Skoda Rapid Brake Systems Eng

Service
Workshop Manual
Rapid NH 2013 ➤
Rapid NH 2014 ➤
Brake systems
Edition 07.2017
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Rapid NH 2013 ➤ , Rapid NH 2014 ➤
Brake systems - Edition 07.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during road tests in which testing and measuring equipment is used . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 PR number assignment – brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Brake inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Installation location overview - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Installation location overview - ABS/ESC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Exploded view – control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 . . . . . . . . . . . . . . 25
3.3 Disconnecting the control unit from the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Fitting the control unit to the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Removing and installing front speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Removing and installing the rear speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . . . 36
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Resetting brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.5 Removing and installing brake anchor plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6 Removing and installing wheel-brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.2 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3 Removing and installing the rear handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Clipping the brake pedal onto the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
1 Front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.1 Summary of components - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Summary of components - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Brake servo unit and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.1 Summary of components - brake servo unit and master brake cylinder . . . . . . . . . . . . . . 101
3.2 Check the operation of the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.4 Checking the master brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.5 Removing and installing master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.6 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1 Exploded view – vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2 Checking the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.3 Checking the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.4 Connecting vacuum gauge for brake servo VAS 6721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.5 Checking vacuum generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.6 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.7 Vacuum generation with manual vacuum pump VAS 6213 . . . . . . . . . . . . . . . . . . . . . . . . 143
4.8 Removing and installing the pressure sensor for the brake servo unit . . . . . . . . . . . . . . . . 144
4.9 Removing and installing vacuum sensor G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.10 Removing and installing electric vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.2 Prebleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.5 Testing leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
ii Contents
00 – Technical data
1 Safety instructions
(SRL001107; Edition 07.2017)
⇒ “1.1 Safety precautions when working on vehicles with start-
stop system”, page 1
⇒ “1.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 1
1.1 Safety precautions when working on ve‐

hicles with start-stop system
When working on vehicles with start/stop system, please observe
the following instructions:
CAUTION
Risk of injury as a result of automatic engine start in vehicles
with start/stop system.
♦ In vehicles with the start/stop system activated (identifiable
by an indication in the dash panel insert) the engine can start
automatically if required.
♦ Make sure that the start-stop system is deactivated when
carrying out work on the vehicle (switch ignition off, if nec‐
essary switch ignition on again).
1.2 Safety precautions during road tests in

which testing and measuring equipment
is used
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
There is a risk of accident from deflection and insufficient se‐
curing of testers and measuring instruments.
♦ Using testers and measuring instruments during driving op‐
eration causes distraction.
♦ There is an increased risk of injury from unsecured testers
and measuring instruments.
♦ Always attach the testing and measurement equipment to
the rear seat.
♦ Always have the testing and measurement equipment op‐
erated by a 2nd person.
♦ Always operate the testing and measurement equipment
from the rear seat.
♦ Do not operate the testing and measurement equipment
from the front passenger seat.
♦ Persons can be injured by the release of the passenger air‐
bag in the event of an accident.
1. Safety instructions 1
2 Identification
⇒ “2.1 PR number assignment – brake”, page 2
2.1 PR number assignment – brake

The brake type installed in the vehicle is indicated by PR num‐
bers.
The PR numbers are indication on the vehicle data sticker in the
luggage compartment floor as well as in the Service Schedule.
Information about the installed brakes can be found in the ELSA
Pro vehicle data system.
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
2 Rep. gr.00 - Technical data

3 Technical data
⇒ “3.1 Technical data for brakes”, page 3
3.1 Technical data for brakes

⇒ “3.1.1 Master brake cylinder and brake servo”, page 3
⇒ “3.1.2 Front brakes”, page 3
⇒ “3.1.3 Rear brake”, page 4
⇒ “3.1.4 Brake fluid”, page 4
3.1.1 Master brake cylinder and brake servo

Master brake cyl‐ mm 20.64
inder - ∅
Brake servo unit Inc Left-hand drive: 10
-∅ h
Right-hand drive: 7"/8"
3.1.2 Front brakes

Explanations concerning PR Numbers
⇒ “2.1 PR number assignment – brake”, page 2 .
Front brake FS-III
Front brake caliper (type denomination) FS-III
PR number 1ZG
Front brake caliper, piston - ∅ m 54.0
m
Front brake disc – ∅ m 256.0
m
Brake disc, thickness m 22.0
m
Brake disc, minimum thickness m 19.0
m
Pad thickness with supporting plate m 19.6
m
Minimum pad thickness without sup‐ m 2.0
porting plate m
Front brake FN3
Front brake caliper (type denomination) FN3
PR number 1ZC
Front brake caliper, piston - ∅ m 54.0
m
Front brake disc – ∅ m 288.0
m
Brake disc, thickness m 25.0
m
Brake disc, minimum thickness m 22.0
m
Volkswagen Technical Site: http://vwts.ru http://vwts.info
3. Technical data 3
Front brake caliper (type denomination) FN3

PR number 1ZC
m
porting plate m
3.1.3 Rear brake

Explanations concerning PR Numbers
⇒ “2.1 PR number assignment – brake”, page 2 .
Rear disc brake C 38
Rear brake caliper (type denomination) C 38
PR number 1KT
Rear brake caliper, piston - ∅ m 38
m
Rear brake disc – ∅ m 230
m
Brake disc, thickness m 9
m
Brake disc, minimum thickness m 7
m
m
porting plate m
Rear drum brake
Rear drum brake
PR number 1KL
Brake drum - diameter ∅ m 228
m
Wheel-brake cylinder - ∅ m 19.05
m
Brake pad, width m 32
m
Pad thickness without supporting shoe m 4.4
m
porting shoe m
3.1.4 Brake fluid
4 Rep. gr.00 - Technical data

Classification Only use new original brake fluid N.052.766.Z0 as per US standard FMVSS 571.116, DOT 4 and VW standard 501 14
Top-up ⇒ Maintenance ; Booklet Rapid NH
5
4 Brake inspection
⇒ “4.1 General points”, page 6
⇒ “4.2 Checking vehicles with front-wheel drive”, page 6
4.1 General points

♦ The test stand is used as drive.
♦ During the testing, the idling speed must be set on vehicles
with manual gearbox and the driving position »N« must be
engaged on vehicles with automatic gearbox.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is off.
4.2 Checking vehicles with front-wheel drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The test speed must not exceed 6 km/h.
The test stands approved by Škoda comply with these conditions.
6
45 – Anti-lock brake system

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

ABS
The following configurations are possible on vehicles with ABS
from TRW:
♦ ABS
♦ ABS/ESC
The ABS brake system is split diagonally. Brake servo assistance
is provided pneumatically by the vacuum brake servo.
Vehicles fitted with ABS do not have a mechanical brake pressure
regulator. Specifically matched software in the ABS control unit -
J104- regulates the brake pressure distribution on the rear axle.
Note
♦ If the ABS hydraulic unit - N55- is damaged, the ABS control

unit - J104- must be fully replaced with the ABS hydraulic unit
- N55- .
♦ The ABS control unit - J104- can be separated from the ABS
hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”,
page 32 .
♦ The hydraulic pump and the ABS hydraulic unit - N55- must
not be separated from each other.
♦ Faults in the ABS do not influence the brake system and servo
assistance. The conventional braking system remains fully
functional even without ABS. There will be a change in braking
behaviour. After the ABS warning lamp comes on, the rear
wheels may lock prematurely during braking.
ABS arrangement, left-hand drive to CW 21/2015

1 - ABS hydraulic unit - N55- with ABS control unit - J104-
2 - Brake servo
1. General points 7
ABS arrangement, left-hand drive to CW 22/2015

1 - Brake servo
Arrangement of the ABS, right-hand drive vehicle

1 - Brake servo
Vehicles with ABS
The ABS control unit - J104- -1- and the ABS hydraulic unit - N55-
-2- form a single unit and cannot be separated. The hydraulic
pump -3- must not be separated from the ABS hydraulic unit -
N55- -2-.
Vehicles with ABS / ESC to 04/2015
-2- form a single unit and cannot be separated. The hydraulic
pump -3- must not be separated from the ABS hydraulic unit -
N55- -2-.
Vehicles with ABS / ESC from 05/2015
8 Rep. gr.45 - Anti-lock brake system

-2- form a single unit. They can only be separated after the
complete unit is removed. The ABS control unit - J104- can be
separated from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page
32 . The hydraulic pump -3- must not be separated from the ABS
hydraulic unit - N55- -2-.
New control units supplied by the spare parts area are not coded.
They must be coded after installation ⇒ Vehicle diagnostic tester.
Continued for all vehicles
♦ Before starting work on anti-lock brake systems, query the
event memory to check for complaints and conduct guided
fault finding ⇒ Vehicle diagnostic tester.
♦ Do not separate plug connections unless the ignition is switch‐
ed off.
♦ Before working on anti-lock braking systems, switch off the
ignition and disconnect the ground strap from the battery ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnect and con‐
nect battery .
♦ If the battery earth strap is disconnected and connected, carry
out additional operations ⇒ Electrical System; Rep. gr. 27 ;
Battery .
♦ Welding work using electric welding equipment may affect the
ABS system.
♦ Do the following before commencing welding work using elec‐
trical welding tool:
– Disconnect the earth strap from the negative terminal of the
battery and cover the negative terminal.
– Connect the earth connection of the electric welding tool di‐
rectly to the part to be welded. There must not be any electri‐
cally insulated parts between the earth connection and the
welding point.
– Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
♦ During painting operations, the ABS control unit - J104- may
be exposed to a maximum temperature of 95 °C for only a
short period, and to a maximum of 85 °C for longer periods
(approx. 2 hours).
♦ Do not drive the vehicle if the connector is unplugged from the
ABS control unit - J104- .
♦ 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 connection points and the surrounding area
before disconnecting, but do not use any aggressive cleaning
agents, such as brake cleaner, petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or close opened components if the repair is not
completed immediately (use plugs from the repair kit - 1H0 698
311 A- ).
♦ Only use lint-free cloths.
♦ Do not remove spare parts from their wrappings until immedi‐
ately before installation.
♦ Use only genuine wrapped parts.
1. General points 9
♦ When the system is open, do not work with compressed air

and do not move the vehicle.
♦ The valve coils in the ABS control unit - J104- must not be
calibrated.
♦ The valve coils in the ABS control unit - J104- cannot be re‐
placed.
♦ The pressure sensor must not be modified or damaged.
♦ The pressure sensor cannot be replaced.
♦ The sensor housing must not be subjected to mechanical load.
♦ No measurements must be carried out at the contact points of
the ABS control unit - J104- .
♦ No measurements must be carried out at the contact points of
the ABS hydraulic unit - N55- .
♦ The valve domes of the ABS hydraulic unit - N55- must not be
damaged or bent.
♦ The contacts on the ABS control unit - J104- and the ABS hy‐
draulic unit - N55- cannot be replaced.
♦ Do not use contact spray.
♦ No contamination or foreign object may located between ABS
control unit - J104- and ABS hydraulic unit - N55- .
♦ Ensure that no brake fluid enters connectors.
♦ Observe the relevant instructions when handling brake fluid.
♦ After completing work which involved opening the brake sys‐
tem, bleed the brake system with the brake filling and bleeding
device , e. g. -VAS 5234- ,
⇒ “6.3 Bleeding hydraulic system following standard proce‐
dure”, page 153 .
♦ During the subsequent road test, ensure that at least one con‐
trolled brake application is performed (pulsing must be felt on
the brake pedal).

2 Installation location overview

⇒ “2.1 Installation location overview - ABS”, page 11
⇒ “2.2 Installation location overview - ABS/ESC”, page 13
2.1 Installation location overview - ABS
Note
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - ABS control unit - J104-

❑ Fitting location: on the
ABS hydraulic unit -
N55- in engine compart‐
ment
⇒ “1.1 Repair instruc‐
tions for repair work on
ABS”, page 7
❑ do not disconnect the
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
The following components are
integrated in the ABS control
unit - J104- :
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
♦ the components cannot be
changed individually
❑ Check ⇒ Vehicle diag‐
nostic tester
❑ Removing and installing
the ABS control unit -
J104- with the ABS hy‐
draulic unit - N55-
⇒ “3.2 Removing and
installing ABS control
unit J104 / ABS hydraul‐
ic unit N55 ”, page 25
2 - ABS hydraulic unit - N55-
The ABS hydraulic unit - N55- consists of these components:
♦ ABS return flow pump - V39-
♦ Valve block (contains inlet and outlet valves).
❑ The ABS return flow pump - V39- and the valve block must not be separated from each other
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 25
3 - ABS warning light - K47-
❑ Fitting location: in the dash panel insert
2. Installation location overview 11

4 - Dual circuit and hand brake system warning light - K7 -

5 - Diagnostic connection
❑ Fitting location: behind bottom part of dash panel, driver side
6 - Brake light switch - F-
❑ Including brake pedal switch - F47-
❑ Removing and installing ⇒ “3.3 Removing and installing brake light switch”, page 105
7 - Front right and left wheel speed sensors - G45- / -G47-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ “4.1 Removing and installing front speed sensors G45 / G47 ”, page 36
8 - Wheel hub with wheel bearing
❑ Sensor ring for ABS is built into the wheel hub
9 - Rear right and left wheel speed sensors - G44- / -G46-
⇒ “4.2 Removing and installing the rear speed sensors G44 / G46 ”, page 36

2.2 Installation location overview - ABS/ESC
Note
♦ If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦ On vehicles manufactured from 05/2015 (⇒ Electronic Catalogue of Original Parts ), you can disconnect
the ABS control unit - J104- from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32 .
♦ The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.

❑ Fitting location: on the
ABS hydraulic unit -
N55- in engine compart‐
ment
❑ do not disconnect the
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
The following components are
integrated in the ABS control
unit - J104- :
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
♦ the components cannot be
changed individually
❑ Check ⇒ Vehicle diag‐
nostic tester
the ABS control unit -
J104- with the ABS hy‐
draulic unit - N55-
installing ABS control
unit J104 / ABS hydraul‐
ic unit N55 ”, page 25
Vehicles as of 05/2015
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit ⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32
❑ Fitting the control unit to the hydraulic unit
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 34
2 - ABS hydraulic unit - N55-
The ABS hydraulic unit - N55- consists of these components:
❑ ABS return flow pump - V39-
❑ Brake pressure sender 1 - G201-
Valve block (contains inlet and outlet valves).
Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Installation location overview 13

❑ The ABS return flow pump - V39- and the valve block must not be separated from each other
3 - Warning light 2 for ESC and TCS - K216-
4 - ABS warning light - K47-
5 - Warning light for ESC and TCS - K155-
6 - Dual circuit and hand brake system warning light - K7 -
7 - Warning light for tyre pressure display - K220-
9 - TCS and ESP button - E256-
❑ Fitting location: in the dash panel
10 - Diagnostic connection
❑ Fitting location: behind bottom part of dash panel, driver side
11 - Steering angle sender - G85-
❑ Fitting location: on the steering column between the steering wheel and the steering column switch
❑ Removing and installing ⇒ Electrical System; Rep. gr. 94
12 - Front right and left wheel speed sensors - G45- / -G47-
14 - Rear right and left wheel speed sensors - G44- / -G46-
⇒ “4.2 Removing and installing the rear speed sensors G44 / G46 ”, page 36

3 Control unit and hydraulic unit

⇒ “3.1 Exploded view – control unit and hydraulic unit”,
page 15
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hy‐
draulic unit N55 ”, page 25
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page
32
3.1 Exploded view – control unit and hy‐

draulic unit
⇒ “3.1.1 Summary of components - control unit and hydraulic unit
for ABS, left-hand drive vehicles”, page 15
for ABS, right-hand drive vehicles”, page 17
for ABS/ESC, left-hand drive vehicles up to 21/2015”, page 19
for ABS/ESC, right-hand drive vehicles from 22/2015”,
page 21
for ABS/ESC, right-hand drive vehicles”, page 23
3.1.1 Summary of components - control unit and hydraulic unit for ABS, left-hand
drive vehicles
Note
3. Control unit and hydraulic unit 15


❑ with ABS hydraulic unit -
N55-
⇒ “3.2 Removing and in‐
stalling ABS control unit
J104 / ABS hydraulic
unit N55 ”, page 25
2 - Brake line
❑ to front right brake cali‐
per
❑ Marking on the ABS hy‐
draulic unit - N55-
-Front right (VR)-
❑ With thread M10 x 1
❑ 14 Nm
3 - Brake line
❑ to rear left brake caliper/
wheel-brake cylinder
draulic unit - N55-
-Rear left (HL)-
❑ 14 Nm
4 - Brake line
❑ to rear right brake cali‐
per/wheel-brake cylin‐
der
draulic unit - N55-
-Rear right (HR)-
❑ 14 Nm
5 - Brake line
❑ to front left brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front left (VL)-
❑ 14 Nm
6 - Brake line
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - N55-
❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 2 (HZ2)-
❑ 14 Nm
7 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55-
❑ 14 Nm
8 - Brake servo
❑ Removing and installing ⇒ “3.6 Removing and installing brake servo”, page 114
9 - Nut
❑ self-locking

