VW Sharan 2011 Brake System Eng PDF

Service
Workshop Manual
Sharan 2011 ➤
Brake system
Edition 06.2015
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.
Sharan 2011 ➤
Brake system - Edition 06.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Test for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Test for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Testing the electromechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 ABS TRW (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Assembly overview - hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 ABS TRW (ABS/EDL/TCS/ESP), left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 ABS TRW (ABS/EDL/TCS/ESP), right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 28
6.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) . . 29
7 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Assembly overview - front brakes FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4 Assembly overview- front brakes C60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Assembly overview - rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Overview of electromechanical parking brake components . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Removing and installing control unit for electromechanical parking brake J540 . . . . . . . . 52
3.2 Removing and installing parking brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Assembly overview - brake pedal, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Assembly overview - brake pedal, right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Contents i
Sharan 2011 ➤
1.1 Assembly overview - brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1.2 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.3 Assembly overview - brake caliper C 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing piston for brake caliper C 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 Repairing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Assembly overview - brake caliper CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.3 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234 . . . . . . . . 78
4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle) . . . . . . . . 81
5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle) . . . . . . 83
5.3 Vacuum pump for brake servo (vehicles with diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . 84
5.4 Vacuum pump for brake servo (vehicles with petrol engine) . . . . . . . . . . . . . . . . . . . . . . . . 85
5.5 Checking brake servo vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.6 Checking non-return valve : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.7 Removing and installing vacuum sender G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8 Removing and installing brake light switch F , left-hand drive . . . . . . . . . . . . . . . . . . . . . . 89
5.9 Removing and installing brake light switch F , right-hand drive . . . . . . . . . . . . . . . . . . . . . . 90
6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.1 Removing and installing brake master cylinder, left-hand drive . . . . . . . . . . . . . . . . . . . . . . 92
6.2 Removing and installing brake master cylinder, right-hand drive vehicle . . . . . . . . . . . . . . 93
7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.1 Removing and installing brake servo, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.2 Removing and installing brake servo, right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 108
8 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.1 Separating point on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.2 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ii Contents
Sharan 2011 ➤
00 – Technical data
1 Brake allocation via PR No.
(VRL007949; Edition 06.2015)
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.
Example of a vehicle data sticker:
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - intended place for rear brakes
♦ Arrow 2 - Front brakes - 1LJ
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
Note
Information on the individual rear brake that is fitted is currently

not available on the vehicle data sticker.
– To find information about the rear brake, please search in EL‐

SA/Vehicle-specific notes.
In this example the rear brake “1KU” is installed in the vehicle.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
♦ The following table explains the PR numbers. These are im‐
portant for the brake caliper/brake disc and brake pads.
1.1 Front brakes

Engine PR No. Front brakes
1.4l - 110 kW TSI 1) 1LJ FN3 (16”)
2.0 l - 100, 103 kW TDI
1)
1.4 l - 110 kW TSI 2+3) 1 LW C60 (16”)

2.0l - 100, 103 kW TDI
2+3)
2.0 l - 147 kW TFSI

2.0l - 125 kW TDI
1) for vehicles with manual gearbox.
2) for vehicles with double clutch gearbox.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Brake allocation via PR No. 1

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3) for vehicles with all-wheel drive and manual gearbox.

Country-specific brake for Japan:
Engine PR No. Front brakes
2.0 l - 147 kW TFSI 1LX C60 (16”)
1.2 Rear brakes

Engine PR No. Rear brakes
1.4l - 110 kW TSI 1KU CII 41 (16”)
2.0 l - 147 kW TFSI
2.0 l - 100, 103 kW TDI
2.0l - 125 kW TDI
Country-specific brake for Japan:
Engine PR No. Rear brakes
2.0 l - 147 kW FSI 1KU CII 41 (16”)
2 Rep. gr.00 - Technical data

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2 Technical data for brakes
2.1 Brake master cylinder and brake servo

Brake master cylinder ∅ in mm 23.8
Brake servo (LHD) ∅ in inches 11
Brake servo (RHD) ∅ in inches 7/8
2.2 Front brakes

2.2.1 Front brakes FN 3
Item PR No. 1LJ / 1ZD
1 Brake caliper FN3 (16”)
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 312
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
4 Brake caliper ∅ in 54
piston mm
2.2.2 Front brakes C60

Item PR No. 1LW / 1LX
1 Brake caliper C60 (16”)
2 Brake pad, mm 13
thickness
limit without
backplate
mm
Brake disc, mm 30
thickness
Brake disc, mm 27
wear limit
piston mm
2. Technical data for brakes 3

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2.3 Rear brakes (disc brakes)

2.3.1 Rear brakes CII 41
Item PR No. 1KU
1 Brake caliper CII 41 (16”)
2 Brake pad, mm 11
thickness
limit without
backplate
mm
Brake disc, mm 12
thickness
Brake disc, mm 10
wear limit
piston mm

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3 Brake test
3.1 General
♦ The drive is provided by the roller dynamometer.
♦ For vehicles with a manual gearbox, ensure that the gear lever
is in neutral for the test. For vehicles with an automatic gear‐
box, ensure that the selector lever is in »N«.
♦ For the test, observe the specifications provided by the man‐
ufacturer of the roller dynamometer.
Note
The brake regulation systems do not function when ignition is off.
3.2 Test for vehicles with front-wheel drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
3.3 Test for vehicles with four-wheel drive
3.3.1 On a regulated roller dynamometer with

counter-rotating rollers for four-wheel
drive vehicles
Note
The brake test must be performed on a controlled counter-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.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
3. Brake test 5
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3.3.2 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 engine off 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 engine off and wait for 2 seconds.
– Carry out rear brake test.
3.4 Testing the electromechanical parking

brake
3.4.1 Vehicles with front-wheel drive:

Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Ignition remains switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate at constant speed between 2.5 and
9 km/h for at least 5 seconds.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp - K214- lighting up.
Note
In »TÜV mode«, the electromechanical parking brake does not

close fully when the button is first pressed.
The tension is increased gradually by actuating the electrome‐

chanical parking brake button - E538- 4 times in succession.
Actuating the electromechanical parking brake button - E538- a
fifth time releases the electromechanical parking brake.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed lower than 2.5 km/h or over 9 km/h

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• Ignition off.
3.4.2 Checking electromechanical parking

brake, vehicles with four-wheel drive:
Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Engine is switched off and ignition is switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate for at least 5 seconds at a constant
speed between 2.5 and 9 km/h.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp - K214- lighting up.
Note
In »TÜV mode«, the electromechanical parking brake does not

close fully when the button is first pressed.
The tension is increased gradually by actuating the electrome‐

chanical parking brake button - E538- 4 times in succession.
Actuating the electromechanical parking brake button - E538- a
fifth time releases the electromechanical parking brake.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed lower than 2.5 km/h or over 9 km/h
• Ignition off.
3. Brake test 7
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45 – Anti-lock brake system

1 General notes on anti-lock brake sys‐
tem
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.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
ABS layout in left-hand drive vehicle:
1 - Hydraulic unit and control unit
2 - Brake servo
ABS layout in right-hand drive vehicle:

1 - Hydraulic unit and control unit
2 - Brake servo
The control unit and hydraulic are combined in a single compo‐
nent. Separation is not possible. Hydraulic pump must not be
separated from hydraulic unit either.
8 Rep. gr.45 - Anti-lock brake system

Sharan 2011 ➤
2 Notes for repair work on anti-lock

brake system
♦ 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”.
“Guided fault finding” is carried out with the ⇒ Vehicle diagnostic
tester.
♦ Disconnect battery earth strap with ignition switched off.
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 78 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- or -V.A.G 1869- ⇒ page 78 .
♦ 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. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating control unit from hydraulic unit, use transport
protection for contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1 H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ 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).
♦ Ensure that no brake fluid enters connectors.
2. Notes for repair work on anti-lock brake system 9

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3 Connecting -VAS 5051- and select‐

ing functions
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system - VAS 5051-
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
WARNING
♦ During a road test, you must always secure testing and

measuring equipment on the back seat.
♦ These devices may be operated only by a passenger while
the vehicle is in motion.
– Connect connector of diagnosis cable -VAS 5051/1- or -

VAS 5051/3- to diagnostic connection.

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– Switch on tester -arrow-.

The tester is ready for operation when the selector buttons for the
operating modes appear on the screen.
– Switch on ignition.
– Touch Guided Fault Finding on screen.
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data entered.
Wait until tester has interrogated all control units in vehicle.
– Press Go to and select function “Function/component selec‐
tion”.
– Select “Running gear” on display.
– Select “Brake systems” on display.
– Select “01 Self-diagnosis capable system …” shown on dis‐
play.
Either:
– Select “Anti-lock brake system …” shown on display.
Or:
– Select “Electromechanical parking brake” on display.
– Select “Function” shown on display.
Now all possible functions from the anti-lock brake system instal‐
led in the vehicle will be displayed.
– Select desired function on display.
3. Connecting VAS 5051 and selecting functions 11

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4 Electrical/electronic components and

locations
4.1 ABS TRW (ABS/EDL/TCS/ESP)
1 - ABS control unit - J104-

❑ Location: on hydraulic
unit, on left in engine
compartment, under
battery.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Must not be separated
from ABS hydraulic unit
- N55-
❑ Removing and installing
⇒ page 16 .
2 - ABS hydraulic unit - N55-
❑ Location: on left in en‐
gine compartment, un‐
der battery.
The hydraulic unit consists of
the components:
❑ Brake pressure sender -
G201-
❑ ABS hydraulic pump -
V64-
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block
must not be separated
from one another.
❑ Must not be separated
from ABS control unit -
J104-
❑ Removing and installing ⇒ page 16 .
3 - Brake pad warning lamp - K32-
❑ Location: in dash panel insert.
4 - ABS warning lamp - K47-
5 - ESP and TCS warning lamp - K155-
6 - Brake system warning lamp - K118-
7 - Brake light switch - F-
❑ Location: on brake master cylinder.
❑ Removing and installing (LHD) ⇒ page 89

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❑ Removing and installing (RHD) ⇒ page 90
8 - TCS and ESP button - E256-
❑ Location: in centre console.
9 - ESP sensor unit - G419- and control unit for electromechanical parking brake - J540-
❑ Location: under centre console.
❑ Combined lateral acceleration sender - G200- , yaw rate sender - G202- and longitudinal acceleration
sender - G251- .
❑ Installed in one housing together with control unit for electromechanical parking brake - J540-
10 - Diagnostic connection
❑ Location: driver side footwell cover.
11 - Steering angle sender - G85-
❑ Fitting location: in steering column electronics control unit - J527-
12 - Wheel bearing housing
13 - Front right/left speed sensor -G45- / -G47-
14 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
16 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing (front-wheel drive) ⇒ page 29
4. Electrical/electronic components and locations 13

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5 Assembly overview - hydraulic unit
5.1 ABS TRW (ABS/EDL/TCS/ESP), left-hand drive vehicle
1 - Brake servo
⇒ page 106 .
2 - Brake line, 14 Nm
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Identification: ∅ 6.5 mm
and union nut with long
thread M12 x 1
❑ Marked on hydraulic
unit with “HZ1”
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
thread M12 x 1
unit with “HZ2”
❑ To front right brake cali‐
per.
❑ Identification: ∅ 5.25
mm and union nut with
thread M10 x 1
unit with “FR”
❑ To rear left brake cali‐
per.
❑ Identification: ∅
5.25 mm and union nut with short thread M12 x 1.
❑ Marked on hydraulic unit with “RL”
❑ To rear right brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
❑ Marked on hydraulic unit with “RR”
❑ To front left brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.
❑ Marked on hydraulic unit with “FL”
8 - ABS control unit - J104-
The control unit and hydraulic unit cannot be separated.

