engine control module bracket.

Unclip cable harness and lay aside

Remove engine control module bracket.

Remove intake housing --> 87 AIR CONDITIONING .

Fig. 32: Disengaging Connector From Control Module Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disengage connector from control module in direction of arrow - 1 - and disconnect (arrow - 2 -).

Attach bleeder hose of bleeder bottle to left front brake caliper bleeder valve and open bleeder valve.

Install Brake Pedal Actuator VAG 1869/2.

Close front left bleeder valve.

Place a lint-free cloths under the control module and hydraulic unit.

Make sure that brake fluid does not come in contact with the terminals.

Identify brake lines and remove at hydraulic unit and intermediate piece.

Seal brake lines and threaded holes with Sealing Plug Repair Set 1H0 698 311A .


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Fig. 33: Removing Hydraulic Unit From Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove - arrows - hydraulic unit from bracket.

Remove hydraulic unit upward together with control module.

Control module, removing from hydraulic unit

Place hydraulic unit with control module on a clean, level surface.

Fig. 34: Removing External Torx Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove external Torx screws - arrows -.


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Fig. 35: Pulling Control Module Off From Hydraulic Unit Without Angling Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull control module off from hydraulic unit - arrow - without angling.

Cover control module magnetic coils with a lint free cloth.

After separating the control module and hydraulic unit, use transport protection for valve body.

Assembling new control module

Surface must be cleaned before assembling.

Place control module without canting it on to hydraulic unit.

Bolt hydraulic unit and control module with new inner Torx screws supplied.

Control module and hydraulic unit, installing

CAUTION: Moisture and dirt particles must not penetrate the interior of control module.

The hydraulic pump must not be separated from the hydraulic unit.

CAUTION: Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.

NOTE: A new control module may be installed a maximum of two times to a used hydraulic unit, to ensure that the elastic gasket seals sufficiently.

A control module which was once in operation must not be installed a second time.

NOTE: Do not remove sealing plugs from the new hydraulic unit until the corresponding brake line is about to be installed.


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Installation is performed in the reverse order of removal.

Remove Brake Pedal Actuator VAG 1869/2.

Bleed brake system --> Bleeding braking system.

Enter radio code.

Perform ABS Control Module (w/EDL) J104 coding using in "Guided Fault Finding".

After replacing the ABS Control Module (w/EDL) J104 , also basic setting must be performed.

ABS SYSTEM COMPONENTS ON FRONT AND REAR AXLES, REMOVING AND INSTALLING

ABS system components on front and rear axles, removing and installing

If the sealing plugs are removed too early, brake fluid can escape. If this occurs, unit may not be sufficiently filled or adequately bled.

Tightening torques Control module to hydraulic unit max. 4 NmHydraulic unit bolt to bracket 8 NmBrake lines at ABS module: Thread M 10 x 1 14 NmThread M 12 x 1 14 Nm


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Fig. 36: Identifying ABS Wheel Speed Sensor, Bolt, Wheel Hub With Wheel Bearing & Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - ABS wheel speed sensor

Before inserting sensor, clean inner surface of bore hole and coat with Polycarbamide Grease G 052 142 A2

Removing and installing --> Speed sensor on front axle, removing and installing

2 - Bolt, 8 Nm

3 - Wheel hub with wheel bearing


4 - Driveshaft


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Speed sensor on front axle, removing and installing

Removing

Raise vehicle.

Fig. 37: Speed Sensor Wiring Connector & Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate speed sensor and speed sensor wiring connector - 1 -.

Remove bolt - 2 - from wheel bearing housing.

Remove ABS speed sensor from wheel bearing housing.

Installing

Before inserting wheel speed sensor, clean inner surface of bore/hole and coat sensor completely with Polycarbamide Grease G 052 142 A2 .

Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm.

Connect speed sensor to speed sensor wiring.

ABS system components on rear axle, removing and installing


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Fig. 38: Identifying ABS Wheel Speed Sensor, Bolt, Wheel Bearing/Hub Unit & Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - ABS wheel speed sensor

Before inserting sensor, clean inner surface of bore hole and coat with Polycarbamide Grease G 052 142 A2

Removing and installing --> Speed sensor on rear axle, removing and installing

2 - Bolt, 8 Nm



4 - Driveshaft


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Speed sensor on rear axle, removing and installing

Removing

Raise vehicle.

Fig. 39: Identifying Speed Sensor Wiring Connector & Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate speed sensor and speed sensor wiring connector - 1 -.

Remove bolt - 2 - from wheel bearing housing.

Remove ABS speed sensor from wheel bearing housing.

Installing

Before inserting wheel speed sensor, clean inner surface of bore hole and coat sensor completely with Polycarbamide Grease G 052 142 A2 .

Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm.

Connect speed sensor to speed sensor wiring.

COMPONENTS OF ESP SYSTEM, REMOVING AND INSTALLING

ESP Sensor Unit G419 , removing and installing

The Transverse Acceleration Sensor G200 , Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251 are installed in a housing under center console.

After replacing ESP Sensor Unit G419 , Transverse Acceleration Sensor G200 and Longitudinal Acceleration Sensor G251 basic setting must take place.

Removing

CAUTION: Strong vibrations can destroy the Transverse Acceleration Sensor G200 , Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251.


BRAKES Brake System

Microsoft


Remove center console --> 68 - INTERIOR EQUIPMENT .

Remove the airbag control module and lay aside slightly toward front --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS .

Fig. 40: Identifying Connector & Sensor Unit Mounting Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 - from ESP Sensor Unit G419.

Remove the two sensor unit mounting nuts - arrows -.

Remove ESP Sensor Unit G419.

Installing


When installing ESP sensor unit, be sure it is properly seated on the bracket and free of tension.

Never force ESP sensor unit into position using mounting nuts.

Tighten the nuts to 8 Nm.

Perform Transverse Acceleration Sensor G200 and Longitudinal Acceleration Sensor G251 basic setting.

VAS 5051 , connecting and selecting functions --> Connecting VAS 5051 and selecting functions.

Steering Angle Sensor G85 , removing and installing

Steering Angle Sensor G85 is installed between steering wheel and steering column switch.

Removing and installing

--> 94 - LIGHTS, SWITCHES - EXTERIOR .

Afterwards, basic setting of Steering Angle Sensor G85 must be performed.


BRAKES Brake System

Microsoft


Vehicle Diagnosis, Testing and Information System VAS 5051 , connecting and selecting functions --> Connecting VAS 5051 and selecting functions.

46 - BRAKES - MECHANICAL COMPONENTS

FRONT BRAKES, SERVICING

Front brakes, FN 3 (16") calipers, servicing

NOTE: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.

Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir.

Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure).


BRAKES Brake System

Microsoft


Fig. 41: Front Brakes, FN 3 (16") Calipers, Servicing Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake disc

Internally ventilated brake disc: diameter 308 mm

Brake disc thickness: 29.5 mm

Wear limit: 25.5 mm

Must always be replaced together on both sides of axle

Remove brake caliper and brake carrier before removing

2 - Bolt, 15 Nm

Brake disc to wheel hub


BRAKES Brake System

Microsoft


3 - Brake pads

Thickness 11.5 mm without backing plate

Wear limit: 2 mm without backing plate

With wear indicator

When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster

Checking thickness --> 01 - MAINTENANCE


Removing and installing --> Brake pads, removing and installing

4 - Retaining spring

Press under brake carrier and insert in both holes of brake caliper

5 - Brake caliper

Do not remove brake hose when replacing brake pads or brake discs

Removing and installing --> Brake caliper, removing and installing

Servicing --> Brake caliper FN 3, servicing

6 - Guide pins, 30 Nm (18 ft lb)

7 - Cap

8 - Bracket for brake pad wear indicator wire

9 - Bolt, 10 Nm

10 - Brake carrier

Bolt to wheel bearing housing

11 - Bolt, 270 Nm


12 - Bracket

13 - Bolt, 9 Nm

14 - Brake hose, 14 Nm

Do not remove when replacing brake pads or brake discs


BRAKES Brake System

Microsoft


Brake pads, removing and installing



Torque Wrench 5-50nm VAG 1331

Fig. 43: Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Piston Resetting Tool T10145

Removing

When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Remove wheels.


BRAKES Brake System

Microsoft


Fig. 44: Pushing Retaining Spring Until It Can Be Pressed Out Of Hole Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push retaining spring toward - direction of arrow A - until it can be pressed out of hole toward - direction of arrow B -.

Fig. 45: Turning Retaining Spring Until It Can Be Removed From Upper Hole Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn retaining spring - 1 - clockwise - arrow - until it can be removed from upper hole.

Fig. 46: Identifying Brake Pad Wear Indicator Connector, Dust Cap & Bracket


BRAKES Brake System

Microsoft



Disconnect the connector - 1 - for brake pad wear indicator.

Remove dust cap - 2 - and remove brake pad wear indicator wire.

Remove wire for the brake pad wear indicator from bracket - 3 - at brake caliper.

Fig. 47: Identifying Covers Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove covers - arrows -.

