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8/3/2019 Servicio Sistemas de Frenos
1/166
Brake
System
from m.y.1997
Brake System On Board
Diagnostic (OBD) from m.y. 1997
8/3/2019 Servicio Sistemas de Frenos
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6HOHFWDWRSLF00 - General, Technical data
7HFKQLFDOGDWDEUDNHV
45 - Anti-lock brake system
$%6DQG$%6('/%RVFK
ABS system, general information
Notes for repair work on ABS, ABS/EDL systemsHydraulic unit, assembly overviewABS hydraulic control unit, removing and installing
$%6DQG$%6('/%RVFK
ABS system, general informationNotes for repair work on ABS systemsHydraulic unit, assembly overviewABS hydraulic control unit, removing and installing
$%6('/$65(63%RVFK
ABS system, general information
Notes for repair work on ABS systemsHydraulic unit, assembly overviewABS hydraulic control unit, removing and installing
$%6V\VWHPFRPSRQHQWVDWIURQWDQGUHDUD[OHUHPRYLQJDQGLQVWDOOLQJ
ABS front axle components, removing and installingABS rear axle components, removing and installing
(63V\VWHPFRPSRQHQWVUHPRYLQJDQGLQVWDOOLQJ
Sender for Rotation Rate -G202- and Sensor for transverse acceleration -G200-, removing andinstallingABS Control Module (w/EDL) -J104-, removing and installing
Steering angle sensor -G85-, removing and installing46 - Brakes - Mechanical components
)URQWEUDNHVVHUYLFLQJ
Distinguishing characteristics of front brake calipersFront brakes, servicing (Lucas C54 fist caliper, 15" wheels)Brake pads, removing and installingFront brakes, servicing (Lucas RC 54 frame caliper, 15" wheels)Brake pads, removing and installingFront brakes, servicing (FN 3 fist caliper, 15" wheels)Brake pads, removing and installingFront brakes, servicing (FN 3 fist caliper, 16" wheels)
Brake pads, removing and installingFront brakes, servicing (FNR fist caliper 16" wheels)Brake pads, removing and installing
5HDUEUDNHVVHUYLFLQJZKHHOV
Brake pads, removing and installingParking brake, adjusting
5HDUEUDNHVVHUYLFLQJZKHHOV
Brake pads, removing and installing
3DUNLQJEUDNHFDEOHUHPRYLQJDQGLQVWDOOLQJ
8/3/2019 Servicio Sistemas de Frenos
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Front parking brake cable, removing and installingPull-lever, removing and installingRear parking brake cable, removing and installing
3DUNLQJEUDNHOHYHUUHPRYLQJDQGLQVWDOOLQJ
%UDNHSHGDODVVHPEO\RYHUYLHZBrake pedal, removing and installing
47 - Brakes - Hydraulic components
)URQWEUDNHFDOLSHUVHUYLFLQJ
Front brake caliper, servicing, (Lucas C54 fist caliper, 15" wheels)Front brake caliper pistons, removing and installing (Lucas C54 fist caliper, 15" wheels)Front brake caliper, servicing (Lucas RC 54 frame caliper 15" wheels)Front brake caliper pistons, removing and installing (Lucas RC 54 frame caliper, 15" wheels) Front brake caliper, servicing (FN3 fist caliper, 15" wheels)Front brake caliper pistons, removing and installing (FN 3 fist caliper, 15" wheels)Front brake caliper, servicing (FN3 fist caliper, 16" wheels)Front brake caliper pistons, removing and installing (FN 3 fist caliper, 16" wheels)Front brake caliper, servicing (FNR fist caliper, 16" wheels)Front brake caliper pistons, removing and installing (FNR fist caliper, 15" wheels)
5HDUEUDNHFDOLSHUVHUYLFLQJ
Rear brake caliper piston, removing and installingPressurized leak test
%UDNHV\VWHPEOHHGLQJYHKLFOHVZLWKDQGZLWKRXW$%6
Brake system, bleeding using US1116 brake bleederBrake system, bleeding without brake filler and bleeder tool
%UDNHERRVWHUUHPRYLQJDQGLQVWDOOLQJ
Brake pressure regulator, adjusting
%UDNHVFKHFNLQJRQG\QDPRPHWHU
%UDNHERRVWHUPDVWHUEUDNHF\OLQGHUDVVHPEO\RYHUYLHZ
Check-valve, checking
0DVWHUEUDNHF\OLQGHUUHPRYLQJDQGLQVWDOOLQJ
%UDNHERRVWHUUHPRYLQJDQGLQVWDOOLQJ
*ORVVDU\
7HFKQLFDOGDWDEUDNHV
8/3/2019 Servicio Sistemas de Frenos
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9HKLFOHVZLWK/XFDV&EUDNHFDOLSHUZKHHOV
,WHPQR
0QXPEHU35QR
/3
)LVWFDOLSHU
Master brakecylinder
in mm 23.81
Brake booster ininches
9 4 + 84
1 Brake caliper Lucas C54
2 Brake pad,thickness
mm 13.5
3 Brake disc in mm 282
Brake disc,
thickness
mm 18
4 Brake caliper,pistons
in mm 54
1) M-number (optional equipment no.), clarificationPage 00-9
9HKLFOHVZLWK/XFDV5&EUDNHFDOLSHUZKHHOV
,WHPQR
0QXPEHU35QR
/(
)UDPHFDOLSHU
Master brakecylinder
inmm
23.81
Brake booster ininches
9 4 +
8 4
1 Brake caliper LucasRC54
2 Brake pad,thickness
mm 13
3 Brake disc inmm
280
8/3/2019 Servicio Sistemas de Frenos
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Brake disc,thickness(internallyvented)
mm 24
4 Brake caliper,pistons
inmm
54
1) M-number (optional equipment no.),clarification Page 00-9
9HKLFOHVZLWK)1EUDNHFDOLSHUZKHHOV
,WHP
QR
0QXPEHU35QR
/8
)LVWFDOLSHU
Master brakecylinder
inmm
25,4
Brake booster ininches
9 4 +
8 4
1 Brake caliper FN 3
2 Brake pad,
thickness
mm 13.5
3 Brake disc inmm
280
Brake disc,thickness(internally vented)
mm 24
4 Brake caliper,pistons
inmm
57
1) M-number (optional equipment no.),clarification Page 00-9
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9HKLFOHVZLWK)1EUDNHFDOLSHUZKHHOV
,WHPQR
0QXPEHU35QR
/%
)LVWFDOLSHU
Master brake
cylinder
in
mm
25,4
Brake booster ininches
9 4 +
8 4
1 Brake caliper FN 3
2 Brake pad,thickness
mm 13.5
3 Brake disc inmm
300
Brake disc,
thickness(internally vented)
mm 26
4 Brake caliper,pistons
inmm
57
1) M-number (optional equipment no.),clarification Page 00-9
9HKLFOHVZLWK)15EUDNHFDOLSHUZKHHOV
,WHPQR
0QXPEHU35QR
/%
)LVWFDOLSHU
Master brakecylinder
in mm 25,4
Brake booster ininches
9 4 + 84
1 Brake caliper FNR
2 Brake pad,thickness
mm 14
3 Brake disc in mm 313
Brake disc, mm 26
8/3/2019 Servicio Sistemas de Frenos
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thickness
4 Brake caliper,pistons
in mm 57
1) M-number (optional equipment no.),clarification Page 00-9
9HKLFOHVZLWKUHDUGLVFEUDNHVZKHHOV
,WHPQR
0QXPEHU35QR
/3)LVWFDOLSHU
/()UDPH
FDOLSHU
Master brakecylinder
inmm
23.81
Brakebooster
ininches
9 4 + 8 4
1 Brake disc inmm
280
Brake disc,thickness
mm 12
2 Brake pad,thickness
mm 11.5
3 Brake caliper,pistons
inmm
38
1) M-number (optional equipment no.),clarification Page 00-9
8/3/2019 Servicio Sistemas de Frenos
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9HKLFOHVZLWKUHDUGLVFEUDNHVZKHHOV
,WHPQR
0QXPEHU35QR
/8
)LVWFDOLSHU
Master brake
cylinder
in mm 25,4
Brake booster ininches
9 4 + 84
1 Brake disc in mm 280
Brake disc,thickness
mm 12
2 Brake pad,thickness
mm 11.5
3 Brake caliper,
pistons
in mm 38
1) M-number (optional equipment no.),clarification Page 00-9
9HKLFOHVZLWKUHDUGLVFEUDNHVZKHHOV
,WHPQR
0QXPEHU35QR
/%
)LVWFDOLSHU
Master brakecylinder
in mm 25.4
Brake booster ininches
9 4 + 84
1 Brake disc in mm 280Brake disc,thickness
mm 12
2 Brake pad,thickness
mm 11.5
3 Brake caliper,pistons
in mm 38
8/3/2019 Servicio Sistemas de Frenos
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clarification Page 00-9
'HWHUPLQLQJEUDNHFDOLSHUDOORFDWLRQYLD0
QXPEHU35QR
Depending on the brake caliper version, there is adifferent PR no. entered on the vehicle data plate.