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9 - ABS hydraulic unit - N55-

The control unit and hydraulic unit cannot be separated.
10 - Spring retainer
11 - Torx socket head bolt, 8 Nm
12 - Rubber damper
5.1.1 Connecting brake lines from brake mas‐

ter cylinder to hydraulic unit
On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: ∅ 6.5 mm and union nut with thread M12 x 1
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
On hydraulic unit:
1 - From hydraulic unit to front left brake caliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x 1.
2 - From hydraulic unit to rear right brake caliper.
3 - From hydraulic unit to rear left brake caliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x 1.
4 - From hydraulic unit to front right brake caliper.
5 - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Identification: ∅ 6.5 mm and union nut with long thread M12 x 1
6 - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Identification: ∅ 6.5 mm and union nut with long thread M12 x 1
5. Assembly overview - hydraulic unit 15

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5.1.2 Removing control unit and hydraulic unit
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
1410-
♦ Brake pedal depressor -
V.A.G 1869/2-

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Sealing plugs repair kit, Part No. 1H0 698 311 A

1 - Transport protection for contact pins (foam)
2 - Sealing plug M10
Removing
Location:
The control unit is bolted to the hydraulic unit and is located on
left in the engine compartment, under the battery tray.
WARNING
Do not bend the brake lines in the area of the hydraulic unit!
– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove air intake hose, air filter and battery. ⇒ Electrical
system; Rep. gr. 27 ; Removing and installing battery
– Remove battery tray.
– Open cable duct, take out the two wiring harnesses and place
on one side.
– Remove cable duct from console.
– Press red locking slide downwards in direction of -arrow-.
– Release connector from control unit in direction of -arrow- and

pull off.

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– Apply brake pedal depressor - V.A.G 1869/2- .
– Connect bleed bottle bleed hose -1- to bleed valve of front left
brake caliper.
– Open bleed valve.
– Connect bleed hose of bleed bottle -1- to bleed valve of rear

left brake caliper.
– Depress brake pedal at least 60mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left and rear left bleeder valve.
– Do not remove brake pedal depressor - V.A.G 1869/2- .
– Place sufficient lint-free cloths under the ABS hydraulic unit -
N55- .
Ensure no brake fluid gets onto contacts.
– First identify both brake lines from brake master cylinder and
then remove.
– Immediately seal brake lines and threaded holes with seal
plugs from repair set Part No. 1H0 698 311 A.
– Mark, unscrew and seal remaining brake lines (brake cali‐
pers).

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– Pull hydraulic unit together with control unit upwards out of

dampers -arrow-.
5.1.3 Installing control unit and hydraulic unit
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going 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.
♦ When installing the hydraulic unit, ensure that the rubber
dampers are not pressed out of bracket. The rubber dampers
must rest on the longitudinal member cover plate.

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– Install in reverse order.

Tightening sequence of brake lines:
1 - ABS hydraulic unit - N55- to front left brake caliper.
- Marking on ABS hydraulic unit - N55- -FL-
2 - ABS hydraulic unit - N55- to rear right brake caliper.
- Marking on ABS hydraulic unit - N55- -RR-
3 - ABS hydraulic unit - N55- to rear left brake caliper.
- Marking on ABS hydraulic unit - N55- -RL-
4 - ABS hydraulic unit - N55- to front right brake caliper.
- Marking on ABS hydraulic unit - N55- -FR-
5 - ABS hydraulic unit - N55- to secondary piston circuit of brake
master cylinder
- Marking on ABS hydraulic unit - N55- -HZ2-
6 - ABS hydraulic unit - N55- to primary piston circuit of brake
master cylinder
– Remove brake pedal depressor - V.A.G 1869/2- .
– Bleed brake system ⇒ page 78 .
– Code radio.
– Code control unit -J104- with ⇒ Vehicle diagnostic tester in
”Guided fault finding”.
To do this, carry out basic setting of the steering angle sender -
G85- , the lateral acceleration sender - G200- , the longitudinal
acceleration sender - G251- and the brake pressure sender -
G201- .
Specified torques:
Hexagon bolt of hydraulic unit to bracket 8 Nm
Brake lines to ABS unit:
Thread M10 x 1 14 Nm
5.2 ABS TRW (ABS/EDL/TCS/ESP), right-hand drive vehicle

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1 - Brake servo
⇒ page 108 .
2 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to ABS hydraulic unit -
N55- .
thread M12 x 1
❑ Marking on ABS hy‐
draulic unit - N55- “HZ2”
❑ 14 Nm
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to ABS hydraulic
unit - N55- .
thread M12 x 1
draulic unit - N55- “HZ1”
❑ 14 Nm
4 - Brake line
❑ To front right brake cali‐
per.
❑ Identification: ∅ 5.25
mm and union nut with
thread M10 x 1
draulic unit - N55- “FR”
❑ 14 Nm
5 - Brake line
❑ To rear left brake caliper.
❑ Marking on ABS hydraulic unit - N55- “RL”
6 - Brake line
❑ To rear right brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
❑ Marking on ABS hydraulic unit - N55- “RR”
❑ 14 Nm
7 - Brake line
❑ To front left brake caliper.
❑ Marking on ABS hydraulic unit - N55- “FL”
❑ 14 Nm
8 - ABS hydraulic unit - N55- with ABS control unit - J104-
ABS control unit - J104- and ABS hydraulic unit - N55- cannot be separated.

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9 - Bracket
10 - Bolt
❑ 8 Nm
❑ Qty. 2
11 - Rubber damper
❑ When installing, ensure that rubber dampers are not pressed out of bracket.
❑ Rubber dampers lie directly on the body
12 - Pin
❑ Welded to body
5.2.1 Connecting brake lines from brake mas‐

ter cylinder to ABS hydraulic unit - N55-
On brake master cylinder:
A - Primary piston circuit of brake master cylinder to ABS hy‐
draulic unit - N55- .
B - Secondary piston circuit of brake master cylinder to ABS hy‐
draulic unit - N55- .
To ABS hydraulic unit - N55- :

A - ABS hydraulic unit - N55- to primary piston circuit of brake
master cylinder
B - ABS hydraulic unit - N55- to secondary piston circuit of brake
master cylinder
1 - ABS hydraulic unit - N55- to rear left brake caliper/wheel brake
cylinder.
- Marking on ABS hydraulic unit - N55- -RL-
2 - ABS hydraulic unit - N55- to rear right brake caliper/wheel
brake cylinder.
- Marking on ABS hydraulic unit - N55- -RR-
- Marking on ABS hydraulic unit - N55- -FL-

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Writing on ABS hydraulic unit - N55- :

1 - FL = front left
2 - RR = rear right
3 - RL = rear left
4 - FR = front right
5 - -HZ1-
6 - -HZ2-
5.2.2 Removing ABS control unit - J104- and ABS hydraulic unit - N55-

equipment required
1331-
1410-
♦ Brake pedal depressor -
V.A.G 1869/2-

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Sealing plug - 1H0 698 311 A-

After removing ABS control unit - J104- and ABS hydraulic unit -
N55- , fit the transport protection.
Without transport protection, the warranty for the ABS hydraulic
unit - N55- will not be recognised.
1 - Transport protection for contact pins (foam)
Removing
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
1 - Brake servo with tandem brake master cylinder
2 - ABS control unit - J104- with ABS hydraulic unit - N55-
WARNING
Do not bend the brake lines in the area of the ABS hydraulic
unit - N55-
– Read out and make a note of the code of ABS control unit -
J104- ⇒ page 10 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
– Remove air filter housing ⇒ Rep. gr. 24 ; Fuel mixture, elec‐
tronic injection, gas .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 .
– Open cable guide, take out the two wiring harnesses and place
on one side.
– Remove cable guide from console.
– Press locking slide downwards in direction of -arrow-.

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– Release connector from control unit -in direction of arrow- and

pull off.
– Connect bleed bottle bleed hose -1- to bleed valve of front left
brake caliper.
– Connect bleed hose of bleed bottle -1- to bleed valve of rear

left brake caliper.
– Depress brake pedal at least 60mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left and rear left bleeder valve.
– Do not remove brake pedal depressor - V.A.G 1869/2- .
– Place sufficient lint-free cloths under the ABS hydraulic unit -
N55- .
Ensure no brake fluid gets onto contacts.

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– First identify the two brake master cylinder brake lines -A- and
-B- and unscrew from ABS hydraulic unit - N55- .
– Immediately seal brake lines and threaded holes with sealing
plugs - 1H0 698 311 A- .
– Mark and unscrew brake lines -1- to -4-.
– Immediately seal brake lines and threaded holes with sealing
plugs - 1H0 698 311 A- .
– Pull hydraulic unit together with control unit in

-direction of arrow- upwards out of brackets.
5.2.3 Installing ABS control unit - J104- and

ABS hydraulic unit - N55-
Install in reverse order. Note the following points:
Note
♦ Do not remove sealing plugs from new ABS hydraulic unit -

N55- until respective brake line is about to be installed.
♦ If sealing plugs are removed too early from the ABS hydraulic
unit - N55- , brake fluid can escape, and it can then no longer
be guaranteed that the unit can be sufficiently filled and bled.
WARNING
When installing, ensure that rubber dampers are pressed into

the bracket correctly. After installation, check that the ABS hy‐
draulic unit - N55- is firmly seated, otherwise malfunctioning
can occur.