Fig. 48: Removing Both Guide Pins From Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove both guide pins - arrows - from brake caliper.

Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

Remove brake pads.

Cleaning:

CAUTION: Do not use compressed air to clean brake dust, the dust produced is


BRAKES Brake System

Microsoft


Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion.

Clean brake calipers (remove adhesive reside) - contact surfaces must be dry and clean.

Use only appropriate solvents for cleaning the brake caliper.

Installing

Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Fig. 49: Pressing Pistons Back Using Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press pistons back using Piston Resetting Tool T10145 - 1 -.

harmful to health!

NOTE: The inner brake pads (piston side) have a predetermined running direction and are marked for this purpose.


BRAKES Brake System

Microsoft


Fig. 50: Identifying Right/Left Brake Pad, Piston Side & Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

Directional brake pads

1 - Right brake pad, piston side

2 - Left brake pad, piston side

When installed, arrow - A - on the backing plate of brake pad must point downward.

Fig. 51: Inserting Brake Pad With Retaining Springs In Piston Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert brake pad with retaining springs in piston - arrows -.

Remove protective foil on backing plate of outer brake pad.


BRAKES Brake System

Microsoft


Fig. 52: Installing Outer Brake Pad On Brake Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install outer brake pad - A - on brake carrier.

When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct installation position has been reached.

Fig. 53: Installing Brake Caliper To Brake Carrier Using Both Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install brake caliper to brake carrier using both guide pins - arrows -.

Install both protective caps.


BRAKES Brake System

Microsoft


Fig. 54: Identifying Brake Pad Wear Indicator Connector, Dust Cap & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect brake pad wear indicator connector - 1 - to the bracket on wheel bearing housing.

Secure wire of brake pad wear indicator with dust cap - 2 - to bleeder valve and bracket - 3 - at brake caliper.

Fig. 55: Inserting Retaining Spring In Upper Hole Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert retaining spring in upper hole - arrow - and rotate in the direction of the - arrow -.

Attach retaining spring at lower brake carrier.


BRAKES Brake System

Microsoft


Fig. 56: Pushing Retaining Spring In First And Then Into Hole Of Brake Caliper At Same Time Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push retaining spring in direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -.

Install wheels.

Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT

Brake caliper, removing and installing


Fig. 57: Torque Wrench V.A.G 1331


Check brake fluid level after replacing brake pads.

Tightening torque Brake caliper 30 Nm


BRAKES Brake System

Microsoft




Fig. 58: Brake Pedal Depressor V.A.G 1869/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Removing

Work procedure applies only for replacing or when performing subsequent service work on brake caliper.

Remove wheels.


Push retaining spring toward the direction of - arrow A - until the spring can be removed from the hole in the caliper. Pull spring out of the caliper in the direction of - arrow B -.


BRAKES Brake System

Microsoft



Rotate the retaining spring - 1 - in the direction of the - arrow - until it can be removed from upper hole.

Fig. 61: Identifying Brake Pad Wear Indicator Connector, Dust Cap & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the electrical connector - 1 - for brake pad wear indicator.

Remove the clip - 2 - and remove brake pad wear indicator wire.

Remove dust cap and then wire for the brake pad wear indicator - 3 - at brake caliper.

Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.

Insert Brake Pedal Actuator VAG 1869/2.

Close bleeder valve and remove bleeder bottle.

Disconnect the brake hose.


BRAKES Brake System

Microsoft




Fig. 63: Removing Both Guide Pins From Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove both guide pins - arrows - from the brake caliper.

Remove the brake caliper from brake carrier.

Remove brake pads from brake caliper.

Installing

Piston is pressed back.

Outer brake pad installed on brake carrier.

Insert inner brake pad with retaining spring in brake caliper (piston).



BRAKES Brake System

Microsoft


Fig. 64: Identifying Right/Left Brake Pad, Piston Side & Position Courtesy of VOLKSWAGEN UNITED STATES, INC.


1 - Right brake pad, piston side

2 - Left brake pad, piston side

When installed, arrow - A - on the backing plate of brake pad must face downward.

When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct installation position has been reached.

Do not damage the adhesion surface.

Tighten brake caliper to brake carrier using both guide pins.


Install the brake caliper hose.



BRAKES Brake System

Microsoft



Insert retaining spring in upper hole - arrow - and turn in the direction of - arrow -.

Attach retaining spring to the lower brake carrier.


Push the retaining spring in direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -.


Install wheels.


NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Check brake fluid level.

Tightening torques:


BRAKES Brake System

Microsoft


Front brakes, servicing, Brembo 17" brake caliper (1LC)

Installation date: through kW 32/05

Brake caliper pins 30 NmBrake line to brake caliper 14 Nm


Use Brake Charger/bleeder Unit VAS 5234 or Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir.



BRAKES Brake System

Microsoft


Fig. 67: Front Brakes, Servicing, Brembo 17" Brake Caliper (1LC) Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake disc

Internally ventilated brake disc: diameter 330 mm

Brake disc thickness: 32 mm

Wear limit: 30 mm


Left differs to right

2 - Installed bolt, 15 Nm



BRAKES Brake System

Microsoft


3 - Brake caliper

Do not disconnect brake line when replacing brake disc


Servicing --> Brembo 17" and 18" brake caliper, servicing

4 - Bolt, 270 Nm


5 - Brake line, 14 Nm

Do not remove brake line when replacing brake disc

6 - Spring clamp

7 - Bracket


8 - Bolt, 9 Nm

9 - Brake hose

Make sure that lugs are properly seated in grooves in bracket.

10 - Bolt, 30 Nm

11 - Tension strut


13 - Brake pads

Thickness 11 mm without backing plate


With wear indicator





14 - Wire for brake pad wear indicator


BRAKES Brake System

Microsoft








Removing


Remove wheels.


BRAKES Brake System

Microsoft


Fig. 70: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Courtesy of VOLKSWAGEN UNITED STATES, INC.



Fig. 71: Removing/Tightening Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt.

Fig. 72: Identifying Retaining Spring & Tension Strut


BRAKES Brake System

Microsoft



Push retaining spring down - arrow - and then remove tension strut - 1 - at the same time.

Fig. 73: Identifying Brake Pad Wear Indicator & Retaining Spring Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove the wire for brake pad wear indicator - arrows - from the brake caliper housing and out of retaining spring - 1 -.

Remove retaining spring.

Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Fig. 74: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press brake pads off brake disc and remove from brake caliper.

If brake pads are to be replaced, carefully remove contact sensor with brake pad wear indicator wire from brake pads and check for damage.

Reuse undamaged contact sensors and wires.


BRAKES Brake System

Microsoft


Cleaning:

Clean brake caliper.

Use only appropriate solvents for cleaning brake caliper.

Installing


Press pistons back.

Carefully install brake pad wear indicator wire contact sensor in new brake pads.


Insert brake pads into brake caliper.

CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health!


BRAKES Brake System

Microsoft


Fig. 76: Identifying Brake Pad Wear Indicator & Retaining SpringCourtesy of VOLKSWAGEN UNITED STATES, INC.

Install retaining spring - 1 -.

Install the wire for the brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows -.

Fig. 77: Identifying Retaining Spring & Tension Strut Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push retaining spring down - arrow - and push tension strut - 1 - in until stop.

Make sure side flat surfaces of tension strut are properly seated in brake caliper housing in order to prevent tension strut from twisting.


Tighten bolt.


BRAKES Brake System

Microsoft



Connect electrical connector - 1 - for the brake pad wear indicator, and install in bracket on wheel bearing housing.

Secure brake pad wear indicator wire with dust cap - 2 - to bleeder valve.

Install wheels.





Check brake fluid level after replacing brake pad.

Tightening torque Bolt to tension strut 30 Nm


BRAKES Brake System

Microsoft








Removing


Remove wheels.




BRAKES Brake System

Microsoft



Remove brake line from brake caliper.

Remove bracket from wheel bearing housing.

Remove brake pads --> Brake pads, removing and installing.

Remove brake caliper.

Installing

Install brake caliper.

Install brake pads --> Brake pads, removing and installing.

Install brake line on brake caliper.

Install bracket to wheel bearing housing.



Install wheels.


Front brakes, servicing, Brembo 17" brake caliper (1LE)

Installation date: from kW 32/05



Tightening torques: Bolt to wheel bearing housing

Use new bolts!

270 Nm

Brake line to brake caliper 14 NmBolt for bracket to wheel bearing housing 9 Nm



Before removing brake caliper or disconnecting brake hose, brake pedal


BRAKES Brake System

Microsoft


Fig. 83: Front Brakes, Servicing, Brembo 17" Brake Caliper (1LE) Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake disc

Internally ventilated brake disc: 330 mm diameter


Wear limit: 30 mm


Left differs to right

actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure).


BRAKES Brake System

Microsoft


2 - Bolt, 15 Nm


3 - Brake caliper




4 - Bolt, 270 Nm




6 - Spring clamp

7 - Bracket


8 - Bolt, 9 Nm

9 - Brake hose


10 - Brake pad retaining pins


12 - Brake pads



With wear indicator






BRAKES Brake System

Microsoft







Removing


Remove wheels.





