VW t6 Brake Systems Eng

Service
Workshop Manual
Transporter 2016 ➤
Brake systems
Edition 12.2018
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.
Brake systems - Edition 12.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using test and measuring instruments during a road test . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Checking vehicles with all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Overview of fitting locations - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Assembly overview - control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 15
3.3 Separating control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Removing and installing brake light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Removing and installing speed sensors on front axle G45 / G47 . . . . . . . . . . . . . . . . . . . . 23
4.5 Removing and installing speed sensors on rear axle G44 / G46 . . . . . . . . . . . . . . . . . . . . 24
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.5 Removing and installing brake carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Removing and installing front brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 Removing and installing rear brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents i
4.4 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Assembly overview - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4 Removing and installing brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 Assembly overview - electric vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.4 Removing and installing non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.5 Removing and installing brake servo pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.4 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ii Contents
00 – Technical data
1 Safety information
(VRL012398; Edition 12.2018)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using test and measuring instru‐
ments during a road test”, page 2
1.1 Safety measures when working on ve‐

hicles with a start/stop system
Please note the following when working on vehicles with a start/
stop system:
WARNING
Risk of injury due to automatic start of engine in vehicles with

Start/Stop system.
♦ If the start/stop system of a vehicle is activated, the engine
can start automatically, if required.
♦ This can be identified by a message in the dash panel in‐
sert.
♦ When working on the vehicle, always make sure that the
start/stop system is deactivated (switch off the ignition;
switch the ignition on again if necessary).
1. Safety information 1
1.2 Safety precautions when using test and

measuring instruments during a road
test
Please observe the following if test and measuring equipment is
required during a road test:
WARNING
Risk of accidents due to distraction and inadequate securing

of test and measuring equipment.
♦ Operation of test and measuring equipment while driving
results in distraction.
♦ Increased risk of injury due to inadequately secured test
and measuring equipment.
♦ Test and measuring equipment must always be secured
on the rear seat.
♦ An additional person responsible for the operation of the
test and measuring equipment needs to be present in the
vehicle.
♦ The person responsible for the operation of the test and
measuring equipment must be sitting on the rear seat.
♦ Never operate the test and measuring equipment while
sitting in the front passenger seat.
♦ In the event of an accident, the person operating the
equipment whilst sitting in the front passenger seat may
receive serious injuries when the front passenger airbag
is triggered.
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Allocation of PR number - brakes”, page 3
2.1 Allocation of PR number - brakes

⇒ “2.1.1 Front brakes”, page 3
⇒ “2.1.2 Rear brakes”, page 3
2.1.1 Front brakes

The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
– The relevant information relating to which braking system is
installed can also be called up via ELSA/vehicle-specific
notes.
The following table shows the allocation of the brake systems and
running gear.
Allocation ⇒ Electronic parts catalogue “ETKA” .
Front brakes are differentiated according to running gear sizes.
Running gear size in inches PR No. Designation of front brake
16 2E3 FN3
17 2E4 2FNR
2.1.2 Rear brakes

The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
– The relevant information relating to which braking system is
installed can also be called up via ELSA/vehicle-specific
notes.
16” and 17” rear brakes (hydraulic disc brakes with mechanically
actuated parking brake)
2. Identification 3
3 Repair notes
⇒ “3.1 Checking vacuum system”, page 4
3.1 Checking vacuum system

The following test 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)
Measuring results will be influenced by the geographical location.
The higher the location is above sea level, the lower the air pres‐
sure will be.
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/1000 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.
Take note of the following test requirements:
♦ Inspect all vacuum hoses for damage (e.g. cracks or marten
bite) and to ensure that they are correctly and firmly attached
♦ Ensure cleanliness when working on vacuum system
♦ Before starting work, clean engine compartment if necessary

4 Technical data
⇒ “4.1 Technical data for brakes”, page 5
4.1 Technical data for brakes

⇒ “4.1.1 Brake master cylinder and brake servo”, page 5
⇒ “4.1.2 Front brakes”, page 5
⇒ “4.1.3 Rear brakes”, page 6
4.1.1 Brake master cylinder and brake servo

Description Dimensions
Brake master cylinder, diame‐ 26.99 mm (tandem)
ter
Brake servo, diameter 9”/10”
4.1.2 Front brakes

Front brake, 16" (2E3)
Item Description Dimensions
[mm]
-1- Brake caliper (FN3) -
-2- Brake pad, thickness 12.5
(without backplate)
-3- Brake disc, diameter 308
Brake disc, thickness 29.5
-4- Brake caliper piston, diameter 60
Front brake, 17" (2E4)

Item Description Dimensions
[mm]
-1- Brake caliper (2FNR) -
-2- Brake pad, thickness 12
(without backplate)
-3- Brake disc, diameter 340
Brake disc, thickness 32.5
-4- Brake caliper piston, diameter 2 x 44
Volkswagen Technical Site: http://vwts.ru http://vwts.info
4. Technical data 5
4.1.3 Rear brakes

Rear brake, 16" and 17"
Item Description Dimensions [mm]
-1- Brake disc Diameter 294
in mm
Brake disc, mm 22
thickness
-2- Brake pad, mm 11.5
thickness (without
backplate)
-3- Brake caliper Diameter 41
piston in mm

5 Brake test
⇒ “5.1 General information”, page 7
⇒ “5.2 Checking vehicles with front-wheel drive”, page 7
⇒ “5.3 Checking vehicles with all-wheel drive”, page 7
5.1 General information

♦ The drive is provided by the test rig.
♦ For the test, ensure for vehicles with a manual gearbox that
the gear lever is in neutral, and for vehicles with an automatic
gearbox that the selector lever is in »N«.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is off.
5.2 Checking vehicles with front-wheel drive

The brake test must be carried out on a single-axle roller dyna‐
mometer.
The maximum test speed is 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
5.3 Checking vehicles with all-wheel drive

⇒ “5.3.1 On a regulated roller dynamometer with counter-rotating
rollers for four-wheel drive vehicles”, page 7
⇒ “5.3.2 Without roller dynamometer for four-wheel drive vehi‐
cles”, page 8
5.3.1 On a regulated roller dynamometer with

counter-rotating rollers for four-wheel
drive vehicles
Note
The brake test must be performed on a controlled contra-rotating

single-axle roller dynamometer for four-wheel drive vehicles.
“Counter-rotating” means that the dynamometer rollers of the sin‐

gle-axle roller dynamometer are driven forwards on one side and
backwards on the other.
The rollers drive the wheels of one axle in opposite directions to
avoid transmitting torque to the other axle.
“Regulated” means that the speed of the brake test stand rollers
is so controlled so that there is no difference in speed during the
brake test.
This prevents the transfer of a force through the stationary wheels
(not on the set of rollers) via the propshaft to the rotating wheels
on the rollers.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed.
5. Brake test 7
The maximum test speed is 6 km/h.

The test rigs authorised by Volkswagen fulfil these requirements.
5.3.2 Without roller dynamometer for four-

wheel drive vehicles
Note
If no test rig is available for four-wheel drive vehicles, the brake

test can also be carried out on a standard single-axle roller dy‐
namometer as follows:
– Drive vehicle forwards onto the rollers.

– Switch off engine and wait for 2 seconds.
– Carry out front brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
– Drive vehicle forwards until rear wheels are positioned on roll‐
ers.
– Switch off engine and wait for 2 seconds.
– Carry out rear brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.

45 – Anti-lock brake system

1 General information
⇒ “1.1 Repair instructions for repair work on ABS”, page 9
1.1 Repair instructions for repair work on

ABS
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Note
Faults in the ABS influence the brake system and servo assis‐
tance. The conventional brake system remains functional even
without ABS. A change in braking behaviour is to be reckoned
with. After the ABS warning lamp comes on, the rear wheels may
lock prematurely during braking.
The hydraulic unit -a- and control unit -b- (47-pin) form one com‐
ponent. They can be separated only when removed.
New control units from the replacement parts service are not co‐
ded. They have to be coded after installation ⇒ Vehicle diagnostic
tester.
The ABS warning lamp - K47- and the ESP and TCS warning
lamp - K155- flash so long as the ABS control unit - J104- has not
been coded.
Layout in left-hand drive vehicles
1. General information 9
Layout in right-hand drive vehicles

♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using “Guided Fault Finding”.
“Fault finding” is performed with the ⇒ Vehicle diagnostic tester.
♦ With ignition switched off, disconnect battery earth strap.
♦ Before carrying out welding work with an electric welding unit,
see ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 98 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 98
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. Auxiliary items containing mineral oil, e.g. oils,
greases, etc. must never be used.
♦ Thoroughly clean all unions and adjacent areas before loos‐
ening. Do not use aggressive cleaning agents such as brake
cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover them over.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing. (Use seal‐
ing plugs from repair kit 1H0 698 311 A)
♦ Only use lint-free cloths.
♦ Remove packing from replacement parts immediately prior to
installation and not before.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ The valve coils in the control unit cannot be adjusted.
♦ The valve coils in the control unit cannot be renewed.
♦ Pressure sensor must not be changed or damaged.
♦ The pressure sensor cannot be renewed.
♦ The sensor housing must not be exposed to mechanical
stress.
♦ No measurements must be taken on contact points of control
unit.
♦ No measurements must be taken on contact points of hy‐
draulic unit.
♦ Contact pins of hydraulic unit must not be bent or damaged.
♦ The contacts cannot be renewed.
♦ No contact sprays may be used on the contacts or the pres‐
sure sensor.
♦ Foreign bodies must not get between the control unit and the
hydraulic unit.
10 Rep. gr.45 - Anti-lock brake system