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Tightening sequence of brake lines:

- Marking on ABS hydraulic unit - N55- -VL-
2 - ABS hydraulic unit - N55- to rear right brake caliper.
- Marking on ABS hydraulic unit - N55- -HR-
3 - ABS hydraulic unit - N55- to rear left brake caliper.
- Marking on ABS hydraulic unit - N55- -HL-
- Marking on ABS hydraulic unit - N55- -VR-
5 - ABS hydraulic unit - N55- to secondary piston circuit of brake
master cylinder
6 - ABS hydraulic unit - N55- to primary piston circuit of brake
master cylinder
After the ABS control unit - J104- and the ABS hydraulic unit -
N55- have been installed, the steering angle sender - G85- , the
lateral acceleration sender - G200- and the brake pressure send‐
er - G201- must be reset ⇒ page 10 .
If a new ABS control unit - J104- has been installed, it must be
coded ⇒ page 10 .
Specified torque
Component Specified torque
Bolt for ABS hydraulic unit - N55- to bracket. 8 Nm
Brake lines to ABS hydraulic unit - N55-

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6 Removing and installing parts of ABS

system on front and rear axle
6.1 Removing and installing parts of ABS system on front axle
1 - ABS speed sensor

❑ Before inserting speed
sensor, clean hole inner
surface and coat with
high-temperature paste
G 052 112 A3.
⇒ page 28 .
2 - Hexagon socket head bolt,
8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing.
4 - Drive shaft
6.1.1 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle.

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– Separate connector -1- from speed sensor line and speed

sensor.
– Unscrew bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert speed sensor into wheel bearing housing hole and tight‐
en bolt to 8 Nm.
– Connect speed sensor to speed sensor line.
6.2 Removing and installing parts of anti-lock brake system on rear axle (front-
wheel drive)

❑ Before inserting speed
sensor, clean hole inner
surface and coat with
high-temperature paste
G 052 112 A3.
⇒ page 30 .
2 - Hexagon socket head bolt,
8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing.
6. Removing and installing parts of ABS system on front and rear axle 29
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6.2.1 Removing and installing speed sensor

on rear axle
Removing
– Raise vehicle.
– Separate connector -1- from speed sensor line and speed
sensor.
– Unscrew bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert speed sensor into wheel bearing housing hole and tight‐
en bolt to 8 Nm.
– Connect speed sensor to speed sensor line.

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7 Removing and installing parts of ESP

system
7.1 Removing and installing ESP sensor

unit - G419-
The lateral acceleration sender - G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender - G251- are in‐
stalled in a housing together with the control unit for electrome‐
chanical parking brake - J540- ; this is located below the centre
console.
After the ESP sensor unit - G419- has been replaced together
with the control unit for electromechanical parking brake - J540- ,
it is necessary to code the ABS control unit - J104- and to carry
out a basic setting of the “brake system” (electromechanical park‐
ing brake).
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit - G419- . The ESP sensor unit - G419- may not
then be used any further.
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .
– Undo and remove the 3 nuts -arrows-.
– Unplug connector -1- from ESP sensor unit - G419- .
– Remove ESP sensor unit - G419- .
Installing
When installing the ESP sensor unit - G419- , make sure it is cor‐
rectly seated in its bracket and is free of stress.
Note
Under no circumstances the securing nuts should be used to for‐

cibly position the ESP sensor unit - G419- .
– Tighten securing nuts to 9 Nm.

To do this, carry out basic setting of steering angle sender - G85- ,
lateral acceleration sender - G200- , brake pressure sender -
G201- and longitudinal acceleration sender - G251- .
– Carry out basic setting of “brake system” (electromechanical
parking brake).
Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 10 .
7. Removing and installing parts of ESP system 31

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7.2 Removing and installing steering angle

sender - G85-
The steering angle sender - G85- is integrated in the steering col‐
umn electronics control unit - J527- .
Removing and installing:
⇒ Electrical system; Rep. gr. 94 ; Lights, bulbs, switches - exte‐
rior; Steering column switch .
– Then perform basic setting of steering angle sender - G85- .
⇒ page 10 .

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46 – Brakes - mechanism
1 Repairing front brakes
1.1 Assembly overview - front brakes FN 3
Note
♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off
brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).
1 - Torx bolt, 12 Nm
2 - Brake disc
❑ Ventilated, ∅ 312 mm
❑ Thickness: 25 mm
❑ Wear limit: 22 mm.
❑ Always renew on both
sides of an axle.
❑ Remove brake caliper
and brake support plate
prior to removing.
3 - Torx bolt, 4 Nm
4 - Brake pads
❑ Thickness: 14 mm not
including backplate.
❑ With brake pad wear in‐
dicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake discs and pads/
linings: Checking condi‐
tion of discs and thick‐
ness of pads/linings .
sides of an axle.
⇒ page 34 .
5 - Retaining spring
❑ Insert into both holes in brake caliper.
1. Repairing front brakes 33

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6 - Brake support plate

❑ Bolt to wheel bearing housing.
7 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Repairing ⇒ page 66 .
8 - Guide pin, 30 Nm
9 - Cover cap
❑ Remove
10 - Brake hose with banjo union and banjo bolt, 35 Nm
12 - Cover cap
❑ Remove
13 - Bolt
15 - Ribbed bolt, 200 Nm
❑ Clean if reused.
❑ With bolted brake support plate.
❑ Before inserting speed sensor, clean hole inner surface and coat with high-temperature paste
G 052 112 A3.
18 - Hexagon socket head bolt, 8 Nm
20 - Splash plate
1.2 Removing and installing brake pads/lin‐

ings
♦ Torque wrench - V.A.G 1331-
34 Rep. gr.46 - Brakes - mechanism

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♦ Piston resetting appliance - T 10145-
1.2.1 Removing
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper
-arrow- with a screwdriver and remove.
– Disconnect connector -1- for brake pad wear indicator.
– Remove cover caps -arrows-.

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– Unscrew both guide pins -arrows- and remove from brake cal‐
iper.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pad out of brake caliper or from brake support
plate.
Cleaning:
WARNING
Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!
– Thoroughly clean brake support plate and contact surfaces for

brake pads and remove corrosion.
– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.
Use only methylated spirits for cleaning the brake caliper housing.
1.2.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press piston back.
– Pull protective foil off outer brake pad backplate.
– Fit outer brake pad to brake support plate.
– Insert inner brake pad with retaining spring into 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.

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– Bolt brake caliper to brake support plate with both guide pins.
– Fit both cover caps.
– Insert retaining spring into brake caliper.
– Connect brake pad wear indicator connector.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .
Note
♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.
Specified torque:
Guide pin to brake support plate 30 Nm
1.3 Removing and installing brake caliper

♦ Brake pedal depressor - V.A.G 1869/2-
1.3.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.

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– Disconnect connector for brake pad wear indicator.

– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
– Pull both cover caps out of brake caliper bearing bushes.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper from brake support plate.
– Take brake pads out of brake caliper.
1.3.2 Installing
• Piston is pressed back.
• Outer brake pad is seated on brake support plate.
– Insert inner brake pad with retaining spring into 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 support plate with both guide pins.
– Fit both cover caps.
– Screw brake hose onto brake caliper.
– Insert retaining spring into brake caliper.
– Fit wheels.
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torques:
Guide pin to brake support plate 30 Nm
Brake hose to brake caliper 35 Nm

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1.4 Assembly overview- front brakes C60
Note
♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off
brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).
1 - Splash plate
3 - Brake disc
❑ Ventilated, ∅ 314 mm
sides of an axle.
prior to removing.
4 - Torx bolt, 4 Nm
❑ Bolt to wheel bearing
housing.
6 - Brake pads
❑ Thickness: 13 mm not
including backplate.
❑ With brake pad wear in‐
dicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake discs and pads/
linings: Checking condi‐
tion of discs and thick‐
ness of pads/linings . Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Always renew on both sides of an axle.
❑ Lightly grease brake pad guide surfaces on brake carrier with grease contained in repair kit.
7 - Brake caliper

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8 - Self-locking hexagon bolt, 35 Nm

❑ Renew.
9 - Ribbed bolt, 200 Nm
❑ Clean if reused.
❑ With bolted brake support plate.
12 - Retaining clip
14 - Bolt, 8 Nm

ings
1.5.1 Removing
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.

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– Disconnect connector -1- for brake pad wear indicator.
– Unscrew both securing bolts from brake caliper; to do this,

counterhold on guide pin.
– Remove brake caliper -1- and secure with wire so that weight
of brake caliper does not strain or damage brake hose.
– Remove brake pads -2 and 3- from brake support plate -4-.
Cleaning:
WARNING
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.

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1.5.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press piston back.
– Apply a thin coat of lithium grease G 052150 A2 to brake pad
guide surfaces on brake carrier.
– Place brake pads -1- together with retaining springs -2- in re‐
cess of brake carrier -3-.
Note
After fitting brake pads, check that all retaining springs -2- are
properly seated -arrow-.
– Carefully place the brake caliper on the brake support plate.
– Secure brake caliper to brake support plate with new self-

locking bolts, counterholding with the guide bolts.

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– Connect brake pad wear indicator connector -1-.

– Fit wheels.
Note
♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.
Specified torque:
Hexagon bolt, brake caliper to brake support plate 35 Nm
♦ Use new bolts!

1.6.1 Removing
– Remove wheels.
– Disconnect connector for brake pad wear indicator.
open bleeder valve.

Sharan 2011 ➤

– Unscrew brake hose.
1.6.2 Installing
• Piston is pressed back.
• The two brake pads are seated in the retaining springs on the
brake support plate.
– Carefully place the brake caliper on the brake support plate.
locking bolts, counterholding with the guide bolts.
– Screw brake hose onto brake caliper.
– Bleed brake system.
– Fit wheels.
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torque:
♦ Use new bolts!

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2 Repairing rear brakes
2.1 Assembly overview - rear brake CII 41
Note
♦ Use the brake filling and bleeding equipment - VAS 5234- or

the extraction unit -V.A.G 1869/4- to draw off brake fluid from
the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
this, release pressure in system).
1 - Splash plate
❑ Allocation ⇒ Electronic
Parts Catalogue (ETKA)
2 - Brake disc
❑ ∅ 280 mm
❑ When worn, renew on
both sides of axle.
prior to removing.
3 - Torx bolt, 4 Nm
4 - Multi-point socket head bolt,
90 Nm and turn 90° further
❑ Always renew after re‐
moving.
❑ Remove and install us‐
ing socket insert -
T10035- ⇒ page 46 .
5 - Brake support plate 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 dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
6 - Pad retainer
❑ Always renew when changing pads.
7 - Brake pad
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
2. Repairing rear brakes 45

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8 - Brake pad
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
9 - Pad retainer
❑ Always renew when changing pads.
10 - Self-locking hexagon bolt, 35 Nm
❑ Renew.
11 - Brake caliper
❑ Basic setting must be carried out after repair work or renewal.
12 - Sealing ring
13 - Parking brake motor.
❑ On subframe
❑ On brake caliper
❑ On brake line, 14 Nm
17 - Retaining clip
Tool insert - T10035-

ings

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♦ Piston resetting appliance - T10145-
2.2.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
Note
Do not separate connectors of parking brake motors.
• Parking brake not operated.

