VW Touareg 2 Brake System Eng

Service
Workshop Manual
Touareg 2010 ➤
Touareg 2015 ➤
Brake systems
Edition 09.2014
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.
Touareg 2010 ➤ , Touareg 2015 ➤
Brake systems - Edition 09.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Example of a vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Testing vehicles with no electric differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Testing vehicles with electric differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Testing the electromechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 General notes for anti-lock brake system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Notes for repair work on the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Assembly overview - hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 ABS MK 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 23
6.1 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Removing and installing speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview - front brake, Brembo 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4 Assembly overview - front brake, Brembo 18" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.5 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Assembly overview - rear brake caliper, 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.4 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.5 Adjusting air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Repairing thread in brake caliper connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Overview of electromechanical parking brake components . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Removing and installing control unit for electromechanical parking brake J540 . . . . . . . . 58
4.2 Removing and installing parking brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contents i
5.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.3 Adjusting brake pedal position sender G100 , LHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . 64
5.4 Adjusting brake pedal position sender G100 , RHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . 66
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 Assembly overview - brake caliper, Brembo 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Removing and installing piston for 17" and 18" Brembo caliper . . . . . . . . . . . . . . . . . . . . . . 70
2 Repairing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234 . . . . . . . . . . 77
4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.1 Removing and installing brake light switch F , left-hand drive . . . . . . . . . . . . . . . . . . . . . . 81
5.2 Removing and installing brake light switch F , right-hand drive . . . . . . . . . . . . . . . . . . . . . . 82
6 Brake servo vacuum supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.1 Overview - vacuum pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 84
6.2 Assembly overview - vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.3 Removing and installing vacuum line with vacuum sender G608 , right-hand drive model
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.4 Checking brake servo vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.5 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.1 Removing and installing brake master cylinder, left-hand drive . . . . . . . . . . . . . . . . . . . . . . 93
7.2 Removing and installing brake master cylinder, right-hand drive vehicle . . . . . . . . . . . . . . 94
8 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.1 Removing and installing brake servo, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.2 Removing and installing brake servo, right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 99
9 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
ii Contents
00 – Technical data
1 Brake allocation via PR No.
(VRL007156; Edition 09.2014)
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.
1.1 Example of a vehicle data sticker

In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes -1KJ
♦ Arrow 2 - Front brakes -1LG
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
The following table explains the PR numbers. These are impor‐
tant for combining the brake caliper/brake disc/brake drum and
brake pads.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
1.2 Front brakes

Engine PR No. Front brakes
3.0l - 150; 176; 180; 1LC Brembo (17")
193 kW TDI 1)
3.6l - 183; 206 kW FSI
1)
3.0l - 235; 245 kW FSI 1LG / 1LW Brembo (18")

4.2l - 250 kW TDI
4.2l - 265 kW FSI
3.0l - 245 kW TSI, hy‐
brid
1) Only for vehicles with no electric differential lock
Country-specific brake for North America:
Engine PR No. Front brakes
3.0l - 176 kW TDI 1LE Brembo (17")
3.6l - 206 kW FSI
3.0l - 245 kW TSI, hy‐ 1LJ Brembo (18")
brid
1.3 Rear brakes

Engine PR No. Rear brakes
3.0l - 150; 176; 180; 1KJ / 2EG Brembo (17")
193 kW TDI
3.6l - 183; 206 kW FSI
1. Brake allocation via PR No. 1

3.0l - 235; 245 kW FSI

4.2l - 250 kW TDI
4.2l - 265 kW FSI
3.0l - 245 kW TSI, hy‐
brid
Country-specific brake for North America:
Engine PR No. Rear brakes
3.0l - 176 kW TDI 1KQ Brembo (17")
3.6l - 206 kW FSI
3.0l - 245 kW TSI, hy‐
brid
Volkswagen Technical Site: http://vwts.ru http://vwts.info
2 Rep. gr.00 - Technical data

2 Technical data
2.1 Brake master cylinder and brake servo

Brake master cylinder Diameter in mm 26.99
Brake servo Diameter in in‐ 9" / 10" - tandem
ches
2.2 Front brakes

2.2.1 Front brake, Brembo (17")
Item PR No. 1LC / 1LE
1 Brake caliper Brembo (17")
2 Brake lining, mm 10.5
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc Diame‐ 330
ter in
mm
Brake disc, mm 32
thickness
Brake disc, mm 30
wear limit
4 Brake caliper Diame‐ 4 x 46
piston ter in
mm
2.2.2 Front brake, Brembo (18")

Item PR No. 1LG / 1LJ / 1LW
2 Brake lining, mm 10
thickness
limit without
backplate
ter in
mm
Brake disc, mm 36
thickness
Brake disc, mm 34
wear limit
4 Brake caliper ∅ in mm 6 x 36
piston
2. Technical data 3
2.3 Rear brakes

2.3.1 Rear brakes (17" brake disc)
Item PR No. 1KJ / 1KQ / 2EG
thickness
limit without
backplate
ter in
mm
Brake disc, mm 28
thickness
Brake disc, mm 26
wear limit
4 Brake caliper Diame‐ 4 x 46
piston ter in
mm
2.3.2 Parking brake (17" brake drum)

Item
1 Brake drum Diame‐ 210
ter in
mm
Brake drum, wear Diame‐ 211
limit ter in
mm
width
Brake lining, total mm 5.5
thickness
Brake lining, mm 1
wear limit without
backplate