♦ During painting operations, the electronic control unit can 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). During longer periods (2 hours), the control unit can
be exposed to a maximum temperature of 85°C. Ensure that
no brake fluid enters connectors.
1. General information 11
2 Overview of fitting locations

⇒ “2.1 Overview of fitting locations - ABS/ESP”, page 12
2.1 Overview of fitting locations - ABS/ESP
1 - ABS control unit - J104-

❑ with integrated ESP
sensor unit - G419-
❑ Can be checked with
⇒ Vehicle diagnostic
tester
❑ Do not separate con‐
nector (47 pin) before
successfully completing
reading of fault memory.
Switch ignition off be‐
fore separating connec‐
tor.
❑ Removing and installing
⇒ page 15
2 - ABS hydraulic unit - N55-
❑ with integrated ABS re‐
turn flow pump - V39-
tester
❑ Do not separate ABS re‐
turn flow pump - V39-
and valve block
⇒ page 15
3 - Brake pad warning lamp -
K32-
❑ In dash panel insert
⇒ Electrical system;
Rep. gr. 90 ; Dash panel
insert; Removing and in‐
stalling dash panel in‐
sert KX2
4 - ABS warning lamp - K47-
❑ Removing and installing ⇒ Electrical system; Rep. gr. 90 ; Dash panel insert; Removing and installing
dash panel insert KX2
5 - Warning lamp for stabilisation programme - K155-
6 - Brake system warning lamp - K118-
7 - TCS and ESP button - E256-
❑ In dash panel.

❑ Removing and installing ⇒ Electrical system; Rep. gr. 96 ; Controls; Removing and installing special
vehicle control unit -E256-
8 - Brake light switch - F-
❑ Can be checked with ⇒ Vehicle diagnostic tester
❑ Installed on tandem brake master cylinder
❑ Removing and installing ⇒ page 22
9 - Steering angle sender - G85-
❑ Installed between steering wheel and steering column switch
❑ Removing and installing ⇒ Electrical system; Rep. gr. 94 ; Steering column switch module; Removing
and installing steering column electronics control unit J527
10 - Diagnostic connection
❑ Installed in footwell cover on driver side
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments/covers; Removing
and installing footwell cover on driver side
11 - Rear right speed sensor - G44- and rear left speed sensor - G46-
12 - Rear wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearings, trailing arm;
Removing and installing wheel bearing unit
13 - Front wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing.
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 40 ; Wheel bearings; Removing and
installing wheel bearing unit .
14 - Front right speed sensor - G45- and front left speed sensor - G47-
2. Overview of fitting locations 13

3 Control unit and hydraulic unit

⇒ “3.1 Assembly overview - control unit and hydraulic unit”, page
14
⇒ “3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 ”, page 15
⇒ “3.3 Separating control unit from hydraulic unit”, page 19
3.1 Assembly overview - control unit and hydraulic unit
1 - ABS control unit - J104-

⇒ page 15
❑ Separating ABS control
unit - J104- from ABS
hydraulic unit - N55-
⇒ page 19
2 - ABS hydraulic unit - N55-
⇒ page 15
3 - Brake line
❑ Overview of brake line
connections
⇒ page 15
❑ 14 Nm
4 - Brake line
connections
⇒ page 15
❑ 14 Nm
5 - Brake line
connections
⇒ page 15
❑ 14 Nm
6 - Brake line
connections
⇒ page 15
❑ 14 Nm
7 - Brake line
connections ⇒ page 15
❑ 14 Nm
8 - Brake line
❑ Overview of brake line connections ⇒ page 15
❑ 14 Nm
9 - Bolts
❑ Qty. 3
❑ Initial tightening torque: 1.5 Nm (to allow seal to settle); final tightening torque: 2.5 Nm
10 - Holder
❑ For ABS hydraulic unit - N55- and ABS control unit - J104- .

11 - Bolts
❑ Qty. 3
❑ 9 Nm
12 - Buffer
❑ Qty. 3
13 - Battery tray
14 - Nut
❑ Qty. 3
❑ 20 Nm
15 - Holder
3.2 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
N55-
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G 1331-

♦ Ring insert tool, open, AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G 1410/7-
3. Control unit and hydraulic unit 15

♦ Torque wrench - VAS 6854-

♦ Brake pedal depressor - V.A.G 1869/2-
♦ Assembly tool - V.A.G 1410/8-
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
the left in the engine compartment under the brake master cylin‐
der.
WARNING
Do not bend the brake lines in the area of the hydraulic unit!
Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove upper screw of trim.
– Pull out lower trim -arrow- upwards.
Vehicles with diesel engine:
– Disconnect lines -1- from coolant expansion tank -4-.
– Pull off electrical connector -2-.
– Unscrew bolts -3-.
– Lay coolant expansion tank -4- to one side, and secure it in
place.
Continued for all vehicles:
– Remove bolt -arrow-.

– Remove trim -1-.

– Remove bolt -arrow A-.

– Unscrew nut -arrow B-.
– Pull off trim -1- from bulkhead bracket -arrow B-.
– Remove fuel filter ⇒ Fuel system; Rep. gr. 20 ; Fuel filter;
Removing and installing fuel filter
Vehicles with petrol engine:
– Disconnect fuel lines underneath brake master cylinder.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Connect bleeder bottle hose to front left brake caliper bleeder
valve and open bleeder valve.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left bleeder valve.
– Do not remove brake pedal depressor - V.A.G 1869/2- .
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
– Remove brake lines -3- and -4-, first unscrew from brake mas‐
ter cylinder then from hydraulic unit.
– Unscrew brake lines -2- from hydraulic unit.
– Seal brake lines and threaded holes using sealing plugs - 1H0
698 311 A- .
– Release connector -5- and pull off in direction of -arrow- from
control unit -1-.
Note
Ensure no brake fluid gets onto contacts.
– Pull out hydraulic unit with control unit upwards from bracket.
– Separate control unit from hydraulic unit ⇒ page 19 .
Installing
Install in reverse order of removal, observing the following:
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ If the rubber buffers -2- are pulled out of the large retainer
during removal, reinsert them into the retainer before installing
the hydraulic unit. The rubber buffers must be inserted “dry”.

– If hydraulic unit -1- has been exchanged, retainer -4- for old
hydraulic unit must be transferred to new hydraulic unit.
– Press hydraulic unit with retainer into rubber buffers.
Note
♦ The hydraulic unit must be inserted vertically (keep straight) in

the bracket as otherwise the insulation rubber will be pushed
out.
♦ Use lubricant if necessary.

– Connect brake lines one after other to ABS hydraulic unit -

N55- and to brake master cylinder.
1 - Brake line to brake caliper, rear left
2 - Brake line to brake caliper, front right
3 - Brake line to brake caliper, front left
4 - Brake line to brake caliper, rear right
5 - Brake line to brake master cylinder, front connection
6 - Brake line to brake master cylinder, rear connection
– Connect electrical connector.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 98 .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Note
Check installation position after fitting hydraulic unit. The surface

with the 4 hydraulic line unions must be horizontal. Deviations of
more than 5° are not permitted. Additionally the installation posi‐
tion must not be turned by more than 5° in the vertical axis. When
the system is operational again a comparison with lateral accel‐
eration and yaw rate sensors must be performed.
– ⇒ Vehicle diagnostic tester Connect ⇒ Maintenance ; Booklet

20.1 ; Work descriptions; Reading fault memory of all systems
with vehicle diagnostic tester, correcting possible faults ac‐
cording to repair guidelines .
– Code ABS control unit - J104- ⇒ Vehicle diagnostic tester,
Brake system , Self-diagnosis compatible systems ,
Anti-lock brake system ABS/EDL/TCS/ESP , Anti-lock
brake system functions , ABS control unit , Commis-
sioning .
To do this, carry out basic setting of steering angle sender - G85- ,

lateral acceleration sender - G200- , longitudinal acceleration
sender - G251- and brake pressure sender - G201- .
Specified torques
♦ ⇒ “3.1 Assembly overview - control unit and hydraulic unit”,
page 14
3.3 Separating control unit from hydraulic

unit
Special tools and workshop equipment required
♦ ESD workplace - VAS 6613-
♦ Torx bit T25
♦ If a control unit is defective, the control unit must be discon‐
nected from the hydraulic unit and only the control unit re‐
newed.
♦ If the hydraulic unit is defective, the hydraulic unit must be re‐
newed together with the control unit.
♦ To separate the control unit from the hydraulic unit, the hy‐
draulic unit must be removed first.