– Remove wheels.
The parking brake pistons must be moved back with -VAS 5051- .
Before resetting pistons, draw off brake fluid from brake fluid res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 10 .

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– Do do this, select electromechanical parking brake and “mov‐

ing parking brake motor pistons forwards and backwards”
function.
– Move the pistons back using ⇒ Vehicle diagnostic tester.
– Then remove securing bolts from brake caliper; to do this,
– Remove brake caliper from brake support plate.
Note
The resetting of the pistons with ⇒ Vehicle diagnostic tester is still

required but is often not sufficient! The thrust nut in the piston is
fitted on a floating bearing, so that the piston can only be com‐
pressed but not pulled back. Only the spindle with the thrust nut
will be moved back.
Caution
The piston must be reset beforehand with ⇒ Vehicle diagnostic

tester.
– Now press piston back fully with piston resetting tool -

T10145- .
– Secure brake caliper with wire so that weight of brake caliper
does not stress or damage brake hose.
– Remove brake pads and pad retainers -arrows-.

Cleaning:
WARNING
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.

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2.2.2 Installing
– Insert pad retainers -arrows- and brake pads into brake sup‐
port plate.
– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Secure brake caliper with new self-locking bolts.
♦ The repair kit includes 4 self-locking hexagon bolts which must
always be installed.
After moving the pistons forwards using ⇒ Vehicle diagnostic
tester, carry out a basic setting of brake system.
– Carry out basic setting of brake system using ⇒ Vehicle diag‐
nostic tester.
– Fit wheels.
Note
Check brake fluid level after changing brake pads.
Specified torque:
♦ Use new bolts!


Sharan 2011 ➤

2.3.1 Removing
Note
Do not separate connectors of parking brake motors.
– Remove wheels.
The parking brake pistons must be moved back with ⇒ Vehicle
diagnostic tester.
Before resetting pistons, draw off brake fluid from brake fluid res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
⇒ page 10 .
– Do do this, select electromechanical parking brake and “mov‐
ing parking brake motor pistons forwards and backwards”
function.
– Move the pistons back using ⇒ Vehicle diagnostic tester.
– Unscrew parking brake motor without separating the connec‐
tor.
open bleeder valve.

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– Unscrew the brake line from the brake hose and the brake
caliper.
2.3.2 Installing
• The brake pads are seated in the retaining springs on the
brake support plate.
locking bolts.
The annular groove and the contact surface of the parking brake
motor must be clean.
– Install new sealing ring.
– Turn spindle back slightly, using an 8 mm multi-point socket
bit, until parking brake motor can be inserted correctly.
– Carefully put the parking brake motor in place, while ensuring
that the sealing ring is correctly seated.
– Turn parking brake motor until bolt hole and thread align.
Make sure that parking brake motor is flush with brake caliper.
Never pull parking brake motor onto brake caliper using securing
bolts.
– Position Torx bolts by hand and then tighten.
– Screw brake line onto brake caliper.
After moving the pistons forwards using ⇒ Vehicle diagnostic
tester, carry out a basic setting of brake system.
– Carry out basic setting of brake system using ⇒ Vehicle diag‐
nostic tester.
– Fit wheels.
Note
Check brake fluid level.
Specified torques:
♦ Use new bolts!

Parking brake motor to brake caliper 12 Nm

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3 Overview of electromechanical parking brake components
1 - Electromechanical parking
brake button - E538-
❑ Location: in centre con‐
sole.
2 - Electromechanical parking
brake warning lamp - K213-
❑ Location: in electrome‐
chanical parking brake
button - E538- .
3 - Auto-hold button - E540-
❑ Location: in centre con‐
sole.
4 - Auto-hold warning lamp -
K237-
❑ Location: in auto-hold
button - E540-
5 - Electric parking brake and
handbrake fault warning lamp
- K214-
❑ Location: in dash panel
insert.
6 - Brake system warning lamp
- K118-
❑ Location: in dash panel
insert.
7 - Acoustic signal
8 - Control unit for electrome‐
chanical parking brake - J540-
and ESP sensor unit - G419-
❑ Installed together in one
housing.
⇒ page 52 .
9 - Sealing ring
10 - Right parking brake motor - V283-
❑ Location: on rear right brake caliper
12 - Left parking brake motor - V282-
❑ Location: on rear left brake caliper
3.1 Removing and installing control unit for

electromechanical parking brake - J540-
The control unit for electromechanical parking brake - J540- and
the ESP sensor unit - G419- are installed in a housing below the
centre console.
After the control unit for electromechanical parking brake - J540-
has been replaced together with the ESP sensor unit - G419- , it

Sharan 2011 ➤
is necessary to code the ABS control unit - J104- and to carry out
a basic setting of the “brake system” (electromechanical parking
brake).
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit - G419- . The ESP sensor unit - G419- may not
then be used any further.
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .
– Undo and remove the 3 nuts -arrows-.
– Unplug connector -1- from control unit for electromechanical
parking brake - J540- .
– Remove control unit for electromechanical parking brake -
J540- .
Installing
When installing control unit for electromechanical parking brake
- J540- , ensure that it is correctly seated in its bracket and is free
of stress.
Note
Under no circumstances the securing nuts should be used to for‐

cibly position the control unit for electromechanical parking brake
- J540- .
– Tighten securing nuts to 9 Nm.

To do this, carry out basic setting of steering angle sender - G85- ,
lateral acceleration sender - G200- , brake pressure sender -
G201- and longitudinal acceleration sender - G251- .
– Carry out basic setting of “brake system” (electromechanical
parking brake).
⇒ page 10 .
3.2 Removing and installing parking brake

motor
3. Overview of electromechanical parking brake components 53

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Removing
Note
Switch off ignition for at least 30 seconds before disconnecting

connector.
– Detach connector -1- from parking brake motor.

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– Undo and remove both Torx bolts -arrows- of parking brake

motor.
– Remove parking brake motor from brake caliper.
– Take out seal.
Take care not to damage annular groove for seal and contact
surface on parking brake motor.
– Clean annular groove and contact surface on parking brake
motor.
Installing
– Slightly moisten new sealing ring with brake fluid, then fit.
– Turn spindle back slightly, using an 8 mm multi-point socket

bit -A-, until parking brake motor can be inserted correctly.
Caution
The sealing ring must not be allowed to turn out while the park‐
ing brake motor is being installed!
– Carefully put the parking brake motor in place, while ensuring

that the sealing ring is correctly seated.
– Turn parking brake motor until bolt hole and thread align.
Make sure that parking brake motor is flush with brake caliper.
Never pull parking brake motor onto brake caliper using securing
bolts.
– Position the two Torx bolts -arrows- by hand and then tighten.
– Fit the connector.
– Perform basic setting of brake system.
⇒ page 10 .
3. Overview of electromechanical parking brake components 55

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4 Assembly overview - brake pedal
4.1 Assembly overview - brake pedal, left-

hand drive
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
Grease all mountings before installing with grease Part No.

G 000 602.
1 - Mounting bracket
2 - Self-locking hexagon nut,
25 Nm
moving.
❑ First tighten hexagon
nuts -A and B-.
3 - Brake pedal
❑ Clip brake pedal to
brake servo plunger rod
⇒ page 57
4 - Cap
5 - Bearing shell
6 - Support
❑ For ball head of brake
servo plunger rod.
7 - Hexagon bolt
8 - Sleeve bearing
9 - Pivot pin
25 Nm
4.1.1 Separating brake pedal from brake ser‐

vo

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♦ Release tool - T10159B-
– Remove footwell cover on driver side ⇒ General body repairs,

interior; Rep. gr. 68 ; Compartments, covers and trims .
– Remove cover for fuse holder in bottom left-hand side of dash
panel.
– Remove footwell vent on driver side.
– Remove crash bar for the brake ⇒ Running gear, axles, steer‐
ing; Rep. gr. 48 .
– First press brake pedal in direction of brake servo and hold.
2 - Push rod
3 - Retaining lugs
– Insert release tool - T10159B- and pull in direction of driver
seat. When doing this, counter-hold on brake pedal. (At this
stage the pedal must not be allowed to move backwards.) This
action will press retaining lugs -3- of mounting off ball head of
plunger rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool - T10159B- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).
4.1.2 Clipping brake pedal to brake servo

– Hold ball head of plunger rod in front of mounting and push
brake pedal in direction of brake servo, so that the ball head
clicks into place.
Continue installation in reverse order.
4.1.3 Removing brake pedal

4. Assembly overview - brake pedal 57

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panel.
ing; Rep. gr. 48 .
– Separate brake pedal from brake servo ⇒ page 56 .
– Remove brake pedal.
4.1.4 Installing brake pedal

Install in reverse order.
– Clip brake pedal to brake servo ⇒ page 57 .
4.2 Assembly overview - brake pedal, right-hand drive
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
Grease all bearing points with polycarbamide grease - G 052 142

A2- before installing.
Brake light switch - F- is located on brake master cylinder.

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1 - Mounting bracket
(RHD) ⇒ page 64
2 - Bolt
❑ 25 Nm
3 - Nut
❑ 25 Nm
4 - Nut
❑ 25 Nm
moving.
5 - Brake pedal
(RHD) ⇒ page 60
6 - Cap
7 - Bearing shell
8 - Support
❑ For ball head of brake
servo plunger rod.
❑ Separating brake pedal
from brake servo
⇒ page 59
❑ Unclip brake pedal from
brake servo
⇒ page 60 .
9 - Sleeve bearing
10 - Pivot pin
11 - Bolt
4.2.1 Separating brake pedal from brake ser‐

vo
♦ Release tool - T 10159B-

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– Undo bolts -arrows- and remove footwell trim -1-.

– Release diagnostics connector -3- and pull off.
– Remove footwell trim -1- in -direction of arrow-.
– First press brake pedal in direction of brake servo and hold.

2 - Push rod
3 - Retaining lugs
– Insert release tool - T10159B- and pull towards driver seat,
counter holding on brake pedal.
Note
♦ Pedal cluster must not move backwards at this moment.

♦ This action will press retaining lugs -3- of mounting off ball
head of plunger rod -2-.
– Pull release tool - T10159B- and brake pedal together towards

driver seat.
As a result, the brake pedal is pulled off.
4.2.2 Clipping brake pedal to brake servo

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


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Removing
– Pull off and remove footwell trim -1- in -direction of arrow-.
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims .
– Remove trim -1-.
Vehicles with ignition/starter switch

– Release connector -1- and pull off.
Vehicles with keyless locking and starting system “Keyless Ac‐

cess”
– Unclip cable from holder on electronic steering column lock
control unit - J764- -arrow-.