BRAKES Brake System

Microsoft


Fig. 86: Removing Brake Pad Retaining Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove brake pad retaining pins - arrows -.


Remove the wire for brake pad wear indicator - arrows - out of brake caliper housing and out of retaining spring - 1 -.




BRAKES Brake System

Microsoft






Cleaning:



Installing


Press pistons back.




BRAKES Brake System

Microsoft



Install brake pads into brake caliper.


Insert retaining spring - 1 -.

Install wire for brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows -.

Press retaining spring down and place pad retaining pin in brake caliper.


BRAKES Brake System

Microsoft


Fig. 91: Driving Pad Retaining Pin Into Brake Caliper As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive pad retaining pin into brake caliper as far as stop.


Install electrical connector - 1 - of brake pad wear indicator into bracket of wheel bearing housing.

Secure wire of brake pad wear indicator with dust cap - 2 - to bleeder valve.

Install wheels.







BRAKES Brake System

Microsoft








BRAKES Brake System

Microsoft



Removing


Remove wheels.







Remove brake caliper from wheel bearing housing.

Installing

Install brake caliper onto wheel bearing housing.

Install brake pads.





Install wheels.


Front brakes, servicing, Brembo 18" brake caliper




Use new bolts!

270 Nm



BRAKES Brake System

Microsoft


Fig. 96: Front Brakes, Servicing, Brembo 18" Brake Caliper Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake disc





BRAKES Brake System

Microsoft




Wear limit: 32 mm

Always replace together on both sides of axle

Left to right are different

2 - Bolt, 15 Nm


3 - Brake caliper

Do not remove the brake line when replacing brake disc



4 - Bolt, 270 Nm




6 - Spring clamp

7 - Bracket


8 - Bolt, 9 Nm

9 - Brake hose


10 - Bolt, 30 Nm

11 - Tension strut


13 - Brake pads


BRAKES Brake System

Microsoft




With wear indicator












BRAKES Brake System

Microsoft



Removing


Remove wheels.





Remove bolt.


BRAKES Brake System

Microsoft


Fig. 101: Identifying Retaining Spring & Tension Strut Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press retaining spring down - arrow - and remove tension strut - 1 - at the same time.


Pull wire for brake pad wear indicator - arrows - out of brake caliper housing and out of retaining spring - 1 -.




BRAKES Brake System

Microsoft






Cleaning:



Installing


Press pistons back.




BRAKES Brake System

Microsoft



Install brake pads into brake caliper.





BRAKES Brake System

Microsoft


Fig. 106: Identifying Retaining Spring & Tension StrutCourtesy of VOLKSWAGEN UNITED STATES, INC.

Press retaining spring down - arrow - and install tension strut - 1 - in until stop.

Make sure side flat surfaces of tension strut are properly seated in brake caliper housing in order to prevent tension strut from twisting.


Tighten bolt.


Connect electrical connector - 1 - of brake pad wear indicator in bracket of wheel bearing housing.

Secure wire of brake pad wear indicator with dust cap - 2 - to bleeder valve.

Install wheels.


NOTE: After replacing brake pads, depress brake pedal firmly several times with


BRAKES Brake System

Microsoft








vehicle stationary so that the brake pads are properly seated in their normal operating position.


Tightening torque Bolt to tension strut 30 Nm


BRAKES Brake System

Microsoft




Removing


Remove wheels.







Remove brake caliper from wheel bearing housing.

Installing







Install wheels.



BRAKES Brake System

Microsoft


REAR BRAKE, SERVICING

Rear brakes, servicing, brake caliper FN 44




Use new bolts!

270 Nm






BRAKES Brake System

Microsoft


Fig. 112: Rear Brakes, Servicing, Brake Caliper FN 44 Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake disc/brake drum

Ventilated brake disc: 314 mm diameter


Wear limit: 18 mm

Brake drum: 185 mm diameter

Wear limit: 186 mm


To remove, first remove brake caliper and brake carrier, do not remove brake line

2 - Bolt, 20 Nm


BRAKES Brake System

Microsoft



3 - Brake carrier


4 - Bolt, 200 Nm

5 - Brake pads



With wear indicator






7 - Brake caliper

Do not remove brake hose when replacing brake pads or brake discs


Servicing --> Brake caliper FN 44, servicing

8 - Bracket for brake pad wear indicator wire

9 - Bolt, 10 Nm


11 - Concealment cap

12 - Bolt, 8 Nm

13 - Bracket

14 - Brake hose with connection and banjo fitting, 38 Nm

Do not remove when replacing brake pads or brake discs

15 - Spring dowel sleeve


BRAKES Brake System

Microsoft


16 - Compression spring

17 - Pull spring

Component location: At adjustment nut

Larger number of spring coil

Can be easily bent by hand

18 - Spring

Component location: At spreader

Smaller number of spring coil

Cannot be easily bent by hand

19 - Brake shoe

Removing and installing --> Brake shoes, removing and installing

Minimum pad thickness 1 mm

Checking thickness

20 - Spreader

21 - Adjustment nut

Adjust parking brake --> Parking brake, adjusting

22 - Brake carrier

23 - Rear brake cable




BRAKES Brake System

Microsoft






Removing


Remove wheels.


Push retaining spring toward direction of - arrow A - until it can be pulled out of hole in the direction of -arrow B -.


BRAKES Brake System

Microsoft



Rotate retaining spring - 1 - in the direction of the - arrow - until it can be removed from upper hole.

Fig. 117: Identifying Brake Pad Wear Indicator Connector, Brake Caliper Bracket, Rake Pad Wear Indicator And Wheel Speed Sensor Wire & Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate the connector - 1 - for brake pad wear indicator.

Release the wire for brake pad wear indicator from bracket - 2 - at brake caliper.

Remove bottom of connector - 3 - of brake pad wear indicator and wheel speed sensor wire - 4 - from brake caliper bracket.


BRAKES Brake System

Microsoft




Fig. 119: Removing Both Caliper Guide Pins From Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove both caliper guide pins - arrows - from brake caliper.

Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

Remove brake pads.

Cleaning:

Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion.





BRAKES Brake System

Microsoft


Installing


Fig. 120: Pressing Pistons Back Using Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press pistons back using Piston Resetting Tool T10145.

Fig. 121: Identifying Directional Brake Pads Position Courtesy of VOLKSWAGEN UNITED STATES, INC.



BRAKES Brake System

Microsoft




Fig. 122: Installing Brake Pad And Retaining Springs Into Caliper Piston Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install brake pad and retaining springs into caliper piston - arrows -.

Install outer brake pad on brake carrier.


Tighten both brake caliper pins to brake carrier - arrows -.



BRAKES Brake System

Microsoft



Install wheel speed sensor wire - 4 - into bracket at brake caliper.

Secure electrical connectors - 3 - and - 1 - of brake pad wear indicator to the brake caliper bracket.

Secure wire of brake pad wear indicator in bracket - 2 - at brake caliper.


Install retaining spring in upper hole - arrow - and rotate in the direction of - arrow -.

Attach retaining spring at lower brake carrier.


BRAKES Brake System

Microsoft



Push retaining spring in direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -.

Install wheels.

Torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT



Fig. 127: Torque Wrench V.A.G 1331



Tightening torque Brake caliper to brake carrier 30 Nm


BRAKES Brake System

Microsoft






Removing


Remove wheels.


Push retaining spring toward direction of - arrow A - until it can be removed from the hole in the direction of - direction of arrow B -.


BRAKES Brake System

Microsoft



Rotate the retaining spring in the direction of the - arrow - until it can be removed from upper hole.


Disconnect the electrical connector - 1 - from the brake pad wear indicator.

Remove the wire for brake pad wear indicator from the bracket - 2 - at brake caliper.

Remove bottom of connector - 3 - of brake pad wear indicator and wheel speed sensor wire - 4 - from brake caliper bracket.




Remove brake line.


BRAKES Brake System

Microsoft





Remove both guide pins - arrows - from the brake caliper.

Remove the brake caliper from brake carrier.

Remove the brake pads from brake caliper.

Installing

Piston is pressed back.

Outer brake pad sits on brake carrier.

Install inner brake pad, with retaining spring, to the brake caliper (piston).



BRAKES Brake System

Microsoft


Fig. 134: Identifying Directional Brake Pads Position Courtesy of VOLKSWAGEN UNITED STATES, INC.




Secure brake caliper to brake carrier using both guide pins - arrows -.


Install brake hose on brake caliper.



BRAKES Brake System

Microsoft



Install wheel speed sensor wire - 4 - into bracket at brake caliper.

Install electrical connectors - 3 - and - 1 - for the brake pad wear indicator into the brake caliper bracket.

Secure brake pad wear indicator wire to the bracket - 2 - at brake caliper.


Insert retaining spring in upper hole - arrow - and rotate in the direction of - arrow -.

Attach retaining spring to lower brake carrier.


BRAKES Brake System

Microsoft



Push retaining spring in the direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -.


Install wheels.