WARNING
♦ Return flow pump must not be separated from hydraulic

unit.
♦ Printed circuit board becomes visible when control unit is
removed.
♦ Neither moisture nor particles of dirt may enter the interior
of the control unit.
♦ Avoid electrostatic charge!
This electrostatic charge can cause malfunctions if you touch

electric components.
– Before working on electric components, touch an earthed ob‐
ject, ESD workplace - VAS 6613- . Do not directly touch
connector contacts or electronic components.
– Lay down hydraulic unit together with control unit on ESD
workplace - VAS 6613- .
– Unscrew Torx bolts -arrows- from control unit and lay them
aside immediately (to avoid interchanging with new Torx
bolts).
– Carefully pull off control unit from hydraulic unit, making sure
that it is not canted.
Specified torques
♦ ⇒ “3.1 Assembly overview - control unit and hydraulic unit”,
page 14

4 Sensors
⇒ “4.1 Assembly overview - speed sensor on front axle”,
page 21
⇒ “4.2 Assembly overview - speed sensor on rear axle”,
page 22
⇒ “4.3 Removing and installing brake light sensor”, page 22
⇒ “4.4 Removing and installing speed sensors on front axle G45 /
G47 ”, page 23
⇒ “4.5 Removing and installing speed sensors on rear axle G44 /
G46 ”, page 24
4.1 Assembly overview - speed sensor on front axle
1 - Speed sensor
❑ Front right speed sensor
- G45- / front left speed
sensor - G47-
⇒ page 23
❑ Clean inside surface of
hole before inserting
sender.
❑ Coat hole with polycar‐
bamide grease - G 052
142 A2- ⇒ Electronic
Parts Catalogue (ETKA)
2 - Bolt
❑ 8 Nm
3 - Drive shaft
4 - Wheel bearing unit
❑ ABS sensor ring is inte‐
grated into wheel bear‐
ing.
5 - Brake disc
6 - Wheel bearing housing
4. Sensors 21
4.2 Assembly overview - speed sensor on rear axle
1 - Speed sensor
❑ Rear left speed sensor -
G46- / rear right speed
sensor - G44-
⇒ page 24
❑ Clean inside surface of
hole before inserting
sender.
❑ Coat hole with polycar‐
bamide grease - G 052
142 A2- ⇒ Electronic
Parts Catalogue (ET‐
KA) .
2 - Bolt
❑ 8 Nm
3 - Brake disc
❑ ABS sensor ring is inte‐
grated into wheel bear‐
ing.
5 - Suspension link
4.3 Removing and installing brake light sen‐

sor
Removing
– Unclip vacuum lines from air intake hose.
– Open clips -1- and -2-.
– Remove air intake hose.

Vehicles with petrol engine:

– Open clips -2- and -3-.
– Remove air ducting hose -1-.

– Release and pull off electrical connector -2- from brake light
switch - F- -1-.
– Unscrew bolt for brake light sensor -3-.
Installing
– Install in reverse order. Observe the following:
– Ensure that brake light sensor -1- sits properly on edge

-arrow- of brake master cylinder.
Specified torque
♦ ⇒ “3.1 Assembly overview - brake servo/brake master cylin‐
der”, page 82
4.4 Removing and installing speed sensors

on front axle -G45- / -G47-
4. Sensors 23
Removing
– Raise vehicle on lift.
– Disconnect connector -1- from speed sensor.
– Unscrew bolt -2- and pull out speed sender from wheel bearing
housing.
Installing
– Clean inner surface of hole and coat with polycarbamide
grease - G 052 142 A2- ⇒ Electronic Parts Catalogue (ETKA) .
Specified torques
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page
21
4.5 Removing and installing speed sensors

on rear axle -G44- / -G46-
Removing

– Disconnect connector -1- from speed sensor.

– Unscrew bolt -2- and pull out speed sender from wheel bearing
housing.
Installing
– Clean inner surface of hole and coat with polycarbamide
grease - G 052 142 A2- ⇒ Electronic Parts Catalogue (ETKA) .
Specified torques
♦ ⇒ “4.2 Assembly overview - speed sensor on rear axle”, page
22
4. Sensors 25
46 – Brakes - mechanism
1 Front brakes
⇒ “1.1.1 Assembly overview - front brake, floating caliper disc
brake FN3”, page 26
brake 2FNR”, page 29
⇒ “1.2 Removing and installing brake pads/linings”, page 30
⇒ “1.3 Removing and installing brake caliper”, page 38
⇒ “1.4 Removing and installing brake disc”, page 47
⇒ “1.5 Removing and installing brake carrier”, page 48
1.1 Assembly overview - front brakes
1.1.1 Assembly overview - front brake, floating caliper disc brake FN3
Note
♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the pads
are properly seated in their normal operating position.
♦ Use brake filling and bleeding equipment -VAS 5234- to draw off brake fluid from brake fluid reservoir.
♦ Fit brake pedal actuator -V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose.
26 Rep. gr.46 - Brakes - mechanism


2 - Bolt
❑ 8 Nm
3 - ABS speed sensor
❑ Clean inner surface of
hole, and coat with pol‐
ycarbamide grease ⇒
Electronic Parts Cata‐
logue (ETKA)
4 - Cover plate
5 - Bolt
❑ 10 Nm
7 - Brake disc
Vehicles with 16'' wheels, 2E3.
♦ Ventilated brake disc: ∅
308 mm
♦ Brake disc thickness:
29.5 mm.
♦ Wear limit: 26.5 mm
♦ Ventilated brake disc: ∅
333 mm
♦ Brake disc thickness:
32.5 mm.
♦ Wear limit: 29.5 mm
❑ When worn, always re‐
new on both sides of
axle.
❑ Never remove brake
discs from wheel hub by
force. If necessary use penetrating fluid, because otherwise brake discs can be damaged.
8 - Bolt
❑ 15 Nm
9 - Connector
❑ When changing pads, remove from bracket ⇒ Item 18 (page 28) .
10 - Brake pads
♦ Brake pad thickness: 12.5 mm not including backplate
♦ Wear limit: 2 mm excluding backing plate.
♦ Brake pad thickness: 11 mm not including backplate
♦ Wear limit: 2 mm excluding backing plate.
❑ Always replace on both sides
❑ The inner pad on the left side of the vehicle has a wear indicator.
❑ When wear reaches a predetermined limit (approx 2-3 mm), a warning lamp in dash panel insert comes
on.
❑ Check thickness ⇒ Maintenance ; Booklet 19.1 .
1. Front brakes 27
11 - Retaining spring
12 - Brake carrier
❑ Bolt to wheel bearing housing.
13 - Brake caliper
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Do not disconnect brake hose when changing pads.
14 - Guide pin
❑ 30 Nm
15 - Cover
16 - Brake hose/brake line
❑ Screw into brake caliper
❑ Do not disconnect brake hose when changing brake pads.
❑ Observe fitting instructions ⇒ page 28 .
❑ 15 Nm
17 - Bracket
18 - Holder
19 - Bolt
❑ 10 Nm
20 - Bolt
❑ Renew after removal
❑ 180 Nm +45°
Fitting instructions for brake hose
Note
♦ Once the front brake hose has been installed, there must be
a minimum of 40 mm ± 10 mm clearance -a- between the cou‐
pling rod and the brake hose.
♦ Clearance must be measured in rebound condition. Wheels
must be in straight-ahead position.

1.1.2 Assembly overview - front brake, floating caliper disc brake 2FNR

2 - Bolt
❑ 8 Nm
3 - ABS speed sensor
logue (ETKA)
4 - Cover plate
5 - Bolt
❑ 10 Nm
7 - Brake disc
❑ Ventilated brake disc: ∅
340 mm
❑ Brake disc thickness:
32.5 mm.
❑ Wear limit: 29.5 mm
❑ When worn, always re‐
new on both sides of
axle.
❑ Never remove brake
discs from wheel hub by
force. If necessary use
penetrating fluid, be‐
cause otherwise brake
discs can be damaged.
⇒ page 47
8 - Bolt
❑ 20 Nm
9 - Brake carrier Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Bolted to wheel bearing housing.
10 - Brake pads
❑ Brake pad thickness: 12 mm not including backplate.
❑ Pad wear limit: 2 mm excluding backing plate.
❑ The inner brake pad on the left side of the vehicle has a wear indicator.
❑ When wear reaches a predetermined limit, the brake pad warning lamp - K32- in the dash panel insert
lights up.
11 - Connector
❑ When changing brake pads, remove from bracket ⇒ Item 17 (page 30) .
❑ Ensure correct seating
13 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
1. Front brakes 29
14 - Guide pin
❑ Use tool 9 mm socket - T50036 - .
❑ 60 Nm
15 - Caps
❑ Cover caps for guide pins.
❑ 15 Nm
17 - Holder
❑ Retainer for electric brake pad wear indicator connector.
❑ Lock electric connector in bracket and ensure it is seated correctly.
18 - Bolt
❑ 10 Nm
19 - Bolt
❑ Threaded connection, brake carrier to wheel bearing housing.
❑ 180 Nm +45°
1.2 Removing and installing brake pads/lin‐

ings
⇒ “1.2.1 Removing and installing brake pads, floating caliper disc
⇒ “1.2.2 Removing and installing brake pads, floating caliper disc
brake 2FNR 44”, page 33
1.2.1 Removing and installing brake pads,

floating caliper disc brake FN3
♦ Piston resetting appliance - T10145-

Removing
Mark brake pads or linings when removing if they are to be
reused. Fit in same position when installing, or braking will be
uneven.
– Remove wheels.
– Press retaining spring in direction of -arrow A- until it can be
pressed out of hole in direction of -arrow B-.
– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from upper hole.
– Remove cover caps -1-.

– Push connector -2- in direction of -arrow- out of retainer on
brake caliper.
– Separate electrical connector -2-.
– Remove cable from retainer -3-.
1. Front brakes 31
– Unscrew and remove both guide pins -arrows- from brake cal‐
iper.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Remove brake pads.
Use only methylated spirits for cleaning the brake caliper housing.
Installing
Before inserting new brake pads, press piston back into the cyl‐
inder using piston resetting tool - T10145- . Before pressing the
piston back, draw off brake fluid from the reservoir with a bleeder
bottle. Otherwise, fluid can overflow and cause damage, particu‐
larly if reservoir has been topped up.
– Press piston back.