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Continuation for all vehicles

– Unscrew nut -arrow- and pull earth cable off steering column.
– Press lugs -arrow- on both side of cable guide -1- inwards and
pull cable guide -1- out of guides on steering column.
– Unscrew bolt -1-.

– Slide footwell trim -2- upwards in -direction of arrow- and re‐
move.
Vehicles with manual gearboxes

– Remove left bolt -1- and remove crash bar for clutch pedal
-2-.

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Vehicles with dual clutch gearbox or automatic gearbox

– Remove left bolt -1- for steering column.

– Remove right bolts -1- and remove crash bar for brake pedal
-2-.
– Unscrew bolts -1- and hold steering column when doing this.
– Remove steering column.
– Place steering column carefully on trim and secure to prevent
it slipping off.
– Remove bolt -1- for brake pedal towards the left, while coun‐
terholding the nut -arrow-.
– Remove brake pedal.
Installing

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Specified torque
Brake pedal on mounting bracket 25 Nm
♦ Use new nut
Steering column to cross member 20 Nm

Crash bar to cross member 20 Nm
4.2.4 Removing and installing mounting

bracket
Removing
– Open flap -2- and remove.
– Remove footwell trim -1- in -direction of arrow-.
– Remove brake pedal ⇒ page 60 .
– Unclip wiring harness -6- from mounting bracket -1-.

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– Unscrew bolt -3- on the right above the brake pedal support.
– Unscrew nut -2- on left beneath brake pedal support.
– Undo nuts -4- and -5-.
– Remove the mounting bracket -1-.
Installing
– Install in reverse order. Note the following points:
– First, screw bolt -3- in loosely.

Installing brake pedal ⇒ page 60
Specified torque
Brake servo to mounting bracket and bulkhead 25 Nm
♦ Use new bolts
Mounting bracket to bulkhead 25 Nm

♦ Use new nut and bolt
Brake pedal ⇒ page 60

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47 – Brakes - hydraulics
1 Repairing front brake calipers
1.1 Assembly overview - brake caliper FN 3
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
5 - Sleeve bearing
❑ Insert into brake caliper.
6 - Brake caliper
❑ Bolt onto brake caliper
8 - Retaining spring
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
⇒ page 66 .
10 - Piston
⇒ page 66 .
sembly paste
G 052 150 A2 to piston
before installing.
11 - Protective cap
❑ Take care not to damage when inserting piston.
1.2 Removing and installing piston for brake

caliper FN 3
66 Rep. gr.47 - Brakes - hydraulics

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♦ Removal wedge - 3409-
♦ Assembly tool for protective caps - T10146/6-
1.2.1 Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.
1. Repairing front brake calipers 67

Sharan 2011 ➤
– Lever off protective cap from brake caliper using wedge 3409.
– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
1.2.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Insert seal in brake caliper.
– Fit protective seal -A- in assembly tool T10146/6 -1-.
– Press protective cap onto brake caliper so that seal is fitted

correctly all round using assembly tool -1- and piston resetting
tool -2-.
Check seat of protective cap:

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– At this stage it should not be possible to remove protective cap

from brake caliper by hand.
– Press piston lightly onto protective seal and lock it in this po‐
sition with, for example, an assembly wedge -2-.
Keep piston straight to prevent damage to sealing collar.
– Blow air into protective cap using compressed air (max 3 bar)
-1-. During this step protective cap will spring on piston.
– Press pistons into brake calipers with piston resetting appli‐

ance - T 10145- -1-.
The outer sealing lip on the protective cap will then slip into the
piston groove.
1.3 Assembly overview - brake caliper C 60

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1 - Dust cap
❑ Fit onto bleeder valve.
sembly paste
before screwing in.
3 - Hexagon bolt, 35 Nm
moving.
4 - Guide pin
5 - Protective cap
❑ Insert into brake support
plate and guide pin
groove; grease groove
beforehand, use repair
kit grease pack.
❑ Supplied as replace‐
ment part, assembled
with guide pin and pro‐
tective caps, and with
guide pins.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Protective cap
⇒ page 70 .
❑ Take care not to dam‐
age when inserting piston.
8 - Piston
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
9 - Sealing ring
10 - Brake caliper
1.4 Removing and installing piston for brake

caliper C 60

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♦ Piston resetting appliance - T10145-
1.4.1 Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.

When removing ensure that the surface of the cylinder is not
damaged.
1.4.2 Installing

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– Place protective cap with outer sealing lip on piston.
– Insert inner sealing lip into groove in cylinder using wedge

3409.
When doing this, hold piston in front of brake caliper.
– Press piston into brake caliper using piston resetting tool.

The outer sealing lip on the protective cap will then slip into the
piston groove.

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2 Repairing rear brake calipers
2.1 Assembly overview - brake caliper CII 41
1 - Brake caliper
❑ Following repair work,
pre-bleed brake caliper
⇒ page 76 .
2 - Self-locking hexagon bolt,
35 Nm
❑ Renew.
❑ When loosening and
tightening, counterhold
on guide pin.
3 - Dust cap
sembly paste
before screwing in.
5 - Torx socket head bolt, 12
Nm
6 - Parking brake motor.
7 - Sealing ring
8 - Guide pin
❑ Grease before fitting
protective cap.
9 - Protective cap
❑ Fit onto brake support
plate and guide pin.
10 - Brake support plate with
guide pin(s) and protective cap
❑ Supplied as genuine
part, assembled with
guide pins.
❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.
11 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
12 - Piston
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
13 - Sealing ring
14 - Thrust nut
2. Repairing rear brake calipers 73

Sharan 2011 ➤

piston
2.2.1 Removing
– Turn spindle -movement arrow- using an 8 mm multi-point
socket bit.
The thrust nut pushes the piston out of the brake caliper.
– Remove piston and protective cap from brake caliper.
2.2.2 Installing

Sharan 2011 ➤
– Place protective cap with outer sealing lip on piston.
– Screw thrust nut onto spindle until dimension -a- 15 mm is

achieved.
– Insert inner sealing lip of protective cap into groove -arrows-

in brake caliper using removal wedge - 3409- .
– Push the piston onto thrust nut; this is only possible in 4 posi‐
tions
– Carefully press the piston into brake caliper, moving the piston
at the same time.
– Then, press the piston into the brake caliper until it is resting
against the thrust nut.
2. Repairing rear brake calipers 75

Sharan 2011 ➤
– Carefully turn spindle clockwise until thrust nut is located on

stop.
– Ensure that protective cap lies flush all around on brake caliper
-arrows-.
– Press piston into brake caliper by hand.

The outer sealing lip will then spring into the piston groove.
2.3 Pre-bleeding brake caliper

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

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3 Pressurised leak test

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

Brake system (hydraulic unit, brake hoses, brake lines and brake
calipers) operating properly and free of leaks.
– Remove bleeder valve at one of front brake calipers. Connect
pressure gauge -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
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.
3. Pressurised leak test 77

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4 Bleeding brake system

Bleeding the brake system is described using brake filling and
bleeding equipment - VAS 5234- .
WARNING
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.
A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
4.1 Bleeding brake system with the brake

filling and bleeding equipment - VAS
5234-
♦ Brake filling and bleeding equipment - VAS 5234-
♦ Tool set for brake bleeding - VAS 6564-

Sharan 2011 ➤
WARNING
Only use new brake fluid conforming to VW standard

(VW 501 14).
Note
If, in vehicles with EDL, EDL/TCS or EDL/TCS/ESP, a chamber

in brake fluid reservoir is completely empty (e.g. brake system
leaking), brake system must be pre-bled first.
4.1.1 Pre-bleeding:
– Connect brake filling and bleeding equipment - VAS 5234- or
-V.A.G 1869- .
Bleeding sequence:
1 - Bleed front left and front right brake calipers simultaneously.
2 - Bleed rear left and rear right brake calipers simultaneously.
– Leave bleeder valves open with brake fluid hoses connected
until brake fluid free from air bubbles flows out.
Hydraulic unit must then be bled again by means of the function
“Basic setting” with the ⇒ Vehicle diagnostic tester.
Initiate basic setting (to bleed brake system):
⇒ page 10 .
– Then bleed brake system as normal.
4.1.2 Bleeding (normal):

Adhere strictly to work sequence when bleeding brake system.
– Connect brake filling and bleeding equipment - VAS 5234- or
-V.A.G 1869- .
– Open bleeder valves in specified order and bleed brake cali‐
pers.
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
Use suitable bleeder hose. It must sit tightly on bleeder valve so
that no air can enter brake system.
– Leave bleeder valve of each brake caliper open with bleeder
hose fitted until brake fluid discharges free of air bubbles.
4.1.3 Subsequent bleeding

This requires the assistance of a second mechanic:
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
4. Bleeding brake system 79

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– Release brake pedal slowly.

This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
A road test must be carried out after the brakes have been bled.
When doing this an ABS regulation must be performed at least
once!
4.2 Changing brake fluid

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

Sharan 2011 ➤
5 Assembly overview - brake servo/

brake master cylinder
5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive ve‐
hicle)
Note
Use only new brake fluid. Observe information on brake fluid reservoir!
1 - Pedal cluster
25 Nm
moving.
❑ First tighten at bottom
left and then at top right.
3 - Seal
❑ For brake servo.
4 - Brake servo
❑ On petrol engines, the
required vacuum is tak‐
en from the intake mani‐
fold.
❑ Vehicles with a 2.0 l pet‐
rol engine are equipped
in addition with an vac‐
uum pump
⇒ page 85 .
❑ Vehicles with HBS are
equipped with a vacuum
sender. ⇒ page 89
❑ Diesel engines are fitted
with an vacuum pump to
create the required vac‐
uum ⇒ page 84 .
❑ Functional check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust vacuum in unit).
– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake servo is functioning properly, the brake pedal will be felt to go down as the servo
takes effect.
❑ Replace completely in the event of a fault (before doing so, check brake servo vacuum system)
⇒ page 85
5 - Sealing ring
6 - Brake master cylinder
❑ Cannot be repaired. If faulty, renew as a complete unit.
5. Assembly overview - brake servo/brake master cylinder 81

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❑ Is fastened at the bottom to the main brake cylinder with a clip
9 - Heat shield
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA)
10 - Self-locking hexagon nut, 25 Nm
❑ Always renew after removing.
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
13 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
14 - Brake fluid reservoir
15 - Cap
16 - Vacuum hose
❑ With non-return valve and additional vacuum sender - G608- on vehicles with HBS
❑ Fit in brake servo.
❑ Removing and installing vacuum sender - G608- ⇒ page 89
17 - Sealing plug
❑ Connection for vacuum hose.