Brake shoes, removing and installing




Tightening torques: Caliper guide pin to brake carrier 30 NmBrake hose banjo fitting to brake caliper 38 Nm


BRAKES Brake System

Microsoft


Fig. 139: Hook 3438 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hook 3438

Removing

Remove wheels.

Remove brake pads --> Brake pads, removing and installing

Remove brake caliper carrier.

Rotate brake disc until adjustment nut of parking brake can be seen through a wheel bolt hole.

Back off parking brake adjustment:

Fig. 140: Turning Adjustment Nut Against Resistance From Pull-Spring Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn adjustment nut - A - against resistance from pull-spring - B -.

Remove brake disc/brake drum.

Remove pull springs.

Remove spring dowel sleeves with compression springs and remove brake shoes.

Installing


Adjust parking brake --> Parking brake, adjusting.

Rear brakes, servicing, brake caliper Brembo (1KF)

Installation date: through kW 22/06

NOTE: After replacing brake pads, depress brake pedal firmly several times with


BRAKES Brake System

Microsoft


Fig. 141: Rear Brakes, Servicing, Brake Caliper Brembo (1KF) Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.



vehicle stationary so that the brake pads are properly seated in their normal operating position.




BRAKES Brake System

Microsoft



Wear limit: 26 mm


Wear limit: 211 mm


To remove, first remove brake caliper, do not remove brake line

2 - Bolt, 14 Nm


3 - Bolt, 14 Nm

For adjustment nut of parking brake

4 - Brake caliper



Servicing --> Brembo 17" brake caliper, servicing

5 - Bolt, 150 Nm + 90° (1/4-turn)


6 - Bolt

7 - Protective plate

8 - Brake pads



With wear indicator


Checking thickness: --> 01 - MAINTENANCE

Must always be replaced as a set, both sides of the axle




BRAKES Brake System

Microsoft


10 - Cotter pin

11 - Pad retaining pin


13 - Bracket

Bolt to brake caliper housing

14 - Bolt, 8 Nm

15 - Spring clamp



17 - Brake hose

Do not remove brake hose when replacing brake disc




20 - Pull spring




21 - Pull-spring




22 - Spreader

23 - Adjustment nut



BRAKES Brake System

Microsoft


24 - Brake shoe



Checking thickness

25 - Brake carrier






Removing

Remove wheels.

NOTE: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!


BRAKES Brake System

Microsoft


Fig. 143: Disconnecting/Connecting Connector For Brake Pad Wear Indicator Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the connector - 1 - for brake pad wear indicator.

Fig. 144: Removing/Installing Cotter Pin From Pad Retaining Pin Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove the cotter pin - arrow - from the pad retaining pin.

Fig. 145: Pushing Retaining Spring Down And Removing Pad Retaining Pin Courtesy of VOLKSWAGEN UNITED STATES, INC.


BRAKES Brake System

Microsoft


Push retaining spring down - arrow - and remove pad retaining pin - 1 - at the same time.

Fig. 146: Removing/Installing Brake Pad Wear Indicator Wire From Brake Caliper Housing And Retaining Spring Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove brake pad wear indicator wire from the brake caliper housing and retaining spring - 1 -.







Cleaning:


BRAKES Brake System

Microsoft




Installing

Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Press pistons back.

Carefully install brake pad wear indicator sensor into the new brake pads.


Insert brake pads into brake caliper housing.

Fig. 149: Removing/Installing Brake Pad Wear Indicator Wire From Brake Caliper Housing And Retaining Spring



BRAKES Brake System

Microsoft





Fig. 150: Pushing Retaining Spring Down And Removing Pad Retaining Pin Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push retaining spring down - arrow - and install pad retaining pin - 1 - in until stop.

Fig. 151: Removing/Installing Cotter Pin From Pad Retaining Pin Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure pad retaining pin using a cotter pin - arrow -.


BRAKES Brake System

Microsoft



Secure brake pad wear indicator electrical connector - 1 - to the brake caliper bracket.

Install wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT



Fig. 153: Torque Wrench V.A.G. 1332 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque Wrench 40-200mm VAG 1332




BRAKES Brake System

Microsoft


Fig. 154: Socket XZN 16 T10198 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Socket XZN 16 T10198



Removing

Work procedure applies only when replacing or when performing subsequent service work on brake caliper.

Remove wheels.






Remove wheel speed sensor wire from bracket at brake caliper.


BRAKES Brake System

Microsoft



Installing



Install brake line to brake caliper.

Secure wheel speed sensor wire to bracket at brake caliper.



Install wheels.







Tightening torques: Brake caliper bolt to wheel bearing housing

Use new bolts!

150 Nm and 90° (1/8 turn)

Brake line to brake caliper 14 Nm


BRAKES Brake System

Microsoft


Hook 3438



Removing

Remove wheels.


Remove wheel speed sensor wire from brake caliper bracket.

Remove brake caliper mounting bolts.

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

Fig. 158: Removing Bolt For Adjustment Nut Of Parking Brake Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrow - for adjustment nut of parking brake.

Set back parking brake:


BRAKES Brake System

Microsoft





Remove pull-springs.


Installing



Rear brakes, servicing, brake caliper Brembo (1KQ)

Installation date: from KW 22/06





BRAKES Brake System

Microsoft


Fig. 160: Rear Brakes, Servicing, Brake Caliper Brembo (1KQ) Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.




Wear limit: 26 mm


Wear limit: 211 mm

Must always be replaced as a set, both sides of axle

To remove, first remove brake caliper, do not remove brake line

2 - Bolt, 14 Nm


BRAKES Brake System

Microsoft



3 - Bolt, 14 Nm

For adjustment nut of parking brake

4 - Brake caliper



Servicing --> Brembo 17" brake caliper, servicing

5 - Bolt, 150 Nm + 90° (1/4-turn)


6 - Brake pads



With wear indicator


Checking thickness: --> 01 - MAINTENANCE




8 - Pad retaining pin


10 - Bracket

Fasten to brake caliper housing

11 - Bolt, 8 Nm

12 - Spring clamp




BRAKES Brake System

Microsoft


14 - Brake hose

Do not remove brake hose when replacing brake disc




17 - Pull-spring




18 - Pull-spring




19 - Spreader

20 - Adjustment nut


21 - Brake shoe



Checking thickness

22 - Brake carrier





BRAKES Brake System

Microsoft




Removing

Remove wheels.



NOTE: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!


BRAKES Brake System

Microsoft


Fig. 163: Removing Brake Pad Retaining Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove brake pad retaining pins - arrows -.


Remove brake pad wear indicator wire from brake caliper housing and retaining spring - 1 -.




BRAKES Brake System

Microsoft






Cleaning:



Installing

Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Press pistons back.

Carefully install brake pad wear indicator contact sensor in new brake pads.



BRAKES Brake System

Microsoft



Install brake pads into brake caliper housing.


Install retaining spring - 1 -.

Install wire for brake pad wear indicator below tab of retaining spring - arrows - and in brake caliper housing.

Press retaining spring down and install pad retaining pin in brake caliper.


BRAKES Brake System

Microsoft


Fig. 168: Installing Pad Retaining Pin Into Brake Caliper As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install pad retaining pin into brake caliper as far as stop.


Secure connector - 1 - of brake pad wear indicator into bracket on the brake caliper housing.

Install wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT






BRAKES Brake System

Microsoft


Fig. 170: Torque Wrench V.A.G. 1332 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque Wrench 40-200mm VAG 1332





BRAKES Brake System

Microsoft



Removing


Remove wheels.






Remove wheel speed sensor wire from the brake caliper bracket.


Installing



Install brake line onto brake caliper.

Secure wheel speed sensor wire to the bracket at brake caliper.



Install wheels.






Tightening torques: Brake caliper bolt to wheel bearing housing

Use new bolts!

150 Nm and 90° (1/8 turn)

Brake line to brake caliper 14 Nm


BRAKES Brake System

Microsoft



Hook 3438



Removing

Remove wheels.

Remove brake pads

Remove wheel speed sensor wire out of bracket at brake caliper.

Remove brake caliper mounting bolts.

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


BRAKES Brake System

Microsoft




Backing off parking brake:




Remove pull-springs.


Installing



Parking brake, adjusting


BRAKES Brake System

Microsoft


Adjustment must only be performed at the rear wheels! Adjustment must never be performed parking brake lever or transfer module on center console!

Observe correct routing and guiding of parking brake cables!

If the brake shoes were replaced, adjust air gap to the 6th tooth. Then run in brake shoes by braking vehicle in a single maneuver from a speed of approximately. 50 km/h. Rear wheels must not lock up when doing so.

Parking brake lever in released position.

Remove rear wheels.

Brake discs must move freely. If necessary, press brake pads slightly back or move rear brake cables slightly to and fro.



Adjusting brake shoes on both wheels:



BRAKES Brake System

Microsoft


Push screwdriver through hole in brake disc and turn adjustment nut - A - against resistance of pull-spring - B - until brake disc can no longer be turned.

Then loosen adjustment nut 6 teeth. Brake discs must move freely again.