,QVWDOODWLRQSRVLWLRQRIWKHYHKLFOHGDWDSODWHDUURZ
Left Hand Drive (LHD) vehicles - left A-pillar, next tocentral electronics
3ODFHPHQWRI0QXPEHU35QRRQYHKLFOHGDWDSODWHDUURZ
1LU = 15" fist caliper FN3
1LP = 15" Lucas fist caliper C54
1LE = 15" Lucas frame caliper RC 54
1LB = 16" fist caliper FN3
1LB = 16" fist caliper FNR
1RWH
7KHEUDNHFDOLSHUDEEUHYLDWLRQFDQEHORFDWHGHOVHZKHUHRQWKHYHKLFOHGDWDSODWHGHSHQGLQJRQWKHDPRXQWRIHTXLSPHQWLQVWDOOHG
$%6DQG$%6('/%RVFK $%6V\VWHPJHQHUDOLQIRUPDWLRQ
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The ABS brake system is divided diagonally (twocircuits). The vacuum brake servo unit boosts thebrakes pneumatically.
The hydraulic unit and control module are one unitand must always be replaced and installedtogether.
&RQQHFWLRQRIEUDNHOLQHVIURPWDQGHPPDVWHUEUDNHF\OLQGHUWRK\GUDXOLFXQLW
1 - Primary piston circuit
2 - Hydraulic control unit to rear right brakecaliper
3 - Hydraulic control unit to front left brake caliper
4 - Secondary piston circuit
5 - Hydraulic control unit to rear left brake caliper
6 - Hydraulic control unit to front right brakecaliper
1RWHVIRUUHSDLUZRUNRQ$%6$%6('/
V\VWHPV
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'LVFRQQHFWEDWWHU\*URXQG*1'VWUDSEHIRUHZRUNLQJRQ$%6$%6('/1RWHUDGLRFRGHIRUYHKLFOHVHTXLSSHGZLWKFRGHGDQWLWKHIWUDGLR
%HIRUHFDUU\LQJRXWZHOGLQJZRUNZLWKDQHOHFWULFZHOGLQJXQLWIROORZDOODSSOLFDEOHVDIHW\SUHFDXWLRQV
8/3/2019 Servicio Sistemas de Frenos
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'XULQJILQDOURDGWHVWFDUU\RXWDWOHDVWRQH$%6FRQWUROOHGEUDNLQJRSHUDWLRQDSSURSULDWHSXOVDWLRQVPXVWEHIHOWDWEUDNHSHGDO
$EVROXWHFOHDQOLQHVVLVUHTXLUHGZKHQZRUNLQJRQWKHDQWLORFNEUDNHV\VWHP'RQRWXVHDQ\SURGXFWVZKLFKFRQWDLQPLQHUDO
RLOVXFKDVRLOVJUHDVHVHWF
7KRURXJKO\FOHDQDOOXQLRQVDQGWKHDGMDFHQWDUHDVEHIRUHORRVHQLQJ'RQRWXVHDJJUHVVLYHFOHDQLQJDJHQWVVXFKDVEUDNH
FOHDQHUIXHOWKLQQHUVRUVLPLODUFKHPLFDOV
3ODFHSDUWVWKDWKDYHEHHQUHPRYHGRQDFOHDQVXUIDFHDQGFRYHU
2QO\XVHOLQWIUHHFORWKV
&DUHIXOO\FRYHURYHURSHQHGFRPSRQHQWVRUVHDOLIUHSDLUVDUHQRWFDUULHGRXWLPPHGLDWHO\
2QO\XQSDFNUHSODFHPHQWSDUWVLPPHGLDWHO\SULRUWRLQVWDOODWLRQ
2QO\XVHSDUWVLQWKHLURULJLQDOSDFNLQJ
'RQRWZRUNZLWKFRPSUHVVHGDLUDQGGRQRWPRYHYHKLFOHZKLOHWKHV\VWHPLVRSHQ
8/3/2019 Servicio Sistemas de Frenos
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0DNHVXUHWKDWEUDNHIOXLGGRHVQRWHQWHUKDUQHVVFRQQHFWRUV
+\GUDXOLFXQLWDVVHPEO\RYHUYLHZ
1RWHV
7KHK\GUDXOLFXQLWLVLQVWDOOHGDWIURQWOHIWLQWKHHQJLQHFRPSDUWPHQW
:KHQUHPRYLQJDQGLQVWDOOLQJEUDNHOLQHVEHVXUHWRPDUNDQGLQVWDOOOLQHVUHODWLYHWRLQGLFDWLRQVRQK\GUDXOLFXQLW
%UDNHOLQHVPXVWQRWEHPL[HGXSZKHQFRQQHFWLQJFKHFNLQJ
7DQGHPPDVWHU
EUDNHF\OLQGHU
With tandembrake booster
%UDNHOLQH
Master brakecylinder/secondarypiston circuit tohydraulic unit
8/3/2019 Servicio Sistemas de Frenos
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%UDNHOLQH
Master brakecylinder/primarypiston circuit tohydraulic controlunit
%UDNHOLQH
Hydraulic controlunit to front leftbrake caliper
%UDNHOLQH
Hydraulic controlunit to rear leftbrake caliper
%UDNHOLQH
Hydraulic controlunit to rear rightbrake caliper
%UDNHOLQH
Hydraulic controlunit to front rightbrake caliper
$%6('/K\GUDXOLFFRQWUROPRGXOH
bolted to controlmodule
The hydrauliccontrol modulemust be replacedcompletely ifmalfunctioning
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%XIIHU
+H[QXW
*URXQG*1'ZLUH
Check for proper
contact
&RQVROH
$%6K\GUDXOLFFRQWUROXQLWUHPRYLQJDQGLQVWDOOLQJ
6SHFLDO7RROVDQG(TXLSPHQW
VAG1331 torque wrench
8/3/2019 Servicio Sistemas de Frenos
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VAG1869/2 brake pedal depressor
Installation location:
The control module is bolted to the hydraulic unitand is located at left in the engine compartment.
:$51,1*
'RQRWEHQGEUDNHOLQHVQHDUWKHK\GUDXOLFXQLW
5HPRYLQJ
- Note radio code (for vehicles equipped withcoded anti-theft radio).
- Disconnect Ground (GND) strap from battery
- Disconnect connector from control module.
- Draw as much brake fluid as possible frombrake fluid reservoir using a bleeder bottle.
- Insert VAG1869/2 brake pedal depressor.
- Operate brake pedal using brake pedaldepressor.
- Attach bleeder hose of bleeder bottle to left-frontbrake caliper bleeder screw and open bleederscrew.
- Close front left bleeder screw.
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- Remove Ground (GND) wire from hydraulicunit.
- Place a sufficient number of lint-free clothsunder control module and hydraulic unit.
- Unscrew brake lines at hydraulic unit. Sealbrake lines and threaded holes using plugs.
- Remove hydraulic unit with control module.
,QVWDOOLQJ
1RWHV
'RQRWUHPRYHVHDOLQJSOXJVDWK\GUDXOLFXQLWXQWLOWKHFRUUHVSRQGLQJEUDNHOLQHLVDERXWWREHLQVWDOOHG
,IWKHVHDOLQJSOXJVDUHUHPRYHGWRRHDUO\EUDNHIOXLGFDQHVFDSH,IWKLVRFFXUVXQLWPD\QRWEHVXIILFLHQWO\ILOOHGRUDGHTXDWHO\EOHG
- Rest of installation is the reverse of removal.
- Bleed brake system Page 47-33 .
7LJKWHQLQJWRUTXHV
Brake lines to ABS aggregate:
Thread M 10 x 1 15 Nm
Thread M 12 x 1 15 Nm
8/3/2019 Servicio Sistemas de Frenos
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$%6DQG$%6('/%RVFK $%6V\VWHPJHQHUDOLQIRUPDWLRQ
ABS allocation in Left Hand Drive (LHD) vehicles.
The ABS brake system is divided diagonally (twocircuits). The vacuum brake servo unit boosts thebrakes pneumatically.
The hydraulic unit and control module are one unitand must always be replaced and installedtogether.
ABS disturbances affect the brake system and thebooster. Account for differences in brakingbehavior. When the ABS warning lamp is lit up,the rear wheels may lock prematurely duringbraking!
Hydraulic unit -a- and control module -b- are oneunit and must always be replaced together if
malfunctioning.
New control modules that are delivered as areplacement part are coded.