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5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive

vehicle)
Note
Use only new brake fluid. Observe information on brake fluid reservoir!
1 - Brake servo
❑ On petrol engines, the
required vacuum is ei‐
ther taken from the in‐
take manifold or gener‐
ated by a mechanical
vacuum pump.
❑ Diesel engines are fitted
with a vacuum pump to
create the required vac‐
uum
❑ Functional check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust vacuum in unit).
– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning proper‐
ly, the brake pedal will
be felt to go down as the
servo takes effect
❑ Replace completely in
the event of a fault (be‐
fore doing so, check
brake servo vacuum
system) ⇒ page 85
⇒ page 108 .
❑ With heat shield if there
is one
2 - Seal
❑ For brake servo.
3 - Bolt
❑ 25 Nm
4 - Nut
❑ 25 Nm
❑ Qty. 3
5 - Pedal cluster
6 - Brake line
❑ 14 Nm
❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .

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7 - Bolt
❑ 5 Nm
❑ Removing and installing ⇒ page 90
9 - Nut
❑ 25 Nm
❑ Qty. 2
10 - Brake master cylinder
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
❑ Cannot be repaired. If faulty, renew as a complete unit.
11 - Sealing ring
12 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
13 - Brake line
❑ 14 Nm
❑ Brake master cylinder/secondary piston circuit to ABS hydraulic unit - N55- .
14 - Bolt
❑ 4 Nm
15 - Brake fluid reservoir
16 - Cap with brake fluid level warning contact - F34-
17 - Vacuum hose
❑ Insert in brake servo with sealing plug
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
5.3 Vacuum pump for brake servo (vehicles

with diesel engine)
Must not be dismantled.
Vacuum pump -1-
Vacuum hose to brake servo -2- with non-return valve.
– Removing and installing vacuum pump ⇒ 4-cylinder diesel
engine (2.0 l engine, common rail); Rep. gr. 15 .

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5.4 Vacuum pump for brake servo (vehicles

with petrol engine)
Must not be dismantled.
Vacuum pump -1-
Vacuum hose to brake servo -2- with non-return valve.
High-pressure pump -3-.
– Removing and installing vacuum pump ⇒ 4-cylinder injection
engine (2.0 l engine); Rep. gr. 15 .
5.5 Checking brake servo vacuum system

The following instructions are intended to help you find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or in the event of a so-called »hard brake
pedal«.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if there is one)
When evaluating the measuring results, bear in mind that they will
be influenced by the geographical location. The higher your lo‐
cation is above sea level, the lower the air pressure will be.
Before checking the vacuum system, please take note of the fol‐
lowing prerequisites for checking:
♦ Visual inspection of all vacuum hoses for damage (e.g. cracks
or marten bite) and to check that they are correctly and firmly
attached
♦ Ensure cleanliness when working on vacuum system
♦ Before starting work, clean engine compartment if necessary
♦ Vacuum gauge for brake servo - VAS 6721-

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5.5.1 Connecting vacuum gauge for brake

servo - VAS 6721-
– Pull vacuum hose out of brake servo.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.
– Place brake servo vacuum gauge - VAS 6721- between them
-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if there is one, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-
C Cut- In direction of brake servo

off
valve
– Push hose -A- of brake servo vacuum gauge - VAS 6721- onto
vacuum hose and press adapter -C- into brake servo.
5.5.2 Checking vacuum generation
Note
♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 86 .
– Open cut-off valve -A-.

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– Close cut-off valves -B+C-.

– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
– Read indicated measured value.
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213- ⇒ page 89 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
5.5.3 Checking for leaks
Note
♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 86 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).

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

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
If the vacuum decrease is greater, check for leaks in the vicinity
of...
1- brake servo
or
2- non-return valve, vacuum hoses with connectors or vacuum
pump/intake pipe
.
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 pipe:
– After generation of a vacuum, close cut-off valve -C- in order

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

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5.5.4 Vacuum generation with manual vac‐

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

♦ Air must pass through non-return valve -A- in direction of ar‐
row.
♦ Non-return valve must remain closed in opposite direction.
Observe correct installation position!
5.7 Removing and installing vacuum sender

- G608-
– Remove engine cover panel.
– Pull vacuum hose together with vacuum sender - G608- out of
brake servo.
– Release clips with pliers -1-.
– Carefully lever out the vacuum sender - G608- -2-.
5.8 Removing and installing brake light

switch - F- , left-hand drive
Removing
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Dis‐
connecting and reconnecting batteries .
– Remove air intake hose, air filter housing and battery. ⇒ Elec‐
trical system; Rep. gr. 27 ; Removing and installing battery

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– Separate connector -1- from brake light switch - F- .
– Remove bolt -2- from brake master cylinder.
– Pull brake light switch - F- -3- off the brake master cylinder at
top and out of the clip at the bottom.
Installing
Specified torque:
Torx bolt to brake master cylinder 8 Nm
5.9 Removing and installing brake light

switch - F- , right-hand drive
Removing
Vehicles with diesel engine
– Remove engine cover ⇒ Rep. gr. 15 .
– Remove heat shield -1- from diesel particulate filter by un‐

screwing nuts -arrows-.
– Remove upper timing belt guard by detaching clips -arrows-.

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– Separate connector -A- from brake light switch - F- and pull
off.
– Remove bolt -1- from brake master cylinder.

– Remove brake light switch - F- -2- from brake master cylinder
at the bottom and out of the clip at the top -arrow-.
Installing
– Insert brake light switch - F- -2- into clip -arrow- correctly.
Specified torque
Brake light switch - F- to brake master cylinder 5 Nm

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6 Removing and installing brake mas‐

ter cylinder
6.1 Removing and installing brake master

cylinder, left-hand drive
6.1.1 Removing
necessary.
connecting and reconnecting battery .
– Remove air filter.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing batteries .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234-
or extraction unit -V.A.G 1869/4- .

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Vehicles with manual gearbox:

– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
Continuation for all models:
– Disconnect connector -A- from brake fluid level warning con‐
tact - F34- .
– Separate connector -C- from brake light switch - F- .
– Remove brake fluid reservoir. To do this press locking tabs on

reservoir outwards and simultaneously pull brake fluid reser‐
voir out of sealing plugs.
– Disconnect brake lines -1- on brake master cylinder and seal
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
– Unscrew brake light switch - F- from brake master cylinder.
6.1.2 Installing
Observe the following important points when installing:
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
Specified torques:
Brake master cylinder to brake servo 25 Nm
♦ Use new nuts!
Brake light switch to brake master cylinder 8 Nm

Brake lines to brake master cylinder 14 Nm
6.2 Removing and installing brake master cylinder, right-hand drive vehicle
6. Removing and installing brake master cylinder 93

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equipment required
♦ Sealing tool - T10249-
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-

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♦ Lambda probe open ring

spanner set - 3337-
♦ Ring ratchet spanner 13
mm - T10384-
♦ Assembly tool - T10365-
♦ Transport lock - T10404-
♦ Set of plugs for engine -
VAS 6122-
♦ Hose clip pliers - VAS 6340-
6.2.1 Removing
– Place sufficient lint-free cloths in area of engine.
ervoir using brake filling and bleeding equipment - VAS 5234- .

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Vehicles with 2.0 l petrol engine and turbocharger

– Pull engine cover upwards at its fastening points -arrows-.
– Remove air hose from air filter to intake fitting by opening
clamp ⇒ 4-cylinder injection engine (1.8 and 2.0 l engine,
chain drive); Rep. gr. 24 ; Assembly overview - air filter .
– Remove air hose -1- by pressing the release buttons.

– Pull air hose -1- off and swivel to side.
– Unscrew bolt -arrow- for air pipe.
– Undo hose clip -2- and remove air pipe.
– Remove intake hose between air pipe and turbocharger.
– Seal turbocharger with the sealing plug set for engine - VAS
6122/40- .

– Remove engine cover ⇒ 4-cyl. diesel engine; Rep. gr. 10/15 ;
Removing and installing engine cover .


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– Remove noise insulation and underbody protection ⇒ General
body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly
overview - noise insulation .
Vehicles with diesel engine and SCR system (Selective Catalytic
Reduction)
WARNING
♦ The reducing agent can irritate the skin, eyes and respi‐
ratory system.
♦ If the skin comes into contact with this fluid, immediately
wash off with a lot of water.
♦ Consult a doctor if necessary.
Caution
Protect electrical plug-in connections with suitable means, e.g.

plastic bag and cable ties, before wetting with reducing agent.
Due to the high tendency to creep combined with subsequent
crystallisation of the reducing agent, the electrical connections
can be damaged.
Seal all openings of the hose and connections immediately
with suitable sealing plugs in order to prevent the ingress of
dirt. Even very small particles of dirt can cause considerable
damage to the system.
Always make sure that reducing agent never comes into con‐
tact with clothing or parts of the vehicle body.
If this nevertheless happens, wash the reducing agent off with
clear water and a lint-free cotton cloth.
If the reducing agent has already crystallised, wet it with warm
water and a sponge.
Residual reducing agent that is not removed crystallises after
a while and can damage the surfaces affected.
– Release connector -4- and remove it from reducing agent in‐

jection valve - N474- -2-.
Note
Clamp -1- for reducing agent injection valve - N474- does not
have to be opened.
– Release retaining clip -3- by pressing in

-direction of arrows 1-.
– Pull plug-in coupling off in -direction of arrow 2- without a tool
by »jerking« it.

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– Remove tunnel bridge by undoing bolts -arrows-.

– Remove clamping sleeve -1-.
– Remove exhaust pipe -1- by loosening nuts -arrows-.

– Remove exhaust pipe -1- together with reducing agent injec‐
tion valve - N474- .
Vehicles with diesel engine and four-wheel drive:
– Remove propshaft ⇒ Rep. gr. 39 .
– Remove bevel gear ⇒ Rep. gr. 34 .
Vehicles with diesel engine and particulate filter

– Undo bolts -arrows-.
– Unclip differential pressure sender - G505- -1-.
– Pull vacuum hose -2- off differential pressure sender - G505-
-1- after loosening the clamp -3-.
– Release connectors -1- to -4- and pull off.

– Unclip connector from holder and uncover lines/cables.

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– Undo and remove securing bolt -1-.
– Loosen bolt -2-.

– Open clamp between particulate filter and turbocharger and
remove.
– Remove Lambda probe - G39- -3-.
– Remove exhaust gas temperature sender -1-.
– Remove exhaust gas temperature sender -1- with tool set 17

mm - T10395- and torque wrench - V.A.G 1331- as shown.

– Unclip bracket -2- for electrical wiring to oil level and oil tem‐
perature sender - G266- on subframe.