Free play of parking brake lever must be checked again.

Install wheels.

Checking free play of foot operated parking brake lever:

Actuate parking brake pedal 2 teeth/clicks, wheels must rotate freely without brake shoes dragging.

Operated parking brake lever 5 to 7 teeth/clicks, wheels must be fixed. If wheels can still be rotated, parking brake must be adjusted.

PARKING BRAKE PEDAL - ASSEMBLY OVERVIEW

Foot operated parking brake


BRAKES Brake System

Microsoft


Fig. 179: Foot Operated Parking Brake - Assembly OverviewCourtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Release handle

2 - Release cable

3 - Mount

4 - Foot operated parking brake lever

Removing and installing --> Foot operated parking brake lever, removing and installing

5 - Bolt, 23 Nm

6 - Bolt, 23 Nm

7 - Front brake cable

Removing and installing --> Front brake cable, removing and installing

8 - Bolt, 2 Nm

9 - Contact switch for parking brake

Transfer module


BRAKES Brake System

Microsoft


Fig. 180: Transfer Module - Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transfer module

2 - Washer

3 - Bumper

4 - Cable anchor bracket

5 - Bolt

6 - Cable anchor

7 - Compensator bracket


BRAKES Brake System

Microsoft


8 - Nut

9 - Bolt, 23 Nm

10 - Clip

11 - Front brake cable

Removing and installing --> Front brake cable, removing and installing

12 - Rear brake cables

Removing and installing --> Rear brake cables, removing and installing

Rear brake cable

Fig. 181: Rear Brake Cable - Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.


2 - Sealing ring

3 - Sealing ring

4 - Sleeve

5 - Securing ring

Foot operated parking brake lever, removing and installing

Removing

Remove trim on drivers side --> 70 - INTERIOR TRIM .

Disconnect connector from contact switch for parking brake.


BRAKES Brake System

Microsoft


Remove left fuse holder and lay aside as far as possible together with wiring harness --> 97 - WIRING .

Fig. 182: Identifying Spring Plate Of Release Spring & Spring For Cable Compensation Courtesy of VOLKSWAGEN UNITED STATES, INC.

First press spring plate of release spring arrow - A - downward in order to compress the spring for cable compensation arrow - B -.

Hold spring - arrow B - compressed.

Fig. 183: Identifying Foot Operated Parking Brake Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure compressed spring by e.g. sliding a drill through holes of the foot operated parking brake lever - arrow - and through the linked cable mounting.


BRAKES Brake System

Microsoft


Fig. 184: Identifying Brake Cable, Cable Mounting & Cable Sleeve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the brake cable - A - from cable mounting - 1 - of foot operated parking brake lever.

Remove cable sleeve - 2 - from mount.

Remove both mounting bolts of foot operated parking brake lever.

Remove foot operated parking brake from mount.

Installing

Installation is performed in the reverse sequence.

Remove transport protection device (drill) from foot operated parking brake lever.

There will be an automatic length compensation of the brake cable caused by the spring.

Check free play at foot operated parking brake lever

BRAKE CABLES

Rear brake cables, removing and installing

Removing

Remove both rear wheels.


Before loosening nut - 1 - , measure dimension - a -.


BRAKES Brake System

Microsoft


Fig. 185: Removing Cable Sleeve From Mount Courtesy of VOLKSWAGEN UNITED STATES, INC.

Note measured value.

Loosen nut - 1 - until brake cables can be disengaged from compensator bracket.

Remove cable sleeve from mount.

Removing brake cable from spreader:

Only possible with released brake cable.

Fig. 186: Removing Locking Bolt For Adjustment Nut Of Parking Brake Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking bolt - arrow - for adjustment nut of parking brake.


BRAKES Brake System

Microsoft


Fig. 187: Pushing Brake Cable Nipple Against Retaining Spring In Spreader Downward Until Brake Cable Can Be Pulled Out Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push brake cable nipple against retaining spring in spreader downward until brake cable can be pulled out.

The right side is a mirror image, that means the brake cable nipple must be pushed upward.

Remove brake cable from retainer on fuel tank.

Remove brake cable from retainer on subframe and remove.

Installing


Brake cable nipple must noticeably engage in spreader.

Install brake cables into compensator bracket.

Fig. 188: Removing/Installing Cable Sleeve From Mount Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install nut - 1 - onto pull rod - 2 - until dimension - a - measured before removal is reached.


BRAKES Brake System

Microsoft


Check free play at foot operated parking brake lever.

Front brake cable, removing and installing

Removing



Remove sill panel trim --> 68 - INTERIOR EQUIPMENT .

Fig. 189: Identifying Spring Plate Of Release Spring & Spring For Cable Compensation Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press spring plate of release spring arrow - A - downward in order to compress the spring for cable compensation arrow - B -.

Hold spring arrow - B - compressed.

Fig. 190: Identifying Foot Operated Parking Brake Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure compressed spring by e.g. sliding a drill through holes of the foot operated parking brake lever - arrow - and through the linked cable mounting.


BRAKES Brake System

Microsoft


Fig. 191: Identifying Brake Cable, Cable Mounting & Cable Sleeve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove brake cable - A - from cable mounting - 1 - of foot operated parking brake lever.


Fig. 192: Identifying Clip & Cable Sleeve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove clip - 1 - and disconnect brake cable from cable mounting.


Lift carpet and pull out brake cable.

Installing


Remove transport protection device (drill) from foot operated parking brake lever.

There will be an automatic length compensation of the brake cable caused by the spring.

Check free play at foot operated parking brake lever.

BRAKE PEDAL, ASSEMBLY OVERVIEW


BRAKES Brake System

Microsoft


Brake pedal, assembly overview

Illustration for automatic transmission

Lubricate all bearings and contact surfaces with Grease G 000 450 02 .

Fig. 193: Brake Pedal, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mounting bracket for pedal assembly


CAUTION: The path of the brake pedal must not be shortened via extra floor mats.


BRAKES Brake System

Microsoft


3 - Pivot pin

4 - Brake pedal

5 - Ball socket

6 - Mount

For ball head of brake servo push rod

7 - Support

8 - Bolt, 8 Nm

9 - Crash bar

10 - Pin

11 - Locking washer

12 - Bracket

13 - Bolt, 8 Nm

14 - Brake Light Switch F and Brake Pedal Switch F47

Removing and installing --> Brake Light Switch F and Brake Pedal Switch F47 , removing and installing

Vehicle from kW 48/06 do not have a brake light switch

Separating brake pedal from brake booster


Fig. 194: Release Tool T10189


BRAKES Brake System

Microsoft



Release Tool T10189


Remove Brake Light Switch F and Brake Pedal Switch F47 --> Brake Light Switch F and Brake Pedal Switch F47 , removing and installing.

Fig. 195: Attaching Release Tool T10189 At Pressure Rod Mount In Brake Pedal And At Mounting Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attach Release Tool T10189 at pressure rod mount in brake pedal and at mounting bracket.

1 - Brake pedal

2 - Pressure rod

3 - Retaining lugs

Push brake pedal slightly toward brake booster and secure.

Push Release Tool T10189 in direction of brake booster, hold at brake pedal (pedal must not move rearward at this point). The mounting retaining lugs - 3 - will thereby be pressed off the ball head of the push rod - 2 -.

Push Release Tool T10189 farther in direction of brake booster and pull brake pedal toward driver seat at the same time. (The brake pedal will thereby be pulled off the ball head of the push rod).

Installing brake pedal to brake booster


BRAKES Brake System

Microsoft


Fig. 196: Removing/Installing Brake Pedal To Brake Booster Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly.

Further installation is in the reverse sequence to removal.

Brake light switch, removing and installing --> Brake Light Switch F and Brake Pedal Switch F47 , removing and installing.

Brake Light Switch F and Brake Pedal Switch F47 , removing and installing

Brake Light Switch must be removed for adjustment.

Removing

Fig. 197: Identifying Brake Light Switch Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Vehicle from kW 48/06 do not have a brake light switch. The signal is generated by the Brake Pressure Sensor 1 G201 and Brake Pressure Release Solenoid F84.


BRAKES Brake System

Microsoft



Disconnect connector from brake light switch.

The brake light switch must only be removed when plunger is pressed (brake pedal not operated), otherwise the retainer on the brake light switch will be damaged.

Remove brake light switch by turning 45° to left.

Brake light switch, installing, adjusting and locking

To ensure secure installation, install brake light switch only once.

Before installing the brake light switch, lube the plunger head with Polycarbamide Grease G 052 142 A2.

Before installing, pull out plunger completely.

When installing brake light switch, brake pedal must always remain in rest position. The brake pedal may only be touched with the brake light switch plunger head during the entire assembly procedure.

Fig. 198: Guiding Brake Light Switch Through Assembly Opening And Pressing It Against Pedal With Plunger Head Courtesy of VOLKSWAGEN UNITED STATES, INC.

Guide brake light switch through assembly opening and press it against pedal with plunger head. Then turn brake light switch 45° to the right until it noticeably engages.

Connect brake light switch connector.

Check function of brake light.