3 Brake test
3.1 General
♦ The drive is provided by the roller dynamometer.
♦ For the test ensure for vehicles with a manual gearbox that the
gear lever is in neutral, and for vehicles with an automatic
gearbox that the selector lever is in »N«.
♦ 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 Testing vehicles with no electric differ‐

ential lock
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 Testing vehicles with electric differential

lock
The brake test must be performed on a regulated contra-rotating
roller brake test stand.
“Contra-rotating” means that the dynamometer rollers are driven
forwards on one side and backwards on the other side.
“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.
3.4 Testing the electromechanical parking

brake
3.4.1 Vehicles with no electric differential lock:

Activate »TÜV mode«:
• Rear axle on single-axle roller dynamometer
• Ignition remains switched on
• Front wheels must be stationary for a minimum of 3 seconds.
• Rear wheels must rotate at constant speed between 2.2 and
12 km/h for at least 3 seconds.
3. Brake test 5
Entering »TÜV mode« is indicated by the yellow electric parking

brake and handbrake fault warning lamp - K214- lighting up.
End »TÜV mode«:
• Release electromechanical parking brake using electrome‐
chanical parking brake button - E538- .
• Ignition off.
• Selector lever not in »N«.
• Speed of all wheels greater then 2.2 km/h.

45 – Anti-lock brake system

1 General notes for anti-lock brake sys‐
tem (ABS)
On vehicles with ABS Mark 25, only the following version is in‐
stalled:
♦ ABS/EDL/TCS with electronic stabilisation program (ABS/
EDL/TCS/ESP)
The ABS brake system is divided front and rear. The servo-as‐
sistance is effected pneumatically by the vacuum brake servo
unit.
Faults in the ABS influence the brake system and servo assis‐
tance. A change in braking behaviour is to be reckoned with. After
the ABS warning lamp comes on, the rear wheels may lock pre‐
maturely during braking.
Models with ABS Mark 25 do not have a mechanical brake pres‐
sure regulator. Specially matched software in the control unit
regulates the brake force distribution on the rear axle.
The hydraulic unit -2- and control unit -1- form one component.
Separation is possible. Hydraulic pump -3- must not be separated
from hydraulic unit.
New control units from the replacement parts service are not co‐
ded. They must be coded once installed. ⇒ Coding control unit
using VAS 5051 via function "Guided fault finding".
1. General notes for anti-lock brake system (ABS) 7

2 Notes for repair work on the ABS

♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault using “Guided Fault Finding”.
“Guided fault finding” is carried out on the vehicle diagnosis, test‐
ing and information system - VAS 5051- .
♦ Before working on the anti-lock brake system, disconnect the
battery earth strap. Note or request radio code on vehicles with
coded radio if necessary.
♦ 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 77 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 77 .
♦ 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.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. ( Sealing plugs - 1 H0 698 311 A- must
be used).
♦ 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.
♦ Ensure that no brake fluid enters connectors.
♦ 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).
8 Rep. gr.45 - Anti-lock brake system

3 Connecting -VAS 5051- and select‐

ing functions
Special tools and workshop equipment required
♦ -VAS 5051- Vehicle Diagnosis, Testing and Information Sys‐
tem
♦ 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 diagnostic cable - VAS 5051/1- or -

VAS 5051/3- to diagnostic cable -arrow-.
3. Connecting VAS 5051 and selecting functions 9

– 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 compatible system…” shown on
the display.
Either:
– Select “Anti-lock brake system…” shown on the 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.

4 Electrical/electronic components and locations
1 - ABS control unit - J104-

❑ Location: on hydraulic
unit on right suspension
strut.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
2 - ABS hydraulic unit - N55-
❑ Location: on right sus‐
pension strut.
The hydraulic unit consists of
the components:
❑ 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.
❑ Brake pressure sender -
G201-
3 - Brake pad warning lamp -
K32-
❑ Location: in dash panel
insert.
4 - ABS warning lamp - K47-
insert.
5 - Brake system warning lamp
- K118-
❑ Location: in dash panel insert.
6 - ESP and TCS warning lamp 2 - K216-
❑ ESP/TCS system has been switched off by the ESP and TCS button - E256- .
7 - ESP and TCS warning lamp - K155-
8 - Brake light switch - F-
❑ Removing and installing ⇒ page 81 .
9 - TCS and ESP button - E256-
❑ Location: in centre console.
10 - Steering angle sender - G85-
❑ Location: on steering column between steering wheel and steering column switch.
❑ Observe installation instructions ⇒ page 27 .
11 - ESP sensor unit - G419-
❑ Location: under centre console.
4. Electrical/electronic components and locations 11

❑ Combined lateral acceleration sender - G200- , yaw rate sender - G202- and longitudinal acceleration
sender - G251- .
❑ Combined in one housing.
❑ Observe installation instructions ⇒ page 26 .
12 - Diagnostic connection
❑ Location: Driver footwell cover.
❑ ⇒ page 12
13 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
14 - Front right speed sensor - G45- / front left speed sensor - G47-
❑ Renewing ⇒ page 23 .
15 - Rear right speed sensor - G44- / rear left speed sensor - G46-
❑ Renewing ⇒ page 25 .
16 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
Diagnostic connection