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– Unbolt exhaust gas temperature sender -arrow-.
– Remove bolts -1- and take out shield plate.
– Undo nuts -1- with ratchet wrench 13 mm - T10384- .

– Undo nuts -2- and take out bracket.
– Remove bracket -1- from top of cylinder head after undoing

nuts -arrow-.

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– Secure decoupling element with transport lock - T10404-

-arrow-.
Caution
Danger of damage to decoupling element

♦ Do not allow the decoupling element to kink by more than
10°.
♦ Do not subject the decoupling element to tensile force.
♦ Do not damage wire mesh on decoupling element.
– Remove bolts -arrows- of bracket.

– Swivel particulate filter downwards and place on subframe.

– Seal openings with sealing plug set for engine - VAS 6122- .
Note
Particulate filter does not have to be removed from the vehicle.

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

– Release and pull off connector -2- from brake fluid level warn‐
ing contact - F34- .
– Unscrew brake pipes -1- from brake master cylinder -3-.
– Seal brake lines using sealing plugs from repair kit - 1H0 698
311 A- .
– Unscrew brake master cylinder nut -4-.

– Remove heat shield (if installed) -2-.

off.
– Unscrew nut -1- from brake master cylinder -2-.
– Carefully take brake master cylinder -2- out of brake servo.
6.2.2 Installing
cylinder.

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– When fitting engine cover, make sure that rubber buffers are
correctly inserted in mountings.
– Carefully press engine cover into catch at points -arrows-.

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Note
♦ Replace seals, self-locking nuts and the clamp for particulate

filter.
♦ Fit cable ties and electrical wires and cables in the same place
as they were before.
♦ Comply with specified installation sequence.
Installation sequence
1 - Position particulate filter on turbocharger
2 - Fit clamp -1- loosely.
3 - Screw bolts -2- and -5- in loosely.
Note
It must still be possible to move particulate filter and bracket.
4 - Tighten clamp -1-.

5 - Tighten securing bolts -2- and -5-.
Caution
The threads of the exhaust gas temperature sender are coat‐

ed. Do NOT grease additionally with high-temperature paste.
Tighten with the tightening torque specified below. Otherwise,
the threaded connection can become loose and subsequent
failures can then occur.
Installation position of exhaust gas temperature sender -pos. 1-.

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– Angled end facing left side of vehicle.

– Angle -α- to mark -arrow- = approx. 17°.
– Tighten bolts of exhaust gas temperature sender with tool set
17 mm - T10395- and torque wrench - V.A.G 1331- .
Four-wheel drive vehicles:
– Install bevel gear ⇒ Rep. gr. 34 .
– Install propshaft ⇒ Rep. gr. 39 .
– Bleed clutch ⇒ Clutch controls; Rep. gr. 30 ; Bleeding clutch
system .
– Set up exhaust system so that it is stress-free ⇒ Exhaust sys‐
tem; Rep. gr. 26 ; Setting up exhaust system so that it is
stress-free .
Specified torque
♦ Use new nuts!

Clamping sleeve for exhaust system 25 Nm
Particulate filter to bracket on cylinder block 25 Nm
Bracket to cylinder block 25 Nm
Clamp between particulate filter and turbocharger 7 Nm
♦ Replace clamp
Exhaust system to subframe 25 Nm

Exhaust gas temperature sender ⇒ Exhaust system; Rep. gr. 26 ; Assembly overview
- exhaust gas temperature regulation

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7 Removing and installing brake servo
7.1 Removing and installing brake servo,

left-hand drive
Note
If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 85 .

7.1.1 Removing
necessary.

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connecting and reconnecting battery .
– Remove air filter.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing batteries .
– Place sufficient lint-free cloths in area of engine and gearbox.
ervoir using brake filling and bleeding equipment - VAS 5234-
or extraction unit -V.A.G 1869/4- .
Vehicles with manual gearbox:
– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
– Disconnect connector -A- from brake fluid level warning con‐
tact - F34- .
– Separate connector -C- from brake light switch - F- .
– Pull vacuum hose out of brake servo.
– Identify both brake lines from brake master cylinder to hy‐
draulic unit and then remove.
– Immediately seal brake lines and threaded holes with seal
plugs from repair set Part No. 1H0 698 311 A.
Additional work for vehicles with 1.4 l FSI engine:
– Open cable duct, take out the two wiring harnesses and place
on one side.
– Remove cable duct from console.
– Remove control unit and hydraulic unit ⇒ page 16 .
Additional work for vehicles with 2.0 l TDI engine:
– Detach solenoid valve for charge pressure limitation - N75-
from front wall and turn to the side.
panel.
ing; Rep. gr. 48 .
– Remove clamping washers for noise insulation and lay noise
insulation to side.
7. Removing and installing brake servo 107

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– Unscrew nuts -1- from brake servo.

– If brake servo sticks in holes, remove both upper nuts -2- on
mounting bracket.
– Carefully remove brake servo from vehicle.
– Remove nuts for brake master cylinder.
– Carefully remove brake master cylinder from brake servo.
7.1.2 Installing
Observe following points when installing:
– Ensure boot is seated correctly.
– After installing, bleed brake system ⇒ page 78 and clutch.
Specified torques:
Brake servo to pedal cluster and bulkhead 25 Nm
♦ Use new nuts!

♦ Use new nuts!
7.2 Removing and installing brake servo,

right-hand drive vehicle
Note
If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 85 .

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equipment required
♦ Sealing tool - T10249-
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-

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♦ Lambda probe open ring

spanner set - 3337-
♦ Ring ratchet spanner 13
mm - T10384-
♦ Assembly tool - T10365-
♦ Transport lock - T10404-
♦ Set of plugs for engine -
VAS 6122-

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♦ Support bracket - 10 - 222

A-
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /8-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-
♦ Rectangular tube - T40091 / 1- of basic engine support bracket

set - T40091-
♦ Connector - T40091/3- of basic engine support bracket set -

T40091-

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♦ Adapter - T40093/3- of supplementary engine support bracket

set - T40093-
♦ Adapter - T40093/3-5 - of supplementary engine support

bracket set - T40093-
7.2.1 Removing
– Detach brake servo from brake pedal ⇒ page 59 .
– Place sufficient lint-free cloths in area of engine.
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Pull engine cover upwards at fastening points -arrows- ⇒ 4-
cyl. injection engine (1.8 and 2.0 l engine, chain drive); Rep.
gr. 15 ; Removing and installing engine cover .
– Remove radiator grille ⇒ Rep. gr. 66 ; Radiator grille .
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
92 ; Windscreen wipe and wash system .
– Remove plenum chamber cover ⇒ Rep. gr. 50 ; Plenum
chamber cover .
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Remove turbocharger ⇒ 4-cylinder injection engine (1.8 and
2.0 l engine, chain drive); Rep. gr. 21 ; Removing and installing
turbocharger .
– Prop up engine in installation position ⇒ 4-cylinder injection
engine (1.8 and 2.0 l engine, chain drive); Rep. gr. 11 ; Prop‐
ping up engine in installation position .
– Release connectors and pull them all off at the same time in
-direction of arrow-.
– Lay the wiring harness to one side.

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– Unscrew water pipe -1- at fastening points -arrows-.

– Place water pipe -1- to one side.
– Unscrew bolts -arrows- of engine/gearbox support on the en‐

gine.
– Lower engine by means of the spindles and pull towards the
front as far as possible.
On the engine side, the distance -a- between the engine support
and the engine mounting must be 4.3 cm.
Note
♦ Make absolutely sure that the drive shafts can move freely in
relation to the engine/gearbox support.
♦ In order to prevent damage, it must be ensured that the drive
shafts do not rest on the engine/gearbox support!

– Remove engine cover ⇒ Rep. gr. 15 .
– Remove radiator grille ⇒ Rep. gr. 66 ; Radiator grille .
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
92 ; Windscreen wipe and wash system .
– Remove plenum chamber cover ⇒ Rep. gr. 50 ; Plenum
chamber cover .
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .

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Vehicles with diesel engine and SCR system (Selective Catalytic
Reduction)
WARNING
♦ The reducing agent can irritate the skin, eyes and respi‐
ratory system.
♦ If the skin comes into contact with this fluid, immediately
wash off with a lot of water.
♦ Consult a doctor if necessary.
Caution
Protect electrical plug-in connections with suitable means, e.g.

plastic bag and cable ties, before wetting with reducing agent.
Due to the high tendency to creep combined with subsequent
crystallisation of the reducing agent, the electrical connections
can be damaged.
Seal all openings of the hose and connections immediately
with suitable sealing plugs in order to prevent the ingress of
dirt. Even very small particles of dirt can cause considerable
damage to the system.
Always make sure that reducing agent never comes into con‐
tact with clothing or parts of the vehicle body.
If this nevertheless happens, wash the reducing agent off with
clear water and a lint-free cotton cloth.
If the reducing agent has already crystallised, wet it with warm
water and a sponge.
Residual reducing agent that is not removed crystallises after
a while and can damage the surfaces affected.

Sharan 2011 ➤
– Release connector -4- and remove it from reducing agent in‐

jection valve - N474- -2-.
Note
Clamp -1- for reducing agent injection valve - N474- does not
have to be opened.
– Release retaining clip -3- by pressing in

-direction of arrows 1-.
– Pull plug-in coupling off in -direction of arrow 2- without a tool
by »jerking« it.

– Remove exhaust pipe -1- by loosening nuts -arrows-.

– Remove exhaust pipe -1- together with reducing agent injec‐
tion valve - N474- .
Vehicle with diesel engine and four-wheel drive
– Remove propshaft ⇒ Rep. gr. 39 .
– Remove bevel gear ⇒ Rep. gr. 34 .

– Undo bolts -arrows-.
– Unclip differential pressure sender - G505- -1-.
– Pull vacuum hose -2- off differential pressure sender - G505-
-1- after loosening the clamp -3-.

Sharan 2011 ➤
– Release connectors -1- to -4- and pull off.

– Unclip connector from holder and uncover lines/cables.
– Undo and remove securing bolt -1-.
– Loosen bolt -2-.

– Open clamp between particulate filter and turbocharger and
remove.
– Remove Lambda probe - G39- -3-.
– Remove exhaust gas temperature sender -1-.
– Remove exhaust gas temperature sender -1- with tool set 17

mm - T10395- and torque wrench - V.A.G 1331- as shown.

Sharan 2011 ➤

– Unclip bracket -2- for electrical wiring to oil level and oil tem‐
perature sender - G266- on subframe.
– Unbolt exhaust gas temperature sender -arrow-.
– Remove bolts -1- and take out shield plate.
– Undo nuts -1- with ratchet wrench 13 mm - T10384- .

– Undo nuts -2- and take out bracket.