BRAKES Brake System

Microsoft


After adjusting the brake light switch ensure the brake pedal is resting on stop (rest position).

Install drivers side trim --> 70 - INTERIOR TRIM .

47 - BRAKES - HYDRAULIC COMPONENTS

FRONT BRAKE CALIPER, SERVICING

Brake caliper FN 3, servicing

Install complete repair kit when servicing.

Only use mineral spirits to clean brake parts.

Apply thin coat of Assembly Paste G 052 150 A2 to brake cylinders, pistons and seals.

Fig. 199: Brake Caliper FN 3, Servicing Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.


BRAKES Brake System

Microsoft


1 - Dust cap

Install onto bleeder valve

Secures brake pad wear indicator wiring

2 - Bleed valve, 12 Nm

Apply a thin coat of Assembly Paste G 052 150 A2 to the threads before screwing in.

3 - Caps

Insert in bushing


5 - Bushing

Insert in brake caliper

6 - Brake caliper

7 - Brake carrier

Bolt to brake caliper


Push under brake carrier and insert in both holes of brake caliper

9 - Sealing ring

Removing and installing --> Brake caliper FN 3 piston, removing and installing

10 - Pistons


11 - Protective cap

Do not damage when installing piston

Brake caliper FN 3 piston, removing and installing



BRAKES Brake System

Microsoft


Fig. 200: Identifying Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Trim Removal Wedge 3409



Fig. 202: Assembly Device For Protective Cap T10146/5 Courtesy of VOLKSWAGEN UNITED STATES, INC.


BRAKES Brake System

Microsoft


Assembly Tool for Protective Cap T10146/1

Removing

Fig. 203: Removing Piston From Brake Caliper Using Compressed Air Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove piston from brake caliper using compressed air.

Place a wooden board into the recess of the caliper housing so it is not damaged.

Fig. 204: Prying Off Protective Cap From Brake Caliper Using Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off protective cap from brake caliper using Trim Removal Wedge 3409.

A - Protective covers


BRAKES Brake System

Microsoft


Fig. 205: Removing Seal Using Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal using Trim Removal Wedge 3409.

When removing, make sure that surface of cylinder is not damaged.

Installing

The surface of the piston and seal must only be cleaned with mineral spirits and then dried.

Thinly coat piston and seal with Assembly Paste G 052 150 A2 before inserting.

Install sealing ring in brake caliper.

Fig. 206: Inserting Protective Cap Into Assembly Tool T10146/4 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert protective cap - A - onto Assembly Tool for Protective Cap T10146/1 - 1 -.


BRAKES Brake System

Microsoft


Fig. 207: Identifying Protective Cap T10146/1 & Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press the protective cap with the Assembly Tool for Protective Cap T10146/1 - 1 - and the Piston Resetting Tool T10145 - 2 - into the brake caliper applying equal pressure all around.

Check seating of protective caps:

Fig. 208: Pulling Protective Cap From Brake Caliper By Hand Courtesy of VOLKSWAGEN UNITED STATES, INC.

Protective cap must no longer be able to be pulled from brake caliper by hand.


BRAKES Brake System

Microsoft


Fig. 209: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully install the protective cap onto the piston, and then secure it in this position using the Trim Removal Wedge 3409 - 2 -.

Do not angle piston, to avoid damaging the seal sleeve.

Blow compressed air (max. 3 bar) on to protective cap - 1 -. Protective cap springs onto piston.


Fig. 210: Pressing Piston Into Brake Caliper Using Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston into brake caliper using Piston Resetting Tool T10145 - 1 -.

Outer sealing lip of protective cap will then engage in piston groove.

Brembo 17" and 18" brake caliper, servicing



BRAKES Brake System

Microsoft




Brake caliper with PR no. 1LC and ILF

Fig. 211: Brake Caliper With PR No. 1LC And ILF Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Dust cap






BRAKES Brake System

Microsoft


SW 10

3 - Brake caliper

4 - Seal for 34/30 mm piston

Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing

5 - Seal for 36/34 mm piston


6 - Seal for 38 mm piston


7 - 34/30 mm piston


First apply thin coat of Assembly Paste G 052 150 A2 on piston

8 - 36/34 mm piston



9 - 38 mm piston



10 - Protective cap for 34/30 mm piston


11 - Protective cap for 36/34 mm piston


12 - Protective caps for 38 mm piston



Brake caliper with PR no. 1LE


BRAKES Brake System

Microsoft


Fig. 212: Brake Caliper With PR No. 1LE Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Dust cap





SW 8

3 - Brake caliper

4 - Sealing ring


BRAKES Brake System

Microsoft



5 - 46 mm piston



6 - Protective cap


Piston for Brembo 17" and 18" brake caliper, removing and installing

Removal and installation of pistons is identical on the various brake calipers.




Fig. 214: Piston Resetting Tool T10145


BRAKES Brake System

Microsoft




Removing

Fig. 215: Identifying Piston Resetting Tool T10145, Wood Blocks, Wooden Board Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove pistons out individually of brake caliper housing using compressed air.

Only one piston can be removed at a time. When doing this, hold the opposing piston in the caliper housing using the Piston Resetting Tool T10145 - a -. Block the other pistons, e.g. using wood blocks - b -. In addition, place a wooden board - c - in front of the piston resetting tool so that the piston will not be damaged when removed.

Fig. 216: Removing Seal With Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal with Trim Removal Wedge 3409.


Installing


BRAKES Brake System

Microsoft




Fig. 217: Inserting Oil Seal Into Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert oil seal into brake caliper housing.

Fig. 218: Installing Protective Cap On Piston Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install protective cap on piston.


BRAKES Brake System

Microsoft


Fig. 219: Using Equal Pressure To Push Piston Into Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using equal pressure, push piston into brake caliper housing.

The protective cap must be seated properly in the groove, push slightly farther if necessary.

REAR BRAKE CALIPER, SERVICING

Brake caliper FN 44, servicing





BRAKES Brake System

Microsoft


Fig. 220: Brake Caliper FN 3, Servicing Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Dust cap





3 - Caps

Install in bushing


BRAKES Brake System

Microsoft



5 - Bushing

Install in brake caliper

6 - Brake caliper

7 - Brake carrier

Bolt to brake caliper


Push under brake carrier and insert in both holes of brake caliper

9 - Sealing ring


10 - Pistons


11 - Protective cap


Brake caliper FN 44 piston, removing and installing




BRAKES Brake System

Microsoft





Fig. 223: Assembly Device For Protective Cap T10146/5 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assembly Device for Protective Cap T10146/1

Removing


BRAKES Brake System

Microsoft


Fig. 224: Removing Piston From Brake Caliper Using Compressed Air Courtesy of VOLKSWAGEN UNITED STATES, INC.

Force piston from brake caliper using compressed air.

Place a wooden board into the recess of the caliper housing so it is not damaged.

Fig. 225: Prying Off Protective Cap From Brake Caliper Using Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off protective cap from brake caliper using Trim Removal Wedge 3409.



BRAKES Brake System

Microsoft


Fig. 226: Removing Seal Using Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal using Trim Removal Wedge 3409.


Installing



Install sealing ring in brake caliper.

Fig. 227: Inserting Protective Cap Into Assembly Tool T10146/4 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert protective cap - A - into Assembly Tool T10146/4 - 1 -.


BRAKES Brake System

Microsoft


Fig. 228: Identifying Protective Cap With The Assembly Tool T10146/4 & Piston Resetting Tool T10145Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press the protective cap with the Assembly Tool T10146/4 - 1 - and the Piston Resetting Tool T10145 - 2 - into the brake caliper applying equal pressure all around.

Ensure protective caps are seated:

Fig. 229: Identifying Protective Cap Courtesy of VOLKSWAGEN UNITED STATES, INC.

Protective cap must no longer be able to be pulled from brake caliper by hand.


BRAKES Brake System

Microsoft


Fig. 230: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal Wedge Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston lightly on to protective cap and then secure it in this position using e.g. Trim Removal Wedge 3409 - 2 -.

Do not angle piston, to avoid damaging the seal sleeve.

Blow compressed air (max. 3 bar) on to protective cap - 1 -. Protective cap springs onto piston.


Fig. 231: Pressing Piston Into Brake Caliper Using Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston into brake caliper using Piston Resetting Tool T10145 - 1 -.

Outer sealing lip of protective cap will then engage in piston groove.

Brembo 17" brake caliper, servicing



BRAKES Brake System

Microsoft




Brake caliper with PR no. 1KF

Fig. 232: Brake Caliper With PR No. 1KF Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Dust cap



Apply a thin coat of Assembly Paste G 052 150 A2 to the threads before assembling.

SW 10


BRAKES Brake System

Microsoft


3 - Brake caliper


Removing and installing --> Rear brake caliper piston, removing and installing



6 - 28 mm piston



7 - 30 mm piston


Apply thin coat on piston beforehand





10 - Connecting line, 17 Nm

11 - Torx bolt

12 - Protective plate

Brake caliper with PR no. 1KQ


BRAKES Brake System

Microsoft


Fig. 233: Brake Caliper With PR No. 1KQ Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Dust cap




SW 8

3 - Brake caliper

4 - Sealing ring


BRAKES Brake System

Microsoft



5 - 44 mm piston



6 - Protective cap


Rear brake caliper piston, removing and installing

Removal and installation of pistons is identical on the various brake calipers.