❑ 20 Nm
10 - Mounting bracket
11 - Screw
❑ 8 Nm
❑ Moisten the bolt of the support with lubricant, e.g. -D 007 000 A2- , before inserting into the rubber
bearings
❑ after installing, check for firm seating
3.1.2 Summary of components - control unit and hydraulic unit for ABS, right-hand
drive vehicles
Note
1 - Brake line
❑ from master brake cylin‐
der (push rod piston cir‐
cuit) to ABS hydraulic
unit - N55-
draulic unit - N55-

-Hydraulic cylinder 2 (HZ2)-

❑ 14 Nm
2 - Brake line
❑ 14 Nm
3 - Brake line
❑ to front right brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front right (VR)-
❑ 14 Nm
4 - Brake line
❑ to rear left brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear left (HL)-
❑ 14 Nm
5 - Brake line
❑ to rear right brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear right (HR)-
❑ 14 Nm
6 - Brake line
❑ 14 Nm
❑ with ABS hydraulic unit - N55-
9 - Screw
❑ 8 Nm
10 - Nut
❑ self-locking
❑ 20 Nm
bearings
12 - Brake servo

3.1.3 Summary of components - control unit and hydraulic unit for ABS/ESC, left-
hand drive vehicles up to 21/2015
Note

❑ with ABS hydraulic unit -
N55-
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit
⇒ “3.3 Disconnecting
the control unit from the
hydraulic unit”,
page 32
❑ Fitting the control unit to
the hydraulic unit
⇒ “3.4 Fitting the control
unit to the hydraulic
unit”, page 34
stalling ABS control unit
J104 / ABS hydraulic
unit N55 ”, page 25
2 - Brake line
❑ to front right brake cali‐
per
draulic unit - N55-
-Front right (VR)-
❑ 14 Nm
3 - Brake line
❑ to rear left brake caliper/
wheel-brake cylinder
draulic unit - N55-
-Rear left (HL)-
❑ 14 Nm
4 - Brake line
❑ 14 Nm

5 - Brake line
❑ 14 Nm
6 - Brake line
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - N55-
❑ 14 Nm
7 - Brake line
❑ 14 Nm
8 - Brake servo
9 - Nut
❑ self-locking
❑ 20 Nm
11 - Screw
❑ 8 Nm
bearings

3.1.4 Summary of components - control unit and hydraulic unit for ABS/ESC,
right-hand drive vehicles from 22/2015
Note
1 - Brake servo
stalling brake servo”,
page 114
2 - Brake line
unit - N55-
draulic unit - N55-

❑ 14 Nm
3 - Brake line

❑ 14 Nm
4 - Brake line
❑ 14 Nm
5 - Brake line
❑ 14 Nm
6 - Brake line
❑ 14 Nm
7 - Brake line
❑ 14 Nm
❑ Disconnecting the control unit from the hydraulic unit
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32
❑ with rubber bearings
❑ attached to the ABS hydraulic unit - N55- by 2 bolts
❑ 8 Nm
bearings
11 - Nut
❑ self-locking
❑ 20 Nm

3.1.5 Summary of components - control unit and hydraulic unit for ABS/ESC,
right-hand drive vehicles
Note
1 - Brake line
unit - N55-
draulic unit - N55-

❑ 14 Nm
2 - Brake line
❑ 14 Nm

3 - Brake line
❑ 14 Nm
4 - Brake line
❑ 14 Nm
5 - Brake line
❑ 14 Nm
6 - Brake line
❑ 14 Nm
❑ Disconnecting the control unit from the hydraulic unit
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32
9 - Screw
❑ 8 Nm
10 - Nut
❑ self-locking
❑ 20 Nm
bearings
12 - Brake servo

3.2 Removing and installing ABS control

unit - J104- / ABS hydraulic unit - N55-
⇒ “3.2.1 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 , left -hand drive vehicles up to 21/2015”, page
25
hydraulic unit N55 , left -hand drive vehicles from 22/2015”, page
28
hydraulic unit N55 , right-hand drive vehicles”, page 30
3.2.1 Removing and installing ABS control

unit - J104- / ABS hydraulic unit - N55- ,
left -hand drive vehicles up to 21/2015
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Repair kit - 1H0 698 311 A-
Removing
Fitting location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located in the engine compartment on the right side.
Note
Do not bend the brake lines in the area of the hydraulic unit.
– Read out and note the actual control unit coding ⇒ Vehicle
diagnostic tester.
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– If present, remove engine cover ⇒ Engine; Rep. gr. 10 .
Vehicles with engines TDI Common Rail DPF (diesel particle fil‐
ter)
– Remove plenum chamber cover ⇒ Body Work; Rep. gr. 66 .
– If present, open heat shield collar.

– Take plug connections -1- to -4- out of the bracket, disconnect
and expose electric cables.
– Remove the connector holder from the bulkhead plenum
chamber.
– Remove intake hose and air filter ⇒ Engine; Rep. gr. 23 .
– Pull the engine control unit out of the bracket and lay to the
side.
– Remove engine control unit bracket.
– Remove the insulation from the bulkhead plenum chamber.
– Remove bulkhead plenum chamber ⇒ Body Work; Rep. gr.
50 .

– Press down the red fuse -arrow-.
– Unlock the plug connection of the control unit -arrow- and pull
out towards the front.
– Attach the bleeder hose of the bleeding bottle onto the vent
valves of the front left and rear left brake caliper and open vent
valves.
– Press down brake pedal with brake pedal load , e.g. -V.A.G
1869/2- , at least 60 mm.
– Close front left and rear left bleeder valves.
– Do not remove brake pedal load , e. g. -V.A.G 1869/2- .
– Place a sufficient non-fluffing cloths under and around the ABS
control unit - J104- and the ABS hydraulic unit - N55- .
NOTICE
Make sure that no brake fluid gets onto the contacts of the ABS
control unit - J104- .

– Mark brake lines -A- and -B- from the ABS hydraulic unit - N55-
to the master brake cylinder.
– Unscrew the brake lines from the ABS hydraulic unit - N55- ,
unclip from the brackets and lay to the side.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit - 1H0 698 311 A- .
– Mark the brake lines (for brake calliper) -1- to -4-, unscrew and
close with plugs from the repair kit - 1H0 698 311 A- .
– Pull ABS hydraulic unit - N55- with ABS control unit - J104-
upwards out of the bracket.
– Slacken nuts and remove bracket (if it is necessary to remove
the bracket).
Note

- N55- .
page 32 .
Installing
Installation is performed in the reverse order; pay attention to the
following points:
Note
♦ Only remove plugs from the new ABS hydraulic unit - N55- if
the relevant brake line is installed.
♦ If the plugs were already removed from the ABS hydraulic unit
- N55- , then brake fluid may escape and adequate filling and
bleeding of the unit can no longer be guaranteed.
♦ Make sure that the rubber bearings are not pressed out of the
console when installing the bracket. After installing, check for
tight fight, otherwise failure may be caused by a malfunction
of the ABS hydraulic unit - N55- .
• Make sure that the multi-pin plug connection latches correctly

with the ABS control unit - J104- .
– Remove brake pedal load , e.g. -V.A.G 1869/2- .
– Bleed brake system.
– Connect the battery and carry out any additional measures
after reconnecting the battery ⇒ Electrical System; Rep. gr.
27 .
– Code new ABS control unit - J104- ⇒ Vehicle diagnostic tester
and adapt.
While doing so, a basic setting of the steering angle sender -
G85- , the lateral acceleration sender - G200- , the brake pressure
sender 1 - G201- and the longitudinal acceleration sender - G251-
must be performed ⇒ Vehicle diagnostic tester.

Tightening torques
♦ ⇒ “3.1.3 Summary of components - control unit and hydraulic
unit for ABS/ESC, left-hand drive vehicles up to 21/2015”,
page 19
♦ Bulkhead plenum chamber ⇒ Body Work; Rep. gr. 50 .
♦ Air filter ⇒ Engine; Rep. gr. 23

left -hand drive vehicles from 22/2015
♦ Repair kit - 1H0 698 311 A-
N55- and is located in the engine compartment -2-.
Note
Do not bend the brake lines in the area of the hydraulic unit.
Removing
– Read out and document the current control unit coding ⇒ Ve‐
hicle diagnostic tester.
For vehicles with 1.6 MPI engine with automatic gearbox
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Undo the mounting bracket with the automatic gearbox control
unit - J217- and place the ⇒ gearbox; Rep. gr. 37 down to the
side.
For vehicles with a 1.4 TDI engine
– Mark and pull off connector -1- of the boost pressure actuator
- V465- and the change over valve for the intake manifold valve
- N239- -2-.
– Remove bracket -3- together with the boost pressure actuator
- N239- , place down to the side.
– Remove bracket with -automatic glow period control unit- J179
-4- from the E-box and place to the side.
– Remove engine cover ⇒ Engine; Rep. gr. 10 .

– Loosen hose clamp -1- and remove the complete air filter
housing -2- ⇒ Engine; Rep. gr. 23 .
– Press fuse -1- upwards in -direction of arrow-.

– Press locking element -2- upwards in -direction of arrow- and
unlock connector -3-.
– Disconnect connector -3- from ABS control unit - J104- and
place to side.
NOTICE
– Drain the brake fluid from the brake fluid reservoir using the
brake filling and bleeding device e.g. -VAS 5234- .
– Mark brake lines -A- and -B- from the ABS hydraulic unit - N55-
to the master brake cylinder.
– Screw off brake lines -A- and -B- from the ABS hydraulic unit
- N55- and brake cylinder.
– Close the openings on the ABS hydraulic unit - N55- and the
master brake cylinder with screw plugs from the repair kit -
H0 698 311 A- .
– Unscrew brake lines (to the brake calipers) -1-4- from the ABS
hydraulic unit - N55- .
– Close the brake lines with the screw plugs from the repair kit
- H0 698 311 A- .

Note

- N55- .
page 32 .
Installing
following points:
Note
– Bleed brake system ⇒ “6 Hydraulic system”, page 152 .

27 .
– Code the control unit - J104- ⇒ Vehicle diagnostic tester.
Tightening torques
unit for ABS/ESC, right-hand drive vehicles from 22/2015”,
page 21

right-hand drive vehicles
Removing
♦ Repair kit - 1H0 698 311 A-

Fitting location:
N55- and is located in the engine compartment on the left side.
– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Press fuse -2- in -direction of arrow-.

– Unlock fuse -1- for plug -3-.
– Disconnect connector -3-.
– Position brake pedal load , e.g. -V.A.G 1869/2- .

valves of the front left and rear left brake caliper and open vent
valves.
1869/2- , at least 60 mm.
– Close front left and rear left bleeder valves.
NOTICE
– Mark brake lines -A- and -B- from the master brake cylinder
and unscrew from the ABS hydraulic unit - N55- .
– Mark the remaining brake lines -1- to -4- and unscrew from the

– Slacken nuts and remove bracket (if it is necessary to remove
the bracket).
Note

- N55- .
page 32 .
Installing
following points:
Note

27 .
– Code the control unit - J104- ⇒ Vehicle diagnostic tester.
Tightening torques
unit for ABS/ESC, right-hand drive vehicles”, page 23
3.3 Disconnecting the control unit from the

hydraulic unit
♦ In the case of a malfunction of the ABS control unit - J104- ,
the control unit must be disconnected from the ABS hydraulic
unit - N55- and replaced individually.
♦ In the case of a malfunction of the ABS hydraulic unit - N55- ,
the ABS hydraulic unit - N55- must be completely replaced
together with the ABS control unit - J104- .

NOTICE
♦ The hydraulic pump - V64- and ABS hydraulic unit - N55-
must not be separated from each other.
♦ On a disconnected ABS control unit - J104- , the printed cir‐
cuit board is exposed.
♦ No moisture and no dirt particles must penetrate into the in‐
terior of the ABS control unit - J104- .
♦ Before handling the ABS control unit - J104- , the technician
must discharge himself electrostatically. The electrostatic
discharge is achieved by touching earthed metal parts. Do
not grab directly at the plug contacts or electronic compo‐
nents.
Note
Electrostatic charge can cause malfunctions of the ABS control

unit - J104- .
– Remove the ABS hydraulic unit - N55- with the ABS control
unit - J104-
⇒ “3.2 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 ”, page 25 .
– Lay the ABS hydraulic unit - N55- with the ABS control unit -
J104- on a clean flat surface facing upwards.
– Unscrew the fixing screws -arrows- of the ABS control unit -
J104- -1- and place aside immediately (danger of mix-ups with
new screws).

– Separate the ABS control unit - J104- from the ABS hydraulic
unit - N55- in the -direction of arrow-.
Note
The ABS control unit - J104- may not tilt when it is pulled off from
the ABS hydraulic unit - N55- .
– Cover the solenoid coils of the ABS control unit - J104- with a
non-fluffing cloth.
After separating from the ABS control unit - J104- and the ABS
hydraulic unit - N55- , use the transport protection for valve
domes.
– Check the sealing surface of the ABS hydraulic unit - N55- for
cleanliness. If necessary clean with white spirits and a non-
fluffing cloth.
Note
♦ The sealing surface of the ABS control unit - J104- may not be
repaired using a file, metal scraper or similar.
♦ If the sealing surface is damaged, replace the sealing surface
of the ABS control unit - J104- .
♦ The seal of the ABS control unit - J104- must not be damaged.
♦ The seal is not designed as spare part, so it is part of the new
ABS control unit - J104- .
3.4 Fitting the control unit to the hydraulic

unit
NOTICE
Strong vibrations (e.g. fall, knock) can destroy the ABS control
unit - J104- . The ABS control unit - J104- must no longer be
used.
• The contact surfaces must be cleaned before assembling.

• The seal of the ABS control unit - J104- must not be damaged.
– Position the ABS control unit - J104- without tilting it onto the

– Tighten the screws in the order -1-, -2-, -3-, -4- in three stages
⇒ page 35 .
Note
♦ The threads in the ABS hydraulic unit - N55- must not be re‐
paired or recut.
♦ If the thread is damaged, the ABS hydraulic unit - N55- must
be replaced.
Note
A new control unit may only be installed on the same hydraulic

unit twice as a maximum to ensure that the elastic seal is still leak-
tight.
Tightening torques
Component Tightening torque

ABS hydraulic unit - J104- to ABS control unit - N55- - 1st stage 1.5
ABS hydraulic unit - J104- to ABS control unit - N55- - 2nd stage 2.5 Nm
ABS control unit - J104- to ABS hydraulic unit - N55- - 3rd stage 3.5 Nm

4 Sensors
⇒ “4.1 Removing and installing front speed sensors G45 / G47 ”,
page 36
⇒ “4.2 Removing and installing the rear speed sensors G44 / G46
”, page 36
4.1 Removing and installing front speed

sensors -G45- / -G47-
Removing
– Raise vehicle.
– Disconnect connector -1- on the front wheel speed sensor .
– Release screw -3-.
– Pull front speed sensor -2- out of the wheel bearing housing.
Installing
– Installation is performed in the reverse order; pay attention to
the following points:
– Before inserting the front speed sensor , clean the inner sur‐
face of the hole and moisten with hot bolt paste - G 052 112
A3- .
Tightening torques
♦ ⇒ “1.1 Assembly overview - front brakes”, page 38
4.2 Removing and installing the rear speed

sensors -G44- / -G46-
Note
The procedure for removal and installation of the speed sensor is

identical for vehicles with drum brakes and for vehicles with disc
brakes.
Removing
– Raise vehicle.
– Disconnect connector -1- on the rear speed sensor .