1- Piston resetting appliance - T10145-
16” brakes:
♦ Clean brake caliper (remove adhesive remains), the adhesive
surface must be clean and dry.
♦ Pull protective covering off backplate of pad.
– Insert brake pad with retaining springs into pistons -arrows-.

– Fit outer brake pad to brake carrier.
– Bolt brake caliper to brake carrier with both guide pins

-arrows-.
– Fit both protective caps.
– Insert wire of brake pad wear indicator into bracket on brake
caliper.
– Reconnect connector, and push it into bracket on brake cali‐
per.

– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
– Position retaining spring at bottom of brake carrier.
– First press retaining spring in direction of -arrow A-, and then

simultaneously into hole in brake caliper in direction of
-arrow B-.
– Fit wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
Note
♦ After changing brake pads, firmly depress brake pedal several

times with vehicle stationary, so that the brake pads are prop‐
erly seated in their normal operating position.
♦ After changing brake pads/linings, check brake fluid level.
Specified torques
♦ ⇒ “1.1.1 Assembly overview - front brake, floating caliper disc
1.2.2 Removing and installing brake pads,

floating caliper disc brake 2FNR 44
1. Front brakes 33
♦ Socket, 9 mm - T50036 -
Removing
Note
Mark brake pads when removing if they are to be reused. Reinstall

brake pads in same position, or braking may be uneven.
– Remove front wheels.

– Use a screwdriver -2- to lever retaining spring -1- off brake
caliper in direction of -arrow-.

– Release and disconnect connector of brake pad wear indicator

-3-.
– Remove mating part of connector from bracket -2-.
– Remove protective caps -1-.
– Unscrew guide pins using bit 9 mm - T50036 - .
– Remove brake caliper -1- in direction of -arrow- from brake

carrier.
– Secure brake caliper -1- with wire to suspension strut -2- so

that brake hose is not strained by weight of brake caliper.
– Remove outer brake pad -4- from brake carrier -3- in direction
of -arrow A-.
1. Front brakes 35
– Position piston resetting appliance - T10145- -1- between in‐

ner brake pad -2- and brake caliper.
– Use piston resetting appliance - T10145- -1- to push both
brake pistons back in direction of -arrow A-.
– Remove inner brake pad in direction of -arrow B- from brake
pistons.
Note
♦ Before pressing brake pistons back, draw off some brake fluid
from the brake fluid reservoir. Otherwise there is a risk of brake
fluid spilling out of the reservoir and causing damage to the
vehicle when the brake pistons are being pressed back.
♦ Use only methylated spirits for cleaning the brake caliper.
Installing
– Guide electrical wire of brake pad wear indicator -1- through

brake caliper -2-.
– Push inner brake pad in direction of -arrow- into pressed-back

brake pistons.

– Insert outer brake pad -3- into brake carrier -2-.

– Fit brake caliper -1- onto brake carrier -2-.
– Insert both guide pins -1- into brake caliper, and tighten them.
– Insert protective caps of both guide pins.
– Push mating part of connector -2- into bracket on brake caliper
-arrow-.
– Fit wiring harness of brake pad wear indicator -3- onto mating
part of connector.
Note
The electrical connector engages audibly.
– Position retaining spring in direction of -arrow A- at bottom of

brake carrier.
– Use a screwdriver to lever in upper metal tab of retaining
spring on upper brake carrier in direction of -arrow B-.
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
Note
♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, to ensure that the brake
pads are properly seated in their normal operating position.
♦ Check brake fluid level in the brake fluid reservoir every time
after brake pads have been changed.
Specified torques
1. Front brakes 37
1.3 Removing and installing brake caliper

⇒ “1.3.1 Removing and installing brake caliper, floating caliper
disc brake FN3”, page 38
⇒ “1.3.2 Removing and installing brake caliper, floating caliper
disc brake 2FNR 44”, page 42
1.3.1 Removing and installing brake caliper,

floating caliper disc brake FN3
Removing and installing brake caliper without opening in hydraul‐
ic circuit ⇒ page 38
Removing and installing brake caliper with opening in hydraulic
circuit ⇒ page 39
ic circuit
Removing
– Remove wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Wheel change .

– Remove brake caliper -1- with brake lines still attached in di‐
rection of -arrow-.
– Suspend brake caliper with wire in area of body so that brake
lines are relieved of load.
Installing
– Press brake piston of brake caliper a few millimetres back us‐
ing piston resetting appliance - T10145- .
– Install brake caliper, ensuring that no foreign bodies are loca‐
ted between brake pads and brake disc.
– After assembly, firmly depress brake pedal several times with
vehicle stationary.
– Check the brake fluid level in the brake fluid reservoir.
Specified torques
circuit

Removing
1. Front brakes 39
– Press retaining spring in direction of -arrow A- until it can be

pressed out of hole in direction of -arrow B-.
– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from the upper hole.

– Remove caps -1-.

– Push connector -2- in -direction of arrow- out of retainer on
brake caliper.
– Separate connector -2- and remove cable from retainer -3-.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper off brake carrier.
– Remove brake pads from brake caliper.
Installing
• The piston is pressed back.
• Outer brake pad is seated on brake carrier.
– Insert inner brake pad with retaining spring in brake caliper
(piston).
When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly.
Do not damage adhesive surface.
– Bolt brake caliper to brake carrier with both guide pins.
– Connect brake hose to brake caliper. When doing this, ob‐
serve fitting instructions. ⇒ page 28
– Insert wire for brake pad wear display into retainer on brake
caliper, join connector and push into bracket on brake caliper.
– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
– Seat retaining spring into lower section of brake carrier.
1. Front brakes 41
– First press retaining spring in -direction of arrow A-, and then

simultaneously into hole in brake caliper
-direction of arrow B-.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads/linings are properly seated in their
normal operating position.
♦ Check brake fluid level.
Specified torques
1.3.2 Removing and installing brake caliper,

floating caliper disc brake 2FNR 44
ic circuit ⇒ page 42
circuit ⇒ page 43
ic circuit

Removing
– Remove brake caliper -1- with brake lines still attached in di‐
rection of -arrow-.
– Suspend brake caliper with wire in area of body so that brake
lines are relieved of load.
Installing
– Press brake piston of brake caliper a few millimetres back us‐
ing piston resetting appliance - T10145- .
– Install brake caliper, ensuring that no foreign bodies are loca‐
ted between brake pads and brake disc.
– After assembly, firmly depress brake pedal several times with
vehicle stationary.
– Check the brake fluid level in the brake fluid reservoir.
Specified torques
circuit

1. Front brakes 43
♦ Socket, 9 mm - T50036 -
Removing
Note
The procedure described below applies only to the exchange or

to the following repair work on the brake caliper.

– Use a screwdriver -2- to lever retaining spring -1- off brake
caliper in direction of -arrow-.

– Release and separate electric connector for brake pad wear

indicator -6-.
– Remove mating part of electric connector -4- from bracket
-5-.
– Connect bleeder bottle hose to brake caliper bleeder valve
-3- and open bleeder valve.
– Close bleeder valve -3- and remove bleeder bottle with bleed‐
er hose.
– Separate brake hose -1- at transition point to body.
– Unscrew brake hose -1- from brake caliper.
– Remove protective caps -2-, unscrew guide pins beneath with

9 mm socket - T50036 - and remove from brake caliper.
– Remove brake caliper -1- from brake carrier in direction of
-arrow-.
– Remove inner brake pad out of brake piston.
Installing
• The brake pistons are pressed back.
• Outer brake pad is seated on brake carrier.
– Screw brake hose hand-tight into brake caliper.
1. Front brakes 45
– Guide electrical cable of brake pad wear indicator -1- through

brake caliper -2-.
– Press inner brake pad into pressed-back brake piston in

-direction of arrow-.
– Position brake caliper -1- onto brake carrier -2-.
– Insert both guide pins -2- into brake caliper and tighten.
– Reinsert both protective caps for guide pins.
– Insert mating part of electric connector -4- into bracket on
brake caliper -5-.
– Connect electric wiring harness for brake pad wear indicator
-6- to mating part and audibly lock connector.
– Screw brake hose into transition point at body.

– Tighten brake hose -1- on brake caliper.