Fig. 235: Piston Resetting Tool T10145


BRAKES Brake System

Microsoft




Removing

Fig. 236: Identifying Resetting Tool, Wood Blocks & Wooden Board Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove piston from brake caliper housing, one at a time, using compressed air.

Only one piston can be pressed out at a time. Secure opposite piston in brake caliper housing using piston resetting tool - a -. Block the other pistons, e.g. using wood blocks - b -. In addition, place a wooden board - c - in front of the piston resetting tool so that the piston will not be damaged when pressed out.

Fig. 237: Removing Seal With Trim Removal Wedge 3409 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal with Trim Removal Wedge 3409.


Installing


BRAKES Brake System

Microsoft




Fig. 238: Inserting Oil Seal Into Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert oil seal in brake caliper housing.

Fig. 239: Installing Protective Cap On Piston Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install protective cap on piston.


BRAKES Brake System

Microsoft


Fig. 240: Using Equal Pressure To Push Piston Into Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push piston into brake caliper housing using constant pressure.

The protective cap must be seated properly in the groove, push slightly farther if necessary.

PRESSURE LEAK TEST

Pressure leak test


Fig. 241: Brake Pressure Gauge V.A.G 1310 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

Brake Pressure Gauge 0-250 Bar VAG 1310 A

Test conditions:

Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) operating properly and free of leaks.

Remove the bleeder valve from one of the front brake calipers. Connect and bleed Brake Pressure Gauge 0-250 Bar VAG 1310 A.


BRAKES Brake System

Microsoft


Apply pressure to brake pedal until the gauge indicates a pressure of 50 bar. The pressure must not drop by more than 4 bar during the test period of 45 seconds. Replace master cylinder if pressure drops greatly.

BLEEDING BRAKING SYSTEM

Bleeding braking system

Description covers bleeding of brake system using the Brake Charger/bleeder Unit VAS 5234 and Brake Pedal Actuator VAG 1869/2.

There must be a positive pressure of 2 bar to bleed the hydraulic unit.

Bleeding brake system using Brake Charger/bleeder Unit VAS 5234 or Brake Pedal Actuator VAG 1869/2


Fig. 242: Brake Charger/Bleeder Unit VAS 5234 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Brake Charger/bleeder Unit VAS 5234 or

NOTE: Bleeding the braking system on vehicles with ABS is carried out as for vehicles with conventional braking systems.

Only use new brake fluid conforming to US-Norm FMVSS 116 DOT 4.

Genuine VW/Audi brake fluid conforms to this specification.

Brake fluid is poisonous. Due to its caustic nature, it must also never be brought into contact with paint.

Brake fluid is hygroscopic, meaning that it absorbs moisture from the surrounding air, and must therefore be stored in air tight containers.

Rinse off spillages, by using plenty of water.


BRAKES Brake System

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Fig. 243: Brake Pedal Actuator VAG 1869/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Extraction Device Upgrade Kit VAG 1869/4

Pre-bleed:

There are two bleeder valves installed on Brembo brake calipers Always bleed at both bleeder valves.

Bleed at outer bleeder valve first.

Connect Brake Charger/bleeder Unit VAS 5234 or Brake Pedal Actuator VAG 1869/2.

Bleeding sequence:

1 - Bleed left front and right front brake caliper together simultaneously

2 - Bleed left rear and right rear brake caliper together simultaneously

With bleeder bottle hoses attached, leave bleeder valves open long enough that brake fluid exits without bubbles.

Then hydraulic unit must be bled once more via function "Basic setting" using Vehicle Diagnosis, Testing info. System VAS 5051.

Initiate basic setting (to bleed brake system):

Vehicle Diagnosis, Testing info. System VAS 5051 , connecting and selecting functions --> Connecting VAS 5051 and selecting functions.

Then, brake system must be bled normally

NOTE: If one chamber of the brake fluid reservoir has run completely empty (e.g. leak in the brake system), the brake system must be pre-bled first.


BRAKES Brake System

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After bleeding brake system, basic setting for Brake Pressure Sensor 1 G201 must be performed.

Bleeding (normal):

Adhere strictly to work sequence when bleeding brake system.

There are two bleeder valves installed on Brembo brake calipers Always bleed at both bleeder valves.

Bleed at outer bleeder valve first.

Connect Brake Charger/bleeder Unit VAS 5234 or VAG 1869.

Open bleeder valves in the prescribed sequence and bleed brake caliper.

1 - Right rear brake caliper

2 - Left rear brake caliper

3 - Right front brake caliper

4- Front left brake caliper

Use suitable bleeder hose. It must fit tightly on bleeder valve so that no air gets into brake system.

With bleeder bottle hose attached, leave bleeder valves open long enough that brake fluid exits without bubbles.

Subsequent bleeding

A second mechanic is required to assist:

Depress brake pedal forcefully and hold.

Open bleeder valve at brake caliper.

Press brake pedal down until the pedal stops.

Close bleeder valve with pedal depressed.

Release brake pedal slowly.

This bleeding procedure must be performed 5 times per brake caliper.

Bleeding sequence:

1 - Right rear brake caliper

2 - Left rear brake caliper

3 - Right front brake caliper


BRAKES Brake System

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4- Front left brake caliper

A road test must be performed after bleeding. During this, at least one ABS assisted stop must be performed!

Changing brake fluid (every 2 years)

Brake fluid, changing

--> 01 - MAINTENANCE

ASSEMBLY OVERVIEW: BRAKE BOOSTER/MASTER BRAKE CYLINDER

Assembly Overview: Brake booster/master brake cylinder

NOTE: Use only new brake fluid. Observe information on brake fluid reservoir!


BRAKES Brake System

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Fig. 244: Assembly Overview: Brake Booster/Master Brake Cylinder Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mounting bracket for pedal assembly



3 - Brake pedal

4 - Gasket

For brake booster

5 - Tandem brake booster


BRAKES Brake System

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On gasoline engines, vacuum is supplied from intake manifold.

Vehicles with gasoline engine and automatic transmission are equipped with a brake system vacuum pump.

On Diesel engines, a vacuum pump is installed for vacuum creation.

Functional check:

With engine switched off, depress brake pedal firmly several times (to deplete vacuum).

Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).

Replace as a unit in the event of malfunction (previously, check all vacuum lines).

Removing and installing --> Brake booster, removing and installing

6 - Sealing ring

7 - Brake Booster Membrane Position Sensor G420

Removing and installing --> Brake Booster Membrane Position Sensor G420 , removing and installing

8 - Snap ring

9 - Sealing ring




Master brake cylinder/primary piston circuit to hydraulic control unit

Identification at hydraulic unit - DK -


Master brake cylinder/secondary piston circuit to hydraulic unit

Identification at hydraulic unit - SK -



14 - Bracket

15 - Brake line


BRAKES Brake System

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To left front brake caliper

16 - Master brake cylinder

Cannot be serviced. Replace as complete unit if malfunctioning.

Removing and installing --> Brake master cylinder, removing and installing

17 - Sealing plugs

Moisten with brake fluid and install into brake fluid reservoir

18 - Brake fluid reservoir

19 - Cap

20 - Vacuum hose

Insert into brake booster

21 - Sealing plugs

Connection for vacuum hose

Brake Booster Membrane Position Sensor G420 , removing and installing

Removing


Disconnect connector from brake booster membrane position sensor.

Fig. 245: Identifying Circlip In Groove Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry circlip out of groove - arrow - and remove brake booster membrane position sensor from brake booster.


BRAKES Brake System

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Installing


Brake Pressure Sensor 1 G201 , removing and installing

The brake pressure sensor is located on the brake master cylinder.

Removing

Remove master brake cylinder --> Removing

Remove Brake Pressure Sensor 1 G201.

Installing



After bleeding brake system, Brake Pressure Sensor 1 G201 basic setting must be performed.


VACUUM SUPPLY FOR BRAKE BOOSTER

Brake System Vacuum Pump V192 - assembly overview

Only on vehicles with gasoline engine and automatic transmission

Tightening torque Brake Pressure Sensor 1 G201 33 Nm


BRAKES Brake System

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Fig. 246: Brake System Vacuum Pump V192 - Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake Booster Pressure Sensor G294

Removing and installing --> Brake Booster Pressure Sensor G294 , removing and installing

2 - Vacuum hose

To brake booster

3 - Brake Booster Relay J569

Removing and installing Wiring diagrams

4 - Check valve


BRAKES Brake System

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Functional check

5 - Clamp

Replace

6 - Clip

7 - Buffer stop

8 - Brake System Vacuum Pump V192

Removing and installing --> Brake System Vacuum Pump V192 , removing and installing

9 - Buffer stop

10 - Bracket

11 - Nut

12 - Bolt

Brake System Vacuum Pump V192 , removing and installing

It is not possible to service the Brake System Vacuum Pump V192. If there is a malfunction, replace Brake System Vacuum Pump V192.