&RQQHFWLRQRIEUDNHOLQHVIURPWDQGHPPDVWHUEUDNHF\OLQGHUWRK\GUDXOLFXQLW
A - Secondary piston circuit
B - Primary piston circuit
1 - Hydraulic control unit to rear left brakecaliper
2 - Hydraulic control unit to rear right brakecaliper
8/3/2019 Servicio Sistemas de Frenos
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3 - Hydraulic control unit to front right brakecaliper
4 - Hydraulic control unit to front left brakecaliper
1RWHVIRUUHSDLUZRUNRQ$%6V\VWHPV
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'LVFRQQHFWEDWWHU\*URXQG*1'VWUDSEHIRUHZRUNLQJRQ$%6$%6('/1RWHUDGLRFRGHIRUYHKLFOHVHTXLSSHGZLWKFRGHGDQWLWKHIWUDGLR
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:KHQZRUNLQJZLWKEUDNHIOXLGREVHUYHUHOHYDQWVDIHW\SUHFDXWLRQVDQGQRWHV3DJH
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XVLQJWKH86EUDNHEOHHGHUWRRO 3DJH
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$EVROXWHFOHDQOLQHVVLVUHTXLUHGZKHQ
8/3/2019 Servicio Sistemas de Frenos
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ZRUNLQJRQWKHDQWLORFNEUDNHV\VWHP'RQRWXVHDQ\SURGXFWVZKLFKFRQWDLQPLQHUDORLOVXFKDVRLOVJUHDVHVHWF
7KRURXJKO\FOHDQDOOXQLRQVDQGWKHDGMDFHQWDUHDVEHIRUHORRVHQLQJ'RQRWXVHDJJUHVVLYHFOHDQLQJDJHQWVVXFKDVEUDNHFOHDQHUIXHOWKLQQHUVRUVLPLODUFKHPLFDOV
3ODFHSDUWVWKDWKDYHEHHQUHPRYHGRQDFOHDQVXUIDFHDQGFRYHU
&DUHIXOO\FRYHURYHURSHQHGFRPSRQHQWVRUVHDOLIUHSDLUVDUHQRWFDUULHGRXWLPPHGLDWHO\XVHVHDOLQJSOXJVIURPUHSDLUNLW+$
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0DNHVXUHWKDWEUDNHIOXLGGRHVQRWHQWHUKDUQHVVFRQQHFWRUV
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8/3/2019 Servicio Sistemas de Frenos
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+\GUDXOLFXQLWDVVHPEO\RYHUYLHZ
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WKHHQJLQHFRPSDUWPHQW
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%UDNHOLQHVPXVWQRWEHPL[HGXSZKHQ
FRQQHFWLQJFKHFNLQJ
7DQGHPPDVWHUEUDNHF\OLQGHU
with tandembrake booster
%UDNHOLQH
Master brakecylinder/secondarypiston circuit to
hydraulic unit
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%UDNHOLQH
Master brakecylinder/primarypiston circuit tohydraulic controlunit
%UDNHOLQH
Hydraulic controlunit to front rightbrake caliper
%UDNHOLQH
Hydraulic controlunit to rear rightbrake caliper
%UDNHOLQH
Hydraulic controlunit to rear leftbrake caliper
%UDNHOLQH
Hydraulic controlunit to front leftbrake caliper
+H[QXWWLJKWHQWR1P
3URWHFWLYHFDS
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$%6('/K\GUDXOLFFRQWUROPRGXOH
bolted to controlmodule
The hydraulic
control modulemust be replacedcompletely ifmalfunctioning
+H[QXWWLJKWHQWR1P
&RQVROH
%ROW1P
$%6K\GUDXOLFFRQWUROXQLWUHPRYLQJDQGLQVWDOOLQJ
6SHFLDO7RROVDQG(TXLSPHQW
VAG1331 torque wrench
8/3/2019 Servicio Sistemas de Frenos
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VAG1869/2 brake pedal depressor
Installation location:
The control module is bolted to the hydraulic unitand is located at left in the engine compartment.
:$51,1*
'RQRWEHQGEUDNHOLQHVQHDUWKHK\GUDXOLFXQLW
5HPRYLQJ
- For vehicles equipped with coded anti-theftradio, note radio code, obtain if necessary.
- Disconnect Ground (GND) strap from battery
- Disengage connector from control module(arrow -1-) and disconnect (arrow -2-).
- Draw as much brake fluid as possible frombrake fluid reservoir using a bleeder bottle.
- Insert VAG1869/2 brake pedal depressor.
- Operate brake pedal using brake pedaldepressor.
- Attach bleeder hose of bleeder bottle to left-frontbrake caliper bleeder screw and open bleederscrew.
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- Close front left bleeder screw.
- Place a sufficient number of lint-free clothsunder control module and hydraulic unit.
- Unscrew brake lines at hydraulic unit. Sealbrake lines and threaded holes using plugs.
- Remove hydraulic unit with control module.
,QVWDOOLQJ
1RWHV
'RQRWUHPRYHVHDOLQJSOXJVDWK\GUDXOLFXQLWXQWLOWKHFRUUHVSRQGLQJEUDNHOLQHLVDERXWWREHLQVWDOOHG
,IWKHVHDOLQJSOXJVDUHUHPRYHGWRRHDUO\EUDNHIOXLGFDQHVFDSH,IWKLVRFFXUVXQLWPD\QRWEHVXIILFLHQWO\ILOOHGRUDGHTXDWHO\EOHG
- Rest of installation is the reverse of removal.
- Bleed brake system Page 47-33 .
7LJKWHQLQJWRUTXHV
Brake lines to ABS aggregate:Thread M 10 x 1 15 Nm
Thread M 12 x 1 15 Nm
$%6('/$65(63%RVFK
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$%6V\VWHPJHQHUDOLQIRUPDWLRQ
ABS allocation in Left Hand Drive (LHD) vehicles.
The ABS brake system is divided diagonally (twocircuits). The vacuum brake servo unit boosts thebrakes pneumatically.
9HKLFOHVZLWK$%6('/$65
The hydraulic unit and control module are one unitand must always be replaced and installedtogether.
9HKLFOHVZLWK$%6('/$65(63
Hydraulic unit and control module are allocatedseparately in vehicle and may be removed andinstalled independently from each other.
ABS disturbances affect the brake system and thebooster. Account for differences in brakingbehavior. When the ABS warning lamp is lit up, therear wheels may lock prematurely during braking!
Hydraulic unit -a- and control module -b- are oneunit and must always be replaced together ifmalfunctioning.
New control modules that are delivered as areplacement part are coded.
&KDUDFWHULVWLFV
1 - Hydraulic unit
2 - ABS return flow pump
3 - Hydraulic pump for traction control withbrake pressure sensor
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&RQQHFWLQJEUDNHOLQHVIURPWDQGHPPDVWHUEUDNHF\OLQGHUDQGK\GUDXOLFSXPSIRUWUDFWLRQFRQWUROWRWKHK\GUDXOLFXQLWIRU
$%6('/$65DQG(63
A - Hydraulic unit to hydraulic pump for tractioncontrol
Identification at hydraulic unit -VLP-,
Identification at hydraulic pump for tractioncontrol -HE-
B - Hydraulic unit to secondary piston circuit of
master brake cylinder
Identification at hydraulic unit -HZ2-
1 - Hydraulic control unit to front left brakecaliper
Identification at hydraulic unit -VL-
2 - Hydraulic control unit to front right brakecaliper
Identification at hydraulic unit -VR-
3 - Hydraulic unit, rear right brake caliper
Identification at hydraulic unit -HR-
4 - Hydraulic unit, rear left brake caliper
Identification at hydraulic unit -HL-
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%HIRUHFDUU\LQJRXWUHSDLUVWRWKH$%6GHWHUPLQHWKHFDXVHRIWKHPDOIXQFWLRQXVLQJ2Q%RDUG'LDJQRVWLF2%'
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+\GUDXOLFXQLWDVVHPEO\RYHUYLHZ
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WKHHQJLQHFRPSDUWPHQW
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On gasolineengines vacuumis supplied fromintake manifold.
On dieselengines, avacuum pump isinstalled forvacuum creation.
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Function test
- With engineswitched off,depress brakepedal firmlyseveral times(to deplete
vacuum intool).
- Depress andhold brakepedal withaverage footpressure andstart engine. Ifbrake boosteris workingproperly, pedal
will be felt togive noticeablyunder foot(boosterassistancebecomeseffective).
If malfunctioning:replace ascomplete unitonly.
Check-valve (invacuum hose)Page 47-55
Function testPage 47-55
Removing andinstalling Page47-59
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%UDNHOLQH
Master brakecylinder/secondarypiston circuit tohydraulic unit
Identification at
hydraulic unit -HZ2-
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Hydraulic controlunit to front leftbrake caliper
Identification athydraulic unit -VL-
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Hydraulic controlunit to front rightbrake caliper
Identification athydraulic unit -VR-
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$%6K\GUDXOLFXQLW
bolted to controlmodule
The hydrauliccontrol module
must be replacedcompletely ifmalfunctioning
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Hydraulic controlunit to rear leftbrake caliper
Identification athydraulic unit -
HL-
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Hydraulic controlunit to rear rightbrake caliper
Identification athydraulic unit -HR-
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Hydraulic unit tohydraulic pumpfor tractioncontrol
Identification athydraulic unit -VLP-
Identification athydraulic pumpfor tractioncontrol -HE-
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For malfunctions,always replacetogether with thehydraulic pumpfor tractioncontrol
Identification at
hydraulic pumpfor tractioncontrol -BA-
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Master brakecylinder/secondarypiston circuit tohydraulic pump fortraction control
Identification athydraulic pumpfor tractioncontrol -HZ-
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6SHFLDO7RROVDQG(TXLSPHQW
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VAG1331 torque wrench
VAG1869/2 brake pedal depressor
Installation location:
The control module is bolted to the hydraulic unitand is located at left in the engine compartment.
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- For vehicles equipped with coded anti-theftradio, note radio code, obtain if necessary.
- Disconnect Ground (GND) strap from battery
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- Disengage connector from control module(arrow -1-) and disconnect (arrow -2-).