– Unscrew screw -arrow-.
Note
The wheel speed sensor is shown on the vehicle with disc brakes.
– Pull the rear speed sensor -1- out of the opening in the axle
stud and unclip its cables on the axle.
Installing
– Installation is carried out in the reverse order.
Tightening torques
♦ ⇒ “2.1.1 Summary of components - rear axle brake, drum
brake”, page 52
♦ ⇒ “2.1.3 Summary of components - rear axle brake, disc
brake”, page 56
4. Sensors 37
46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brakes”, page 38
⇒ “1.2 Removing and installing brake pads”, page 41
⇒ “1.3 Removing and installing brake caliper”, page 46
1.1 Assembly overview - front brakes

⇒ “1.1.1 Summary of components - front brake FS-III”,
page 38
⇒ “1.1.2 Summary of components - front brake FN3”, page 40
1.1.1 Summary of components - front brake FS-III
Note
♦ Observe the instructions for changing the pad

⇒ “1.2.1 Changing the brake pads of the front brake - Mounting instructions”, page 41
♦ Brake inspection ⇒ “4 Brake inspection”, page 6 .
♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
ensure the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding device , e.g. -VAS 5234- , to drain the brake fluid from the brake fluid
reservoir.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2- , before removing a brake calliper or separating a brake hose
from the brake calliper.
38 Rep. gr.46 - Brakes - mechanism

1 - Brake disc
❑ internally ventilated
❑ Dimensions and wear
limit
⇒ “3.1.2 Front brakes”,
page 3
❑ always replace axle-
wise
❑ unscrew the brake cali‐
per before removing
❑ Do not use force to sep‐
arate the brake discs
from the wheel hub, if
necessary use rust sol‐
vent; as you could oth‐
erwise damage the
brake discs.
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
2 - Screw
❑ 8 Nm
3 - Brake pads
limit
page 3
❑ Inspect thickness
⇒ Maintenance ; Book‐
let Rapid NH
❑ Observe the instruc‐
tions for changing the
pad
⇒ “1.2.1 Changing the
brake pads of the front
brake - Mounting in‐
structions”, page 41 Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ always replace axle-wise
⇒ “1.2.2 Removing and installing brake pads, floating caliper disc brake FS-III”, page 42
4 - Brake caliper
❑ Removing and installing ⇒ “1.3.1 Removing and installing brake caliper FS-III”, page 46
❑ Summary of components ⇒ “1.1.1 Exploded view – front brake caliper - brake FS III”, page 90
❑ Assignment ⇒ Electronic Catalogue of Original Parts
5 - Guide bolt
❑ 30 Nm
6 - Cap
❑ Disconnect
7 - Tensioning sleeve
8 - Brake hose
❑ with banjo union and hollow screw
❑ 35 Nm
❑ for vehicles with ABS the sensor ring is built into the wheel hub
1. Front brakes 39
10 - Screw
❑ 12 Nm
11 - Cover plate
12 - Wheel bearing housing
13 - ABS wheel speed sensor
14 - Screw
❑ 8 Nm
1.1.2 Summary of components - front brake FN3
1 - Brake disc
❑ internally ventilated
limit
page 3
wise
❑ To remove, detach the
brake caliper -6- and
brake carrier -5- first
❑ Do not use force to sep‐
arate the brake discs
from the wheel hub, if
necessary use rust sol‐
vent; as you could oth‐
erwise damage the
brake discs.
Parts
2 - Screw
❑ 8 Nm
3 - Brake pads
limit
page 3
❑ Inspect thickness
⇒ Maintenance ; Book‐
let Rapid NH
❑ Observe the instruc‐
tions for changing the
pad
⇒ “1.2.1 Changing the
brake pads of the front
brake - Mounting instructions”, page 41
❑ Removing and installing ⇒ “1.2.3 Removing and installing brake pads, brake calliper FN3”, page 44
4 - Spring
❑ inserted into both bore holes of the brake caliper
5 - Brake carrier
❑ screwed onto the wheel-bearing housing

6 - Brake caliper
❑ Removing and installing ⇒ “1.3.2 Removing and installing brake caliper FN3”, page 49
❑ Summary of components ⇒ “1.1.2 Exploded view – front brake caliper - brake FN3”, page 92
7 - Guide bolt
❑ 30 Nm
8 - Cap
❑ remove
9 - Brake hose
❑ with banjo union and hollow screw
❑ 35 Nm
10 - Screw
❑ clean when using again
❑ 124 Nm
11 - Screw
❑ 8 Nm
13 - Wheel bearing housing
14 - Cover plate
15 - Screw
❑ 12 Nm
❑ for vehicles with ABS the sensor ring is built into the wheel hub
1.2 Removing and installing brake pads

⇒ “1.2.1 Changing the brake pads of the front brake - Mounting
instructions”, page 41
⇒ “1.2.2 Removing and installing brake pads, floating caliper disc
brake FS-III”, page 42
⇒ “1.2.3 Removing and installing brake pads, brake calliper FN3”,
page 44
1.2.1 Changing the brake pads of the front

brake - Mounting instructions
When changing the pads, pay attention to the following points:
– Check protective collar of brake calliper piston.
Replace protective cap if damaged.
When replacing the protective cap:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxidation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing cap.
– Check the brake piston and the brake caliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake caliper completely if damaged.
For brake caliper piston, press into the initial position:
1. Front brakes 41
– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective cap.
Replace the brake caliper completely if damaged.
1.2.2 Removing and installing brake pads,

floating caliper disc brake FS-III
♦ Piston jig - T10145-
Note

instructions”, page 41 .
♦ When removing mark the brake pads (inner, outer) you intend
to keep using. Fit in same position when installing, or braking
will be uneven!
♦ After replacing the brake pads, depress brake pedal firmly
several times when the vehicle is stationary to ensure the
brake pads are properly seated in their normal operating po‐
sition.
♦ Do not unscrew the brake hose when replacing the brake pad.
Removing
– Remove front wheels.
– If present, disconnect the connector for the brake pad wear
indicator.
– Remove caps -1-.
– Unscrew and remove the two guide bolts -arrows- from the
brake caliper.

– Remove the brake caliper -1- and secure with wire in such a
way that the weight of the brake caliper does not burden or
damage the brake hose.
– Remove brake pads -2- and -3- from the brake caliper.
Clean
WARNING
Do not flush the brake system with compressed air. The dust
that is generated is hazardous to health!
– Thoroughly clean guiding surface for brake pads on brake

carrier and remove corrosion.
– Clean brake caliper.
Note
Use spirits only to clean the brake caliper housing.
Installing
• Drain some brake fluid from the brake fluid reservoir before
resetting the pistons. Otherwise, particularly if reservoir has
been topped up, fluid will overflow and cause damage.
WARNING
Brake fluid is toxic and must never be sucked up by mouth!
– Push piston back with piston jig - T10145- -1-.
Note
Different version of the inner and outer brake pad. Do not mix up
when installing
– Insert the inner brake pad -1- (with the large 3-finger clip with
metallic gloss and with the marking “piston side” on the steel
supporting plate) on the piston.
– Insert the outer brake pad -2- (with the small black 3-finger
clip) into the brake caliper housing.
1. Front brakes 43
– First position the brake caliper with brake pads on the bottom
wheel bearing housing -arrow-.
– Tilt the brake caliper so that the guide bolts of the brake caliper
are flush with the threaded holes of the wheel-bearing hous‐
ing.
The bolts of the brake caliper -arrows- must only be inserted into
the brake caliper in such a way that the brake caliper can be tilted.
– Screw on both guide bolts -arrows- on the wheel bearing

housing.
– Connect the plug connection for the brake pad wear indicator
(where the vehicle is fitted with this).
– Insert the caps of the guide bolts.
– Install front wheels.
• After each brake pad replacement, forcefully apply the brake
pedal repeatedly to ensure the brake pads go into their normal
operating position.
• Check brake fluid level after replacing the brake pads, if nec‐
essary top up with brake fluid.
Tightening torques
♦ ⇒ “1.1.1 Summary of components - front brake FS-III”,
page 38
♦ Wheel bots ⇒ Wheels, tyres; Rep. gr. 44
1.2.3 Removing and installing brake pads,

brake calliper FN3
• Observe the instructions for changing the pad
• When removing mark the brake pads (inner, outer) you intend
will be uneven!
• After replacing the brake pads, depress brake pedal firmly
sition.
• Do not unscrew the brake hose when replacing the brake pad.
Removing
– Remove front wheels.
indicator.

– Lever up the retaining spring of the brake pads out of the brake
caliper -arrow- using a screwdriver and remove.
– Remove caps -arrows-.
– Loosen and remove the two guide bolts -arrows- from the
brake caliper.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take out the brake pads from the brake caliper or from the
brake carrier.
Clean
WARNING

Note
Installing
• Drain some brake fluid from the brake fluid reservoir before
resetting the pistons. Otherwise, particularly if reservoir has
been topped up, fluid will overflow and cause damage.
WARNING
1. Front brakes 45
– Push piston back with piston jig - T10145- -1-.

– Remove the protective foil from the supporting plate of the
outer brake pad.
– Place the outer brake pad on the brake carrier.
– Insert the inner brake pad with retaining spring into the brake
caliper (piston).
When installing the brake caliper make sure that the brake pad
does not stick to the brake caliper before reaching its correct in‐
stalled position.
Do not damage the surface to be glued.
– Screw the brake caliper with both guide bolts to the brake car‐
rier.
– Insert both caps.
– Insert retaining spring in brake caliper.
– If present, connect the connector for the brake pad wear indi‐
cator.
– Attach the wheels.
• After each brake pad replacement, forcefully apply the brake
operating position.
• Check brake fluid level after changing brake pads.
Tightening torques
♦ ⇒ “1.1.2 Summary of components - front brake FN3”,
page 40
1.3 Removing and installing brake caliper

⇒ “1.3.1 Removing and installing brake caliper FS-III”,
page 46
⇒ “1.3.2 Removing and installing brake caliper FN3”, page 49
1.3.1 Removing and installing brake caliper

FS-III
♦ Brake pedal load e.g. -V.A.G 1869/2-
♦ Bleeding bottle (commercially available)

Note

will be uneven!
sition.
Removing
– Remove front wheel.
indicator.
– Brake pedal load e.g. -V.A.G 1869/2-
valve of the brake caliper and then open then bleeder valve.
– Press the brake pedal by at least 60 mm and lock with brake
pedal load , e. g. -V.A.G 1869/2- .
– Close the vent valve and remove the bleeding bottle.
– Remove brake hose.
– Remove caps -1-.
1. Front brakes 47
– Unscrew and remove the two guide bolts -arrows- from the
brake caliper.
– Remove brake calliper from the wheel bearing housing.
– Take out the brake pads from the brake caliper.
Clean
WARNING

Note
Installing
• The piston is pushed back.
Note
Different version of the inner and outer brake pad. Do not mix up
when installing
– Insert the inner brake pad -1- (with the large 3-finger clip with
metallic gloss and with the marking “piston side” on the steel
supporting plate) on the piston.
– Insert the outer brake pad -2- (with the small black 3-finger
clip) into the brake caliper housing.
– First, position the brake caliper with the brake pads at the bot‐
tom -arrow- of the brake carrier.
– Tilt the brake caliper so that the guide bolts of the brake caliper
are flush with the threaded holes of the wheel-bearing hous‐
ing.
The bolts of the brake caliper -arrows- must only be inserted into
the brake caliper in such a way that the brake caliper can be tilted.

– Screw on both guide bolts -arrows- on the wheel bearing

housing.
cator.
– Insert the caps of the guide bolts.
– Bolt brake hose to brake caliper.
– Remove brake pedal load e.g. -V.A.G 1869/2- .
– Bleed brake system
⇒ “6.2 Prebleeding the hydraulic system”, page 152 .
– Install wheel ⇒ Wheels, Tyres; Rep. gr. 44 .
• Firmly depress brake pedal several times with vehicle station‐
ary so that the brake pads are properly seated in their normal
operating position.
• Check brake fluid level.
Tightening torques
♦ ⇒ “1.1.1 Summary of components - front brake FS-III”,
page 38

FN3
Note

will be uneven!
sition.
Removing
– Remove front wheel.
indicator.
1. Front brakes 49
– Insert brake pedal load, , e.g. -V.A.G 1869/2- .

valve of the brake caliper and then open then bleeder valve.
– Lever up the retaining spring of the brake pads out of the brake
caliper -arrow- using a screwdriver and remove.
– Remove caps -arrows-.

– Loosen and remove the two guide bolts -arrows- from the
brake caliper.
– Pull off brake caliper from brake carrier.
– Take out the brake pads from the brake caliper.
Clean
WARNING

Note
Installing
• The outside brake pad is fitted on the brake carrier.
– Insert the inner brake pad with retaining spring into the brake
caliper (piston).
When installing the brake caliper make sure that the brake pad
does not stick to the brake caliper before reaching its correct in‐
stalled position.
Do not damage the surface to be glued.
– Screw the brake caliper with both guide bolts to the brake car‐
rier.
– Insert both caps.
– Bolt brake hose to brake caliper.
– Remove brake pedal load e.g. -V.A.G 1869/2- .
– Insert retaining spring in brake caliper.
– If present, connect plug connection of the brake pad wear in‐
dicator.
• Firmly depress brake pedal several times with vehicle station‐
operating position.
• Check brake fluid level.
Tightening torques
♦ ⇒ “1.1.2 Summary of components - front brake FN3”,
page 40
1. Front brakes 51
2 Rear brakes
⇒ “2.1 Assembly overview - rear brakes”, page 52
⇒ “2.2 Removing and installing brake pads”, page 58
⇒ “2.3 Removing and installing brake caliper”, page 61
⇒ “2.4 Resetting brake”, page 63
⇒ “2.5 Removing and installing brake anchor plate”, page 64
⇒ “2.6 Removing and installing wheel-brake cylinder”,
page 65
⇒ “2.7 Removing and installing brake shoes”, page 66
2.1 Assembly overview - rear brakes

⇒ “2.1.1 Summary of components - rear axle brake, drum brake”,
page 52
⇒ “2.1.2 Summary of components - drum brake”, page 54
⇒ “2.1.3 Summary of components - rear axle brake, disc brake”,
page 56
2.1.1 Summary of components - rear axle brake, drum brake
Note

♦ After renewing wheel brake cylinder, brake backplate and brake shoes, depress brake pedal firmly several
times with vehicle stationary so that the brake shoes are properly seated in their normal operating position.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
♦ Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid from the brake
fluid reservoir. Brake fluid is toxic and must never be sucked up by mouth!
♦ Use brake pedal load , e. g. -V.A.G 1869/2- , before removing a brake cylinder, a brake carrier or before
separating a brake line from the brake cylinder.

1 - Screw
❑ 8 Nm
2 - Brake drum
❑ Brake drum diameter,
wear limit
⇒ “3.1.3 Rear brake”,
page 4
❑ clean carefully, and
check damage, dimen‐
sional accuracy and
perfect brake surface
❑ Thoroughly clean the
centering hole of the
drum before installing
and subsequently treat
it with approx. 0.5 g of
anti-corrosion agent -
AKR 322 000-
Note
The anti-corrosion agent - AKR 322

000- must not get into the threads of
the wheel screws!
3 - Cap
❑ Replace after removal
❑ Driving in and out ⇒
Axles, steering; Rep. gr.
42 .
4 - Nut
❑ self-locking
⇒ Axles, steering; Rep.
gr. 42
❑ must be replaced completely
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
❑ Before installing the brake drum, thoroughly clean the centering shoulder for the brake drum and sub‐
sequently treat it with approx. 0.5 g of anti-corrosion agent - AKR 322 000-
Note
The anti-corrosion agent - AKR 322

000- must not get into the threads of
the wheel screws!
6 - Screw
❑ Tightening torque ⇒ Axles, steering; Rep. gr. 42
7 - Brake carrier with brake shoes
❑ Removing and installing ⇒ “2.5 Removing and installing brake anchor plate”, page 64
❑ Summary of components ⇒ “2.1.2 Summary of components - drum brake”, page 54
8 - Handbrake
❑ Adjusting parking brake ⇒ “3.2 Adjusting parking brake”, page 72 .
2. Rear brakes 53
9 - Axle stud
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
10 - Brake line
❑ 14 Nm
12 - Plug
❑ for vehicles without ABS
❑ to plug the hole for the speed sensor in the axle stud
13 - Screw
❑ 8 Nm
14 - Axle beam
2.1.2 Summary of components - drum brake
1 - Wheel-brake cylinder
❑ Repairs not allowed
❑ Check for leaks
⇒ page 56
stalling wheel-brake cyl‐
inder”, page 65
2 - Brake carrier
3 - Fit pin
4 - Screw
❑ 10 Nm
5 - Ventilation valve cap
6 - Vent valve
❑ 10 Nm
7 - Plug
❑ remove to check brake
pad thickness
8 - Top brake spring
❑ Grease contact surfa‐
ces with solid lubricant
paste - G 000 650-
9 - Expansion rod
❑ with thermal clip
❑ with setting wheel and
self-adjuster
❑ Fitting position
⇒ page 56
❑ Grease contact surfa‐
ces with solid lubricant
paste - G 000 650-

10 - Brake shoe
❑ with lever for hand-brake
❑ Dimensions and wear limit ⇒ “3.1.3 Rear brake”, page 4
❑ Check pad thickness ⇒ page 56
❑ Observe the instructions when replacing the brake shoes
⇒ “2.7.1 Replacing the brake shoes of the rear brake - Mounting instructions”, page 66
❑ Removing and installing ⇒ “2.7.2 Removing and installing brake shoes”, page 67
❑ Setting the hand-brake ⇒ “3.2 Adjusting parking brake”, page 72
11 - Clamp
❑ for locking the brake shoe
❑ Fitting position ⇒ page 55
12 - Bottom retractor spring
❑ Grease contact surfaces with solid lubricant paste - G 000 650-
13 - Brake shoe
❑ Check pad thickness ⇒ page 56
❑ Removing and installing ⇒ “2.7.2 Removing and installing brake shoes”, page 67
Fitting position of securing clamp

The securing clamp must point with its closed part to the wheel
hub.
2. Rear brakes 55
Fitting position of expansion rod

1 - Brake shoe
2 - Handbrake lever
3 - Expansion rod with thermal clip
• Thermal clip - bimetal strip must point towards the brake drum.
Checking wheel-brake cylinder for leaks
Note
♦ The tightness test is performed only visually without using any

tools and without removing the dust cap.
♦ The dust cap may get damaged in case of removal.
♦ Slight traces of grease in the area of the wheel-brake cylinder
do not point to a leakage. It is essentially assembly grease.
– Check the wheel-brake cylinder.