Sharan 2011 ➤
– Remove bracket -1- from top of cylinder head after undoing

nuts -arrow-.
– Secure decoupling element with transport lock - T10404-

-arrow-.
Caution
Danger of damage to decoupling element

♦ Do not allow the decoupling element to kink by more than
10°.
♦ Do not subject the decoupling element to tensile force.
♦ Do not damage wire mesh on decoupling element.
– Remove bolts -arrows- of bracket.

Sharan 2011 ➤

– Swivel particulate filter downwards and place on subframe.
– Seal openings with sealing plug set for engine - VAS 6122- .
Note
Particulate filter does not have to be removed from the vehicle.
– Unscrew bolts -1- to -3- and remove pendulum support.
Assembly of the support bracket

• Assemble following special tools according to instructions:
• Adapters - 10-222 A /8- have to be mounted as illustrated with
the support bracket fitted.
• Rubber blocks -A- must face outwards.
• -Arrow- points in direction of travel.
• Bolt adapter - T40093/3-5 - onto adapter - T40093/3- .
Note
♦ The adapter - T40093/3-5 - or adapters - 10-222 A /8- for the

support bracket - 10-222 A- are positioned near the radiator
grille and the plenum chamber cover.
♦ Fit support bracket - 10-222 A- behind the bonnet support.
Place support bracket - 10 - 222 A- with adapters, as shown in

diagram, and take weight of engine.

Sharan 2011 ➤
– Position the adapter -10-222A/8- -A- next to the bolts

-arrow-.
– Fit support bracket - 10-222A- behind the bonnet support. Po‐
sition the right adapter - 10-222A/8- next to the bolts as well
-arrow-.
– Fit adapter - T40093/3-5 - on the front end in front of the radi‐
ator -A-.
– Unscrew bolts -arrows- of engine/gearbox support on the en‐
gine.
– Lower engine by means of the spindles and pull towards the
front as far as possible.

Sharan 2011 ➤
On the engine side, the distance -a- between the engine support
and the engine mounting must be 3cm.
Note
♦ Make absolutely sure that the drive shafts can move freely in
relation to the engine/gearbox support.
♦ In order to prevent damage, it must be ensured that the drive
shafts do not rest on the engine/gearbox support!

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

– Undo and remove bolts -arrows-, remove bracket together
with cut-off valve for heater coolant - N279- and place to one
side.
Note
Do not open water hoses.

– Release and pull off connector -2- from brake fluid level warn‐
ing contact - F34- .
– Unscrew brake pipes -1- from brake master cylinder.
– Seal brake lines using sealing plugs from repair kit - 1H0 698
311 A- .

Sharan 2011 ➤
– Pull vacuum line -1- out of brake servo unit -3-.

– Unscrew brake master cylinder nut -4-.
– Remove heat shield (if installed) -2-.

off.
– Unscrew nut -1- from brake master cylinder -2-.
– Carefully take brake master cylinder -2- out of brake servo.
– Undo nuts -4- and -5- on mounting bracket -1-.

– Carefully remove brake servo from the vehicle.
7.2.2 Installing
– Carefully insert brake servo and tighten nuts.
cylinder.

Sharan 2011 ➤

– Remove turbocharger ⇒ 4-cylinder injection engine (1.8 and
2.0 l engine, chain drive); Rep. gr. 21 ; Removing and installing
turbocharger .
– When fitting, make sure that rubber buffers are correctly in‐
serted in mountings.
– Carefully press engine cover into catch at points -arrows-.

Sharan 2011 ➤
Vehicles with 2.0 l diesel engine and particulate filter
Note
♦ Replace seals, self-locking nuts and the clamp for particulate

filter.
♦ Fit cable ties and electrical wires and cables in the same place
as they were before.
♦ Comply with specified installation sequence.
Installation sequence
1 - Position particulate filter on turbocharger
2 - Fit clamp -1- loosely.
3 - Screw bolts -2- and -5- in loosely.
Note
It must still be possible to move particulate filter and bracket.
4 - Tighten clamp -1-.

Caution
The threads of the exhaust gas temperature sender are coat‐

ed. Do NOT grease additionally with high-temperature paste.
Tighten with the tightening torque specified below. Otherwise,
the threaded connection can become loose and subsequent
failures can then occur.
Installation position of exhaust gas temperature sender -pos. 1-.

Sharan 2011 ➤
– Angled end facing left side of vehicle.

– Angle -α- to mark -arrow- = approx. 17°.
– Tighten bolts of exhaust gas temperature sender with tool set
17 mm - T10395- and torque wrench - V.A.G 1331- .
Four-wheel drive vehicles:
– Install bevel gear ⇒ Rep. gr. 34 .
– Install propshaft ⇒ Rep. gr. 39 .
– Bleed clutch ⇒ Clutch controls; Rep. gr. 30 ; Bleeding clutch
system .
– Set up exhaust system so that it is stress-free ⇒ Exhaust sys‐
tem; Rep. gr. 26 ; Setting up exhaust system so that it is
stress-free .
Specified torque
Brake servo to mounting bracket and bulkhead 25 Nm
♦ Use new nuts.

♦ Use new nuts.

Clamping sleeve for exhaust system 25 Nm
Particulate filter to bracket on cylinder block 25 Nm
Bracket to cylinder block 25 Nm
Clamp between particulate filter and turbocharger 7 Nm
♦ Replace clamp
Exhaust system to subframe 25 Nm

Pendulum support to gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing front wheel suspension, drive shaft
Pendulum support to subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing front wheel suspension, drive shaft
Engine/gearbox assembly support on engine Removing and installing ⇒ engine/gearbox assembly;
Rep. gr. 10 ;
Exhaust gas temperature sender ⇒ Exhaust system; Rep. gr. 26 ; Assembly overview
- exhaust gas temperature regulation

Sharan 2011 ➤

Turbocharger 2.0 l petrol engine ⇒ 4-cylinder injection engine (1.8 and 2.0 l engine,
chain drive); Rep. gr. 21 ; Assembly overview - turbo‐
charger .

Sharan 2011 ➤
8 Brake lines
8.1 Separating point on underbody
Connection:
1- Union nut, 14 Nm
2- Ring
3- Flange F
4- Flange E, cannot be pinched
5- Nut, counterhold when tightening.
8.2 Repairing brake lines

The flanging tool for brake lines - VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this allows sections of brake lines
to be renewed at less expense.
The use of flanging tool V.A.G. 1356 is not permitted due to the
coating and the diameter of the black brake lines.
Note
♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict the cross-section
of the line to an impermissible degree.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle; merely clean with methylated spirits.

♦ Flanging tool for brake lines - VAS 6056-

List of individual tools:
8. Brake lines 127

Sharan 2011 ➤
1 - Flanging tool - VAS 6056/1-

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

Sharan 2011 ➤
8.2.1 Assembly overview - flanging tool
1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws
2 - Fastening for handle
❑ Must be removed to ac‐
cess retaining screw for
upper part
3 - Retaining screw
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ For centring and holding
flanging jaws
❑ Hexagon socket head
bolt, 2 mm
5 - Flanging jaws
❑ Various
❑ Assembly instructions
⇒ page 129
Flanging jaw assembly instructions:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (light) for green brake lines
Note
The arrow on the rounded side of the flanging jaws must point to
the edge of the housing, and the straight side of the flanging jaws
must be installed towards the spindle, or the flange will not be
formed correctly.
8.2.2 Work instructions

– Unbolt relevant brake line at brake caliper or wheel brake cyl‐
inder; catch escaping brake fluid and dispose of this as per
regulations.
8. Brake lines 129

Sharan 2011 ➤
– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.
– Clamp brake line tightly in set of grips -4- so that approx. 50

mm project from plastic jaws.
– Clamp scraper -3- into a drill and place it onto brake line.
– At slow drill speed and with gentle pressure on brake line,
scrape coating off brake line.
Length of scraping is determined by stop in scraper.
– Pull scraper off brake line and remove scrapings.
– Remove set of grips and slide union bolt -D- onto brake line.
– Slide brake line -B- up to stop -A- in flanging tool.
Note
Brake line must be positioned against stop when the hexagon

socket head bolts are tightened, or the flange will not be formed
correctly.
– Tighten brake line in flanging tool until brake line can no longer
be moved. Fold up stop -A- and now tighten hexagon socket
head bolts diagonally using special wrench -C-.

Sharan 2011 ➤
– Turn spindle to stop in flanging tool.

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

– Install brake line.
8. Brake lines 131

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Service

Service Department. Technical Information

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

1.1 Assembly overview - brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Information on the individual rear brake that is fitted is currently

– To find information about the rear brake, please search in EL‐

1.1 Front brakes

1.4 l - 110 kW TSI 2+3) 1 LW C60 (16”)

2.0 l - 147 kW TFSI

1. Brake allocation via PR No. 1

3) for vehicles with all-wheel drive and manual gearbox.

1.2 Rear brakes

2 Rep. gr.00 - Technical data

2 Technical data for brakes

2.1 Brake master cylinder and brake servo

2.2 Front brakes

2.2.2 Front brakes C60

2. Technical data for brakes 3

2.3 Rear brakes (disc brakes)

4 Rep. gr.00 - Technical data

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

3.2 Test for vehicles with front-wheel drive

3.3 Test for vehicles with four-wheel drive

3.3.1 On a regulated roller dynamometer with

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

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

3.3.2 Without roller dynamometer for four-

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

– Drive vehicle forwards onto the rollers.

3.4 Testing the electromechanical parking

3.4.1 Vehicles with front-wheel drive:

In »TÜV mode«, the electromechanical parking brake does not

The tension is increased gradually by actuating the electrome‐

6 Rep. gr.00 - Technical data

3.4.2 Checking electromechanical parking

In »TÜV mode«, the electromechanical parking brake does not

The tension is increased gradually by actuating the electrome‐

45 – Anti-lock brake system

ABS layout in right-hand drive vehicle:

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

2 Notes for repair work on anti-lock

2. Notes for repair work on anti-lock brake system 9

3 Connecting -VAS 5051- and select‐

♦ During a road test, you must always secure testing and

– Connect connector of diagnosis cable -VAS 5051/1- or -

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

– Switch on tester -arrow-.

3. Connecting VAS 5051 and selecting functions 11

4 Electrical/electronic components and

4.1 ABS TRW (ABS/EDL/TCS/ESP)

1 - ABS control unit - J104-

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

4. Electrical/electronic components and locations 13

5 Assembly overview - hydraulic unit

5.1 ABS TRW (ABS/EDL/TCS/ESP), left-hand drive vehicle

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

9 - ABS hydraulic unit - N55-

5.1.1 Connecting brake lines from brake mas‐

5. Assembly overview - hydraulic unit 15