- Draw as much brake fluid as possible frombrake fluid reservoir using a bleeder bottle.
- Insert VAG1869/2 brake pedal depressor.
- Operate brake pedal using brake pedaldepressor.
- Attach bleeder hose of bleeder bottle to left-frontbrake caliper bleeder screw and open bleederscrew.
- Close front left bleeder screw.
- Place a sufficient number of lint-free clothsunder control module and hydraulic unit.
- Unscrew brake lines at hydraulic unit andhydraulic pump for traction control. Seal brakelines and threaded holes using plugs.
- Remove hydraulic unit with control moduleand hydraulic pump for traction control.
,QVWDOOLQJ
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,IWKHVHDOLQJSOXJVDUHUHPRYHGWRRHDUO\EUDNHIOXLGFDQHVFDSH,IWKLVRFFXUVXQLWPD\QRWEHVXIILFLHQWO\ILOOHGRUDGHTXDWHO\EOHG
- Rest of installation is the reverse of removal.
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- Bleed brake system Page 47-33 .
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Brake lines to ABS aggregate:
Thread M 10 x 1 15 Nm
Thread M 12 x 1 15 Nm
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LQVWDOOLQJ
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Always replaceafterdisassembly
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Before insertingsensor, cleaninner surface ofbore hole andcoat withsecuring greaseG 000 650
Note assemblysequence: Installsensor next and
then wire;starting atsensor, install inappropriatebrackets alongwith rubbergrommets
Wire routingFig. 1
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For 16" wheels, adifferent bracketis installed Fig.
2
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With rotor forspeed sensor
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)LJ :LUHURXWLQJRIZKHHOVSHHGVHQVRUDWIURQWD[OH
)LJ :LUHURXWLQJRIZKHHOVSHHGVHQVRUDWIURQWD[OHIRUZKHHOV
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VHQVRUDWIURQWD[OH
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- Raise vehicle.
- Remove bolt -1- from wheel speed sensor.
- Pull ABS wheel speed sensor out of wheelbearing housing.
- Unclip wire -2- from bracket (arrow).
- Disconnect harness connector -3- for wheelspeed sensor wire.
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- Connect harness connector -3- for wheel speedsensor wire.
The two tabs at the connectors for harnessconnector -3- must align with each other.
- Clip wire -2- into bracket (arrow).
- Before inserting wheel speed sensor, clean
inner surface of bore hole and coat sensorcompletely with securing grease G 000 650
- Insert wheel speed sensor in hole of wheelbearing housing and tighten bolt Page 45-36 .
- Turn wheels completely to left and right stoppositions and check clearance to ABS wheelspeed sensor wiring.
&KHFNLQJUHPRYLQJDQGLQVWDOOLQJURWRUDWIURQWD[OH
- Raise vehicle.
- Check rotor for dirt and damage by rotatingdrive axle.
- If rotor is damaged, drive axle must beremoved together with rotor and the outerconstant velocity joint must be replaced.
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Always replaceafterdisassembly
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Ejecting andpressing in
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pressing in
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When installing,hook into controlarm first
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Before inserting
sensor, cleaninner surface ofbore hole andcoat withsecuring greaseG 000 650
Note assemblysequence: Installsensor next andthen wire;starting atsensor, install inappropriatebrackets alongwith rubbergrommets
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Only for FrontWheel Drive(FWD) vehicles
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Always replace
Only for FrontWheel Drive(FWD) vehicles
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With rotor forspeed sensor
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- Raise vehicle.
- For vehicles with brake pad wear indicator,additionally rotate harness connector for brake
pad wear indicator by 90 and remove fromcable channel to side.
- Disconnect harness connector for brake padwear indicator.
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- Remove bolt from wheel speed sensor.
- Remove wheel speed sensor from control arm.
- Unclip wire (arrow -A- and -B-) from bracket atcontrol arm.
- Disconnect harness connectors -1- and -2-.
- Unclip wire from bracket -3- in direction ofarrow.
,QVWDOOLQJ
- Before inserting wheel speed sensor, cleaninner surface of bore hole and coat sensorcompletely with securing grease G 000 650
- Insert wheel speed sensor in hole of controlarm and tighten bolt Page 45-41
Rest of installation is the reverse of removal.
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- Raise vehicle.
- Check rotor for dirt and damage.
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- If rotor is damaged, tension disc must be
removed and replaced.
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- Raise vehicle.
- Check rotor for dirt and damage.
- If rotor is damaged, drive axle must be
removed together with rotor and the drive axlemust be replaced along with the outerconstant velocity joint.
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A description of the construction and function ofthe ESP system is included in self study programno. 204.
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- For vehicles equipped with coded anti-theftradio, note radio code, obtain if necessary.
- Disconnect battery.
- Remove passenger-side storagecompartment.
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,QVWUXPHQWSDQHO ,QVWUXPHQWFOXVWHUUHPRYLQJDQGLQVWDOOLQJ
- Pull back the front right foot carpet far enough
that the Sender for Rotation Rate -G202- andthe Sensor for transverse acceleration -G200-are accessible.
Installation location: The Sender for RotationRate -G202- and the Sensor for transverse
acceleration -G200- are secured on the wheelhousing, inside at the A-pillar.
- Disconnect connector from Sender forRotation Rate -G202- and Sensor fortransverse acceleration -G200-.
- Unscrew nuts and remove Sender forRotation Rate -G202- and Sensor fortransverse acceleration -G200-.
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- Installation is the reverse of removal.
- Code radio.
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- For vehicles equipped with coded anti-theftradio, note radio code, obtain if necessary.
- Disconnect battery.
- Remove passenger-side storage compartment.
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Location: ABS Control Module (w/EDL) -J104- islocated behind instrument panel on passenger-side, right next to center console.
- Fold foam matting forward.
- Disconnect connector from ABS Control Module(w/EDL) -J104-, move lever -1- in direction ofarrow to do so.
2 - Center console
- Remove control module -3-.
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,QVWDOOLQJ
- Installation is the reverse of removal.
- Code radio.
- Code control module.
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- Initiate basic setting
5HSDLU0DQXDO%UDNH6\VWHP2Q%RDUG'LDJQRVWLF2%'IURPP\5HSDLU*URXSFRQGXFWLQJ2Q%RDUG'LDJQRVWLF2%'LQLWLDWLQJEDVLFVHWWLQJ
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- Put wheels in straight-ahead position.
- Remove airbag unit and steering wheel.
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- Remove trim below steering column switch.
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- Remove trim above steering column switch.
- Disconnect connectors (arrows).
- Carefully lift hooks (arrows A) and removesteering angle sensor -G85-.
Arrow B points to the hole for the center positionmarking. This marking is required for installation.
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- Position the steering angle sensor -G85- untiltabs (arrows A) engage.
- A yellow dot must be visible in the hole (arrow -1-
)
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Rest of installation is the reverse of removal.
- Install airbag unit and steering wheel.
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IURPP\5HSDLU*URXS$LUEDJVUHPRYLQJDQGLQVWDOOLQJ$LUEDJXQLWGULYHUVLGHUHPRYLQJDQGLQVWDOOLQJ
- Code control module.
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'LDJQRVWLF2%'IURPP\5HSDLU*URXSFRQGXFWLQJ2Q%RDUG'LDJQRVWLF2%'FRGLQJFRQWUROPRGXOH
- Initiate basic setting
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Characteristics:
Symmetrical vibration dampener -A-
VW symbol -B- behind protrusion -C-
Continuous strengthening ribs -D-
Additional technical data Page 00-1
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/XFDVIUDPHFDOLSHU5&0QXPEHU/(3DJH
Characteristics:
Closed frame -A-
Brake pads visible from above
Additional technical data Page 00-1
ILVWFDOLSHU)10QXPEHU/8 3DJH
Characteristics:
Engage retaining spring -A- in brake caliperhousing.
Additional technical data Page 00-1
ILVWFDOLSHU)10QXPEHU/% 3DJH
Characteristics:
Engage two-part retaining spring -A- withadditional dampening sheet in brake caliperhousing.
With brake pad wear indicator -B-
16" is engraved on brake caliper -C-
Additional technical data Page 00-1
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ILVWFDOLSHU)150QXPEHU/% 3DJH
Characteristics:
Larger, outer frame -A-
With brake pad wear indicator -B-
Retaining spring is engaged in outer brakepad
Additional technical data Page 00-1
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Pads on bothsides of axle
must always bereplacedtogether.
Brake padthickness: 13.5mm
Checkingthickness
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Wear limit: 2 mmwithout brakepad mountingplate (remainingpad thickness)
Removing andinstalling Page46-7
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Always replace
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Servicing Page47-1
DistinguishingcharacteristicsPage 46-1
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Pads on bothsides of axlemust always be
replacedtogether.
Remove brakecaliper beforeremoving
Unventilated
brake disc:282 mm
Brake disc
thickness: 18mm
Wear limit: 15mm
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- Remove wheels.
- Unscrew lower mounting bolt for brake caliperhousing. Counterhold at guide pin.
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- Swing brake caliper housing upward.
- Remove brake pads.
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- Press piston back.
- Insert brake pads.
- Swing brake caliper housing downward andtighten mounting bolts to correct tighteningtorque.