– If brake fluid drips out of the wheel-brake cylinder, the wheel-
brake cylinder must be replaced
page 65 .
Checking the brake pad thickness through the inspection hole in
the brake carrier
– Loosen the cap -1- from the brake carrier -2-.

– Checking the brake pad thickness through the inspection hole
in the brake carrier.
Minimum pad thickness without supporting shoe (wear dimen‐
sion).
Note
The brake pads must not be soiled with brake fluid or grease.
2.1.3 Summary of components - rear axle brake, disc brake
Note

⇒ “2.2.1 Changing the brake pads of the rear brake - Mounting instructions”, page 58
♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
ensure the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding device , e.g. -VAS 5234- , to drain the brake fluid from the brake fluid
reservoir.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2- , before removing a brake calliper or separating a brake hose
from the brake calliper.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.

1 - Screw
❑ 8 Nm
2 - Brake disc
limit
⇒ “3.1.3 Rear brake”,
page 4
Parts
wise
❑ unscrew the brake cali‐
per before removing
3 - Cap
❑ pressing off and driving
in ⇒ chassis, axles,
steering; Rep. gr. 42
4 - Nut
❑ self-locking
❑ Tightening torque ⇒
Chassis, axles, steer‐
ing; Rep. gr. 42 .
5 - Wheel hub with wheel bear‐
ing
❑ must be replaced com‐
pletely
❑ removing and installing
⇒ chassis, axles, steer‐
ing; Rep. gr. 42
Parts
6 - Screw
❑ Tightening torque ⇒ Chassis, axles, steering; Rep. gr. 42 .
7 - Cover plate
8 - Axle stud
10 - Screw
❑ 8 Nm
11 - Axle beam
12 - Handbrake
❑ Adjusting parking brake ⇒ “3.2 Adjusting parking brake”, page 72 .
13 - Hexagon socket head bolt
❑ 30 Nm + 30°.
14 - Brake line
❑ with supports, hollow bolt and seal
❑ must be replaced completely, do not dismantle
❑ do not unscrew when replacing the brake pad
2. Rear brakes 57
❑ 38 Nm
15 - Screw
❑ self-locking
❑ 35 Nm
16 - Brake caliper
❑ Removing and installing ⇒ “2.3 Removing and installing brake caliper”, page 61
17 - Brake pads
❑ Inspect thickness ⇒ Maintenance ; Booklet Rapid NH
❑ Observe the instructions for changing the pad
❑ Removing and installing ⇒ “2.2.2 Removing and installing brake pads”, page 58
18 - Brake carrier with guide bolts and protective caps
❑ must be assembled with sufficient grease on the guide bolt, supplied as a spare part
❑ fit a repair set if there is any damage to the protective caps or guide bolts; (use the enclosed grease
packing to lubricate the guide bolts)
❑ Observe the instructions for changing the pad
2.2 Removing and installing brake pads

⇒ “2.2.1 Changing the brake pads of the rear brake - Mounting
⇒ “2.2.2 Removing and installing brake pads”, page 58
2.2.1 Changing the brake pads of the rear

When changing the pads, pay attention to the following points:
– Check protective collar of brake calliper piston.
Replace protective cap if damaged.
When replacing the protective cap:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxidation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing cap.
– Check the brake piston and the brake caliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake caliper completely if damaged.
For brake caliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective cap.
Replace the brake caliper completely if damaged.
2.2.2 Removing and installing brake pads


♦ Resetting tool - T 10165-
Note

will be uneven!
Removing
– Remove wheel.
indicator.
– Push the brake lever -in direction of arrow- and unhook the
hand-brake cable.
– Slacken the spring bushing -arrows- for the hand-brake cable
from the bracket on the brake caliper.
– Unscrew the fixing screws of the brake carrier while counter‐

holding the guide bolts.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
2. Rear brakes 59
– Take out the brake pads -arrows-.

Clean
WARNING

Note
Installing
Note

♦ The adherend for the brake pads must be free from glue res‐
idues and grease.
♦ Drain the brake fluid from the brake fluid reservoir using a
ventilation bottle before resetting the piston. Otherwise, par‐
ticularly if reservoir has been topped up, fluid will overflow and
cause damage.
♦ When resetting the piston with a piston resetting device the
automatic reset in the brake caliper is destroyed.
WARNING
– Screw in the piston by turning the knurled wheel clockwise on

the resetting tool - T10165- , during this procedure do not
damage the protective cap.
Use open-jawed spanner on the provided spanner surfaces arrow
-A- if the piston is difficult to move.
• Turn the resetting tool - T10165- simultaneously when reset‐
ting the piston, in order to initiate pressure onto the piston.

– Insert the new brake pads -arrows- in the brake carrier.

– Remove the protective foil from the supporting plate of the
brake pad.
Note
There are four self-locking screws in the repair set, which must
be fitted.
– Secure the brake caliper to the brake carrier using new self-
locking screws.
Hold the guide bolts while tightening the screws.
– Insert the spring bushing for the handbrake cable into the
holder of the brake calliper until the spring pegs -arrows- au‐
dibly engage.
– Push the brake lever in -direction of arrow- and hook in the
hand-brake cable.
cator.
Note
♦ After each brake pad replacement, forcefully apply the brake

operating position.
♦ Check brake fluid level after replacing the brake pads, if nec‐
essary top up with brake fluid.
– Adjust handbrake
⇒ “3.2 Adjusting parking brake”, page 72 .
– Attach the wheel.
Tightening torques
brake”, page 56

2. Rear brakes 61
Removing
Note

will be uneven!
sition.
– Remove wheel.
– Push the brake lever -in direction of arrow- and unhook the
hand-brake cable.
– Release the two retaining tabs -arrows- and undo the spring
bushing for the handbrake cable from the holder on the brake
calliper.
valve of the brake caliper and open bleeder valve.
– Position the brake pedal load , e.g. -V.A.G 1869/2 - and press
down the brake pedal at least 60 mm.
– Remove brake line from brake caliper.

– Unscrew the fixing screws of the brake carrier while counter‐

holding the guide bolts.
– Remove brake caliper from brake carrier
Clean
WARNING

Note
Installing
– Secure the brake caliper to the brake carrier using new self-
locking screws.
– Fit brake line to the brake caliper.
– Install hand-brake cable.
Note
♦ Firmly depress brake pedal several times with vehicle station‐

operating position.
♦ Check brake fluid level.
Tightening torques
brake”, page 56
2.4 Resetting brake

– Put hand-brake back.
– Remove storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .
2. Rear brakes 63
– Release resetting nut -3- and unhook hand-brake cables -1-

from compensating clamp -2-.
– Press the handbrake lever through a hole for the wheel screw
using a screwdriver.
2.5 Removing and installing brake anchor

plate
Removing
– Resetting brake ⇒ “2.4 Resetting brake”, page 63 .
– Unscrew screw, position -1-
⇒ “2.1.1 Summary of components - rear axle brake, drum
brake”, page 52 .
– Remove the brake drum.
– Remove wheel hub with wheel bearing ⇒ Axles, steering; Rep.
gr. 42 .

– Position brake pedal load , e.g. -V.A.G 1869/2- .

– Fit the bleeder hose of the bleeding bottle onto the bleeder
valve and release bleeder valve.
1869/2- , at least 60 mm.
– Tighten the drain plug.
– Remove screws position -6-
brake”, page 52 .
– Remove brake carrier.
– Unhook hand-brake cable where applicable.
Installing
– Install brake carrier.
– Screw on screws, position -6-
brake”, page 52 .
– Hook hand-brake cable where applicable.
– Install wheel hub with wheel bearing ⇒ Axles, steering; Rep.
gr. 42 .
– Screw on the brake line.
– Remove brake pedal load .
– Install brake drum.
– Insert screw position -1-
brake”, page 52 .
Tightening torques
brake”, page 52
2.6 Removing and installing wheel-brake

cylinder
Removing
– Remove the brake shoes
⇒ “2.7.2 Removing and installing brake shoes”, page 67 .
2. Rear brakes 65
– Insert brake pedal load, , e.g. -V.A.G 1869/2- .

– Fit the bleeder hose of the bleeding bottle onto the vent valve
of the wheel-brake cylinder.
– Open vent valve.
– Shut the vent valve once the brake fluid flowed out.
– Remove brake line.
– Remove screws Pos. -4-
⇒ “2.1.2 Summary of components - drum brake”, page 54 .
– Remove wheel-brake cylinder.
Installing
– Insert the wheel-brake cylinder.
– Install screws Pos. -4-
⇒ “2.1.2 Summary of components - drum brake”, page 54 .
– Install brake line.
– Remove brake pedal load .
– Install the brake shoes
⇒ “2.7.2 Removing and installing brake shoes”, page 67 .
Tightening torques
brake”, page 52
♦ ⇒ “2.1.2 Summary of components - drum brake”, page 54
2.7 Removing and installing brake shoes

⇒ “2.7.1 Replacing the brake shoes of the rear brake - Mounting
⇒ “2.7.2 Removing and installing brake shoes”, page 67
2.7.1 Replacing the brake shoes of the rear

When changing the brake shoes, pay attention to the following
points:
– Check the protective collars of the wheel-brake cylinders.
Replace the wheel-brake cylinders if the protective collars are
damaged
⇒ “2.6 Removing and installing wheel-brake cylinder”, page 65 .
– Test wheel-brake cylinder for tightness ⇒ page 56 .
Replace the wheel-brake cylinder if leaking
⇒ “2.6 Removing and installing wheel-brake cylinder”, page 65 .
– Check if the pistons can be slightly pressed into the wheel-
brake cylinder.
If the pistons cannot be slightly pressed into the wheel-brake cyl‐
inder:

– Replace the wheel-brake cylinder

page 65 .
2.7.2 Removing and installing brake shoes

♦ Hook - 3438-
♦ Assembly tool - T30114-
♦ Assembly pliers - T30115-
♦ Solid lubricant paste - G 000 650-
Removing
– Remove wheel.
– Resetting brake ⇒ “2.4 Resetting brake”, page 63 .
– Put the handbrake lever -A- with the hook - 3438- back into
the operating position.
– Remove the bottom retractor spring with the hook - 3438- .
– Remove the securing clamp and the pin of the brake shoe
-in direction of arrow- .
2. Rear brakes 67
– Carefully release the brake shoe and detach the expansion

rod in direction of arrow -B- from the brake shoe.
NOTICE
Do not cut through the rubber bowl for the wheel-brake cylinder
when handling the brake shoe.
– Detach the expansion rod in direction of arrow -A- from the

brake shoe with handbrake lever.
– Remove the top brake spring and the brake shoe.

– Unhook the hand-brake cable.
– Remove the securing clamp with the pin of the brake shoe with
handbrake lever.
– Remove brake shoe.
Installing
– Grease contact surfaces -arrows- with solid lubricant paste -

G 000 650- .
– Insert the brake shoe with handbrake lever and interlock the
securing clamp on the pin with the assembly device - T30114- .
– Note installation position ⇒ page 55 .

– Insert the top brake spring.
– Insert the pin and the fixing clamp for the brake shoe.
– Hook in the bottom retractor spring with the hook - 3438- .

– Carefully screw the expansion rod to its shortest dimension,
do not tighten.
Note
If the expansion rod is tightened too much, the self-adjuster

mechanism does no longer operate.
– Pull apart the brake shoes with assembly pliers - T30115- .
2. Rear brakes 69
– First of all, position the expansion rod of the self-adjuster in

direction of arrow -A- on the brake shoe with handbrake lever.
– Insert the lever for the self-adjuster into the recess of the sec‐
ond brake shoe -arrow B-.
– Note installation position ⇒ page 56 .
– Repeatedly pull apart the brake shoes using the assembly pli‐
ers - T30115- , so that the self-adjuster presets the distance
from the edges of the brake shoes with lining to the dimension
-a-.
a - 227.8 mm
– Clean the centring seat of the wheel hub for the brake drum
and subsequently treat it with anti-corrosion agent - AKR 322
000- .
– Clean the centring hole of the brake drum and subsequently
treat it with anti-corrosion agent - AKR 322 000- .
Note
The anti-corrosion agent - AKR 322 000- must not get into the
threads of the wheel screws!
– Install brake drum.

– Activate the brake pedal forcefully several times, so that the
rear brake is adjusted.
– Attach the wheel.
Tightening torques
brake”, page 52

3 Handbrake
⇒ “3.1 Assembly overview - parking brake”, page 71
⇒ “3.2 Adjusting parking brake”, page 72
⇒ “3.3 Removing and installing the rear handbrake cable”,
page 74
3.1 Assembly overview - parking brake
1 - Parking brake lever

❑ Removing the centre
console ⇒ Body Work;
Rep. gr. 68
Parts
2 - Handbrake handle
Parts
⇒ page 72
3 - Compensating clamp
4 - Adjusting nut
❑ Adjusting parking brake
⇒ “3.2 Adjusting parking
brake”, page 72 .
5 - Grommet
❑ removing:
– Pull cable out of the
guide tube.
– Release grommet.
– Pull grommet from

guide tube.
❑ Installing:
Installation is carried out
in the reverse order. After
installing make sure the
grommet fits correctly in
the body recess.
6 - Right guide tube

❑ for handbrake cable
7 - Left guide tube
❑ for handbrake cable
8 - Hand-brake cable
❑ Removing and installing ⇒ “3.3 Removing and installing the rear handbrake cable”, page 74
9 - Handbrake control switch - F9-
❑ clipped onto hand-brake lever
❑ replace if defective
3. Handbrake 71
10 - Nut
❑ 23 Nm
Removing and installing the handbrake lever handle

Removing
– Engage the handbrake lever -2-.
– For example, insert a cross-head screwdriver into the recess
of the handle and unlock the securing lock in
- direction of arrow A -.
– Push out the handbrake lever handle -1- in
-direction of arrow B-.
Note
On vehicles with the leather package, the recess for unlocking the
safety bar must be at a clearance -a- 97 mm from the front face
of the handle. The position is covered, which means that a thin
scriber must be used to unlock it through which the bar must be
unlocked in the same way after piercing the leather, as is the case
in vehicles with a classic handle.
Installing
– Fit the handle for handbrake lever to the parking brake lever
and press until the securing clip engages.
3.2 Adjusting parking brake

⇒ “3.2.1 Adjusting the handbrake – disc brake”, page 72
⇒ “3.2.2 Adjusting the handbrake – drum brake”, page 73
3.2.1 Adjusting the handbrake – disc brake
Note
♦ There is no need to adjust the handbrake due to automatic

adjustment of the rear brake.
♦ Resetting is only required after replacing the handbrake cable,
the brake carrier or after replacing the brake discs.

gr. 68 .
– Release hand-brake (hand brake lever in rest position).
– Forcefully apply the foot brake at least three times.
– Pull the handbrake on and release it three times.
This sets the components into position.
– Release handbrake lever.

– Tighten adjusting nut -arrow-, …
– … until the lever -1- rises and is no longer in contact -2- with
the brake calipers.
Note
The adjusting nut arrow -A- must be screwed over the end of the
tension rod (self-locking effect).
– The distance -a- to the stop -2- on the left and right brake cal‐
iper must together not exceed 1.5 mm.
– Engage and release the handbrake, and check that both
wheels spin freely; if necessary, turn back the adjustment nut
slightly.
– Install storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .
3.2.2 Adjusting the handbrake – drum brake
Note
♦ Resetting of the hand-brake is not required after resetting of

the rear brake due to automatic resetting of the rear wheel-
brake.
♦ Resetting is required after replacing the hand-brake cable, the
brake carrier or the brake pads/brake shoes or brake drum.

gr. 68 .
– Release hand-brake (hand brake lever in rest position).
– Forcefully apply the foot brake at least three times.
– Pull the handbrake on and release it three times.
This sets the components into position.
– Put the hand-brake lever into the 1st catch position (after being
in the release position).
3. Handbrake 73
– Tighten adjusting nut -arrow- until both wheels are hard to turn
by hand.
Note
The adjusting nut arrow -A- must be screwed over the end of the
tension rod (self-locking effect).
– Release hand-brake and check whether both wheels rotate

freely, if necessary release adjusting nut slightly.
– Put the hand-brake lever into the 4th catch position (after being
in the release position).
No wheel should be rotatable; tighten the adjusting nut if nec‐
essary.
– Release hand-brake and check whether both wheels rotate
freely, if necessary release adjusting nut slightly.
– Put the hand-brake lever into the 1st catch position and re‐
lease the hand-brake.
The hand brake must automatically return to the release po‐
sition below the 1st catch.
– Install storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .
3.3 Removing and installing the rear hand‐

brake cable
⇒ “3.3.1 Removing and installing the rear handbrake cable, disc
brake”, page 74
⇒ “3.3.2 Removing and installing the rear handbrake cable, drum
brake”, page 76
3.3.1 Removing and installing the rear hand‐

brake cable, disc brake
Removing
gr. 68 .
– Remove wheel.
– Raise vehicle.