5 Assembly overview - hydraulic unit
5.1 ABS MK 25
1 - ABS control unit - J104-

❑ Removing and installing
⇒ page 18 .
2 - ABS hydraulic unit - N55-
⇒ page 18 .
3 - Torx bolt, 2+0.8 Nm
❑ Without canting, tighten
in stages using diagonal
sequence.
4 - Bracket
❑ Allocation ⇒ Electronic
Parts Catalogue (ET‐
KA) .
5 - Bolt, 9 Nm
6 - Rubber damper
7 - Brake line, 18 Nm
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
❑ Identification: 8.5 mm in
diameter and union nut
with thread M12 x 1.
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Identification: 8.5 mm in
diameter and union nut
with thread M12 x 1.
9 - Brake servo and brake mas‐
ter cylinder
❑ Assembly overview ⇒ page 80 .
❑ Removing and installing (LHD) ⇒ page 98
❑ Removing and installing (RHD) ⇒ page 99
❑ To rear left brake caliper.
❑ Identification: 5.25 mm in diameter and union nut with thread M12 x 1.
❑ To front right brake caliper.
❑ Identification: 5.25 mm in diameter and union nut with thread M10 x 1
❑ To front left brake caliper.
❑ Identification: 5.25 mm in diameter and union nut with thread M12 x 1.
5. Assembly overview - hydraulic unit 13

❑ To rear right brake caliper.
❑ Identification: 5.25 mm in diameter and union nut with thread M10 x 1
Connecting brake lines from brake master cylinder to hydraulic

unit
On brake master cylinder:
On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Identification: 8.5 mm in diameter and union nut with thread M12
x 1.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Identification: 8.5 mm in diameter and union nut with thread M12
x 1.
1 - From hydraulic unit to rear left brake caliper.
- Identification: 5.25 mm in diameter and union nut with thread
M12 x 1.
2 - From hydraulic unit to front right brake caliper.
M10 x 1
3 - From hydraulic unit to front left brake caliper.
M12 x 1.
4 - From hydraulic unit to rear right brake caliper.
M10 x 1
5.1.1 Removing and installing control unit

separately

♦ Torque wrench - V.A.G 1783-
Removing:
– 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 pipe (not fitted on all engines), release hose
clips -arrows- and pull off hose -1-.
Vehicles with diesel engine:
– Unscrew fuel filter -arrows-, do not disconnect fuel lines, place

fuel filter to side.
– Disconnect connector for air suspension, unscrew securing

bolts -arrows- and remove bracket for fuel filter.

Continuation for all vehicles

– Remove bolts -arrows- on coolant expansion tank -1-.
– Slide coolant expansion tank -1- in -direction of arrow- out of
retainer.
– Place coolant expansion tank -1- to one side.
Note
Do not pull off coolant hoses.
– Thoroughly clean control unit, hydraulic unit and surrounding

area.
– Use a vacuum cleaner to vacuum the control unit, the hydraulic
unit and the extended area off to prevent dirt and moisture from
entering the system.
– Release control unit connector -arrow 1- and pull off

-arrow 2-.
– Unscrew control unit -2- and pull it off hydraulic unit -3- without
canting it.

The illustration shows the expansion tank -1- removed and placed
on side.
– Check valve for damage.
– Clean sealing surface.
Note
♦ Do not use aggressive cleaning agents (use enclosed clean‐

ing agent).
♦ Check sealing surface for damage (visual inspection).
Caution
No moisture or particles of dirt may enter control unit.

If sealing surface or contact tabs are damaged, hydraulic unit
must be renewed.
Severe shocks (e.g. dropping, impact) may destroy control
unit. Control unit must not then be used.
Installing:
Note
♦ Use new bolts.

♦ A new control unit may be mounted on an existing hydraulic
unit max. twice to guarantee impermeability of the elastic
seals.
♦ A control unit which has already been operated in a vehicle
must not be installed a second time.
– Carefully push control unit onto hydraulic unit without canting

it.
– Tighten hydraulic unit and control unit diagonally in stages to
specified torque with enclosed new Torx bolts.
– Fit connector.
– Install coolant expansion tank.
– If fitted, install fuel filter and suction hose.
– Code radio.
– Code ABS control unit - J104- with ⇒ Vehicle diagnostic tester
in “Guided fault finding”.
– Basic setting must additionally be performed when ABS con‐
trol unit - J104- is replaced.
Specified torque:
Control unit to hydraulic unit 2+0.8 Nm

5.1.2 Removing and installing control unit and

hydraulic unit
Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1410-
♦ Brake pedal depres‐

sor - V.A.G 1869/2-
Sealing plugs repair kit,

Part No. 1H0 698 311 A
The transport protection
for the contact pins must
always be placed on the
hydraulic unit after the
control unit has been dis‐
connected from the hy‐
draulic unit.
No warranty can be as‐
sumed for hydraulic units
without transport protec‐
tion.
1 - Transport protection
for contact pins (foam)
2 - Sealing plug M10
3 - Sealing plug M12
Location:
The control unit is bolted
to the hydraulic unit and
is located on right in ple‐
num chamber.

WARNING
Do not bend the brake

lines in the area of the
hydraulic unit!
5.1.3 Removing control unit and hydraulic unit

– Note or request radio code on vehicles with coded radio if
necessary.
– Release control unit connector -arrow 1- and pull off
-arrow 2-.
– 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.
– Open bleed valve.
– 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 control unit and hy‐
draulic unit.
Ensure no brake fluid gets onto contacts.
– Open brake line retainers on left and right of hydraulic unit and
pull off.
– Mark brake lines and unscrew from hydraulic unit.
– Seal brake lines and threaded holes using sealing plugs -
1H0 698 311 A- .
– Pull hydraulic unit with control unit upwards out of dampers.

– Unscrew hydraulic unit from bracket.
5.1.4 Unscrewing control unit from hydraulic

unit
Note
– Place hydraulic unit with control unit upwards on a clean flat

level surface.
– Unscrew Torx bolts out of control unit.