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Bolt to brakecaliper housing
Fig. 1
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Pads on bothsides of axlemust always bereplacedtogether.
To remove, firstremove lowerbolt of brakecarrier andloosen upper bolt
Internallyventilated brake
disc: 280 mm
Brake discthickness: 24mm
Wear limit: 20mm
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2XWHUEUDNHSDG
With adhesivefoil on brake padmounting plate
Pads on bothsides of axle
must always bereplacedtogether.
Removing andinstalling Page46-15
Brake padthickness: 13mm
Checkingthickness
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Wear limit: 2 mmwithout brakepad mountingplate (remainingpad thickness)
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Pads on bothsides of axlemust always bereplacedtogether.
Removing andinstalling Page46-15
Brake padthickness: 13mm
Checkingthickness
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Wear limit: 2 mmwithout brakepad mountingplate (remainingpad thickness)
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Check fordamage
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Servicing Page47-5
Bolt to bridgeFig. 1
DistinguishingcharacteristicsPage 46-1
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- Position bridge using socket-head bolts andtighten.
- Insert sheet -1- (50 x 24 x 2 mm self-prepared) between surface of brake disc andunderside of bridge. This ensures sufficientclearance between bridge and brake disc.
- Press brake caliper housing/bridge againstsheet and tighten hex nuts of guide pins.
- Remove sheets and check clearance of brakedisc.
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Socket-head bolt Page 46-9
Nuts for guide pins Page 46-9
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- Remove wheels.
- Remove securing spring.
- Drive out brake pad retaining pins using drift -a-.
- Remove inner brake pad.
- Shift frame.
- Loosen outer brake pad from brake padmounting surface at bridge using a screwdriveror something similar.
- Press piston back.
,QVWDOOLQJ
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- Clean brake caliper housing, especially theadhesive surface for the brake pad, it must befree of residual adhesive and grease.
- Install inner brake pad.
- Install pad retaining pins enough that innerpad is held on.
- Remove protective foil from outer brake pad.
- Carefully insert outer brake pads.
- Press brake pad retaining pins completelythrough and install securing spring.
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Brake discthickness: 24mm
Wear limit: 20mm
Always replacepads on bothsides of axle ifworn.
Do not separatebrake discs fromwheel hub withforce or rustsolvent,otherwise brake
discs will bedamaged.
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Modified wheelbolt
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Brake padthickness: 13.5mm
Brake pad withretaining spring
sits at piston
Brake pad withadhesive foil onmounting platesits on outside
Wear limit: 2 mmwithout brakepad mountingplate (remainingpad thickness)
Checkingthickness
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Pads on bothsides of axlemust always bereplaced
together.
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Insert in bothholes of brakecaliper housing
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Supplied as pre-assembledreplacement partwith sufficientgrease on guidepins
Use repair kitwhen protectivecaps aredamaged.
Use greasepacket suppliedto lubricate guidepins
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Removing andinstalling Page46-22
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With rotor forspeed sensor
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- Remove wheels.
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- Remove protective caps (arrows).
- Disengage brake pad retaining spring frombrake caliper housing and remove.
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- Remove both guide pins from brake caliper.
- Remove brake caliper housing and set asideso that the weight of the brake caliper doesnot burden or damage the brake hose.
- Remove brake pads from brake caliperhousing or from brake carrier.
- Clean brake caliper housing, especially theadhesive surface for the brake pad, it must befree of residual adhesive and grease.
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WRSSHGRIIIOXLGZLOORYHUIORZDQGFDXVHGDPDJH
- Press piston back.
- Insert brake pad with retaining spring in brakecaliper housing.
- Install outer brake pad on brake carrier.
- Tighten brake caliper housing to brake carrierusing both guide pins (25 Nm).
- Install both protective caps.
- Place one bow of the retaining spring under thebrake carrier and insert a tab into hole in housing(arrow A).Tension second bow under the brake
carrier and engage second tab in hole (arrow B).
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disassembly
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Brake disc
thickness: 26mm
Wear limit: 22mm
Always replacepads on bothsides of axle ifworn.
Do not separate
brake discs fromwheel hub withforce or rustsolvent,otherwise brakediscs will bedamaged.
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Pads on bothsides of axle
must always bereplacedtogether.
With wearindicator
- When theappropriatewear limit hasbeen reached(limit: 2 to 3
mm), thewarning lamplights up
Brake padthickness: 13.5mm
Checkingthickness
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Wear limit: 8 mm(including brake padmounting plate)
Removing andinstalling Page 46-30
Brake pad withretaining spring sits at
piston
Brake pad withadhesive foil onbacking plate sits onoutside
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For padreplacement,
remove frombracket, -item no.12 -
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with additionaldampening sheet
Insert in bothholes of brakecaliper housing
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Supplied as pre-assembledreplacement partwith sufficientgrease on guidepins
Use repair kitwhen protective
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caps aredamaged.
Use greasepacket suppliedto lubricate guidepins
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Removing andinstalling Page46-30
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Before insertingsensor, cleaninner surface ofbore hole andcoat with
securing greaseG 000 650
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- Remove wheels.
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- Remove protective caps (arrows).
- Disengage brake pad retaining spring frombrake caliper housing and remove.
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- Disconnect harness connector -1- for brakepad wear indicator.
- Lift securing strap slightly at bottom of
connector -2- and then rotate 90 .
- Remove bottom of connector from bracketand unclip wire from protective cap -3- forvent valve.
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- Remove both guide pins from brake caliper.
- Remove brake caliper housing and set asideso that the weight of the brake caliper doesnot burden or damage the brake hose.
- Remove brake pads from brake caliperhousing or from brake carrier.
- Clean brake caliper housing, especially theadhesive surface for the brake pad, it must befree of residual adhesive and grease.
,QVWDOOLQJ
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- Press piston back.
- Insert brake pad with retaining spring in brakecaliper housing.
- Place outer brake pad with wear indicator onbrake carrier.
- Tighten brake caliper housing to brake carrierusing both guide pins (25 Nm).
- Insert lower part of connector for brake padwear indicator into bracket at brake caliper.
- Install both protective caps.
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- Place one bow of the retaining spring underthe brake carrier and insert a tab into hole inhousing (arrow A).Tension second bow underthe brake carrier and engage second tab inhole (arrow B).
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With rotor forspeed sensor
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Brake discthickness: 26mm
Wear limit: 22mm
Internallyventilated brake
disc: 313 mm
Always replacepads on bothsides of axle ifworn.
Do not separatebrake discs from
wheel hub withforce or rustsolvent,otherwise brakediscs will bedamaged.
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For padreplacement,remove frombracket, -item no.22 -
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Thickness 14mm
Brake pad withretaining springsits at piston
- When theappropriate
wear limit hasbeen reached(limit: 2 to 3mm), thewarning lamplights up
Brake pad withadhesive foil onbacking plate sitson outside
Wear limit: 7 mmincluding backingplate
Checkingthickness
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Pads on bothsides of axlemust always bereplacedtogether.
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8/3/2019 Servicio Sistemas de Frenos
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46-41
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Supplied as pre-assembledreplacement partwith sufficientgrease on guidepins
Use repair kit
when protectivecaps aredamaged.
Use greasepacket suppliedto lubricate guidepins
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Do not unscrewbrake hose whenreplacing brakepad
Removing:
- Remove brakepads -item no.13 - Page46-41
- InsertVAG1869/2brake pedaldepressor
- Unscrew brake
hose -item no.23 - from brakecaliper
Installing:
- Install brakepads -item no.13 - Page46-42
- Attach brake
hose -item no.23 - at brakecaliper
- RemoveVAG1869/2brake pedaldepressor
- Bleed brakesystem Page47-33
Servicing Page47-19
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Removing andinstalling Page46-41
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- Remove protective caps.
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- Using screwdriver, pry off brake pad retainingspring from brake caliper housing (arrow) andremove.
- Disconnect harness connector of brake padwear indicator.
- Lift securing strap slightly at bottom of
connector -1- and then rotate 90 .
- Remove bottom of connector from bracket indirection of arrow.
- Remove both guide pins (arrows) from brakecaliper.
- Remove brake caliper housing and set asideso that the weight of the brake caliper doesnot burden or damage the brake hose.
- Remove brake pads from brake caliperhousing or from brake carrier.
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WRSSHGRIIIOXLGZLOORYHUIORZDQGFDXVHGDPDJH
- Press piston back.
- Insert brake pad with retaining spring in brakecaliper housing.
- Install outer brake pad on brake carrier.
- Tighten brake caliper housing to brake carrierusing both guide pins Page 46-34 .
- Install both protective caps.
- Install retaining spring in brake caliperhousing.
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Always replaceafterdisassembly
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Thickness 12mm
Wear limit: 10mm
Always replacepads on bothsides of axle ifworn.