– Unclip the hand-brake cable out of the clips on the axle body
and body -arrows-.
– Push the handbrake lever in the -direction of the arrow- and

unhook the hand-brake cable.
– Release the two retaining tabs -arrows- and undo the spring
bushing for the handbrake cable from the holder on the brake
calliper.
– Pull hand-brake cable -2- (in -direction of arrow-) out of the

guide tube -1-.
Installing
Installation is carried out in the reverse order.
Note
When installing the hand brake cables, pay attention to the fitting
position.
Fitting position of the hand-brake cables
Note
Fitting position of the hand-brake cables is identical on vehicles

with drum or disc brake (only version with drum brake is shown).
– The hand-brake cables must be clipped in.
3. Handbrake 75
– The clamping ring -arrow A- at the hand-brake cable must rest

in the centre of the clip -arrow B-.
Note
Before setting the handbrake, slightly pretension the handbrake

cable with the adjustment nut on the compensator.
– Adjusting parking brake

Tightening torques
3.3.2 Removing and installing the rear hand‐

brake cable, drum brake
Removing
gr. 68 .
– Remove wheel.
– Raise vehicle.
– Unclip the hand-brake cable out of the clips on the axle body
and body -arrows-.
– Unhook the hand-brake cable at the hand-brake lever.
– Pull hand-brake cable out of brake carrier.

– Pull hand-brake cable -2- in -the direction of the arrow- out of

the guide tube -1-.
Installing
Note
When installing the hand brake cables, pay attention to the fitting
position.
Fitting position of the hand-brake cables

– The hand-brake cables must be clipped in.
– The clamping ring -arrow A- at the hand-brake cable must rest

in the centre of the clip -arrow B-.
Note
Before setting the hand-brake, slightly pretension the hand-brake

cable with the adjusting nut at the compensation clamp.
– Adjusting parking brake

Tightening torques
3. Handbrake 77
4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 78
⇒ “4.2 Removing and installing bearing bracket”, page 84
⇒ “4.3 Separating brake pedal from brake servo”, page 87
⇒ “4.4 Clipping the brake pedal onto the brake servo unit”,
page 88
⇒ “4.5 Removing and installing brake pedal”, page 88
4.1 Assembly overview - brake pedal

⇒ “4.1.1 Summary of components - brake pedal, left-hand drive
vehicles up to 10/2013”, page 78
⇒ “4.1.2 Summary of components - brake pedal, left-hand drive
vehicles from 11/2013”, page 79
⇒ “4.1.3 Summary of components - brake pedal, right-hand drive
⇒ “4.1.4 Summary of components - brake pedal, right-hand drive
4.1.1 Summary of components - brake pedal, left-hand drive vehicles up to

10/2013
WARNING
The travel of the brake pedal must not be shortened by addi‐
tional foot mats.
Note
♦ Grease all bearing surfaces with polycarbamide grease - G 052 142 A2- before assembly.
♦ Do not grease the bearing bolt. The bearing bolt must remain dry.
♦ The brake light switch - F- and brake pedal switch - F47- are located on the master brake cylinder.

1 - Bearing bracket
❑ for foot controls
⇒ “4.2.1 Removing and
installing bearing brack‐
et, left-hand drive vehi‐
cles from 10/2013”,
page 84
2 - Nut
❑ self-locking
❑ 25 Nm
3 - Bushing
4 - Brake pedal
installing brake pedal,
left-hand drive vehicles
up to 10/2013”,
page 88
5 - Cap
6 - Bearing shell
7 - Retaining clip
❑ for the spherical head of
the brake servo push
rod
8 - Bearing shaft
❑ must only be fitted once,
because the tabs break
off when removing
9 - Bushing
4.1.2 Summary of components - brake pedal, left-hand drive vehicles from

11/2013
WARNING
tional foot mats.
4. Brake pedal 79
Note
1 - Bearing bracket
❑ with brake and acceler‐
ator pedal
Note
♦ Brake pedal cannot be replaced

individually.
♦ Turbocharger can only be re‐
placed completely with exhaust
manifold
⇒ “4.2.2 Removing and installing
bearing bracket, left-hand drive
vehicles from 11/2013”,
page 84 .
❑ Separating brake pedal
from brake servo
⇒ “4.3 Separating brake
pedal from brake servo”,
page 87
❑ Clipping the brake pedal
onto the brake servo
⇒ “4.4 Clipping the
brake pedal onto the
brake servo unit”,
page 88
et, left-hand drive vehi‐
page 84
2 - Nut
❑ self-locking
❑ 25 Nm
3 - Fixing clamp
❑ not replaceable individually
4 - Cap
5 - Brake pedal
Note

individually.


manifold
bearing bracket, left-hand drive
page 84 .
❑ Separating brake pedal from brake servo ⇒ “4.3 Separating brake pedal from brake servo”, page 87
❑ Clipping the brake pedal onto the brake servo
⇒ “4.4 Clipping the brake pedal onto the brake servo unit”, page 88
6 - Bearing shaft
❑ not replaceable individually
7 - Retaining clip
❑ for the spherical head of the brake servo push rod
8 - Bearing shell
9 - Bushing
4.1.3 Summary of components - brake pedal, right-hand drive vehicles up to

10/2013
WARNING
tional foot mats.
4. Brake pedal 81
Note
1 - Screw
2 - Bushing
3 - Brake pedal
installing brake pedal,
right-hand drive vehi‐
cles up to 10/2013”,
page 89
4 - Bearing bracket
❑ for foot controls
et, right-hand drive vehi‐
cles up to 10/2013”,
page 85
5 - Nut
❑ self-locking
❑ 25 Nm
6 - Nut
❑ self-locking
❑ 25 Nm
7 - Cap
8 - Bearing shell
9 - Retaining clip
❑ for the spherical head of
the brake servo push
rod
4.1.4 Summary of components - brake pedal, right-hand drive vehicles from

11/2013
WARNING
tional foot mats.

Note
1 - Partition panel
2 - Screw
❑ remove from engine
compartment
❑ 20 Nm
3 - Bearing bracket
❑ with brake and acceler‐
ator pedal
Note

individually.
manifold
bearing bracket, right-hand drive
page 86 .
❑ Separating brake pedal
from brake servo
page 87
❑ Clipping the brake pedal
onto the brake servo
⇒ “4.4 Clipping the
brake pedal onto the
brake servo unit”,
page 88
et, right-hand drive vehi‐
page 86 Volkswagen Technical Site: http://vwts.ru http://vwts.info
4 - Nut
❑ self-locking
❑ 25 Nm
5 - Nut
❑ self-locking
❑ 25 Nm
6 - Cap
7 - Retaining clip
❑ for the spherical head of the brake servo push rod
4. Brake pedal 83
4.2 Removing and installing bearing bracket

⇒ “4.2.1 Removing and installing bearing bracket, left-hand drive
⇒ “4.2.2 Removing and installing bearing bracket, left-hand drive
⇒ “4.2.3 Removing and installing bearing bracket, right-hand drive
⇒ “4.2.4 Removing and installing bearing bracket, right-hand drive
4.2.1 Removing and installing bearing brack‐

et, left-hand drive vehicles from 10/2013
Removing
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Separating the brake pedal from the brake servo unit
⇒ “4.3 Separating brake pedal from brake servo”, page 87 .
– Disconnect the plug connection from the accelerator pedal
position sender.
– Remove gas pedal ⇒ Engine; Rep. gr. 20 .
– Remove the nuts -arrows- for the bearing bracket.
– Remove bracket.
Installing
Tightening torques
♦ ⇒ “4.1.1 Summary of components - brake pedal, left-hand
drive vehicles up to 10/2013”, page 78

et, left-hand drive vehicles from 11/2013
Removing
– Remove brake servo unit
⇒ “3.6 Removing and installing brake servo”, page 114 .
– Remove cover of fuse box in -direction of arrow-.
– Unscrew screws for fuse box and place box to one side ⇒
Electrical System; Rep. gr. 97 .
position sender.

– Unscrew bolt -arrow- and detach universal joint -1- (in

-direction of arrow-) from the input shaft of the power-steering
gear.
– Place universal joint with steering column to one side.
– Remove the nuts -arrows- from the bearing bracket.

– Remove foot controls.
Installing
Installation is carried out in the reverse order; pay attention to the
following points:
– Clipping the brake pedal onto the brake servo
page 88
Tightening torques
♦ ⇒ “4.1.2 Summary of components - brake pedal, left-hand
drive vehicles from 11/2013”, page 79
♦ Accelerator pedal ⇒ Engine; Rep. gr. 20
♦ Footwell vent ⇒ Heating, Air Conditioning; Rep. gr. 87

et, right-hand drive vehicles up to
10/2013
Removing
– Remove right footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 80 .
position sender.
– Unscrews nuts -arrow A- and -arrow B-.
– Remove the foot rest -1- and the steering column trim panel
-2-.
4. Brake pedal 85
– Remove the nuts -arrows- for the bearing bracket.

– Remove bracket.
Installing
Tightening torques
♦ ⇒ “4.1.3 Summary of components - brake pedal, right-hand
drive vehicles up to 10/2013”, page 81

et, right-hand drive vehicles from
11/2013
Removing
– Unscrews nuts -arrow A- and -arrow B-.
– Remove the foot rest -1- and the steering column trim panel
-2-.
– Removing the left footwell vent on the driver side ⇒ Heating,
Air Conditioning; Rep. gr. 87 .
– Remove cover of fuse box in -direction of arrow-.

– Unscrew screws for fuse box and place box to one side ⇒
Electrical System; Rep. gr. 97 .
position sender.
– Remove brake servo unit
– Unscrew bolt -arrow- and detach universal joint -1- (in

-direction of arrow-) from the input shaft of the power-steering
gear.
– Place universal joint with steering column to one side.

– Remove the nuts arrows -A- for the bearing bracket.

– Remove the screw -arrow B-, which secures the foot controls
from the engine compartment.
– Remove foot controls.
Installing
Installation is carried out in the reverse order; pay attention to the
following points:
– Clipping the brake pedal onto the brake servo
page 88
Tightening torques
♦ ⇒ “4.1.4 Summary of components - brake pedal, right-hand
♦ Accelerator pedal ⇒ Engine; Rep. gr. 20
♦ Footwell vent ⇒ Heating, Air Conditioning; Rep. gr. 87
4.3 Separating brake pedal from brake ser‐

vo
♦ Release tool - T10159A- or -T10159B-
– Press the brake pedal towards the brake servo unit and hold
it in position.
2 - Plunger rod
3 - Retaining lugs
– Insert release tool - T10159A- or -T10159B- and pull it in the
direction of the driver's seat while counterholding the brake
pedal (the pedal must not move backwards during this oper‐
ation). This pushes the retaining lugs -3- of the mount off the
ball head of the push rod -2-.
The fig. shows the separation of the brake pedal from the brake
servo unit with the foot controls removed for clarity.
– Pull release tool - T10159A- or -T10159B- and brake pedal
together towards the driver's seat. (This causes the brake
pedal to be drawn off the ball head of the push rod).
4. Brake pedal 87
4.4 Clipping the brake pedal onto the brake

servo unit
– Hold ball head of push rod in front of mount and push brake
pedal in direction of brake servo, so that the ball head clicks
into place.
– Check that it is correctly locked in place by briefly pulling on
the brake pedal.
4.5 Removing and installing brake pedal

⇒ “4.5.1 Removing and installing brake pedal, left-hand drive ve‐
hicles up to 10/2013”, page 88
⇒ “4.5.2 Removing and installing brake pedal, right-hand drive
4.5.1 Removing and installing brake pedal,

left-hand drive vehicles up to 10/2013
Removing
– Removing bracket
⇒ “4.2.1 Removing and installing bearing bracket, left-hand
drive vehicles from 10/2013”, page 84 .
– Turn the bearing axle to the left in -direction of arrow- using a
10 mm socket wrench, while doing so the tabs break off
-arrows 1-.
– Pull out bearing bolt.
– Remove brake pedal.
Installing
following points:
– Insert the bearing axle and turn clockwise in

-direction of arrow- using a 10 mm socket wrench until the tabs
-arrows 2- rest against the stop.
– Installing bracket
⇒ “4.2.1 Removing and installing bearing bracket, left-hand
drive vehicles from 10/2013”, page 84 .
– Clip the brake pedal onto the brake servo
page 88 .

4.5.2 Removing and installing brake pedal,

right-hand drive vehicles up to 10/2013
Removing
– Removing bracket
⇒ “4.2.3 Removing and installing bearing bracket, right-hand
drive vehicles up to 10/2013”, page 85 .
– Remove nut - 2 -.
– Release screw -1-.
– Remove brake pedal.
Installing
following points:
– Installing bracket
⇒ “4.2.3 Removing and installing bearing bracket, right-hand
drive vehicles up to 10/2013”, page 85 .
page 88 .
4. Brake pedal 89
47 – Brakes - hydraulics
1 Front brake calipers
⇒ “1.1 Summary of components - front brake caliper”, page 90
⇒ “1.2 Removing and installing brake caliper piston”, page 93
1.1 Summary of components - front brake

caliper
⇒ “1.1.1 Exploded view – front brake caliper - brake FS III”, page
90
⇒ “1.1.2 Exploded view – front brake caliper - brake FN3”,
page 92
1.1.1 Exploded view – front brake caliper - brake FS III
Note
♦ Install the complete repair set when undertaking repairs.

♦ Use only methylated spirit for cleaning.
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease - G 052 150 A2- .
90 Rep. gr.47 - Brakes - hydraulics

1 - Dust cap
❑ place on the vent valve
2 - Vent valve
❑ thinly coat thread with
lithium grease - G 052
150 A2- before screwing
in
❑ 10 Nm
3 - Bushing
❑ insert into the brake cal‐
iper housing
4 - Guide bolt
❑ Tightening torque
⇒ “1.1.1 Summary of
components - front
brake FS-III”, page 38
5 - Cover caps
❑ insert in bushing
6 - Brake caliper
installing brake caliper
FS-III”, page 46
7 - Sealing ring
piston of front FS-III
brake”, page 93
❑ before installing, thinly
coat piston with lithium
grease - G 052 150 A2-
8 - Piston
⇒ “1.2.1 Removing and installing brake caliper piston of front FS-III brake”, page 93
❑ before installing, thinly coat piston with lithium grease - G 052 150 A2-
9 - Collar
⇒ “1.2.1 Removing and installing brake caliper piston of front FS-III brake”, page 93
❑ do not damage when inserting the piston
1. Front brake calipers 91

1.1.2 Exploded view – front brake caliper - brake FN3
Note
♦ Install the complete repair set when undertaking repairs.

♦ Use only methylated spirit for cleaning.
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease - G 052 150 A2- .
1 - Cover caps
❑ insert in bushing
2 - Guide bolt
⇒ “1.1.2 Summary of
components - front
brake FN3”, page 40
3 - Bushing
❑ insert into the brake cal‐
iper housing
4 - Dust cap
❑ place on the vent valve
5 - Vent valve
lithium grease -
G 052 150 A2- before
screwing in
❑ 10 Nm
6 - Brake caliper
FN3”, page 49
7 - Brake carrier
❑ crewed to the brake cal‐
iper
8 - Spring
❑ insert with both ends in‐
to the bores in the brake
caliper
9 - Sealing ring
⇒ “1.2.2 Removing and installing piston of brake caliper FN3”, page 94
❑ First thinly coat piston with lithium grease - G 052 150 A2-
10 - Piston
❑ Removing and installing ⇒ “1.2.2 Removing and installing piston of brake caliper FN3”, page 94
❑ First thinly coat piston with lithium grease - G 052 150 A2-
11 - Boot
❑ Removing and installing ⇒ “1.2.2 Removing and installing piston of brake caliper FN3”, page 94


piston
⇒ “1.2.1 Removing and installing brake caliper piston of front FS-
III brake”, page 93
⇒ “1.2.2 Removing and installing piston of brake caliper FN3”,
page 94

piston of front FS-III brake
♦ Plastic wedge - 3409-
♦ Grease - G 052 150 A2-
Removing
– Remove brake caliper
⇒ “1.3.1 Removing and installing brake caliper FS-III”,
page 46 .
– Insert wooden plate to avoid damaging the piston as it is being
pressed out.
– Press the piston out of the brake caliper housing using com‐
pressed air -arrow-.
Note
Make sure that the cylinder surface is not damaged when remov‐
ing the gasket ring.
– Remove gasket ring with disassembly wedge - 3409- .

Installing
Note
♦ Always install the complete repair kit when repairing the brake
calliper.
♦ Use only methylated spirits for cleaning the brake.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ It is absolutely necessary, if repairs are being undertaken, to
pre-bleed the brake calipers before installing them in the ve‐
hicle (without brake pads) ⇒ page 94 .
– Clean piston and gasket ring with white spirits and dry off.
– Before installing the piston and sealing ring in the brake cali‐
per, thinly coat with lithium grease - G 052 150 A2- .
– Insert new gasket ring in the groove of the brake caliper.