– Without canting it, pull control unit off from hydraulic unit
-arrow-.
WARNING
♦ Printed circuit board becomes visible when control unit is

removed.
♦ No moisture or particles of dirt may enter control unit.
♦ Avoid electrostatic charge!
– Cover control unit solenoids with a lint-free cloth.

After separating control unit and hydraulic unit, use transport pro‐
tection for contact pins.
5.1.5 Installing new control unit
WARNING
Severe shocks (e.g. dropping, impact) may destroy control

unit. Control unit must not then be used.
• Clean surfaces before assembling.
Note
♦ Use new bolts.

♦ A new control unit may be mounted on an existing hydraulic
unit max. twice to guarantee impermeability of the elastic seal.
♦ A control unit which has already been operated in a vehicle
must not be installed a second time.
– Carefully push control unit onto hydraulic unit without canting

it.
– Tighten hydraulic unit and control unit diagonally in stages to
specified torque with enclosed new Torx bolts.
5.1.6 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.
– Install in reverse order.

– Before installing bracket for ABS hydraulic unit - N55- , spray
rubber dampers with silicone lubricant D 007 000 A2 to make
installation easier.

WARNING
Ensure that rubber dampers are not pressed out of bracket

when installing. After installing, check hydraulic unit with con‐
trol unit for proper seating, otherwise malfunctions can occur.
– Remove brake pedal depressor - V.A.G 1869/2- .

– Bleed brake system ⇒ page 77 .
– Code radio.
– Code ABS control unit - J104- with ⇒ Vehicle diagnostic tester
in “Guided fault finding”.
– Basic setting must additionally be performed when ABS con‐
trol unit - J104- is replaced.
Specified torques:
Control unit to hydraulic unit 2 Nm + 0.8
♦ Use new bolts! Nm
Bolt for bracket on hydraulic unit 9 Nm

Brake lines to brake master cylinder (8.5 mm in di‐ 18 Nm
ameter):
Brake lines to brake calipers (5.25 mm in diameter): 14 Nm

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

❑ Before inserting sensor,
clean fitting hole inner
surface and coat with
polycarbamide grease -
G 052 142 A2- .
⇒ page 23 .
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 Removing and installing speed sensor

on front axle
6.1.1 Removing
– Raise vehicle.
6. Removing and installing parts of ABS system on front and rear axle 23
– Separate connector -1- from speed sensor wire and from

speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
6.1.2 Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with polycarbamide grease - G
052 142 A2- .
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.
6.2 Removing and installing parts of ABS system on rear axle
1 - ABS speed sensor

❑ Before inserting sensor,
clean fitting hole inner
surface and coat with
polycarbamide grease -
G 052 142 A2- .
⇒ page 25 .
2 - Hexagon socket head bolt,
8 Nm
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing.
4 - Drive shaft

6.3 Removing and installing speed sensor

on rear axle
6.3.1 Removing
– Raise vehicle.
– Remove wheel.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Separate connector -1- from speed sensor wire and from
speed sensor.
– Remove bolt -arrow- from wheel bearing housing.

– Pull ABS speed sensor -1- out of wheel bearing housing.
6.3.2 Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with polycarbamide grease - G
052 142 A2- .
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.
6. Removing and installing parts of ABS system on front and rear axle 25
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 beneath the centre console.
After exchanging the ESP sensor unit - G419- , perform basic
setting for lateral acceleration sender - G200- and the longitudinal
acceleration sender - G251- .
WARNING
Shocks or jolts can destroy the lateral acceleration sender -

G200- , the yaw rate sensor - G202- and the longitudinal
acceleration sender - G251- .
7.1.1 Removing
Location: behind selector mechanism, under centre console (from
driver's perspective).
– Remove gearshift trim ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling gearshift trim .
– Fold up centre console armrest, remove mat and cover ⇒
General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims; Removing and installing centre console .
WARNING
When working on the Airbag control unit - J234- , please follow

the general safety procedures for working on the airbag, belt
tensioner and battery isolation units (pyrotechnical units) ⇒
General body repairs, interior; Rep. gr. 69 .

– Remove airbag control unit ⇒ General body repairs, interior;
Rep. gr. 69 ; Airbag; Removing and installing airbag unit J234 .
– Pull connector -1- off ESP sensor unit - G419- .
– Move wiring harness aside, routed before ESP sensor unit -
G419- .
– Remove protective cap from forward securing nut.
– Remove the two securing nuts -arrows-.
– Remove ESP sensor unit - G419- .

7.1.2 Installing
When installing the ESP sensor unit, make sure it is correctly
seated in its bracket and is free of stress.
Do not use the securing nuts to forcibly position ESP sensor unit.
– Tighten securing nuts to 8 Nm.
– Carry out basic settings for lateral acceleration sender - G200-
and longitudinal acceleration sender - G251- .
Connecting -VAS 5051- and selecting functions ⇒ page 9 .
7.2 Removing and installing steering angle

sender - G85-
The steering angle sender - G85- is located between the steering
wheel and steering column switch.
7.2.1 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- .
7. Removing and installing parts of ESP system 27