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Adjusting brakepressureregulator Page47-41
Not installed invehicles with AllWheel Drive(AWD), ABSBosch 5.3 andclosedconstruction
(box-type van,combi, caravelle,multivan)
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Always replace
Only for FrontWheel Drive(FWD) vehicles
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With rotor for
speed sensor
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Check for properfitting
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Vehicles up toVIN no.70ZWH130 482or 70ZWX121
939 withoutbrake padretention plates
Supplied as pre-assembledreplacement partwith sufficientgrease on guidepins
If protective caps
or guide pins aredamaged, installrepair kit. Usegrease packetsupplied tolubricate guidepins
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Thickness: 11.5without mounting
plate
Checkingthickness:
5HSDLU0DQXDO0DLQWHQDQFH
Wear limit: 2 mmwithout brakepad mounting
plate (remainingpad thickness)
Pads on bothsides of axlemust always bereplacedtogether.
Removing andinstalling Page
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46-50
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Always replace
When looseningand tightening,counter-hold onguide pin
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Modification:Adapted forvehicles fromVIN no.70ZWH130 483and 70ZWX121940 withimplementation
of the brake padretention plate -item no. 29 - andbrake carrier -item no. 30 -.
Servicing Page47-25
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Parking brake,adjusting Page46-55
6SULQJFODPS
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Installed invehicles fromVIN no.70ZWH130 483and 70ZWX121
940
Only install withnew brake carrier-item no. 30 -
Always replacewhen pads arereplaced
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Installed invehicles fromVIN no.70ZWH130 483and 70ZWX121940 withimplementationof the brake padretention plate -item no. 29 -.
Supplied as pre-assembledreplacement partwith sufficientgrease on guidepins
If protective capsor guide pins aredamaged, installrepair kit. Use
grease packetsupplied tolubricate guidepins
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- Remove wheels.
- Remove parking brake cable at brake caliper.
- Unscrew attachment bolts (arrows) from brakecaliper housing.
- Remove brake caliper housing and set aside sothat the weight of the brake caliper does not
burden or damage the brake hose.
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- Remove brake pads.
- If present, remove brake pad retention plates.
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- Brake caliper housing hangs on a hook (arrowB).
- Install pistons at knurled wheel of special tool-3272- by turning toward right. Do not damageprotective caps.
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)RUSLVWRQVWKDWDUHGLIILFXOWWRPRYHDQRSHQHQGZUHQFKVL]HPPFDQEH
DSSOLHGDWWKHDSSURSULDWHZUHQFKVXUIDFHDUURZ$
:KHQSLVWRQLVPLVDGMXVWHGZLWKDSLVWRQUHVHWWLQJWRRORULIIRRWEUDNHLVRSHUDWHGWKHDXWRPDWLFUHVHWIXQFWLRQRIWKHEUDNHFDOLSHULVFRPSURPLVHG
)RUYHKLFOHVXSWR9,1QR=:+DQG=:;
- Thoroughly clean contact surfaces for brakepads at brake carrier, remove corrosion.
- Insert brake pads in brake carrier.
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- Using a feeler gauge -A-, measure play betweenbrake pads -1- and contact surfaces for brakepads -2- at brake carrier.
Play: At least 0.4 mm to ensure proper functionof brake system.
If play is less than 0.4 mm, clean contact
surfaces for brake pads at brake carrier again.
- Remove brake pads.
- Lightly grease contact surfaces for brake padsusing solid lubricant G000 650.
- Insert brake pads in brake carrier.
)RUYHKLFOHVIURP9,1QR=:+DQG=:;
- Thoroughly clean contact surfaces for brake padretention plates at brake carrier, removecorrosion.
- Insert brake pad retention plates and brake
pads in brake carrier.
- Using a feeler gauge -A-, measure play betweenbrake pads -1- and brake pad retention plates -2- at brake carrier.
Play: At least 0.4 mm to ensure proper functionof brake system.
If play is less than 0.4 mm, clean contactsurfaces for brake pad retention plates at brake
carrier again.
&RQWLQXDWLRQIRUDOOYHKLFOHV
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- Secure brake caliper housing using new self-
locking bolts.
5HSDLUNLWLQFOXGHVIRXUVHOIORFNLQJKH[EROWVZKLFKPXVWDOZD\VEHLQVWDOOHG
- Secure parking brake cable (arrow) at brakecaliper housing.
- Adjusting parking brake Page 46-55 .
'RQRWRSHUDWHIRRWEUDNHXQWLODIWHUSDUNLQJEUDNHLVDGMXVWHG
- Mount wheels.
1RWHV
$IWHUUHSODFLQJEUDNHSDGVDQGEHIRUHPRYLQJYHKLFOHDOZD\VGHSUHVVEUDNHSHGDOVHYHUDOWLPHVILUPO\WRSURSHUO\VHDWEUDNHSDGVLQWKHLUQRUPDORSHUDWLQJSRVLWLRQ
&KHFNEUDNHIOXLGOHYHODIWHUUHSODFLQJEUDNHSDG
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-Parking brake lever in released position. Tightenadjustment nut (arrow) in until...
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- ... the levers (arrow) lift off stops at brakecalipers.
- Maximum permitted play is 1.0 mm to stop.
- Tighten parking brake and then release again.
1RWH
%HFDXVHWKHUHDUEUDNHVKDYHDQDXWRPDWLFDGMXVWPHQWIXQFWLRQUHDGMXVWLQJWKHSDUNLQJEUDNHLVXVXDOO\QRWQHFHVVDU\IROORZLQJLQLWLDODGMXVWPHQW
- Check whether wheels turn freely.
5HDUEUDNHVVHUYLFLQJZKHHOV6RFNHWKHDG
VFUHZ1P
+H[EROW1P
$%6ZKHHOVSHHGVHQVRU
Before insertingsensor, cleaninner surface ofbore hole andcoat withsecuring greaseG 000 650
+DUQHVVFRQQHFWRU
For padreplacement,remove frombracket, -item no.7 -
&RQWURODUP
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+H[EROWVHOIORFNLQJ1P
Always replace
When looseningand tightening,counter-hold on
guide pin
%UDFNHW
*XLGHSLQV
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Pads on bothsides of axlemust always bereplacedtogether.
With wearindicator
- Warning lamplights up whenrelevant wearlimit has beenreached
Thickness: 13.5mm
Wear limit: 8.5mm including
backing plate
Checkingthickness:
5HSDLU0DQXDO0DLQWHQDQFH:RUNSURFHGXUHGHVFULSWLRQ)URQWDQGUHDUEUDNH
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Removing andinstalling Page46-61
%UDNHSDGUHWHQWLRQSODWH
Always replacewhen pads arereplaced
5HWDLQLQJVSULQJ
Clip into brakecaliper
Secures wire forbrake pad wearindicator
%UDNHFDOLSHU
Do not unscrewbrake hose when
replacing brakepad
Removing:
- Remove brakepads -item no.10 - Page46-61
- InsertVAG1869/2
brake pedaldepressor
- Unscrew brakehose withbrake caliper
Installing:
- Install brakepads -item no.
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10 - Page46-63
- Attach brakehose withbrake caliper
- Remove
VAG1869/2brake pedaldepressor
- Bleed brakesystem Page47-33
After servicing orreplacing, parkingbrake cable must beadjusted first.
Parking brake,adjusting Page 46-55
Servicing Page 47-
25
6SULQJFODPS
3DUNLQJEUDNHFDEOH
%UDNHFDUULHUZLWKJXLGHSLQVDQGSURWHFWLYHFDS
Supplied as pre-
assembledreplacement partwith sufficientgrease on guidepins
If protective capsor guide pins aredamaged, installrepair kit. Usegrease packet
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supplied tolubricate guidepins
6RFNHWKHDGEROW1P
%UDNHGLVF
Thickness: 13.5mm
Wear limit: 11.5mm
Always replacepads on bothsides of axle ifworn.
+H[EROW1P
%DFNLQJSODWH
Allocation
3DUWVFDWDORJ
%DFNLQJSODWH
To remove, drillout pop rivet -item no. 22 -
Allocation
3DUWVFDWDORJ
3RSULYHW
4x
&RQQHFWLQJEUDFH
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%UDNHSDGVUHPRYLQJDQGLQVWDOOLQJ
6SHFLDO7RROVDQG(TXLSPHQW
3272 reset tool
VAG1331 torque wrench
1RWH
:KHQUHPRYLQJPDUNEUDNHSDGVWKDWZLOOEHXVHGDJDLQ,QVWDOOLQWKHVDPHSRVLWLRQRWKHUZLVHEUDNLQJHIIHFWZLOOEHXQHYHQ
5HPRYLQJ
- Remove wheels.
- Unclip spring clamp -1-.
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- Remove parking brake cable -2- from brakecaliper.
- Rotate harness connector for brake pad wear
indicator by 90 and remove from cablechannel toward side.
- Disconnect harness connector for brake pad
wear indicator.
- Unclip retaining spring -A- for brake pad wearindicator wire from brake caliper.
- Unscrew attachment bolts (arrows) from brakecaliper housing.
- Remove brake caliper housing and set aside sothat the weight of the brake caliper does notburden or damage the brake hose.
- Remove brake pads and brake pad retentionplates (arrows).
,QVWDOOLQJ
1RWH
%HIRUHSXVKLQJEDFNWKHSLVWRQVLSKRQVRPHRIWKHEUDNHIOXLGRXWRIWKHEUDNHIOXLGUHVHUYRLU:KHQVLSKRQLQJEUDNHIOXLGDOZD\VXVHDSODVWLFEOHHGHUERWWOHWKDWLVXVHGH[FOXVLYHO\IRUEUDNH
IOXLG%UDNHIOXLGLVSRLVRQRXV1(9(5VLSKRQEUDNHIOXLGZLWK\RXUPRXWK
- Brake caliper housing hangs on a hook (arrowB).