– Position retaining spring on bottom of brake carrier in
-direction of arrow A-.
– Use a screwdriver to lever upper metal tab of retaining spring
in on upper brake carrier in -direction of arrow B-.
– Mount front wheel ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres
Note
♦ Depress brake pedal firmly several times with vehicle station‐

ary, so that brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level in brake fluid reservoir.
Specified torques
1.4 Removing and installing brake disc

Removing
– Remove brake caliper without opening in hydraulic circuit
⇒ page 38 .
– Unscrew bolt -1-.
– Remove brake disc -2-.
Note
Do not use force to separate the brake disc from the wheel hub.
Brake disc damage may otherwise occur on reuse. Use penetra‐
tion spray.
Installing
1. Front brakes 47
– Clean contact surfaces -1- of wheel bearing unit using me‐

chanical means.
Torque settings
♦ Vehicles with floating caliper disc brake FN3
♦ Vehicles with floating caliper disc brake 2FNR
1.5 Removing and installing brake carrier

Removing
– Remove brake caliper ⇒ page 38 .
– Remove backplate -2-.
Installing
Specified torques
♦ Vehicles with floating caliper disc brake FN3
♦ Vehicles with floating caliper disc brake 2FNR

2 Rear brakes
⇒ “2.1 Assembly overview - rear brakes”, page 49
⇒ “2.2 Removing and installing brake pads/linings”, page 50
⇒ “2.3 Removing and installing brake caliper”, page 53
2.1 Assembly overview - rear brakes
Note
♦ Every time after changing the brake pads, depress the brake pedal firmly several times with the vehicle
stationary so that the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Brake pedal actuator - V.A.G 1869/2- must be inserted before removing a brake caliper or separating a
brake hose.
1 - Suspension link
⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Suspension link, track
rod; Assembly overview
- transverse link
2 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
logue (ETKA)
tester
⇒ page 24
3 - Bolt
❑ 8 Nm
4 - Bolts
❑ Qty. 2
❑ Bolts of brake carrier to
wheel bearing housing
❑ 165 Nm
5 - Bolts
❑ Qty. 2
❑ 35 Nm
6 - Pad retainers
❑ Qty. 2 Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Always renew when changing pads.
2. Rear brakes 49
7 - Brake caliper
❑ 15 Nm
9 - Brake pads
❑ Brake pad thickness: 11.5 mm not including backplate
❑ Wear limit: 2 mm excluding backing plate.
❑ The inner pad on the right side of the vehicle has a wear indicator.
❑ When wear reaches a predetermined limit (approx 2-3 mm), a warning lamp in dash panel insert comes
on.
10 - Brake carrier
❑ Bolt to wheel bearing housing.
11 - Bolt
❑ 20 Nm
12 - Brake disc
❑ Ventilated brake disc: ∅ 294 mm.
❑ Brake disc thickness: 22 mm.
❑ Wear limit: 19.9 mm
❑ When worn, always renew on both sides of axle.
❑ Never remove brake discs from wheel hub by force. If necessary use penetrating fluid, because otherwise
brake discs can be damaged.
❑ Fitting location: on rear suspension link ⇒ Item 1 (page 49)
❑ ABS sensor ring is integrated into wheel bearing.
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearings, trailing arm;
Removing and installing wheel bearing unit
14 - Bolts
❑ Qty. 3
❑ 9.5 Nm
15 - Cover plate
16 - Rear handbrake cable
❑ Adjusting ⇒ page 56
2.2 Removing and installing brake pads/lin‐

ings

♦ Piston compressing tool - T10165-
Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
WARNING
It is only permissible to change the position of the brake piston

with the piston compressing tool - T10165- .
– Remove wheels.
– Turn connector for break wear display (only on right side of
vehicle) 90° and pull out of metal retainer.
– Disconnect connector for brake pad wear indicator.
2. Rear brakes 51
– Unhook handbrake cable -1- from retainer on brake caliper.

– Remove securing bolts -arrows- for brake caliper.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Remove brake pads.
– Remove pad retainers.
Cleaning
WARNING
Do not blow out brake system with compressed air as the re‐
sulting dust is dangerous to health!
Note
Use only methylated spirits for cleaning the brake caliper housing.
– Thoroughly clean contact surfaces for brake pads on brake

carrier and remove corrosion.
Installing
WARNING
Before pressing pistons back, draw off some brake fluid from
the brake fluid reservoir. Use a bleeder bottle or a plastic bottle
which is used exclusively for brake fluid. Brake fluid is poison‐
ous and must on no account be sucked out by mouth using a
hose!
Apply piston compressing tool - T10165- so that collar -arrow- of

tool rests on brake caliper.
– Screw in piston by turning knurled wheel clockwise, taking
care not to damage protective cap.
– Insert brake pads with pad retainers.
If existing brake pads are to be re-used, re-install the marked
brake pads at the same position.
With new brake pads, use the pad retainers included in the repair
kit.

– Ensure that brake pads are seated correctly in anti-rattle

springs -arrows-.
– Check guide pins on brake carrier for ease of movement.
– Install brake caliper and secure with new self-locking bolts

-arrows-.
The repair kit includes 4 self-locking hexagon bolts which must
always be installed.
– Attach handbrake cable -1-.
– Join connector for brake pad wear indicator (only on right side
of vehicle), insert in metal retainer and turn 90°.
– Fit wheels. ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres
Note
♦ After changing brake pads, firmly depress brake pedal several

times with vehicle stationary, so that the brake pads are prop‐
erly seated in their normal operating position.
♦ After changing brake pads/linings, check brake fluid level.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 49
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
2. Rear brakes 53

equipment required

Removing
– Remove wheels.


– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Close bleeder screw and remove bleeder bottle.
– Unscrew brake line from brake caliper.
– Remove securing bolts -arrows- for brake caliper.
– Pull brake caliper from brake carrier.
Installing
• The piston is pressed back.
• The brake pads are seated in the retaining springs on the
brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts.
– Screw brake line to brake caliper.
– Adjust handbrake ⇒ page 56 .
– Fit wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads/linings are properly seated in their
normal operating position.
♦ Check brake fluid level.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 49
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
2. Rear brakes 55
3 Parking brake
⇒ “3.1 Assembly overview - parking brake”, page 56
⇒ “3.2 Adjusting parking brake”, page 56
⇒ “3.3 Removing and installing front brake cable”, page 57
⇒ “3.4 Removing and installing rear brake cable”, page 59
3.1 Assembly overview - parking brake
1 - Push-button
2 - Handbrake lever trim
❑ Press down locking lug
underneath handle and
pull off forwards.
3 - Bracket trim
4 - Nut
❑ For adjusting hand‐
brake ⇒ page 56 .
5 - Nut
❑ Qty. 2
❑ 20 Nm
6 - Pull cable
7 - Handbrake lever
8 - Console
9 - Handbrake cable
10 - Holder
11 - Return spring
12 - Spring retainer
13 - Adjustment nut
14 - Compensation element
3.2 Adjusting parking brake

Adjustment of the handbrake is necessary if the handbrake ca‐
bles, brake calipers, brake pads or brake discs are renewed or
the cables are sagging.
– Depress foot brake hard at least 3 times.
– Pull handbrake on three times and then release again.
Below the first notch, the handbrake lever must return to its re‐
leased position.
• Handbrake lever in rest position.


– Tighten adjusting nut -arrow- until levers on brake calipers lift
off stop.
– The total of distances -a- between levers and stops on both

sides must not exceed 2 mm.
– Make sure that the wheels are free to turn.
3.3 Removing and installing front brake ca‐

ble
Removing
– Apply handbrake.
– Using a screwdriver, carefully press retaining tab -arrow- for
handbrake level trim outwards.
– Pull trim forwards off handbrake lever.
– Release handbrake.
– Pull off bracket trim -1-.

– Unscrew adjuster nut -arrow- from cable.
3. Parking brake 57
– Detach return spring -arrow- from underbody and from spring

retainer -1-.
– Unscrew spring retainer -1-.
– Unscrew nut -arrow- from cable.
– Press pull cable -1- out of bracket -2-.

– Pull pull cable -1- forwards out of bracket -3- and then pull out
of underbody.
Installing
– Guide pull cable through underbody into interior.

– Insert cable -1- into retainer -3-.

– Insert cable -1- into retainer -2-.
– Attach pull cable to hand brake lever using adjusting nut.
– Screw nut -arrow- onto cable.
– Screw on spring retainer -1-.
– Attach return spring -arrow- to underbody and to spring re‐

tainer -1-.
– Insert bracket trim.
– Attach handbrake lever trim.
3.4 Removing and installing rear brake ca‐

ble
Removing
– Release handbrake.
3. Parking brake 59
– Detach return spring -arrow- from underbody and from spring

retainer -1-.
– Unscrew spring retainer -1-.
– Unscrew nut -arrow- from cable.
– Pull compensator off cable.

– Detach handbrake cable -1- from compensator -2-.

– Unhook handbrake cable from retainers on transverse link

-arrows-.
– Press together lugs on handbrake cable -arrows-, and push

handbrake cable towards rear and out of cable support brack‐
et.
– Detach handbrake cable -1- from compensator -2-.

Installing
– Guide handbrake cable through cable support bracket and at‐
tach to compensator.
3. Parking brake 61
– Engage handbrake cable properly in underbody -arrow-.
– Attach handbrake cable in retainers -arrows- on suspension

link.
– Attach handbrake cable -1- to brake caliper.
– Attach handbrake cable -1- to compensator -2-.

– Fit compensator onto cable.

– Screw on cable nut -arrow-.