46 – Brakes - mechanism
1 Repairing front brakes
1.1 Assembly overview - front brake, Brem‐

bo 17"
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.
the brake system with brake filling and bleeding unit -
VAS 5234- or extraction unit -V.A.G 1869/4- .
♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a
brake caliper or disconnecting a brake hose (release pressure
in system).
1 - Brake disc
❑ Ventilated brake disc:
330 mm in diameter.
❑ Brake disc thickness: 32
mm.
❑ Wear limit: 30 mm.
❑ Always renew on both
sides of an axle.
❑ Different designs on left
and right.
❑ Unscrew brake caliper
prior to removing disc,
do not disconnect brake
line but remove brack‐
ets
⇒ Item 14 (page 29)
and
⇒ Item 16 (page 29) .
2 - Fitted bolt, 15 Nm
❑ Brake disc to wheel hub.
3 - Dust cap
❑ Fit onto bleeder valve.
❑ Retainer for wiring for
brake pad wear indica‐
tor.
4 - Brake caliper
❑ Do not disconnect brake
line when changing
brake discs.
⇒ page 32 .
❑ Repairing ⇒ page 69 .
28 Rep. gr.46 - Brakes - mechanism

5 - Retaining spring
6 - Pad retaining pins
7 - Hexagon bolt, 270 Nm
❑ Always renew after removing.
8 - Brake pad wear indicator wire.
❑ Changed to 1 contact on inside
9 - Brake linings
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ With break pad wear indicator.
❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
comes on.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
❑ Always renew on both sides of an axle.
❑ Do not disconnect brake line when changing brake discs.
11 - Spring clip
12 - Brake hose, 14 Nm
13 - Torx bolt, 9 Nm
14 - Upper retainer
❑ Bolt to wheel bearing housing.
15 - Hexagon socket head bolt, 20 Nm
16 - Lower retainer
1.2 Removing and installing brake pads or

linings
♦ Piston resetting appliance - T10145-
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.
1. Repairing front brakes 29

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

– Pull off dust cap -2- and lift off brake pad wear indicator wire.
– Drive out brake pad retaining pins -arrows-.
– Pull brake pad wear indicator wire -arrows- out of brake caliper
and out of retaining spring -1-.
– Remove retaining spring.
Before pressing back brake pads, draw off brake fluid from res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Push brake pads off brake disc and remove from brake caliper.
– If the brake pads are to be renewed, carefully remove sensor
with wire for brake pad wear indicator from the brake pads and
check for damage.
Sensors and wires which are not damaged can be used again.
Cleaning:
WARNING
Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!
– Clean brake caliper.

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 pistons back.
– Carefully insert sensors of brake pad wear indicator wire into
new brake pads.
– Insert brake pads into brake caliper.
– Fit retaining spring -1-.

– Insert brake wear indicator wire under the retainer in the re‐
taining spring and into brake caliper housing -arrows-.
– Press retaining spring down and insert brake pad retaining
pins in brake caliper.
– Drive brake pad retaining pins into brake caliper to stop.

– Reconnect brake wear indicator connector -1- to connector on

bracket on wheel bearing housing.
– Secure brake wear indicator wire on bleed valve with the dust
cap -2-.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .
Note

♦ Check brake fluid level after changing brake pads.
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.
– Connect bleeder bottle hose to a bleeder valve on brake cali‐
per and open bleeder valve.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake line from brake caliper.
– Disconnect bracket ⇒ Item 16 (page 29) from wheel bearing
housing.
– Remove brake pads ⇒ page 29 .
– Unbolt brake caliper from wheel bearing housing.
1.3.2 Installing
– Bolt brake caliper to wheel bearing housing.
– Install brake pads.
– Reconnect brake line to brake caliper.
– Bolt bracket ⇒ Item 16 (page 29) to wheel bearing housing.
– 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:
Hexagon bolt to wheel bearing housing 270 Nm
♦ Use new bolts!
Brake line to brake caliper 14 Nm

Bolt for bracket to wheel bearing housing. 20 Nm

1.4 Assembly overview - front brake, Brem‐

bo 18"
Note

the brake system with brake filling and bleeding unit -
VAS 5234- or extraction unit -V.A.G 1869/4- .
♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a
brake caliper or disconnecting a brake hose (release pressure
in system).
1 - Brake disc
368 mm in diameter.
mm.
sides of an axle.
❑ Different designs on left
and right.
❑ Unscrew brake caliper
prior to removing disc,
unscrew brake hose
bracket and insert as‐
sembly pin - T10439- ,
do not disconnect brake
hose.
3 - Brake pad wear indicator
wire.
4 - Brake caliper
❑ Do not disconnect brake
hose when changing
brake pads or brake
disc.
⇒ page 39 .
❑ For brake pads.
6 - Multi-point socket head bolt,
30 Nm + 90°
❑ Repairing thread in wheel bearing housing member ⇒ page 52
7 - Dust cap
❑ Retainer for wiring for brake pad wear indicator.

8 - Brake linings
❑ Thickness: 10 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
comes on.
9 - Brake hose, 14 Nm
11 - Upper retainer
12 - Hexagon socket head bolt, 20 Nm
13 - Lower retainer
1.5 Removing and installing brake pads/lin‐

ings
♦ Assembly pin - T10439-

1.5.1 Removing
– Remove wheels.
– Remove upper retainer for brake hose -1- from wheel bearing
housing -arrow-.
– Disconnect brake pad wear indicator connector -1- and pull

connector out of retainer -3-.
– Unscrew and remove bolt -2- and pull lower brake hose re‐
tainer -3- off wheel bearing housing.
– Pull dust cap off brake caliper bleed valve and take off brake
pad wear indicator wire.
– Pull brake pad wear indicator wire out of brake caliper.
– Disconnect connector -1- from speed sensor.

– Push brake pads off brake disc.