– Position the protective cap with the outer sealing lip on the
piston.
– Insert inner sealing lip of the protective cap with disassembly

wedge - 3409- in the groove of the cylinder.
To do so hold the piston with the hand.
– Press the piston with the piston jig - T10145- -1- into the brake
caliper.
The outer sealing lip of the protective cap will clip into the piston
groove.
Pre-bleeding the brake caliper
Set up brake caliper for pre-bleeding as shown in the fig.

– Open vent valve -arrow A-.
– Using a commercially available ventilation reservoir pour in
brake fluid until bubble-free brake fluid drips out of the threa‐
ded bore (brake hose connection) -arrow B-.
– Close vent valve.
1.2.2 Removing and installing piston of brake

caliper FN3
♦ Disassembly wedge - 3409-
♦ Assembly tool - T10146/6-

♦ Grease - G 052 150 A2-

Removing
– Removing brake calliper
⇒ “1.3.2 Removing and installing brake caliper FN3”,
page 49
– Insert wooden plate to avoid damaging the piston as it is being
pressed out.
– Press the piston out of the brake caliper housing using com‐
pressed air -arrow-.
– Lever off protective cap with disassembly wedge - 3409- from

the brake caliper.
Note
When removing, make sure that the cylinder surface is not dam‐
aged.
Installing
Note
♦ Always install the complete repair kit when repairing the brake
calliper.
♦ Use only methylated spirits for cleaning the brake.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ It is absolutely necessary, if repairs are being undertaken, to
pre-bleed the brake calipers before installing them in the ve‐
hicle (without brake pads) ⇒ page 97 .
– Before inserting the piston and gasket ring, thinly coat with
lithium grease - G 052 150 A2- .
– Insert sealing ring into the brake caliper.

– Position the protective cap -A- on the assembly tool -

T10146/6- -1-.
– Press the protective cap with the assembly tool -T10146/6-

-1- and the piston resetting jig -T10145- -2- onto the brake
caliper so that this lies in contact all around the brake caliper.
– Check fitting of the protective cap.
Note
The protective cap should no longer be removable by hand from

the brake caliper.
– Press the pistons lightly onto the protective cap and lock in this
position, e.g. with Disassembly wedge -3409- -2-.
Note
Do not tilt the piston, in order to avoid damage to the protective

cap.
– Blow up the protective cap with compressed air (max. 0.3

MPa) -1-. At the same time the protective cap jumps onto the
piston.

– Press the piston with the piston jig -T10145- -1- into the brake
caliper.
The outer sealing lip of the protective cap will clip into the piston
groove.


2 Rear brake caliper

⇒ “2.1 Summary of components - rear brake caliper”, page 98
⇒ “2.2 Removing and installing brake caliper piston”, page 99
2.1 Summary of components - rear brake caliper
1 - Self-locking screw
❑ counterhold on the
guide bolt when releas‐
ing and tightening
❑ 35 Nm
2 - Dust cap
3 - Vent valve
lithium grease - G 052
150 A2- before screwing
in
❑ 10 Nm
4 - Guide bolt
❑ grease before fitting
protective cap - Pos.
-5-
❑ Use the grease packing
supplied with the repair
kit for greasing
5 - Collar
❑ pull onto brake carrier
and guide bolt
6 - Brake carrier with guide
bolts and boots
❑ must be assembled with
sufficient grease on the
guide bolt, supplied as a
spare part
❑ if there is any damage to
the protective caps or
guide bolts fit a repair
set (use the enclosed
grease packing to lubri‐
cate the guide bolts) Volkswagen Technical Site: http://vwts.ru http://vwts.info
7 - Collar
❑ Removing and installing ⇒ “2.2 Removing and installing brake caliper piston”, page 99
8 - Piston with automatic adjusting device
9 - Sealing ring
10 - Brake caliper housing with lever for the handbrake cable
❑ replace brake caliper housing if the lever for the handbrake cable is not sealed
❑ pre-bleed brake caliper housing after undertaking replacement ⇒ page 100


piston
♦ Resetting tool - T10165-
♦ Disassembly wedge - 3409-
♦ Grease - G 052 150 A2-
• Install the complete repair set when undertaking repairs.
• The brake calipers must be pre-bled before installing them in
the vehicle (without brake pads) in case of a repair or when
replacing them with new brake calipers ⇒ page 100 .
• Thinly coat brake cylinder, piston and gasket ring with lithium
grease - G 052 150 A2- .
Removing
– Insert the resetting tool - T10165- in such a way that the collar
of the resetting tool is resting on the piston.
– Release the piston by turning the knurled wheel of the reset‐
ting tool - T10165- to the left.
Use open-jawed spanner on a provided spanner surface -A- if the
piston is difficult to move.
Note
Make sure that the cylinder surface is not damaged when remov‐
ing the gasket ring.

Installing
– Before inserting the piston and gasket ring in the brake caliper,
thinly coat with grease - G 052 150 A2- .
– Insert new gasket ring in the brake caliper.
– Position the protective cap with the outer sealing lip on the
piston.
2. Rear brake caliper 99

– Insert inner sealing lip of the protective cap with disassembly

wedge - 3409- in the groove of the cylinder.
To do so hold the piston with the hand.
– Insert resetting tool - T10165- .

– Use special tool - T10165/1- for assembly.
– Screw in piston by turning the knurled wheel to the right.
Use open-jawed spanner on a provided spanner surface -A- if the
piston is difficult to move.
Note
♦ When resetting the piston with a resetting tool the automatic

piston setting in the brake caliper is destroyed.
♦ The brake calipers must be pre-bled before installing them in
the vehicle (without brake pads) in case of a repair or when
replacing them with new brake calipers ⇒ page 100 .
– Insert brake pads.



3 Brake servo unit and master brake

cylinder
⇒ “3.1 Summary of components - brake servo unit and master
brake cylinder”, page 101
⇒ “3.2 Check the operation of the brake servo unit”, page 104
⇒ “3.3 Removing and installing brake light switch”, page 105
⇒ “3.4 Checking the master brake cylinder for tightness”,
page 105
⇒ “3.5 Removing and installing master brake cylinder”,
page 106
⇒ “3.6 Removing and installing brake servo”, page 114
3.1 Summary of components - brake servo

unit and master brake cylinder
⇒ “3.1.1 Summary of components - brake servo unit/master brake
cylinder, left-hand drive vehicles”, page 101
⇒ “3.1.2 Summary of components - brake servo unit/master brake
cylinder, right-hand drive vehicles”, page 103
3.1.1 Summary of components - brake servo unit/master brake cylinder, left-hand

drive vehicles
3. Brake servo unit and master brake cylinder 101

1 - Screw cap
2 - Brake fluid level warning
contact - F34-
3 - Brake fluid reservoir
4 - Plugs
5 - Brake servo
Parts
❑ Inspect proper opera‐
tion
⇒ “3.2 Check the opera‐
tion of the brake servo
unit”, page 104
❑ Non-return valve (in
vacuum hose); Func‐
tional test
⇒ “4.2 Checking the
non-return valve”,
page 140
❑ separate from brake
pedal
page 87
page 114
6 - Seal
❑ for brake servo
7 - Nut
❑ self-locking
❑ Tightening torque ⇒ “4.1 Assembly overview - brake pedal”, page 78
8 - Sealing ring
9 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ Check for leaks ⇒ “3.4 Checking the master brake cylinder for tightness”, page 105
❑ Removing and installing ⇒ “3.5 Removing and installing master brake cylinder”, page 106
11 - Screw
❑ 7 Nm
12 - Nut
❑ self-locking
❑ 25 Nm

13 - Securing pin
14 - Plugs
❑ moisten with brake fluid and press in brake fluid reservoir
3.1.2 Summary of components - brake servo unit/master brake cylinder, right-

hand drive vehicles
1 - Brake servo
❑ different versions ⇒
electronic catalogue of
original parts
❑ Inspect proper opera‐
tion
⇒ “3.2 Check the opera‐
tion of the brake servo
unit”, page 104
❑ separate from brake
pedal
page 87
page 114
2 - Seal
❑ for brake servo
3 - Vacuum line
❑ Non-return valve (in
vacuum hose); Func‐
tional test
⇒ “4.2 Checking the
non-return valve”,
page 140
4 - Nut
❑ self-locking
⇒ “4.1 Assembly over‐
view - brake pedal”,
page 78
5 - Bearing bracket
❑ Removing and installing ⇒ “4.2 Removing and installing bearing bracket”, page 84
6 - Sealing ring
7 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
⇒ “3.5.3 Removing and installing master brake cylinder, right-hand drive vehicles”, page 112
❑ Check for leaks ⇒ “3.4 Checking the master brake cylinder for tightness”, page 105
8 - Screw
❑ 7 Nm


10 - Nut
❑ self-locking
❑ 25 Nm
11 - Brake line
12 - Brake line
13 - Plugs
❑ moisten with brake fluid and press in brake fluid reservoir
14 - Brake fluid reservoir
15 - Screw cap
16 - Screw
❑ 4 Nm
3.2 Check the operation of the brake servo

unit
Note
♦ on petrol engines the required negative pressure is drawn from

the intake manifold
♦ vehicles using a diesel engine are fitted with a vacuum pump
for generating a low pressure
– Check all underpressure lines of the brake servo unit.

– Checking the non-return valve
⇒ “4.2 Checking the non-return valve”, page 140
– With the engine off press down brake pedal repeatedly with
force, this reduces the low pressure already present in the
system.
– Hold the brake pedal in brake position using a medium foot
pressure and start the engine.
If the brake servo unit operates perfectly the brake pedal must
yield noticeably under your foot after starting the engine (servo
boost takes effect).
Replace faulty brake servo units

3.3 Removing and installing brake light

switch
⇒ “3.3.1 Removing and installing brake light switch, left-hand
drive vehicles”, page 105
⇒ “3.3.2 Removing and installing brake light switch, right-hand
drive vehicles”, page 105
3.3.1 Removing and installing brake light

switch, left-hand drive vehicles
Removing
For better access to the connector for the brake light switch, the
air filter ⇒ Engine; Rep. gr. 24 (petrol engines) or ⇒ Engine; Rep.
gr. 23 (diesel engines), possibly the air guide pipe, can be re‐
moved.
– Unlock and disconnect connector -3- from the brake light
switch - F- .
– Unscrew screw for brake light switch - F- -6- from the master
brake cylinder -5-.
– Pull the brake light switch - F- -1- off the master brake cylinder
-5- and then remove from the retaining tab -4- of the master
brake cylinder.
Installing
Tightening torques
♦ ⇒ “3.1 Summary of components - brake servo unit and master
3.3.2 Removing and installing brake light

switch, right-hand drive vehicles
Removing
– Unlock and disconnect connector from the brake light switch
- F- .
– Unscrew screw -arrow B- for brake light switch - F- -1- from
the master brake cylinder.
– Remove brake light switch - F- -1- from the master brake cyl‐
inder.
– Take the brake light switch - F- -1- out of the retaining tab
-arrow A- of the master brake cylinder.
Installing
Tightening torques
♦ ⇒ “3.1 Summary of components - brake servo unit and master
3.4 Checking the master brake cylinder for

tightness
♦ Brake-power regulator or brake system tester , e.g. -V.A.G
1310- or -V.A.G 1310 A-

♦ Lithium grease - G 052 150 A2-

Test condition
• Function and tightness of the brake system (hydraulic control
unit or load-dependent brake-power regulator, brake lines,
brake hoses, brake caliper and wheel-brake cylinder) O.K.
Checking
– Unscrew and remove the bleeder screw on one of the front
brake calipers.
– Connect the pressure gauge of the tester - V.A.G 1310 - or -
V.A.G 1310 A- and bleed.
– Push down brake pedal until the pressure gauge on the tester
indicates 5 MPa (50 bar).
– Throughout the test which lasts 45 seconds the pressure loss
must not exceed 0.4 MPa (4 bar).
– If the pressure loss exceeds 0,4 MPa (4 bar) replace the mas‐
ter brake cylinder.
Tightening torques
♦ ⇒ “1.1 Summary of components - front brake caliper”,
page 90
3.5 Removing and installing master brake

cylinder
⇒ “3.5.1 Removing and installing master brake cylinder, left-hand
⇒ “3.5.2 Removing and installing master brake cylinder, left-hand
⇒ “3.5.3 Removing and installing master brake cylinder, right-
hand drive vehicles”, page 112
3.5.1 Removing and installing master brake

cylinder, left-hand drive vehicles from
21/2015
♦ Assembly pliers , e.g. -VAS 6340-
♦ Vehicle diagnosis tester - VAS-
♦ Extraction bottle (commercially available)
♦ Repair kit -1H0 698 311 A-
Brake fluid assignment ⇒ Electronic Catalogue of Original Parts .
• The master brake cylinder must not be repaired.
Removing

– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒

– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Lay sufficient non-fluffing cloths around the engine.
For vehicles with manual gearbox
– Detach the hose -2- of the running-on line to the clutch master
cylinder from the brake fluid reservoir -4-.
– Seal off the hole in the hose -2- using the closing tool - T10249-
-1-.
– Tie up hose -2-.

– Disconnect plug -1- from the brake fluid level warning contact
- F34- .
– Pull the securing pin -1- in -direction of arrow- out of the master
brake cylinder.
– Pull the brake fluid reservoir carefully out of the plugs of the
master brake cylinder.
– Disconnect connector -2- from the brake light switch - F- .

– Mark brake lines -1-.
– Unscrew the brake lines -1- from the master brake cylinder and
shut off.
– Shut-off the connections of the brake lines on the master brake
cylinder with screw plugs from the repair kit -1H0 698 311 A- .

– Remove nuts for master brake cylinder -arrows-.

– Carefully pull off the master brake cylinder -1- from the brake
servo unit.
– Remove brake light switch - F-
⇒ “3.3 Removing and installing brake light switch”, page 105 .
Installing
• Install new gasket ring between the master brake cylinder and
the brake servo unit.
• When installing the master brake cylinder with the brake servo
unit pay attention to the correct positioning of the pressure rod
in the master brake cylinder.
• Only fill up with new brake fluid.
– Fill up with new brake fluid.
– Bleed clutch (vehicles fitted with manual gearbox) ⇒ Manual
gearbox; Rep. gr. 30 .
– Install air filter ⇒ Engine; Rep. gr. 24 (petrol engines) or ⇒
– Install the battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Install engine cover ⇒ Engine; Rep. gr. 10 .
Tightening torques
♦ ⇒ “3.1.1 Summary of components - brake servo unit/master
brake cylinder, left-hand drive vehicles”, page 101
♦ ⇒ “3 Control unit and hydraulic unit”, page 15

cylinder, left-hand drive vehicles from
22/2015
♦ Repair kit - 1H0 698 311 A-
♦ Closing tool - T10249-
♦ Release tool - T10527- (for 1.2 TSI engine)
Removing
For vehicles with the battery in the rear.
The battery is located in the luggage compartment at the spot for
the spare wheel.

– Disconnect earth strap -A- of the battery ⇒ Electrical system;

Rep. gr. 27 .
For vehicles with a 1.2 TSI engine

– Release hose clamps -1- and -2- and remove air guide pipe.
– Undo hose clamp -arrow- and press out air guide pipe from
holding clamps -1-.
– Remove air guide pipe -2-.
– Disconnect plug from charge pressure sender - GX26- -1-.

– Using the release tool - T10527- , unlock the catches

-arrows- and remove the air guide pipe -1-.
For vehicles with a 1.6 MPI engine
– Remove air filter housing ⇒ Engine; Rep. gr. 24 .
For vehicles with 1.6 MPI engine with automatic gearbox
– Undo the mounting bracket with the automatic gearbox control
unit - J217- and place the ⇒ gearbox; Rep. gr. 37 down to the
side.
– Remove air filter housing ⇒ Engine; Rep. gr. 23 .
– Mark and pull off connector -1- of the boost pressure actuator
- N239- -2-.
– Remove bracket -3- together with the boost pressure actuator
- N239- , place down to the side.
– Pinch the release button on the hose for the housing ventila‐
tion -1- and remove.
– Open hose clamp -2- loosen the air guide pipe and place it
down to the side together with the boost pressure actuator -
V465- and the change over valve for the intake manifold valve
- N239- .
– Loosen hose clamp -1- and remove the complete air filter
housing -2- ⇒ Engine; Rep. gr. 23 .
– Lay sufficient non-fluffing cloths in the plenum chamber in the
area underneath the master brake cylinder.


-1-.

- F34- .
– Mark the brake lines -A- and -B- from the hydraulic unit to
– Disconnect and remove brake lines -A- and -B- from the hy‐
draulic unit and the master brake cylinder.
– Close the openings at the hydraulic unit and the master brake
cylinder using screw plugs from the repair kit -1H0 698 311 A- .
– Pull out fixing pin -1- for brake fluid reservoir -2- in
-direction of arrow-.
– Pull the brake fluid reservoir -2- carefully out of the plugs of
the master brake cylinder -3-.