– Screw spring retainer onto cable.
– Attach return spring -arrow- to underbody and to spring re‐

tainer -1-.
3. Parking brake 63
4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 64
⇒ “4.2 Removing and installing brake light switch”, page 65
⇒ “4.3 Separating brake pedal from brake servo”, page 65
⇒ “4.4 Connecting brake pedal to brake servo”, page 66
⇒ “4.5 Removing and installing brake pedal”, page 66
4.1 Assembly overview - brake pedal
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
Lubricate all bearing points and contact surfaces using grease -

G 000 450 02- .
1 - Brake pedal mounting

bracket
2 - Nut
❑ Qty. 1
❑ 25 Nm
3 - Nut
❑ Qty. 1
❑ 25 Nm
4 - Nut
❑ Qty. 4
❑ 25 Nm
5 - Nut
❑ Qty. 1
❑ 25 Nm
6 - Brake pedal
❑ Separating brake pedal
from brake servo
⇒ page 65
❑ Connect brake pedal to
brake servo
⇒ page 66
⇒ page 66
7 - Bearing bush
8 - Mounting
❑ For ball head of brake
servo plunger rod.
9 - Nut
❑ Qty. 1
❑ 9 Nm

10 - Angled retainer
11 - Fitted bolt
12 - Bulkhead
4.2 Removing and installing brake light

switch
The brake light switch is no longer installed on the brake pedal.
Instead, it is installed on the brake master cylinder as a brake light
sensor.
– Removing and installing brake light sensor ⇒ page 22 .
Removing:
4.3 Separating brake pedal from brake ser‐

vo
♦ Release tool - T10159-
– Remove footwell cover on driver side ⇒ General body repairs,

interior; Rep. gr. 68 ; Compartments/covers .
– Remove brake light switch ⇒ page 65 .
– First press brake pedal in direction of brake servo and hold.
1- Brake pedal
2- Push bar
3- Retaining lugs
– Insert release tool - T10159- and pull in direction of driver seat
while counter-holding on brake pedal -1-. (At this moment,
brake pedal must not be allowed to move towards front of ve‐
hicle). This action will press retaining lugs -3- of mounting off
ball head of plunger rod -2-.
For clarity, separation of brake pedal from brake servo is shown
with pedal cluster removed.
– Pull release tool - T10159- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).
4. Brake pedal 65
4.4 Connecting brake pedal to brake servo

– Hold push rod ball head -2- in front of mounting and push
-arrow- brake pedal -1- in direction of brake servo so that ball
head audibly engages.
– Check engagement by pulling briefly on brake pedal.
The remaining installation steps are carried out in the reverse or‐
der of removal.
4.5 Removing and installing brake pedal

Removing
– Separate brake pedal from brake servo ⇒ page 65 .

– Remove nuts from brake servo -arrows-.

– Working from engine compartment, pull off brake servo ap‐
prox. 1 cm from plenum chamber bulkhead.
Note
Ensure that the brake lines are not damaged.
– Remove nut -1- and push out brake pedal pin

-in direction of arrow-.
– Remove brake pedal.
Ensure that brake servo piston rod always remains straight.
If necessary, have a second mechanic pull brake servo into en‐
gine compartment in order to remove brake pedal.
Installing
– Insert brake pedal in pedal mounting, insert pin from left and
screw on nut.
Ensure that brake servo piston rod always remains straight.
If necessary, have a second mechanic push brake servo against
plenum chamber bulkhead in order to install brake pedal.
– Secure brake servo with nuts -arrows-.

– Clip brake pedal to brake servo ⇒ page 66 .
The remaining installation steps are carried out in the reverse or‐
der of removal.
Specified torques
♦ ⇒ “4.1 Assembly overview - brake pedal”, page 64
4. Brake pedal 67
47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - front brake caliper”, page 68
⇒ “1.2 Removing and installing brake caliper piston”, page 71
1.1 Assembly overview - front brake caliper

⇒ “1.1.1 Assembly overview - front brake caliper, floating caliper
disc brake FN3”, page 68
⇒ “1.1.2 Assembly overview - front brake caliper, floating caliper
disc brake 2FNR”, page 70
1.1.1 Assembly overview - front brake caliper, floating caliper disc brake FN3
Note
♦ When conducting repairs on the brake caliper, always install the complete repair kit.
♦ Use only methylated spirits to clean the brake.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake cylinder, piston and seal.
♦ When repairs are performed, it is essential to appropriately pre-bleed the brake calipers (without brake pads)
before installing them in the vehicle ⇒ page 79 .
68 Rep. gr.47 - Brakes - hydraulics

1 - Dust cap
❑ Fit onto bleeder valve.
❑ Secures brake pad wear
indicator wiring.
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread
❑ 17 Nm
3 - Caps
❑ Insert into mounting
bush.
4 - Guide pin
❑ 30 Nm
5 - Bearing bush
❑ Insert into brake caliper.
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
⇒ page 71
10 - Piston
⇒ page 71
11 - Protective cap
❑ Do not damage when inserting piston.
1. Front brake caliper 69

1.1.2 Assembly overview - front brake caliper, floating caliper disc brake 2FNR
Note
♦ When conducting repairs on the brake caliper, always install the complete repair kit.
1 - Brake carrier
❑ Bolt to brake caliper
housing.
2 - Guide pin
❑ Guide pin with Allen
head, AF 9 mm.
❑ 60 Nm
3 - Caps
❑ Cover caps for guide
pins.
4 - Dust cap
❑ Fit onto bleeder valve.
5 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread
❑ 17 Nm
6 - Bearing bush
❑ Insert into brake caliper
housing.
7 - Brake caliper
⇒ page 48
❑ Ensure correct seating
⇒ page 30
9 - Protective caps
❑ Take care not to dam‐
age when inserting pis‐
ton.
❑ Apply a thin coat of lithium grease.
10 - Brake piston
❑ ∅ 2 x 44 mm.
❑ Apply a thin coat of lithium grease onto pistons before installing.
❑ Removing and installing brake caliper piston ⇒ page 73

11 - Oil seals
❑ Before installing in, coat with assembly paste.

piston
⇒ “1.2.1 Removing and installing brake caliper piston, floating
caliper disc brake FN3”, page 71
⇒ “1.2.2 Removing and installing brake caliper piston, floating
caliper disc brake 2FNR”, page 73
1.2.1 Removing and installing brake caliper

piston, floating caliper disc brake FN3
♦ Removal wedge - 3409-
♦ Assembly tool for protective caps - T10146/1-
Removing
• Front brake caliper is removed

– Press piston out of brake caliper using compressed air

-arrow-.
Place a piece of wood in the recess to prevent damage to the
piston.
– Lever off protective cap from brake caliper using removal

wedge - 3409- .
A - Vice clamps
– Remove seal using removal wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of assembly paste - G 052 150 A2- to piston
and seal before installing.
– Insert seal in brake caliper.
– Fit protective cap -A- in assembly tool - T10146/1- -1-.

– Push protective cap onto brake caliper using assembly tool -

T10146/1- -1- and piston resetting appliance - T10145- -2- in
such a way that protective cap lies against brake caliper all
around its circumference.
Check seat of protective cap:
– At this stage it should not be possible to remove protective cap

from brake caliper by hand.
– Press piston lightly onto protective cap and lock it in this po‐
sition using e.g. removal wedge - 3409- -2-.
Do not cant piston to prevent damage to sealing collar.
– Blow out protective cap using compressed air (max 3 bar)
-1-. Protective cap will spring over the piston.
A - Vice clamps
– Press piston into brake caliper using piston resetting tool -

T10145- -1-.
The outer sealing lip of the protective cap will then lock in the
groove of the piston.
Specified torques
♦ ⇒ “1.1.1 Assembly overview - front brake caliper, floating cal‐
iper disc brake FN3”, page 68
1.2.2 Removing and installing brake caliper

piston, floating caliper disc brake 2FNR

♦ Assembly tool for protective caps - T10146/5-
Removing
Note
Removal and installation of brake pistons are described for one

of the two brake pistons only. Proceed in the same way when
removing and installing the second brake piston.
• Front brake caliper is removed

– Position piston resetting appliance - T10145- -1- on one of the

two brake pistons.
– Place a piece of wood in brake caliper shaft in front of other
brake piston to prevent it from being damaged when pressing
out.
– Press out brake piston from brake caliper housing using com‐
pressed air.
– Lever off protective cap from brake caliper using removal
wedge - 3409- -1-.
– Remove piston resetting appliance - T10145- -1- from brake

caliper.
– Remove seal from brake caliper housing using removal wedge
- 3409- -2-.
Note
When removing, ensure that the surface of the brake piston is not
damaged.
Installing
Note
The surfaces of the piston and oil seals must be cleaned only with
– Apply thin coat of assembly paste to brake piston and seal

before installing.

– Insert seal into groove of brake caliper housing.
– Press protective cap into brake caliper housing using piston

resetting appliance - T10145- -2- and assembly tool for pro‐
tective caps - T10146/5- -1-.
– Push protective cap onto brake caliper housing so that it
comes into contact all around housing -arrow-.
Check seat of protective cap:

– Make sure that protective cap -1- can no longer be pulled off
brake caliper housing -2- by hand.
– Apply thin coat of assembly paste to brake piston and seal

before installing.
– Position piston resetting appliance - T10145- -3- on second
brake piston and preload tool.
– Press brake piston lightly onto protective cap e.g. using a
commercially available extension -1-. When doing this, do not
cant piston (keep straight) to prevent damage to protective
cap.
– Inflate protective cap with compressed air (maximum 3 bar)
-2-. The protective cap will then locate around the brake piston.

– Slowly press brake piston into brake caliper housing by hand.
Note
The inner sealing lip on the protective cap -1- will then slip into
the brake piston groove -2-.
– Install brake caliper ⇒ page 38 .

Specified torques
♦ ⇒ “1.1.2 Assembly overview - front brake caliper, floating cal‐
iper disc brake 2FNR”, page 70

2 Rear brake caliper

⇒ “2.1 Assembly overview - rear brake caliper”, page 78
⇒ “2.2 Removing and installing brake caliper piston”, page 79
2.1 Assembly overview - rear brake caliper
Note
♦ When conducting repairs, use complete repair kit.

1 - Bolt
❑ When loosening and
tightening, counter hold
on guide pin.
❑ 35 Nm
2 - Sealing ring
⇒ page 79
3 - Piston with automatic ad‐
justment
⇒ page 79
4 - Protective cap
❑ Pull on so that outer
sealing lip goes over
piston.
5 - Dust cap
6 - Bleeder valve
❑ 12 Nm
7 - Brake caliper with hand‐
brake cable lever
❑ If there is a leak at hand‐
brake cable lever, re‐
new brake caliper.
❑ Following repair work,
pre-bleed brake caliper
⇒ page 79 .
8 - Guide pin
❑ Grease before fitting
protective cap.
9 - Protective cap
❑ Fit onto brake carrier and guide pin.
10 - Brake carrier with guide pin(s) and protective cap
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.

❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.

piston
♦ Piston compressing tool - T10165-
Removing
WARNING
It is only permissible to change the position of the brake piston

with the piston compressing tool - T10165- .
• Rear brake caliper removed

– Apply piston resetting appliance - T10165- so that collar
-arrow- is in front of piston.
– Screw piston out of brake caliper by turning thumb wheel anti-
clockwise. Do not damage protective cap.
– If pistons are difficult to move, a 13 mm open-end spanner can
be used on intended flats -arrow A-.
2. Rear brake caliper 79

– Remove seal using removal wedge - 3409- .

Installing
Note
♦ When conducting repairs on the brake caliper, always install

the complete repair kit.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake
cylinder, piston and seal.
♦ When repairs are performed, it is essential to appropriately
pre-bleed the brake calipers (without brake pads) before in‐
stalling them in the vehicle ⇒ page 79 .
♦
– The surfaces of the piston and seal must be cleaned only with
– Insert seal into groove.
– Apply thin coat of assembly paste - G 052 150 A2- to piston
and seal before installing.
– Place protective cap with outer sealing lip on piston.
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper.

Apply piston compressing tool - T10165- so that collar -arrow- of

tool rests on brake caliper.
– Screw in piston by turning knurled wheel of piston resetting
appliance - T10165- clockwise; do not damage protective cap
when doing this.
Pre-bleeding brake caliper

– Position brake caliper as illustrated to pre-bleed.
– Open bleeder valve -arrow A- and, using a commercially avail‐
able bleeder bottle, fill with brake fluid until bubble-free brake
fluid flows out of threaded hole of brake hose connection
-arrow B-. Then close bleeder screw.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear brake caliper”, page 78
2. Rear brake caliper 81

3 Brake servo and brake master cylin‐

der
⇒ “3.1 Assembly overview - brake servo/brake master cylinder”,
page 82
⇒ “3.2 Removing and installing brake servo”, page 84
⇒ “3.3 Removing and installing brake master cylinder”,
page 85
⇒ “3.4 Removing and installing brake fluid reservoir”, page 88
3.1 Assembly overview - brake servo/brake master cylinder
WARNING
♦ Never allow brake fluid to come into contact with fluids

containing mineral oil (oil, petrol, cleaning agents) as
these damage the brake system's plugs and sleeves.
♦ Brake fluid is poisonous and must never be sucked out by
mouth through a hose.
♦ Due to its corrosive effect brake fluid must not come into
contact with paintwork.
♦ Observe applicable regulations for disposal.
♦ Only use brake fluid conforming to VW standard
(VW 501 14).

1 - Brake servo
❑ Operation check:
❑ If faulty renew complete
⇒ page 84
2 - Brake fluid reservoir
⇒ page 88
3 - Sealing cover
4 - Sealing plug
❑ Moisten with propylene
glycol - 294440- assem‐
bly fluid from outside
and press into brake
master cylinder
❑ Moisten with propylene
glycol - 294440- from in‐
side and press into
brake fluid reservoir
5 - Hexagon nut
❑ Qty. 2
❑ 25 ± 4 Nm
6 - Securing pin
❑ Secures brake fluid res‐
ervoir on tandem brake
master cylinder
7 - Tandem brake master cyl‐
inder
❑ Cannot be repaired, re‐
new completely when
faulty.
8 - Brake line
❑ Brake master cylinder/secondary piston circuit to ABS hydraulic unit - N55- .
❑ 14 Nm
9 - Brake line
❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .
❑ 14 Nm
10 - Brake light switch
11 - Bolt
❑ Qty. 1
❑ 8 Nm
12 - Vacuum hose
❑ With non-return valve
❑ Press in brake servo with propylene glycol - 294440- assembly fluid axially onto rubber plug as far as it
will go
13 - Sealing plug
❑ Connection for vacuum hose.
14 - Sealing ring
❑ Oil seal between brake servo and brake master cylinder.
3. Brake servo and brake master cylinder 83

15 - Seal
❑ For brake servo
16 - Brake pedal with mounting bracket
17 - Nut
❑ 25 Nm
3.2 Removing and installing brake servo

♦ Brake filling and bleeding equipment - VAS 5234-
Removing
necessary.
– Remove bolt -arrow- and remove cover -1- to left of battery.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery carrier.

– Remove trim -1-.

– For vehicles with brake assist system, pull off connector -2-.
– Detach supply hose of clutch master cylinder -1- from retainer

-2-.
– Raise bracket -2- slightly at rear tab and pull off brake servo
in -direction of arrow-.
– Unbolt cooling system expansion tank and lay to side without
opening cooling system.
– Remove fuel filter ⇒ Fuel system; Rep. gr. 20 ; Fuel filter;
Removing and installing fuel filter
– Disconnect vacuum hose from brake servo.
– On vehicles with brake assist system, pull off electrical con‐

nector -1- from brake servo.
– Remove brake master cylinder ⇒ page 85 .
– Separate brake pedal from brake servo ⇒ page 65 .
– Remove nuts from brake servo -arrows-.

– Carefully remove brake servo from the vehicle.
Installing
– Install brake master cylinder ⇒ page 85 .
– Clip brake pedal to brake servo ⇒ page 65 .
– Install and adjusting brake light switch ⇒ page 65 .
– Code radio.
After bleeding brake system, perform basic settings for brake
pressure sender -1- - G201- ⇒ Vehicle diagnostic tester.
Specified torques
der”, page 82
3.3 Removing and installing brake master cylinder


equipment required


Removing
WARNING

(VW 501 14).

necessary.
– Place sufficient lint-free cloths in area of control unit and hy‐
draulic unit.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Pull clutch master cylinder supply hose off brake fluid reservoir
and tie in place.
– Pull connector off brake fluid level warning contact - F34- .

– Unhook wire -1- from bracket -2-.

– Unscrew brake lines -3- from brake master cylinder.
– Seal brake lines with sealing plugs - 1H0 698 311 A- .
– Unscrew both nuts securing brake master cylinder to brake
servo.
– Carefully take brake master cylinder out of brake servo.
Installing
Note
♦ When assembling brake master cylinder with brake servo,

make sure plunger rod is properly positioned in brake master
cylinder.
♦ Ensure that the seal between the brake master cylinder and
the brake servo is properly installed.

– On vehicles with manual gearbox, bleed clutch master cylinder
⇒ Rep. gr. 30 ; Clutch mechanism; Bleeding clutch mecha‐
nism .
– Code radio.
After bleeding brake system, perform basic settings for brake
pressure sender -1- - G201- ⇒ Vehicle diagnostic tester.
Specified torques
der”, page 82
3.4 Removing and installing brake fluid res‐

ervoir

Removing
WARNING

(VW 501 14).
– Remove upper battery cover.

– Unscrew bolt -arrow- Remove “large” side cover -1- and
“small” side cover from battery.
– Open cap of brake fluid reservoir -1-.

– As protection against escaping brake fluid, place a sufficient
number of lint-free cloths in area beneath brake master cylin‐
der.
– Extract as much brake fluid as possible -5- from brake fluid
reservoir using brake filling and bleeding equipment - VAS
5234- .
– Separate electrical connector from brake fluid level warning
contact - F34- -2-.
– Pull off return hose -3- for clutch master cylinder from brake
fluid reservoir -5-.
– Pull out locking pin -4- in direction of -arrow A- from brake fluid
reservoir.
– Remove brake fluid reservoir -5- from brake master cylinder in
direction of -arrow B-.
Installing

– Coat sealing plug on brake master cylinder -1- with propylene

glycol - 294440- assembly fluid.
– Insert brake fluid reservoir in sealing plug -1-.
– Push locking pin -4- through brake fluid reservoir -5-.

– Attach electrical connector to brake fluid level warning contact
- F34- -2-.
– Fit supply hose -3- on brake fluid reservoir -5-.
– On vehicles with manual gearbox, bleed clutch master cylinder
⇒ Rep. gr. 30 ; Clutch mechanism; Bleeding clutch mecha‐
nism .
– Install battery cladding.