– Remove multi-point socket head bolts -A- from brake caliper.
– Fit assembly pins - T10439- for this.
– Then push brake caliper forwards -movement arrow- until cal‐

iper engages in recesses -arrows- of assembly pins -
T10439- .
– Lever brake pads out of brake caliper -arrows- using a com‐

mercially available screwdriver, not to damage dust caps
when doing this.
– Take brake pads out of brake caliper.
– Carefully remove contact sender with brake pad wear indicator
wire from brake pad and check for damage.
Cleaning:
WARNING


1.5.2 Installing
damage.
• The retaining springs are correctly seated in the brake caliper.
– Fit brake pads onto the 4 contact surfaces of brake pad re‐
taining pins -arrows-.
– Fit brake pads onto the 4 brake pad retaining pins -arrows-.
WARNING
The brake pads must be correctly seated in the brake pad re‐
taining springs and on the retaining pins.
– Carefully set brake caliper over brake disc.
– Unscrew assembly pins - T10439- and install multi-point sock‐

et head bolts-A-.
– Install both retainers -arrows- on wheel bearing housing.

– Insert brake wear indicator wire into brake caliper and under
dust cap.

– Insert brake pad wear indicator connector -arrow- into retainer.
– Reconnect connector -1- to speed sensor.

– Fit wheels.
Note

several times with vehicle stationary so that brake pads are
Specified torques:
Multi-point socket head bolt to wheel bearing hous‐ 30 Nm +
ing 90°
♦ Use new bolts!
Upper retainer to wheel bearing housing 9 Nm

Lower retainer to wheel bearing housing 20 Nm


1.6.1 Removing
– Remove wheels.
– Separate connector for brake pad wear indicator.
– Disconnect brake hose from brake caliper.
1.6.2 Installing
– Install brake pads ⇒ page 35 .
– Reconnect brake hose to brake caliper.
– Carefully insert sensors of brake pad wear indicator wire into
new brake pads.
– Insert brake pad wear indicator wire under retainers in retain‐
ing spring and into clip.
– Reconnect connector for brake pad wear indicator.
– Fit wheels.
Note

operating position.

Specified torques:
ing 90°
♦ Use new bolts!
Brake hose to brake caliper 14 Nm

2 Repairing rear brakes
2.1 Assembly overview - rear brake caliper,

17"
After replacing brake pads/linings, depress brake pedal firmly
several times with vehicle stationary so that the brake pads/linings
are properly seated in their normal operating position.
Use brake filling and bleeding equipment -VAS 5234- to draw off
brake fluid from brake fluid reservoir.
Fit brake pedal depressor -V.A.G 1869/2- before removing a
brake caliper or disconnecting a brake hose (release pressure in
system).
1 - Brake disc/drum
330 mm in diameter.
mm.
❑ Brake drum: 210 mm in
diameter.
sides of an axle.
❑ For removal, first unbolt
brake caliper. Do not un‐
bolt brake line.
❑ Bring parking brake mo‐
tors to assembly posi‐
tion beforehand
❑ After renewing, perform
basic setting of electro‐
mechanical parking
brake.
3 - Screw plug, 15 Nm
❑ For electromechanical
parking brake adjust‐
ment nut.
ing
5 - Brake linings
❑ Thickness: 10 mm not
including backplate.
❑ Wear limit: 2 mm not in‐
cluding backplate.
comes on.

❑ For brake pads.
7 - Brake pad wear indicator wire.
8 - Brake caliper
9 - Multi-point socket head bolt, 30 Nm + 75°
10 - Brake hose
❑ Do not disconnect brake hose when changing brake discs.
❑ Ensure that lugs are properly seated in grooves in bracket.
11 - Bolt, 8 Nm
12 - Bracket
❑ Brake pad wear indicator wire.
❑ Do not disconnect brake line when changing brake pads or brake disc.
14 - Bolt, 10 Nm
15 - Bracket
16 - Wheel bearing housing
17 - Brake carrier plate
❑ To remove, remove wheel bearing unit ⇒ Running gear, axles, steering; Rep. gr. 42 ; Assembly overview:
wheel bearings .
18 - Bolt, 8 Nm
19 - Brake shoes
❑ Without wear indicator.
❑ Minimal thickness of brake lining: 1 mm.
❑ Apply hot bolt paste G 052 112 A3 to sliding and side surfaces of brake shoe web in area of mounting
for parking brake motor, see ⇒ page 49
❑ After renewing, perform basic setting of electromechanical parking brake.
20 - Parking brake motor.
❑ Apply hot bolt paste G 052 112 A3 to sliding and side surfaces of mounting for brake shoes, see
⇒ page 49
❑ After renewing, perform basic setting of electromechanical parking brake.
21 - Clip
❑ Retainer for parking brake motor wiring.
❑ Parking brake motor to wheel bearing housing.
23 - Return spring
❑ Parking brake motor.
2. Repairing rear brakes 43

24 - Hold-down pin
25 - Compression spring
26 - Spring
❑ Adjustment nut
27 - Adjustment nut
❑ Adjusting air gap ⇒ page 49 .
2.2 Removing and installing brake pads or

linings
2.2.1 Removing
Note

– Remove rear wheels.

– Disconnect connector -2- for brake pad wear indicator.

– Lever brake pads out of brake caliper -arrows- using a com‐

mercially available screwdriver, not to damage dust caps
when doing this.
– Also take brake pads out of brake caliper.
– Take inner brake pad out of brake caliper until connector for
brake pad wear indicator wire lies on retaining spring.
– Carefully remove contact sender with brake pad wear indicator
wire from brake pad and check for damage.
Cleaning:
WARNING

2.2.2 Installing
damage.
• The retaining spring is correctly seated in the brake caliper.
– Insert brake pad wear indicator wire between brake caliper
and retaining spring and into inner brake pad.