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- Install pistons at knurled wheel of special tool
-3272- by turning toward right. Do not damageprotective caps.
,QVHUWVSHFLDOWRROVRWKDWWKHFROODUDUURZRIWKHWRROUHVWVDWEUDNHFDOLSHU
)RUSLVWRQVWKDWDUHGLIILFXOWWRPRYHDQ
RSHQHQGZUHQFKVL]HPPFDQEHDSSOLHGDWWKHDSSURSULDWHZUHQFKVXUIDFHDUURZ$
:KHQSLVWRQLVPLVDGMXVWHGZLWKDSLVWRQUHVHWWLQJWRRORULIIRRWEUDNHLVRSHUDWHGWKHDXWRPDWLFUHVHWIXQFWLRQRIWKHEUDNHFDOLSHULVFRPSURPLVHG
- Thoroughly clean contact surfaces for brake padretention plates at brake carrier, removecorrosion.
- Insert brake pad retention plates and brake padsin brake carrier.
- Using a feeler gauge -A-, measure play betweenbrake pads -1- and brake pad retention plates -2- at brake carrier.
Play: At least 0.4 mm to ensure proper functionof brake system.
If play is less than 0.4 mm, clean contactsurfaces for brake pad retention plates at brakecarrier again.
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- Insert pad retaining springs (arrows) and brakepads, inner brake pad with wire for brake padwear indicator, in the brake carrier.
- Secure brake caliper housing using new self-locking bolts.
1RWH
5HSDLUNLWLQFOXGHVIRXUVHOIORFNLQJKH[EROWVZKLFKPXVWDOZD\VEHLQVWDOOHG
- Press brake lever -3- in direction of arrow andengage parking brake cable -2-.
- Install spring clamp -1-.
- Connect connection -5- for brake pad wearindicator and press it into the cable channel -4-.
- Rotate harness connector in cable channel by
90 .
- Adjusting parking brake Page 46-55 .
'RQRWRSHUDWHIRRWEUDNHXQWLODIWHUSDUNLQJEUDNHLVDGMXVWHG
- Mount wheels.
1RWHV
$IWHUUHSODFLQJEUDNHSDGVDQGEHIRUHPRYLQJYHKLFOHDOZD\VGHSUHVVEUDNHSHGDOVHYHUDOWLPHVILUPO\WRSURSHUO\VHDWEUDNHSDGVLQWKHLUQRUPDORSHUDWLQJSRVLWLRQ
&KHFNEUDNHIOXLGOHYHODIWHUUHSODFLQJEUDNHSDG
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3DUNLQJEUDNHFDEOHUHPRYLQJDQGLQVWDOOLQJ
)URQWSDUNLQJEUDNHFDEOHUHPRYLQJDQGLQVWDOOLQJ
5HPRYLQJ
- Release parking brake.
- Raise vehicle.
- Remove nut (arrow) from front parking brake
cable.
- Pry both brackets out from underbody.
- Remove trim from parking brake lever.
- Place brake lever in upper end position.
- Remove cable tie from locking latch.
- Disengage front parking brake lever fromlocking latch -1- (arrow).
,QVWDOOLQJ
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- Guide front parking brake cable through
underbody into interior.
- Place brake lever in upper end position.
- Engage front parking brake cable in locking
latch -1- (arrow).
- Attach new cable ties at locking latch in front offront parking brake.
- Attach trim at parking brake lever.
- Raise vehicle.
- Clip brackets into underbody.
- Install nut (arrow) at front parking brake cable.
- Adjusting parking brake Page 46-55 .
3XOOOHYHUUHPRYLQJDQGLQVWDOOLQJ
5HPRYLQJ
- Release parking brake.
- Raise vehicle.
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- Remove nut (arrow) from front parking brakecable.
- Disengage pull-lever from compensatorbracket.
- Remove pull-lever -1- from rear parking brakecable.
,QVWDOOLQJ
- Engage pull-lever -1- in rear parking brakecable -2-.
- Engage pull-lever in compensator bracket.
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- Install nut (arrow) at front parking brake cable.
- Adjusting parking brake Page 46-55 .
5HDUSDUNLQJEUDNHFDEOHUHPRYLQJDQG
LQVWDOOLQJ
5HPRYLQJ
- Unclip spring clamp -1-.
- Remove parking brake cable -2- from brakecaliper.
- Disengage parking brake cable from bracket atcontrol arm (arrow A).
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- Unclip parking brake cable from bracket atunderbody (arrow).
- Disengage parking brake cable -1- from pull-
lever -2-.
,QVWDOOLQJ
- Engage parking brake cable -1- in pull-lever -2-.
- Clip parking brake cable into bracket at
underbody.
- Engage parking brake cable in bracket atcontrol arm (arrow A).
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- Attach parking brake cable -2- at brake
caliper.
- Clip in spring clamp -1-.
- Adjusting parking brake Page 46-55 .
3DUNLQJEUDNHOHYHUUHPRYLQJ
DQGLQVWDOOLQJ+DQGOH
Remove forward,first pressretaining tabsunder handledownward
7ULPIRUSDUNLQJ
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Installationposition Fig.1
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Installationposition Fig.1
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/RFNLQJZDVKHU
3DUNLQJEUDNHOHYHU
3LQ
6HOIORFNLQJQXW1P
Not installed onRight Hand Drive(RHD) vehicles
Always replace
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Welded tostructure onRight Hand Drive(RHD) vehicles
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6HOIORFNLQJQXW
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Always replace
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Only for RightHand Drive(RHD) vehicles
3XOOOHYHU
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%UDFNHW
5HWXUQVSULQJ
6SULQJEUDFNHW
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Parking brake,adjusting Page46-55
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Only installed inplatform trucks
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1 - Locking latch
2 - Spring sleeve
3 - Compression spring
Dimension -a- approx. 126 mm
Slide spring sleeve -2- onto coil spring -3-when installing.
4 - Button
Screw in until stop.
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5 - Latch rod
6 - Parking brake lever
%UDNHSHGDODVVHPEO\RYHUYLHZ:$51,1*
7KHSDWKRIWKHEUDNHSHGDOPXVWQRWEHVKRUWHQHGYLDH[WUD
IORRUPDWV
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&DS
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With sieve
Switch for brakefluid levelindicatorintegrated inreservoir
6HDOLQJSOXJV
Coat with brake
fluid and pressinto expansiontank
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+H[QXWWLJKWHQWR1P
7DQGHPPDVWHUEUDNHF\OLQGHU
Cannot beserviced.
Replace ascomplete unit ifmalfunctioning.
Bleeding Page47-35
6HDO
Always replace
/RFNLQJZDVKHU
Check for securefitting
3LQ
Lubricate with G000 602
6HOIORFNLQJQXW1P
Always replace
3UHVVXUHURGZLWKIRUNKHDGHGEUDNHERRVWHU
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7DQGHPEUDNHERRVWHU
On gasolineengines vacuumis supplied fromintake manifold.
On dieselengines, avacuum pump isinstalled forvacuum creation.
Function test
- With engineswitched off,depress brakepedal firmly
several times(to depletevacuum intool).
- Depress andhold brakepedal withaverage footpressure andstart engine. Ifbrake booster
is workingproperly, pedalwill be felt togive noticeablyunder foot(boosterassistancebecomeseffective).
If malfunctioning:replace as
complete unitonly.
Check-valve (invacuum hose)Page 47-55
Function testPage 47-55
Removing and
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installing Page47-59
*DVNHW
For tandembrake booster
/RFNLQJZDVKHU
5HWXUQVSULQJIRUEUDNHSHGDO
%XVKLQJIRUEUDNH
SHGDO
%UDNHSHGDO
3LYRWSLQIRUEUDNHSHGDO
%UDNHOLJKWVZLWFK
Secure brakepedal at pressurerod of brake
booster beforeinstalling brakelight switch
Before installing,remove plungercompletely
Guide switchthroughassembly holeand install by
rotating 90toward right.
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+H[EROW1P
0RXQWLQJEUDFNHW
+H[EROW1P
0RXQWLQJSODWH
&URVVSDQHO
%UDNHSHGDOUHPRYLQJDQGLQVWDOOLQJ
1RWHV
/XEULFDWHDOOEHDULQJDQGFRQWDFWVXUIDFHVZLWK0R6
OXEULFDQW
5HPRYHRQO\WKHIRUNKHDGFRQQHFWLRQWREUDNHSHGDOZKHQUHPRYLQJWKHEUDNHERRVWHU
5HPRYLQJ
- Remove covers before removing brake pedal.
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- Remove brake light switch.
- Remove securing disc at pins for fork-headconnection to brake pedal.
- Remove pins.
- Remove securing disc of pivot pins for clutchand brake pedal.
- Remove clutch pedal.
5HSDLU0DQXDO0DQXDO7UDQVPLVVLRQ5HSDLU*URXS&OXWFKPHFKDQLVPVHUYLFLQJ
5HPRYLQJDQGLQVWDOOLQJFOXWFKSHGDO
- Remove pivot pins.