4 Vacuum system
⇒ “4.1 Assembly overview - electric vacuum pump”, page 91
⇒ “4.2 Assembly overview - vacuum pump”, page 91
⇒ “4.3 Checking non-return valve”, page 92
⇒ “4.4 Removing and installing non-return valve”, page 93
⇒ “4.5 Removing and installing brake servo pressure sensor”,
page 93
⇒ “4.6 Checking vacuum system”, page 94
4.1 Assembly overview - electric vacuum pump
1 - Vacuum pump for brakes -

V192-
2 - Vacuum line
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
3 - Bolt
❑ 8 Nm
❑ Qty. 2
4 - Holder
5 - Rubber damper
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Qty. 3
❑ Do not push rubber
damping elements out
of the bracket during in‐
stallation
6 - Holder
7 - Bolt
❑ 25 Nm
4.2 Assembly overview - vacuum pump

Petrol engine ⇒ Rep. gr. 15 ; Cylinder head; Assembly overview
- cylinder head
Diesel engine ⇒ Lubrication; Rep. gr. 17 ; Oil sump/oil pump;
Assembly overview - oil sump/oil pump
4. Vacuum system 91
4.3 Checking non-return valve

⇒ “4.3.1 Checking mechanical non-return valve”, page 92
⇒ “4.3.2 Checking non-return valve with pressure sensor”,
page 92
4.3.1 Checking mechanical non-return valve

– Carefully pull non-return valve with vacuum line -1- out of
brake servo.
– Blow a little air through non-return valve, first in one direction
and then in other.
• Air must pass through non-return valve -1- in direction of
-arrow A-.
• Non-return valve -1- must remain closed in opposite direction
of -arrow B-. If this is not the case, renew non-return valve or,
if necessary, complete vacuum line.
Note
When installing the vacuum line with non-return valve, make sure
that the installation position is correct.
4.3.2 Checking non-return valve with pres‐

sure sensor
– Carefully pull out non-return valve with pressure sensor and
vacuum line -1- from brake servo.
– Blow a little air through non-return valve, first in one direction
and then in other.
• Air must pass through non-return valve -1- in
-direction of arrow-.
• The non-return valve -1- must remain closed in the opposite
-direction of arrow-. If this is not the case, renew non-return
valve or, if necessary, complete vacuum line.
Note
When installing the vacuum line with non-return valve, make sure
that the installation position is correct.

4.4 Removing and installing non-return

valve
4.4.1 Removing and installing mechanical

non-return valve
– Carefully pull non-return valve with vacuum line -1- out of
brake servo.
– Pull off vacuum hose in direction of -arrow- from non-return
valve.
4.4.2 Removing and installing non-return

valve with pressure sensor
– Carefully pull out non-return valve with pressure sensor and
vacuum line -1- from brake servo.
– Pull off connector -2- in direction of -arrow A-
– Carefully pull off non-return valve with pressure sensor and
vacuum line -1- from vacuum pump suction pipe in direction
of -arrow B-.
4.5 Removing and installing brake servo

pressure sensor
Note
The vacuum sender - G608- is only installed in selected petrol

engines.
4. Vacuum system 93
Removing
– Disconnect connector -3- from vacuum sender - G608- -1-.
– Unclip vacuum sender - G608- -1- from vacuum line -2-.
Do not damage plastic locking mechanisms.
Installing
Note
♦ Make sure to check the seal for damage before installing the
vacuum sender - G608- .
♦ If the seal is damaged, the vacuum sender must be renewed.
4.6 Checking vacuum system

⇒ “4.6.1 Connecting brake servo tester VAS 6721 ”, page 94
⇒ “4.6.2 Checking vacuum generation”, page 95
⇒ “4.6.3 Checking for leaks”, page 96
⇒ “4.6.4 Vacuum generation with manual vacuum pump VAS
6213 ”, page 97
4.6.1 Connecting brake servo tester - VAS

6721-
♦ Vacuum gauge for brake servo - VAS 6721-
Observe the notes before performing any tests ⇒ page 9 .

– 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 tester - VAS 6721- in between

-see following illustrations-.
Item Component Explanation

A Cut-off valve In direction of vacuum hose, non-return valve and, if fitted, vacuum pump
B Cut-off valve ♦ Open to facilitate removal of brake servo tester - VAS 6721-
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS 6213-
C Cut-off valve In direction of brake servo
– Fit hose -A- of brake servo tester - VAS 6721- on vacuum hose
and press adapter -C- into brake servo.
4.6.2 Checking vacuum generation

Observe the notes before performing any tests on the vacuum
system.
– Connect brake servo tester - VAS 6721- ⇒ page 94 .
– Open cut-off valve -A-.
4. Vacuum system 95
– Close shut-off valves -B- and -C-.

– Start warm engine (>60°C), press accelerator briefly (engine
speed above 2000 rpm).
– Read indicated measured value.
Normally, the vacuum that is generated should be between 600
and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions have been met, the vacuum system must first be checked
for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213- ⇒ page 97 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.6.3 Checking for leaks

system ⇒ page 4 .
– Connect brake servo tester - VAS 6721- ⇒ page 94 .
– Open cut-off valve -A-.
– Close shut-off valves -B- and -C-.
– Start warm engine (>60°C), press accelerator briefly (engine
speed above 2000 rpm).
Normally, the vacuum that is generated should be between 600
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, check for leaks in the vicinity
of
1- Brake servo
or
2- non-return valve, vacuum hoses with push-on connections
and vacuum pump/intake manifold
if the leak can be found there.
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:
– After generating a vacuum, close shut-off valve -C- in order to

check vacuum system from brake servo tester - VAS 6721- to
intake pipe or to vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.6.4 Vacuum generation with manual vac‐

uum pump - VAS 6213-
system ⇒ page 4 .
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump - VAS 6213- in certain cases.
– To do this, connect hand vacuum pump - VAS 6213- to vac‐
uum hose from connection -B- on brake servo tester - VAS
6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump - VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge - VAS 6721- .
– Then, carry out the corresponding checks.
4. Vacuum system 97
5 Hydraulic system
⇒ “5.1 General notes on brake fluid”, page 98
⇒ “5.2 Bleeding hydraulic system following standard procedure”,
page 98
⇒ “5.3 Subsequent bleeding of hydraulic system”, page 99
⇒ “5.4 Testing for leaks”, page 100
5.1 General notes on brake fluid
WARNING

♦ Always observe the relevant regulations for disposal.
♦ Only use new brake fluid conforming to VW standard
(VW 501 14).
Note
♦ Brake fluid is poisonous. Also due to its corrosive effect brake

fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
5.2 Bleeding hydraulic system following

standard procedure
♦ Brake filling and bleeding unit - VAS 5234-

♦ Tool set for brake bleeding - VAS 6564-
Strictly adhere to procedure when bleeding brake system.

– Connect brake filling and bleeding equipment - VAS 5234- and
switch on.
A pre-pressure of 2 bar must be maintained to bleed the hydraulic
system.
– Open bleeder valves in specified order and bleed brake cali‐
pers.
1. Front right brake caliper
2. Front left brake caliper
3. Rear right brake caliper
4. Rear left brake caliper
Note
Make sure to use a suitable bleeder hose. It must sit tightly on the
bleeder valve so that no air can enter the brake system.
– Leave bleeder valve of each brake caliper open with bleeder

hose fitted until brake fluid discharges free of air bubbles.
5.3 Subsequent bleeding of hydraulic sys‐

tem
Note
♦ This bleed sequence must be carried out 5 times per brake

caliper.
♦ After bleeding, a road test must be carried out, during which
at least one ABS intervention must be triggered.
Repeat bleeding is carried out in connection with excessive brake

pedal travel or so-called »spongy« brakes.
This requires the assistance of a second mechanic:
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper. Observe bleeding se‐
quence.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
– Release brake pedal slowly.
5. Hydraulic system 99
Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
– Carry out road test.
5.4 Testing for leaks

♦ Tester for brake pressure regulator - V.A.G 1310 A-
♦ Adapter M10 - V.A.G 1310/6-

Prerequisites for testing:
• Brake system (hydraulic unit, brake hoses, brake lines and
brake calipers) operating properly and free of leaks.
Check
– Remove bleeder valve at one of front brake calipers.
– Connect tester for brake pressure regulator - V.A.G 1310 A-
and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar.
The pressure must not drop by more than 4 bar during the test
period of 45 seconds. Renew brake master cylinder if drop in
pressure exceeds specification.

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Service

Service Department. Technical Information

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.4 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1.1 Safety measures when working on ve‐

Risk of injury due to automatic start of engine in vehicles with

1.2 Safety precautions when using test and

Risk of accidents due to distraction and inadequate securing

2 Rep. gr.00 - Technical data

2.1 Allocation of PR number - brakes

2.1.1 Front brakes

2.1.2 Rear brakes

3.1 Checking vacuum system

4 Rep. gr.00 - Technical data

4.1 Technical data for brakes

4.1.1 Brake master cylinder and brake servo

4.1.2 Front brakes

Front brake, 17" (2E4)

Volkswagen Technical Site: http://vwts.ru http://vwts.info

4.1.3 Rear brakes

6 Rep. gr.00 - Technical data

5.1 General information

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

5.2 Checking vehicles with front-wheel drive

5.3 Checking vehicles with all-wheel drive

5.3.1 On a regulated roller dynamometer with

The brake test must be performed on a controlled contra-rotating

“Counter-rotating” means that the dynamometer rollers of the sin‐

The maximum test speed is 6 km/h.

5.3.2 Without roller dynamometer for four-

If no test rig is available for four-wheel drive vehicles, the brake

– Drive vehicle forwards onto the rollers.

8 Rep. gr.00 - Technical data

45 – Anti-lock brake system

1.1 Repair instructions for repair work on

Layout in left-hand drive vehicles

Layout in right-hand drive vehicles

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

♦ During painting operations, the electronic control unit can be

2 Overview of fitting locations

2.1 Overview of fitting locations - ABS/ESP

1 - ABS control unit - J104-

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

2. Overview of fitting locations 13

3 Control unit and hydraulic unit

3.1 Assembly overview - control unit and hydraulic unit

1 - ABS control unit - J104-

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

Special tools and workshop

♦ Torque wrench - V.A.G 1331-

3. Control unit and hydraulic unit 15

♦ Torque wrench - VAS 6854-

– Remove bolt -arrow-.

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

– Remove bolt -arrow A-.

Ensure no brake fluid gets onto contacts.

3. Control unit and hydraulic unit 17

♦ The hydraulic unit must be inserted vertically (keep straight) in

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