– Press brake pads against retaining spring in brake caliper and

slide onto pad retaining pins -arrows-.
WARNING
The brake pads must be correctly seated in the brake pad re‐
taining springs and on the retaining pins.
– Carefully set brake caliper over brake disc.

– Push brake pad wear indicator wire into recess in brake cali‐
per.
– Insert brake wear indicator connector -2- into retainer on brake

caliper.
– Fit wheels.
Note

several times with vehicle stationary so that brake pads are
Specified torques:
ing 75°
♦ Use new bolts!


2.3.1 Removing
– Disconnect connector for brake pad wear indicator.
– Disconnect brake line from brake caliper.
2.3.2 Installing
– Install brake pads ⇒ page 44 .
– Reconnect brake line to brake caliper.
– Push brake pad wear indicator wire into recess in brake cali‐
per.
– Reconnect brake wear indicator connector and secure in re‐
tainer on brake caliper.
– Fit wheels.
Note

operating position.

Specified torques:
ing 75°
♦ Use new bolts!
Brake line to brake caliper 14 Nm
2.4 Removing and installing brake shoes

♦ Hook - 3438-
2.4.1 Removing
Note
Mark brake pads/shoes when removing if they are to be reused.

Fit in same position when installing, otherwise different air gap
and braking will be uneven.

– Do do this, select electromechanical parking brake and “mov‐
ing parking brake motor to assembly position” function.
– Use -VAS 5051- to move parking brake motors to assembly
position.
Note
Pull connector off parking brake motor as a precaution. If the

brake disc/brake drum is removed this may cause a problem
when, for example, the ignition key is withdrawn and the parking
brake motor closes.
– Release and disconnect connector -1- on parking brake motor.


– Remove fitted bolt -1-.

– Remove brake disc/brake drum -2-.
– Detach tension spring -1- and return spring -2-.

– Remove hold-down pins -3 + 4- along with compression
springs and remove brake shoes.
2.4.2 Installing
Install in reverse order.
Additional work:
Grease brake shoe web and parking brake motor mounting
-arrows-:
– Apply hot bolt paste G 052 112 A3 to sliding and side surfaces
of brake shoe web -1- and parking brake motor mounting -2-.
WARNING
Ensure that no grease gets on friction surfaces of brakes shoes

and brake drum!
– Then perform basic setting of electromechanical parking

brake.
2.5 Adjusting air gap

The brake discs must rotate freely, if necessary press brake lining
back slightly.
– Select electromechanical parking brake and function “adjust‐
ing air gap”.
Air gap OK., example display on -VAS 5051- :
Evaluation
Air gap lies within tolerance.

Evaluation
Left air gap: 2.19 mm
Right air gap: 2.17 mm
Difference left/right air gaps: 0.02 mm
Air gap not OK., example display on -VAS 5051- :
Evaluation Specification / Actual value 2 or
1 3)
Air gap lies outside tolerance.

Left air gap Spec./Act. 1.9 - 2.4 mm / 1.61 mm
Right air gap Spec./Act. 1.9 - 2.4 mm / 2.54 mm
Difference left/right air 0 - 0.2 mm / 0.93 mm
gaps:
1- Specification (black lettering)
2- Actual value within tolerance (blue lettering)
3- Actual value outside tolerance (red lettering)
If air gap lies outside tolerance, carry out following procedures:
– Unscrew sealing plug -arrow- for parking brake adjustment
nut.
– Insert a screwdriver through the hole in the brake disc and turn
the adjustment nut -A- back against the resistance of the
spring -B-.
Note
Turning adjustment nut one tooth equals approx. 0.15 mm.
– Calculate difference between actual value and specified value

and divide this figure by 0.15 mm. This will provide approx.
number of teeth for which the adjustment nut must be turned
in the respective direction (loosen or tighten).
Left adjustment nut:

♦ Turning in arrow direction -A- reduces air gap (= tightens).
♦ Turning in arrow direction -B- increases air gap (= loosens).
♦ Arrow -C- shows the direction of travel (forwards).
Note
The adjustment nut on the right side of the vehicle is a mirror im‐
age.

Right adjustment nut:

♦ Turning in arrow direction -A- reduces air gap (= tightens).
♦ Turning in arrow direction -B- increases air gap (= loosens).
♦ Arrow -C- shows the direction of travel (forwards).
– After adjusting air gap, press Complete button to up-date ac‐
tual values.
brake.
– To do this, select electromechanical parking brake and func‐
tion “Basic settings of electromechanical parking brake”.
– Install sealing plug -arrow- for parking brake adjustment nut.

– Fit rear wheels.
– Perform basic setting.

3 Repairing thread in brake caliper con‐

nection
For vehicles with aluminium wheel bearing housing
Note
All operations while repairing the thread must be carried out man‐
ually without additional tools.
List of individual tools for VAS 6627:

1 - Drilling jig
2 - Fitted bolt M12x1.5
3 - Fitted bolt M14x1.5
4.1 - Brass sleeve M12 for special drill bit and seat milling cutter
4.2 - Brass sleeve M12 for screw tap
5.1 - Brass sleeve M14 for special drill bit and seat milling cutter
5.2 - Brass sleeve M14 for screw tap
6 - Gripping tool
7 - Container for cutting oil
List of individual tools for VAS 6627/8 for M12x1.5 thread:

1- Special drill bit
2- Seat milling cutter
3- Screw tap M12x1.5
4- Driving tool M12x1.5
5- Insert M12x1.5
List of individual tools for VAS 6627/9 for M14x1.5 thread:

1- Special drill bit
2- Seat milling cutter
3- Screw tap M14x1.5
4- Driving tool M14x1.5
5- Insert M14x1.5
3.1 Work instructions

The description refers to the rear brake caliper since this has re‐
stricted space availability and the procedure involves slightly
more operations.
The thread repair for the front brake caliper is identical.
– Remove wheel.