– Disconnect connector -3- from the brake light switch - F1- .

– Remove bracket for electrical line -2- from the screw (if
present).

servo unit.
Installing
– Install air filter ⇒ Engine; Rep. gr. 24 (petrol engines) or ⇒
– Install and/or connect the battery ⇒ Electrical system; Rep.
gr. 27 .
Tightening torques

cylinder, right-hand drive vehicles
♦ Vehicle diagnosis tester - VAS-
♦ Repair kit -1H0 698 311 A-

Removing
-1-.

- F34- .
– Remove retaining screw for brake fluid reservoir-1- -arrow-.


– Disconnect the brake lines -1- from the master brake cylinder
and shut off.
– Shut-off the connections of the brake lines on the master brake
cylinder with screw plugs from the repair kit -1H0 698 311 A- .


servo unit.
– Remove brake light switch - F-
⇒ “3.3 Removing and installing brake light switch”, page 105 .
Installing
Tightening torques
brake cylinder, right-hand drive vehicles”, page 103
3.6 Removing and installing brake servo

⇒ “3.6.1 Removing and installing brake servo, left-hand drive ve‐
hicles from 21/2015, 1.2 TSI engine”, page 114
hicles from 22/2015, 1.2 TSI engine”, page 116
hicles up to 21/2015, 1.6 MPI engine”, page 118
hicles from 22/2015, 1.6 MPI engine”, page 119
hicles up to 21/2015, 1.4 TDI engine”, page 120
hicles from 22/2015, 1.4 TDI engine”, page 121
hicles up to 21/2015, 1.6 TDI engine”, page 123
hicles from 22/2015, 1.6 TDI engine”, page 124
⇒ “3.6.9 Removing and installing brake servo, right-hand drive -
diesel engines”, page 126
⇒ “3.6.10 Removing and installing brake servo, right-hand drive -
petrol engines”, page 131
3.6.1 Removing and installing brake servo,

left-hand drive vehicles from 21/2015,
1.2 TSI engine


Removing
– Remove master brake cylinder
page 106 .
– Unscrew the screws -arrows- and remove the connection of
the exhaust gas turbocharger.
– Pull the engine control unit - J623- out of the bracket and lay
to the side ⇒ Engine; Rep. gr. 23 .
– Disconnect vacuum line from the brake servo.

– Remove nuts for brake servo -arrows-.
Note
The brake servo unit for vehicles with C-EPS steering is only fixed
with two nuts.
– Guide the brake servo unit towards the front.

Installing
following points:
• Before installing the brake fluid reservoir in the master brake
cylinder, wet the seal with brake fluid.
page 88 .
– Fill up with new brake fluid ⇒ “3.1.4 Brake fluid”, page 4 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
Tightening torques
♦ Support of the exhaust gas turbocharger ⇒ Engine; Rep. gr.
21

1.2 TSI engine
Removing
page 106 .

– Unscrew the screws -arrows- and remove the connection of

the exhaust gas turbocharger.
– Remove the engine control unit - J623- and lay the cable to
the side ⇒ Engine; Rep. gr. 23 .
– Remove ABS control unit - J104- / ABS hydraulic unit - N55-
hydraulic unit N55 , left -hand drive vehicles from 22/2015”,
page 28 .
– Remove bracket for ABS control unit - J104- / ABS hydraulic
unit - N55-
⇒ “3.1.4 Summary of components - control unit and hydraulic
page 21
Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques
♦ Support of the exhaust gas turbocharger ⇒ Engine; Rep. gr.
21


left-hand drive vehicles up to 21/2015,
1.6 MPI engine
Removing
page 106 .
Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques


1.6 MPI engine
Removing
page 106 .
page 28 .
unit - N55-
page 21

Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques

1.4 TDI engine
Removing
page 106 .

– Loosen clamp -1- on the charge air hose of the exhaust gas
turbocharger.
– Unscrew screws -3- and remove pulsation dampener -2- in‐
cluding charge air hose.
Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques
♦ Pulsation dampener to exhaust gas turbocharger ⇒ Engine;
Rep. gr. 21

1.4 TDI engine
Removing
page 106 .


– Loosen clamp -1- on the charge air hose of the exhaust gas
turbocharger.
– Unscrew screws -3- and remove pulsation dampener -2- in‐
cluding charge air hose.
page 28 .
unit - N55-
page 21
Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques
Rep. gr. 21


1.6 TDI engine
Removing
page 106 .
– Remove bolts -1- for pulsation dampener.
Note
Only one screw -1- is visible in the figure; the other screw is lo‐
cated in the lower part.
– Remove screws -arrows-.

– Remove charge air pipe -1- including pulsation dampener.

Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques
Rep. gr. 21

1.6 TDI engine
Removing
page 106 .

– Remove bolts -1- for pulsation dampener.
Note
Only one screw -1- is visible in the figure; the other screw is lo‐
cated in the lower part.

– Remove charge air pipe -1- including pulsation dampener.
– Disconnect electrical plug connection -1- on the charge pres‐

sure control solenoid valve - N75- -2-.
– Unlock catch -arrow-, remove holder with solenoid valve and
with connect vacuum lines upwards and place to side.
page 28 .
unit - N55-
page 21

Note
with two nuts.

Installing
following points:
page 88 .
Tightening torques
Rep. gr. 21

right-hand drive - diesel engines
♦ Brake filling and bleeding device , e.g. -VAS 5234- .
♦ Screw plug set - 1H0 698 311 A-
♦ Workshop crane - VAS 6100-
Removing
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .


– Remove air filter ⇒ Engine; Rep. gr. 23 .
– Disconnect electrical plug connection -1- on the charge pres‐
sure control solenoid valve - N75- -2-.
– Unlock catch -arrow-, remove holder with solenoid valve up‐
wards and place to side.
– Remove the bracket for engine control unit - J623- with the
control unit from the bulkhead plenum chamber and place to
side with the cable.

– Take plug connections -1- to -4- out of the bracket, disconnect
– Remove the connector holder from the bulkhead plenum
chamber.
– Detach the vacuum line -3- from the brake servo.

– Disconnect the vacuum line from the bulkhead plenum cham‐
ber and from the charge air pipe and place to one side.
– Expose the wiring harness on the bulkhead plenum chamber.
– Remove noise insulation for bulkhead plenum chamber.
50 .
– Remove windscreen wiper arms with linkage ⇒ Electrical Sys‐
tem; Rep. gr. 92 .
– Remove noise insulation ⇒ Body Work; Rep. gr. 50 .
– Remove pendulum support ⇒ Engine; Rep. gr. 10 .

– Remove bolts -1- and remove heat shield for right drive shaft,
if present.
– Remove pre-exhaust pipe with exhaust gas cleaning module
and lower as far as the assembly carrier ⇒ Engine; Rep. gr.
26 .
Note
♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Do not bend the decoupling element by pulling it.
♦ Do not damage the wire mesh of the decoupling element.
– Fit transport security - T10403- to the decoupling element of

the pre-exhaust pipe.
– Secure the separated parts of the exhaust pipe at the under‐
body by inserting the clamping sleeve again.

– Remove screws -3- and put the coolant expansion reservoir
-1- with connected hoses to one side.
– Remove coolant expansion reservoir with connected hoses
and place to one side ⇒ Engine; Rep. gr. 19 .
For vehicles with air conditioning
Note
Repairs may only be carried out in specialist service centres

which have suitably trained personnel and are fitted out for work‐
ing on the refrigerant circuit.
– Empty the refrigerant circuit with the aid of the A/C service
station . Follow the notes ⇒ Heating, air conditioning; Rep. gr.
87 .
– Remove refrigerant lines from expansion valve ⇒ Heating, Air
conditioning; Rep. gr. 87 .
Note
To prevent ingress of moisture, all components of the refrigerant

circuit which have been opened must be sealed with suitable
plugs.
– Unclip the refrigerant lines from the front wheelhouse and the
frame side rail and place to the side.


-1-.

- F34- .


– Unclip the wiring harness from the brackets on the bulkhead
and on the front wheelhouse and place to the side.


– Remove brake lines -2- from the master brake cylinder and
seal with blind plugs from the screw plug set - 1H0 698 311 A- .

servo unit.
– Unclip the brake lines from the bracket on the bulkhead

-arrow-.
Note
with two nuts.

– Remove bolts -1- to -4- for engine mounting.

– Use the workshop crane - VAS 6100- to move engine by ap‐
prox. 3.5 cm in area of engine mount in -direction of arrow-.
– Remove brake servo.
Installing
following points:
page 88 .
Tightening torques
♦ Wiper arms ⇒ Electrical system; Rep. gr. 92 .
♦ Plenum chamber cover ⇒ Body Work; Rep. gr. 50 .
♦ Air filter ⇒ Engine; Rep. gr. 23 .
♦ Wiper motor with linkage ⇒ Electrical system; Rep. gr. 92 .
♦ Noise insulation ⇒ Body Work- Assembly; Rep. gr. 50
♦ Exhaust System ⇒ Engine; Rep. gr. 26
♦ Refrigerant lines ⇒ Heating, Air Conditioning; Rep. gr. 87
♦ Coolant expansion reservoir ⇒ Engine; Rep. gr. 19
♦ Engine mount and pendulum support ⇒ Engine; Rep. gr. 10 .

right-hand drive - petrol engines
♦ Brake filling and bleeding device , e.g. -VAS 5234- .
♦ Screw plug set - 1H0 698 311 A-

♦ Workshop crane - VAS 6100-

Removing
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .
– Remove the bracket for engine control unit - J623- with the
control unit from the bulkhead plenum chamber and place to
side with the cable.
– Take plug connections -3- out of the bracket -1-, disconnect
– Remove the bracket -1- from the bulkhead plenum chamber.
– Detach the vacuum line -3- from the brake servo.

– Disconnect the vacuum line from the bulkhead plenum cham‐
ber and from the charge air pipe and place to one side.
– Expose the wiring harness on the bulkhead plenum chamber.
– Remove noise insulation for bulkhead plenum chamber.
50 .
– Remove windscreen wiper arms with linkage ⇒ Electrical Sys‐
tem; Rep. gr. 92 .
– Remove lambda probe 1 upstream of catalytic converter -
GX10- ⇒ Engine; Rep. gr. 26 .
– Remove securing bolts for the coolant lines of the exhaust gas
turbocharger on the cylinder head cover.

– Detach cable for lambda probe 1 after catalytic converter -
GX7- from heat shield -1- and remove heat shield.
– Remove pre-exhaust pipe with catalytic converter from ex‐
haust gas turbocharger ⇒ Engine; Rep. gr. 26 .
– Remove noise insulation ⇒ Body Work; Rep. gr. 50 .
– Remove pendulum support ⇒ Engine; Rep. gr. 10 .

– Remove bolts -1- and remove heat shield for right drive shaft,
if present.
– Remove pre-exhaust pipe with catalytic converter from brack‐

et on cylinder block ⇒ Engine; Rep. gr. 26 .
Note
♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Do not bend the decoupling element by pulling it.
♦ Do not damage the wire mesh of the decoupling element.
– Fit transport security - T10403- to the decoupling element of

the pre-exhaust pipe.
– Unclip retaining straps -3- for pre-exhaust pipe with catalytic
converter -1- from the assembly carrier -2- in direction of
-arrows-.
– Loosen the clamping sleeve -arrow- and slide it backwards.

– Lower pre-exhaust pipe as far as the assembly carrier.
– Secure the separated parts of the exhaust pipe at the under‐
body by inserting the clamping sleeve again.


– Remove screws -3- and put the coolant expansion reservoir
-1- with connected hoses to one side.
– Remove coolant expansion reservoir with connected hoses
and place to one side ⇒ Engine; Rep. gr. 19 .
For vehicles with air conditioning
Note
Repairs may only be carried out in specialist service centres

which have suitably trained personnel and are fitted out for work‐
ing on the refrigerant circuit.
– Empty the refrigerant circuit with the aid of the A/C service
station . Follow the notes ⇒ Heating, air conditioning; Rep. gr.
87 .
– Remove refrigerant lines from expansion valve ⇒ Heating, Air
conditioning; Rep. gr. 87 .
Note
To prevent ingress of moisture, all components of the refrigerant

circuit which have been opened must be sealed with suitable
plugs.
– Unclip the refrigerant lines from the front wheelhouse and the
frame side rail and place to the side.

-1-.


- F34- .


– Unclip the wiring harness from the brackets on the bulkhead
and on the front wheelhouse and place to the side.

– Remove brake lines -2- from the master brake cylinder and
seal with blind plugs from the screw plug set - 1H0 698 311 A- .


servo unit.
– Unclip the brake lines from the bracket on the bulkhead

-arrow-.
Note
with two nuts.

– Remove bolts -1- to -4- for engine mounting.

– Use the workshop crane - VAS 6100- to move engine by ap‐
prox. 3.5 cm in area of engine mount in -direction of arrow-.
– Remove brake servo.
Installing
following points:
page 88 .
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .
Tightening torques
♦ Wiper arms ⇒ Electrical system; Rep. gr. 92 .
♦ Plenum chamber cover ⇒ Body Work; Rep. gr. 50 .
♦ Air filter ⇒ Engine; Rep. gr. 23 .
♦ Wiper motor with linkage ⇒ Electrical system; Rep. gr. 92 .
♦ Noise insulation ⇒ Body Work- Assembly; Rep. gr. 50
♦ Exhaust System ⇒ Engine; Rep. gr. 26
♦ Heat shield ⇒ Engine; Rep. gr. 21
♦ Lambda probe 1 upstream of catalytic converter - GX10- ⇒
Engine; Rep. gr. 24
♦ Refrigerant lines ⇒ Heating, Air Conditioning; Rep. gr. 87
♦ Coolant expansion reservoir ⇒ Engine; Rep. gr. 19
♦ Engine mount and pendulum support ⇒ Engine; Rep. gr. 10 .

4 Vacuum system
⇒ “4.1 Exploded view – vacuum pump”, page 138
⇒ “4.2 Checking the non-return valve”, page 140
⇒ “4.3 Checking the vacuum system”, page 140
⇒ “4.4 Connecting vacuum gauge for brake servo VAS 6721 ”,
page 140
⇒ “4.5 Checking vacuum generation”, page 141
⇒ “4.6 Checking for leaks”, page 142
⇒ “4.7 Vacuum generation with manual vacuum pump VAS 6213
”, page 143
⇒ “4.8 Removing and installing the pressure sensor for the brake
servo unit”, page 144
⇒ “4.9 Removing and installing vacuum sensor G608 ”,
page 144
⇒ “4.10 Removing and installing electric vacuum pump”,
page 145
4.1 Exploded view – vacuum pump

⇒ “4.1.1 Summary of components - vacuum pump, vehicles with
petrol engines”, page 138
gasoline engines, 1.0 TSI engine”, page 138
diesel engines”, page 139
4.1.1 Summary of components - vacuum

pump, vehicles with petrol engines
on petrol engines the required negative pressure is drawn from
the intake manifold
Vehicles with 1.0 l TSI engines are fitted with the electric vacuum
pump: removing and installing
⇒ “4.10 Removing and installing electric vacuum pump”,
page 145 .
Check electrical vacuum pump is working ⇒ Vehicle diagnostic
tester.
4.1.2 Summary of components - vacuum pump, vehicles with gasoline engines,

1.0 TSI engine
Note
♦ Vacuum pump for brake - V192- cannot be repaired. If the Vacuum pump for brake - V192- fails, it must be
replaced.
♦ The brake vacuum pump - V192- is located on the right in the engine compartment.

1 - Screw
❑ 8 Nm
3 - Vacuum pump for brake -
V192-
installing electric vac‐
uum pump”, page 145
4 - Pressure sensor for the
brake servo unit - G294-
Parts
❑ only on vehicles equip‐
ped with automatic
gearbox
stalling the pressure
sensor for the brake ser‐
vo unit”, page 144
5 - Vacuum line
6 - Rubber bearing
Parts
7 - Screw
Parts
❑ 20 Nm
8 - Rubber bearing
4.1.3 Summary of components - vacuum

pump, vehicles with diesel engines
The vacuum supply to the brake servo on vehicles with turbo‐
charged engines is provided by a vacuum pump which is part of
the oil pump ⇒ Engine; Rep. gr. 17 ; Oil sump/Remove and install
oil pump .
4. Vacuum system 139

4.2 Checking the non-return valve

– Air must pass through non-return valve -A- in direction of ar‐
row.
– Non-return valve must remain closed in opposite direction.
Pay attention to correct installation position.
4.3 Checking the vacuum system

The following instructions are intended to help you find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or in the event of a so-called »»hard brake
pedal««.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if included)
The measuring results will be influenced by the geographical lo‐
cation. The higher the location is above sea level, the lower the
air pressure will be.
Take note of the following test requirements:
♦ Visual inspection of all vacuum hoses for damage (e.g. cracks
or marten bite) and to check that they are correctly and firmly
attached
♦ Ensure cleanliness when working on vacuum system.
♦ Before starting work, clean engine compartment if necessary.
4.4 Connecting vacuum gauge for brake

servo - VAS 6721-
♦ Vacuum gauge for brake servo - VAS 6721-
– Pull vacuum hose out of brake servo.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.