Removing

Fig. 247: Identifying Connector & Vacuum Hose Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 -.

Disconnect vacuum hose - 2 - from Brake System Vacuum Pump Brake System Vacuum Pump V192.


BRAKES Brake System

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Fig. 248: Removing Brake System Vacuum Pump V192 Upward From Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disengage clip in direction of arrow and remove.

Remove Brake System Vacuum Pump V192 upward from bracket.

Installing


Brake Booster Pressure Sensor G294 , removing and installing

Removing


Fig. 249: Identifying Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 -.


BRAKES Brake System

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Fig. 250: Prying On Sensor Brake Booster Pressure Sensor G294 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully pry on sensor Brake Booster Pressure Sensor G294 and remove.

Installing


Checking check valve:

Valve must allow air to flow in direction of arrow.

Valve must remain closed in opposite direction.

Observe correct installation position.

BRAKE MASTER CYLINDER, REMOVING AND INSTALLING

Brake master cylinder, removing and installing


Fig. 251: Brake Charger/Bleeder Unit VAS 5234


BRAKES Brake System

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Brake Charger/bleeder Unit VAS 5234

Removing


Remove engine compartment seal and cover strip in area of brake booster.

Remove facing wall of plenum chamber.

Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder.

Extract as much brake fluid as possible from brake fluid reservoir using Brake Charger/bleeder Unit VAS 5234 or Extraction Device Upgrade Kit VAG 1869/4.

Disconnect electrical connector from float warning indicator sensor.

Disconnect electrical connector from brake pressure sensor.

On vehicles with manual transmission, disconnect clutch master cylinder supply hose and seal with plug.

Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs.

Remove left front brake line from retainer on master brake cylinder.

Disconnect brake lines from master brake cylinder and seal brake lines using Sealing Plugs 1H0 698 311 A from repair kit.

Remove brake master cylinder nuts.

Carefully take brake master cylinder out of brake booster.

Installing

Installation is performed in the reverse order of disassembly.

Observe the following points when installing:

When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly located in the brake master cylinder.

O-ring between master brake cylinder and brake booster is present.

Bleed braking system --> Bleeding braking system



BRAKE BOOSTER, REMOVING AND INSTALLING


BRAKES Brake System

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Brake booster, removing and installing


Fig. 252: Brake Charger/Bleeder Unit VAS 5234 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Removing


Remove brake light switch/brake pedal switch --> Brake Light Switch F and Brake Pedal Switch F47 , removing and installing.

Remove brake light switch bracket.

Disconnect brake pedal from brake booster --> Separating brake pedal from brake booster.

Fig. 253: Removing/Installing Brake Pedal To Brake Booster Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove support on mounting bracket through which pressure rod of brake booster runs.


Remove engine compartment seal and cover strip in area of brake booster.


BRAKES Brake System

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Remove facing wall of plenum chamber.

Disconnect electrical connector from brake pressure sensor.

Disconnect electrical connector from float warning indicator sensor.

Remove ground cable from ground point on body behind E-box, remove wiring harness from retainer behind brake booster and lay aside.

Fig. 254: Removing/Installing E-Box Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove E-box from left plenum chamber from retainer and lay as far as possible aside --> 97 - WIRING .

Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder.

Extract as much brake fluid as possible from brake fluid reservoir using Brake Charger/bleeder Unit VAS 5234 or Extraction Device Upgrade Kit VAG 1869/4.

On vehicles with manual transmission, disconnect clutch master cylinder supply hose and seal with plug.

Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs.

Remove left front brake line from retainer on master brake cylinder.

Disconnect brake lines from master brake cylinder and seal brake lines using Sealing Plugs 1H0 698 311 A .

Remove brake master cylinder nuts.

Carefully take brake master cylinder out of brake booster.

Remove Brake Booster Membrane Position Sensor --> Brake Booster Membrane Position Sensor G420 , removing and installing.

Pull vacuum hose out of brake booster.

Remove brake lines from the 3 compartment bracket at brake booster.

Disconnect left front brake line at separating point in left front wheel housing.


BRAKES Brake System

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Fig. 255: Removing Nuts From Brake Booster Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts from brake booster.

Carefully remove brake booster from plenum chamber.

Installing


Observe the following points when installing:

Installing brake pedal to brake booster

Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly.

After installing, bleed brake system --> Bleeding braking system and clutch.



Brake light switch, removing and installing --> Brake Light Switch F and Brake Pedal Switch F47 , removing and installing.

BRAKE LINE REPAIRS

Brake line repairs

Flare brake lines with 5 mm outer diameter using Flaring Tool VAS 6056 without damaging coating. In this way, brake lines can be inexpensively partially replaced in certain cases.

Work with brake line kit VAG 1356 is not permitted because of the coating and diameter of black brake lines.


BRAKES Brake System

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Fig. 256: Flaring Tool VAS 6056 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Flaring Tool VAS 6056


NOTE: Brake lines must not be bent more than 90° , otherwise they kink or deform causes unacceptable constriction in the line.

Disconnect brake lines preferably at vehicle floor.

Position of intermediate pieces should be selected so that they cannot rub against moving parts.

Do not lubricate spindle, clean only with mineral spirits.


BRAKES Brake System

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Fig. 257: Brake Line Repairs Tools Courtesy of VOLKSWAGEN UNITED STATES, INC.

Listing of individual tools:

Item Tool Tool number1 Flaring Tool (including Flaring

Jaws VAS 6056/6) VAS 6056/1

2 Tube cutter VAS 6056/23 Brake line shearing tool * See

noteVAS 6056/3

4 Self-grip pliers with plastic clamping jaws

VAS 6056/4

5 Line bending tool VAS 6056/56 SW6 angle screwdriver -


BRAKES Brake System

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*The threaded pins (in shaft and at sides) are set and must not be adjusted!

Flaring tool - assembly overview

Fig. 258: Flaring Tool - Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Upper part of flaring tool

Remove to change flaring jaws

2 - Hand grip mount

Must be removed to reach retaining screw for upper part

7 Flaring jaws VAS 6056/7


BRAKES Brake System

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3 - Retaining screw

For upper part of flaring tool

4 - Flaring jaws threaded pins

Center and hold the flaring jaws

2 mm hex socket head

5 - Flaring jaws

Various

Assembly instructions Flaring jaws assembly instructions:

Flaring jaws assembly instructions:

Fig. 259: Flaring Jaws Assembly Instructions: Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAS 6056/6 (dark) for black brake lines

VAS 6056/7 (light) for green brake lines

Instructions

Remove affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid and dispose of it correctly.

NOTE: The arrow on the rounded side of the flaring jaws must face toward edge of housing and the straight side of the flaring jaws must be installed toward spindle, otherwise flared head will not be formed correctly.


BRAKES Brake System

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Fig. 260: Disconnecting Brake Line At Appropriate Location With Line Cutter Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect brake line at appropriate location (straight, accessible part) with line cutter - 2 -.

Remove piece to be replaced.

Lubricate brake line surface.

Fig. 261: Brake Line Clamped In Self-Grip Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clamp brake line in self-grip pliers - 4 - so that 50mm of the plastic clamping jaws show.

Clamp shearing tool - 3 - in a drill and place it on brake line.

Shear coating from brake line at a slow drill RPM and with light pressure against the line.

The length of the sheared-off portion is determined by the stop in the shearing tool.

Remove shearing tool from brake line and remove shearing remains.


BRAKES Brake System

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Fig. 262: Identifying Self-Grip Pliers, Tube Fitting And Brake Line Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove self-grip pliers and tube fitting - D - from brake line.

Fig. 263: Sliding Brake Line Against Stop In Flaring Tool Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide brake line - B - against stop - A - in flaring tool.

Secure the brake line in the flaring tool until it cannot be moved any more. Rotate stop - A - up and tighten flaring tool screws diagonally with angle screw driver - C -.

NOTE: Brake line must contact stop when the screws are tightened, otherwise flare will not be formed correctly.


BRAKES Brake System

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Fig. 264: Identifying Stop In Down Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 265: Turning Spindle To Stop In Flaring Tool Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn spindle until it stops.

Turn spindle back.

Loosen screws.

Remove brake line from flaring tool, clean and check brake line and flared head.

Briefly rinse part of brake line remaining in vehicle.

Connect Brake Charger/bleeder Unit VAS 5234 , place bleeder container hose on flanged head of brake line and run Brake Charger/bleeder Unit VAS 5234 briefly until some brake fluid runs through.

Blow out brake line to be installed with compressed air.


BRAKES Brake System

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Fig. 266: Connecting Brake Lines With Union Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect the brake lines with a union - E -.

Assemble brake line.

Bleed braking system


BRAKES Brake System

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Documents

00 - GENERAL, TECHNICAL DATAkankondemuamba.a.k.f.unblog.fr/files/2012/04/brakes1.pdf · neutral position for vehicles equipped with manual transmission. ... Charger/bleeder Unit VAS