- Remove brake pedal.
,QVWDOOLQJ
- Installation is the reverse of removal.
- Adjust brake light switch Page 46-80 , itemno. 18 .
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)URQWEUDNHFDOLSHUVHUYLFLQJ)URQWEUDNHFDOLSHUVHUYLFLQJ/XFDV
&ILVWFDOLSHUZKHHOV
1RWHV
,QVWDOOFRPSOHWHUHSDLUNLWZKHQVHUYLFLQJ
$SSO\DWKLQFRDWRIEUDNHF\OLQGHUSDVWH*$WREUDNHF\OLQGHUVSLVWRQVDQGVHDOV
%UDNHFDOLSHUKRXVLQJ
6HDO
Removing andinstalling Page47-2
3URWHFWLYHFDS
Do not damagewhen installingpiston
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Removing andinstalling Page47-2
)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ/XFDV&ILVWFDOLSHUZKHHOV
6SHFLDO7RROVDQG(TXLSPHQW
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3409 wedge
Brake piston resetting tool
5HPRYLQJ
- Force piston from brake caliper housing usingcompressed air.
1RWH
3ODFHDZRRGHQERDUGLQWRWKHUHFHVVRIWKH
FDOLSHUKRXVLQJWRFDWFKWKHSLVWRQVRLWLVQRWGDPDJHG
- Removing seal using 3409 assembly wedge.
1RWH
:KHQUHPRYLQJPDNHVXUHWKDWVXUIDFHRIF\OLQGHULVQRWGDPDJHG
,QVWDOOLQJ
- Use only appropriate solvent to clean surfaces
of piston and protective seal, then dry.
- Apply thin coat of brake cylinder paste G 052150 A2 to piston and protective seal beforeinstalling.
- Install sealing ring in brake caliper housing.
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- Place protective cap with outer sealing lip on
piston.
- Using 3409 assembly wedge, insert innersealing lip into cylinder groove.
1RWH
+ROGSLVWRQLQIURQWRIFDOLSHUKRXVLQJIRUWKLVSURFHGXUH
- Press piston into brake caliper housing usingpiston resetting tool.
1RWH
2XWHUVHDOLQJOLSRISURWHFWLYHFDSZLOOWKHQHQJDJHLQSLVWRQJURRYH
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)URQWEUDNHFDOLSHUVHUYLFLQJ/XFDV5&IUDPHFDOLSHUZKHHOV
1RWHV
,QVWDOOFRPSOHWHUHSDLUNLWZKHQVHUYLFLQJ
%UDNHFDOLSHUGLVDVVHPEOLQJDQGDVVHPEOLQJ 3DJH
$SSO\DWKLQFRDWRIEUDNHF\OLQGHUSDVWH*$WR
EUDNHF\OLQGHUVSLVWRQVDQGVHDOV
9HQWVFUHZ
%UDNHFDOLSHUKRXVLQJ
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Removing andinstalling Page47-6
3URWHFWLYHFDS
Do not damagewhen installingpiston
3LVWRQV
Removing andinstalling Page47-6
)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ/XFDV5&IUDPHFDOLSHUZKHHOV
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6SHFLDO7RROVDQG(TXLSPHQW
3409 wedge
Brake piston resetting tool
5HPRYLQJ
- Force piston from brake caliper housing usingcompressed air.
1RWH
3ODFHDZRRGHQERDUGLQWRWKHUHFHVVRIWKHFDOLSHUKRXVLQJWRFDWFKWKHSLVWRQVRLWLVQRWGDPDJHG
- Removing seal using 3409 assembly wedge.
1RWH
:KHQUHPRYLQJPDNHVXUHWKDWVXUIDFHRIF\OLQGHULVQRWGDPDJHG
,QVWDOOLQJ
- Use only appropriate solvent to clean surfacesof piston and protective seal, then dry.
- Apply thin coat of brake cylinder paste G 052150 A2 to piston and protective seal beforeinstalling.
- Install sealing ring in brake caliper housing.
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- Place protective cap with outer sealing lip on
piston.
- Insert inner sealing lip into cylinder groove.
1RWH
+ROGSLVWRQLQIURQWRIFDOLSHUKRXVLQJIRUWKLVSURFHGXUH
- Press piston into brake caliper housing usingpiston resetting tool.
1RWH
2XWHUVHDOLQJOLSRISURWHFWLYHFDSZLOOWKHQHQJDJHLQSLVWRQJURRYH
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)URQWEUDNHFDOLSHUVHUYLFLQJ)1ILVWFDOLSHUZKHHOV
1RWHV
,QVWDOOFRPSOHWH
UHSDLUNLWZKHQVHUYLFLQJ
$SSO\DWKLQFRDWRIEUDNHF\OLQGHUSDVWH*$WREUDNHF\OLQGHUVSLVWRQVDQGVHDOV
'XVWFDS
Push onto
bleeder valve
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Apply thin coat ofbrake cylinderpaste G 052 150A2 to threadsbefore screwingin
&DSV
Insert inmountingbushing
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Insert in brakecaliper housing
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%UDNHFDOLSHUKRXVLQJ
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Bolt to brakecaliper housing
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Insert with bothends in holes ofbrake caliperhousing
6HDO
Removing andinstalling Page47-11
3LVWRQV
Removing andinstalling Page47-11
3URWHFWLYHFDS
Do not damagewhen installingpiston
)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ)1ILVWFDOLSHUZKHHOV
6SHFLDO7RROVDQG(TXLSPHQW
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3409 wedge
Brake piston resetting tool
5HPRYLQJ
- Force piston from brake caliper housing usingcompressed air.
1RWH
3ODFHDZRRGHQERDUGLQWRWKHUHFHVVRIWKH
FDOLSHUKRXVLQJWRFDWFKWKHSLVWRQVRLWLVQRWGDPDJHG
- Removing seal using 3409 assembly wedge.
1RWH
:KHQUHPRYLQJPDNHVXUHWKDWVXUIDFHRIF\OLQGHULVQRWGDPDJHG
,QVWDOOLQJ
- Use only appropriate solvent to clean surfaces
of piston and protective seal, then dry.
- Apply thin coat of brake cylinder paste G 052150 A2 to piston and protective seal beforeinstalling.
- Install sealing ring in brake caliper housing.
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- Place protective cap with outer sealing lip on
piston.
- Using 3409 assembly wedge, insert innersealing lip into cylinder groove.
1RWH
+ROGSLVWRQLQIURQWRIFDOLSHUKRXVLQJIRUWKLVSURFHGXUH
- Press piston into brake caliper housing usingpiston resetting tool.
1RWH
2XWHUVHDOLQJOLSRISURWHFWLYHFDSZLOOWKHQHQJDJHLQSLVWRQJURRYH
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)URQWEUDNHFDOLSHUVHUYLFLQJ)1ILVWFDOLSHUZKHHOV
1RWHV
,QVWDOOFRPSOHWH
UHSDLUNLWZKHQVHUYLFLQJ
$SSO\DWKLQFRDWRIEUDNHF\OLQGHUSDVWH*$WREUDNHF\OLQGHUVSLVWRQVDQGVHDOV
'XVWFDS
Push onto
bleeder valve
Secures wire forbrake pad wearindicator
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Apply thin coat ofbrake cylinderpaste G 052 150A2 to threadsbefore screwingin
&DSV
Insert inmountingbushing
*XLGHSLQV1PIWOE
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%HDULQJEXVKLQJ
Insert in brakecaliper housing
%UDNHFDOLSHUKRXVLQJ
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Bolt to brakecaliper housing
5HWDLQLQJVSULQJ
Insert with bothends in holes ofbrake caliperhousing
6HDO
Removing andinstalling Page47-16
3LVWRQV
Removing andinstalling Page47-16
3URWHFWLYHFDS
Do not damagewhen installingpiston
)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ)1ILVWFDOLSHUZKHHOV
6SHFLDO7RROVDQG(TXLSPHQW
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3409 wedge
Brake piston resetting tool
5HPRYLQJ
- Force piston from brake caliper housing usingcompressed air.
1RWH
3ODFHDZRRGHQERDUGLQWRWKHUHFHVVRIWKH
FDOLSHUKRXVLQJWRFDWFKWKHSLVWRQVRLWLVQRWGDPDJHG
- Removing seal using 3409 assembly wedge.
1RWH
:KHQUHPRYLQJPDNHVXUHWKDWVXUIDFHRIF\OLQGHULVQRWGDPDJHG
,QVWDOOLQJ
- Use only appropriate solvent to clean surfaces
of piston and protective seal, then dry.
- Apply thin coat of brake cylinder paste G 052150 A2 to piston and protective seal beforeinstalling.
- Install sealing ring in brake caliper housing.
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- Place protective cap with outer sealing lip on
piston.
- Using 3409 assembly wedge, insert innersealing lip into cylinder groove.
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- Press piston into brake caliper housing usingpiston resetting tool.
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Push ontobleeder valve
Secures wire forbrake pad wearindicator
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Apply thin coat of
brake cylinderpaste G 052 150A2 to threadsbefore screwingin
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Insert inmountingbushing
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Insert in brakecaliper housing
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Bolt to brakecaliper housing
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