– Place brake servo vacuum gauge - VAS 6721- in between.

Item Com‐ Meaning
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if included, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-
C Cut- In direction of brake servo

off
valve
– Push hose -A- of brake servo vacuum gauge - VAS 6721- onto
vacuum hose and press adapter -C- into brake servo.
4.5 Checking vacuum generation

The average air pressure of the earth's atmosphere at sea level
is 1013 mbar and decreases steeply as the altitude increases
(approx. 100 mbar/1,000 m altitude). Local and time variations
also influence the vacuum generation.
A cold engine, a switched-on air-conditioning system as well as
engine idling have an adverse influence on generation of a vac‐
uum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Place vacuum gauge for brake servo - VAS 6721- in between
⇒ “4.4 Connecting vacuum gauge for brake servo VAS 6721
”, page 140 .

– Open locking valve -A-.

– Close cut-off valves -B- and -C-.
– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
– Read indicated measured value.
Normally (see notes), the vacuum that is generated should be
between 700 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for tightness.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213-
⇒ “4.7 Vacuum generation with manual vacuum pump VAS
6213 ”, page 143 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.6 Checking for leaks

The average air pressure of the earth's atmosphere at sea level
is 1013 mbar and decreases steeply as the altitude increases
(approx. 100 mbar/1,000 m altitude). Local and time fluctuations
also influence vacuum generation.
A cold engine, a switched-on air-conditioning system as well as
engine idling have an adverse influence on generation of a vac‐
uum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Place vacuum gauge for brake servo - VAS 6721- in between
⇒ “4.4 Connecting vacuum gauge for brake servo VAS 6721
”, page 140 .
– Open locking valve -A-.
– Close cut-off valves -B- and -C-.
– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
Normally (see notes), the vacuum that is generated should be
between 700 and 950 mbar (depending on engine size).

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

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
If the vacuum decrease is greater, then check for leaks in the
vicinity of:
1- Brake servo
or
2- Non-return valve, vacuum hoses with connectors and vac‐
uum pump/intake manifold.
If there are large leaks, the vacuum decreases steeply within a
few seconds.
Vacuum check in vicinity of brake servo
– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake manifold:
– Once vacuum has been generated, close the shut-off valve

-C- in order to check the vacuum system of the brake servo
vacuum gauge - VAS 6721- up to the intake manifold or the
vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.7 Vacuum generation with manual vac‐

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

4.8 Removing and installing the pressure

sensor for the brake servo unit
Note
Only for vehicles with automatic gearbox
Removing
Note
The vacuum line must not be removed.
– Disconnect the plug -2- from the pressure sensor for the brake
servo unit - G294- -1-.
– Release the catches with pliers -1-.

– Carefully lever out the pressure sensor for brake booster -
G294- -2-.
Installing
following points:
– Carefully connect the pressure sensor for brake booster -
G294- to the vacuum line.
4.9 Removing and installing vacuum sensor

- G608-
Note
♦ The vacuum sender - G608- is only installed with some petrol

engines.
♦ The vacuum encoder - G608- Is on the vacuum hose from the
intake manifold to the brake booster.
♦ The exact location of the vacuum encoder - G608- on the vac‐
uum hose differs depending on the engine version.

Removing
– Disconnect plug -3- for vacuum sensor - G608- -1-.
– Pull vacuum hose out of brake servo.
– Carefully lever the vacuum sender - G608- -1- out of the vac‐
uum line -2-.
Installing
4.10 Removing and installing electric vacuum

pump
Note
♦ Vacuum pump for brake - V192- cannot be repaired. If the

Vacuum pump for brake - V192- fails, it must be replaced.
♦ The brake vacuum pump - V192- is located on the right in the
engine compartment.
Removing
NOTICE
Do not damage the vacuum hose. Replace if damaged.
– Remove the vacuum hose -2- from the brake vacuum pump -
V192- -1-.

– Pull out the vacuum pump for brake - V192- together with the
mounting bracket in the direction of -arrow B-. and put to one
side.
– Disconnect the plug connection of the brake vacuum pump -
V192- .
– Remove the screws -arrows- and separate the bracket -2-

from the vacuum pump for brake - V192- -1-.
Installing
following points:
Note
Ensure that the vacuum pump for brake - V192- is fitted correctly.
Tightening torques
♦ ⇒ “4.1.2 Summary of components - vacuum pump, vehicles
with gasoline engines, 1.0 TSI engine”, page 138

5 Brake lines
⇒ “5.1 Repairing brake lines”, page 147
5.1 Repairing brake lines

⇒ “5.1.1 Assembly overview - Flaring tool”, page 147
⇒ “5.1.2 Work instruction”, page 148
5.1.1 Assembly overview - Flaring tool

List of individual tools
1 - Flaring tool - VAS 6056/1-

❑ The flaring chucks -
VAS 6056/6- are inclu‐
ded in the flaring tool -
VAS 6056/1-
2 - Pipe cutter - VAS 6056/2-
3 - Brake line-peeler - VAS
6056/3-
❑ The grub screws (in the
shank and sideways)
are adjusted and must
not be altered!
4 - Gripping pliers with plastic
chuck jaws - VAS 6056/4-
5 - Pipe bending tool - VAS
6056/5-
6 - Screwdriver SW6
❑ Short
7 - Flaring chucks - VAS
6056/7-
Assembly overview - Flaring tool
5. Brake lines 147

1 - Flaring tool upper part

❑ unscrew for changing
the flaring chucks
2 - Attachment for door handle
❑ must be unscrewed to
access securing bolt for
upper part
3 - Fixing screw
❑ For flanging tool upper
part
4 - Grub screws for flaring
chucks
❑ For centring and holding
the flaring chucks
❑ 2 mm hexagon socket
5 - Flaring chucks
❑ Various
❑ Assembly instructions
⇒ Fig. ““Mounting in‐
struction for flaring
chucks:”“ , page 148
Mounting instruction for flaring chucks:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (bright) for green brake lines
Note
The arrow, on the rounded side of the flaring chucks, must point
to the housing edge and the straight side of the flaring chucks
must be installed to the spindle, otherwise the flaring head is not
properly formed.
5.1.2 Work instruction

♦ Brake line flaring tool - VAS 6056-
♦ Brake filling and bleeding device - VAS 5234-

NOTICE
♦ Brake fluid must never come into contact with fluids contain‐
ing mineral oils (oil, petrol, cleaning agent, because the fluids
damage the sealing rings and boots of the brake system.
♦ Because of its caustic effect, the brake fluid must not come
into contact with paint.
♦ Observe the applicable disposal instructions.
♦ Only use new brake fluid.
WARNING
Brake fluid is toxic and must never be sucked through a hose
by mouth.
Note
♦ Brake lines must only be bent max. 90°, otherwise they kink
or present deformations, which constrain the line cross-sec‐
tion in an unauthorized manner.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle and only clean with methylated spirits.
♦ The arrow, on the rounded side of the flaring chucks, must
point to the housing edge. The straight sides of the flaring
chucks must be installed facing the spindle, otherwise the flar‐
ing head is not correctly positioned.
Using the brake line flaring tool - VAS 6056- , the brake lines can
be crimped with a pipe outside diameter of 5 mm, without dam‐
aging the coating. So that in certain cases parts of the brake lines
can be replaced cheaply.
Separate
– Unscrew the affected brake line on the brake caliper or wheel-
brake cylinder, while doing so collect escaping brake fluid and
dispose according to the specifications.
– Cut through the brake line in a suitable location (straight, freely
accessible piece) with the pipe cutter -2-.
– Remove the part to be replaced.
– Degrease the surface of the brake line.
5. Brake lines 149

– Clamp the brake line in the gripping pliers -4- tight enough, so
that it protrudes approx. 50 mm out of the plastic chuck jaws.
– Tension the peeler -3- in a boring machine and place it onto
the brake line.
– Peel off the coating of the brake line using the slower speed
of the boring machine and by exerting a slight pressure against
the brake line.
The length of the peeling is determined by the stop in the peeler.
– Separate the peeler from the brake line and remove peel res‐
idues.
– Remove gripping pliers.
Crimping
– Slide pipe screw -D- onto the brake line.
– Push the brake line -B- against the stop -A- in the flaring tool.
Note
When tightening the Allen screws the brake line must lie against
the stop, otherwise the flaring head does not function properly.
– Pre-tension the brake line in the flaring tool so that the brake
line can no longer be moved. Fold up the stop -A- and then
tighten the Allen screws crosswise completely with the offset
screwdriver -C-.
– Turn the spindle in the flaring tool up to the stop.

– Turn back the spindle once again.
– Loosen the Allan screws crosswise.
– Take the brake line out of the flaring tool, clean and check the
brake line as well as the flaring head.
Briefly flush the part of the brake line still in the vehicle:
– Connect the brake filling and bleeding device - VAS 5234- , fit
the hose of the bleeding bottle onto the flaring head of the
brake line and allow the brake filling and bleeding device - VAS
5234- to run briefly until some brake fluid has passed through.
– Purge the brake line that you will be fitting with compressed
air.

– Assemble the brake lines together with the connecting piece

-E-.
– Install brake line.
– Bleeding Brake System
dure”, page 153
5. Brake lines 151

6 Hydraulic system
⇒ “6.1 General notes on brake fluid”, page 152
⇒ “6.2 Prebleeding the hydraulic system”, page 152
⇒ “6.3 Bleeding hydraulic system following standard procedure”,
page 153
⇒ “6.4 Subsequent bleeding of hydraulic system”, page 154
⇒ “6.5 Testing leak-tightness”, page 155
6.1 General notes on brake fluid

♦ The brake fluid is hygroscopic, i.e. it retains humidity from the
ambient air, and must therefore always be stored in airtight
containers.
♦ Brake fluid must never come into contact with fluids containing
mineral oils (oil, petrol, cleaning agent). Mineral oils damage
the plugs and boots of the brake system.
♦ Drained (used) brake fluid must never be used again.
♦ The brake fluid is toxic, avoid skin contact.
♦ Because of its caustic effect, the brake fluid must not come
into contact with paint.
♦ Rinse off spilled brake fluid using plenty of water.
♦ Dispose of brake fluid in compliance with the applicable waste
disposal and environmental regulations.
♦ Only use new brake fluid in accordance with the specification
⇒ “3.1.4 Brake fluid”, page 4 .
6.2 Prebleeding the hydraulic system

♦ Brake filling and bleeding device , e. g. - VAS 5234-
♦ Brake fluid
Note
For vehicles with EDL/TCS, or with EDL/TCS/ESC, if one cham‐

ber of the brake fluid return tank has run dry e.g. due to a leak,
the system must be bled first.
– Note the general instructions on brake fluid

⇒ “6.1 General notes on brake fluid”, page 152 .

A pre-pressure of 0,2 MPa (2 bar) is required to bleed the brake

system.
– Unscrew cap -1- from the brake fluid reservoir
– Connect the thread plug -1- of the brake filling and bleeding
device e.g. -VAS 5234- to the brake fluid reservoir.
– Provide a suitable catch pan for used brake fluid.
1. Bleed the front left and front right brake calipers at the same
time.
2. Bleed the rear left and rear right brake calipers/cylinders at
the same time.
– Allow brake fluid to drain until even the smallest air bubbles
have escaped.
– Initiate basic setting ⇒ Vehicle diagnostic tester.
– Then perform normal bleeding
dure”, page 153 .
6.3 Bleeding hydraulic system following

standard procedure
♦ Brake filling and bleeding device , e. g. - VAS 5234-
♦ Brake fluid
– Note the general instructions on brake fluid
⇒ “6.1 General notes on brake fluid”, page 152 .
A pre-pressure of 0,2 MPa (2 bar) is required to bleed the brake
system.
– Unscrew cap -1- from the brake fluid reservoir
6. Hydraulic system 153

– Connect the thread plug -1- of the brake filling and bleeding
device e.g. -VAS 5234- to the brake fluid reservoir.
– Provide a suitable catch pan for used brake fluid.
– Remove the dust caps of the bleeder valves at the brake cal‐
ipers.
– Switch on the brake filling and bleeding device and activate
the system with a brake fluid pressure of approx. 0.2 MPa.
– Fit the hose of the bleeding bottle -1- onto the corresponding
bleeder valve.
– Loosen bleeder valve.
– Extract as much brake fluid as possible until even the smallest
air bubbles have escaped.
– Repeat this procedure for all brake calipers in the prescribed
sequence until the brake system is fully bled.
Bleeding sequence
1. Front left brake caliper
2. Front right brake caliper
3. Rear left brake caliper
4. Rear right brake caliper
– Inspect pedal position and idle travel at brake pedal. Idle trav‐
el: max. 1/3 of pedal travel.
– Repeat the whole procedure if necessary (several times), until
perfect bleeding is achieved.
– After bleeding close the relevant vent valve and fit dust cap.
– If necessary, correct the brake fluid level in the brake fluid res‐
ervoir.
– Disconnect the brake filling and bleeding device .
– Disconnect the brake filling and bleeding device from the
brake fluid reservoir.
– Perform a test drive. While doing so, at least one ABS adjust‐
ment must be carried out on vehicles with ABS!
6.4 Subsequent bleeding of hydraulic sys‐

tem
♦ Bleeder bottle
♦ Brake fluid
Subsequent bleeding must be performed if the brake pedal travels
too far or if the »brake pedal "feels" soft«.
Note
A second mechanic is needed for this task.

– Firmly push the brake pedal to the floor and keep it held down.
– Connect the bleeder bottle.
– Open the bleeder screw on the brake caliper.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
– Release brake pedal slowly.
– Repeat this operation on all calipers in the prescribed se‐
quence at least 5 times.
Bleeding sequence
1. Front left brake caliper
2. Front right brake caliper
3. Rear left brake caliper
4. Rear right brake caliper
– Perform a test drive. While doing so, at least one ABS adjust‐
ment must be carried out on vehicles with ABS!
6.5 Testing leak-tightness

♦ Brake system tester e. g. -V.A.G 1310 A-
♦ Adapter M 10 e.g. -V.A.G 1310/6-
Test requirements:
• Function and tightness of the brake system (brake lines, brake
hoses, brake calipers, hydraulic unit) O.K.
– Unscrew and remove the bleeder screw on one of the front
brake calipers.
– Connect the brake system tester e.g. - V.A.G 1310 A- to the
brake caliper and bleed.
– Push down brake pedal until the pressure gauge indicates 5
MPa (50 bar). Throughout the test which lasts 45 s the pres‐
sure loss must not exceed 0.4 MPa (4 bar). If the loss of
pressure is higher, replace the master brake cylinder.
– Separate brake system tester e.g. - V.A.G 1310 A- .
– Screw the bleeder screw into the caliper and bleed the brake
caliper.
6. Hydraulic system 155

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Service

Service Department. Technical Information

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

1 Front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.1 Safety precautions when working on ve‐

1.2 Safety precautions during road tests in

2.1 PR number assignment – brake

2 Rep. gr.00 - Technical data

3.1 Technical data for brakes

3.1.1 Master brake cylinder and brake servo

3.1.2 Front brakes

Front brake caliper (type denomination) FN3

3.1.3 Rear brake

3.1.4 Brake fluid

4 Rep. gr.00 - Technical data

4.1 General points

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

4.2 Checking vehicles with front-wheel drive

45 – Anti-lock brake system

1.1 Repair instructions for repair work on

♦ If the ABS hydraulic unit - N55- is damaged, the ABS control

ABS arrangement, left-hand drive to CW 21/2015

ABS arrangement, left-hand drive to CW 22/2015

Arrangement of the ABS, right-hand drive vehicle

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

♦ When the system is open, do not work with compressed air

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

2 Installation location overview

2.1 Installation location overview - ABS

1 - ABS control unit - J104-

2. Installation location overview 11

4 - Dual circuit and hand brake system warning light - K7 -

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

2.2 Installation location overview - ABS/ESC

1 - ABS control unit - J104-

Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Installation location overview 13

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

3 Control unit and hydraulic unit

3.1 Exploded view – control unit and hy‐

3. Control unit and hydraulic unit 15

1 - ABS control unit - J104-

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

3. Control unit and hydraulic unit 17

-Hydraulic cylinder 2 (HZ2)-

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

1 - ABS control unit - J104-

3. Control unit and hydraulic unit 19

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

-Hydraulic cylinder 2 (HZ2)-

3. Control unit and hydraulic unit 21

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

-Hydraulic cylinder 2 (HZ2)-

3. Control unit and hydraulic unit 23

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

3.2 Removing and installing ABS control

3.2.1 Removing and installing ABS control

– If present, open heat shield collar.

3. Control unit and hydraulic unit 25

– Press down the red fuse -arrow-.

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