– Unscrew brake caliper from wheel bearing housing.
position.
– Remove brake disc.
– Secure drilling jig -1- using relevant fitted bolt (M12 at rear or
M14 at front) -2-.
– Slide brass sleeve -A- from rear onto special drill bit -B-
-arrow 1- so that special drill bit cutting edges do not damage
brass sleeve.
– Then insert special drill bit together with brass sleeve into drill‐
ing jig -C- -arrow 2-.
– Locate gripping tool -1- on special drill bit -2- and tighten.
The special drill bit from the tool kit has the appropriate length
(including the jig) for the correct depth of the bore.
3. Repairing thread in brake caliper connection 53

– Manually drill until gripping tool -1- touches brass sleeve -3-
-arrow A-.
– Loosen fitted bolt -2- slightly and then swing drilling jig -1- to
one side.
– Clamp seat milling cutter -2- in gripping tool -1- and counter‐
sink bore until bit stop of seat milling cutter is reached (see
following drawing N46-10330).
Bit stop -A- on seat milling cutter

– To check depth of countersink, place insert -1- other way

round, i.e. with seat -A- first, into countersink.
Seat of insert must disappear fully inside countersink.
– Remove swarf, wear safety goggles.
– Swing drilling jig -1- back over bore and fasten with fitted bolt
-2-.
– Then slide appropriate brass sleeve -D- from rear onto screw
tap -E- -arrow 1- so that special drill bit cutting edges do not
damage brass sleeve.
– Apply a little cutting oil to screw tap.
– Insert screw tap together with brass sleeve into drilling jig
-C- -arrow 2-.
Initially the brass sleeve still protrudes a little from the drilling jig.
The guiding action is nonetheless assured.
– Locate gripping tool -1- on screw tap -2- and tighten.
3. Repairing thread in brake caliper connection 55

– Manually cut thread until gripping tool -1- touches brass sleeve
-3- -arrow A-.
– Clean bore, remove swarf and cutting oil, wear safety goggles.
– Turn insert -1- manually onto driving tool -2- until you can feel
slight resistance.
The insert must not be fully screwed onto the driving tool because
the insert would otherwise be prematurely deformed.
– Screw insert -1- in manually using driving tool -2- until it is flush
with wheel bearing housing -A-.
The driving tool -2- must not screw further into the insert -1- until
the insert -1- is flush with the wheel bearing housing -A-.
WARNING
The insert must be completely covered by the wheel bearing

housing or the brake caliper cannot be guaranteed to be firmly
seated.
– Clamp the gripping tool on the driving tool -2- and then turn
the driving tool through the insert -1-.
The turning resistance becomes noticeably greater.

The threads of the insert -1- are pressed into the wheel bearing
housing -A- in the process.
The thread repair is complete once the driving tool -2- can be
easily turned through the insert -1-.
– Fit brake disc, brake caliper and wheel.

4 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 - Warning lamp with 2 func‐
tions
♦ Electromechanical parking
brake warning lamp - K213-
lights up red.
♦ Auto-hold warning lamp -
K237- lights up green.
Additionally in central display
in dash panel.
❑ Electromechanical
parking brake fault indi‐
cator lamp - K214- lights
up yellow.
Note
Additionally an acoustic signal is

sounded.
insert.
5 - Brake system warning lamp
- K118-
6 - Electromechanical parking brake control unit - J540-
7 - Clip
❑ Retainer for parking brake motor wiring.
8 - Left parking brake motor - V282-
❑ Location: on rear left wheel bearing housing.
9 - Right parking brake motor - V283-
❑ Location: on rear right wheel bearing housing.
❑ Parking brake motor to wheel bearing housing.
4. Overview of electromechanical parking brake components 57

4.1 Removing and installing control unit for

electromechanical parking brake - J540-
The electromechanical parking brake control unit - J540- is loca‐
ted behind the right luggage compartment side panel trim.
After control unit for electromechanical parking brake - J540- has
been replaced, recode ABS control unit - J104- and carry out ba‐
sic setting of “brake system” (electromechanical parking brake).
WARNING
Severe shocks (e.g. dropping, impact) may destroy the control

unit for electromechanical parking brake - J540- . The control
unit for electromechanical parking brake - J540- may then no
longer be used.
Removing
– Switch off ignition and all electrical consumers and remove
ignition key.
– Remove right side panel in luggage compartment ⇒ General
body repairs, interior; Rep. gr. 70 ; Load area and luggage
compartment trim; Removing and installing side panel in lug‐
gage compartment .
– Press locking catch outwards -arrows- on both sides and pull
control unit for electromechanical parking brake - J540- -1- out
of bracket, taking length of connected wiring into account.
– Release and disconnect connector and remove control unit for
electromechanical parking brake - J540- .
Installing
– Then readapt control unit for electromechanical parking brake
- J540- .
– To do this, select electromechanical parking brake and the
function “Renew control unit for electromechanical parking
brake J540”.
4.2 Removing and installing parking brake

motor
♦ Vehicle diagnosis, testing and information system - VAS 5051-

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
Removing
Note
Do not separate connectors of parking brake motors.
• Electromechanical parking brake not operated.

– Do do this, select electromechanical parking brake and “mov‐
ing parking brake motor to assembly position” function.
position.
If this is not possible, turn parking brake adjustment nut back.
– Remove rear wheel.
– Remove brake disc/drum.
Note
Mark brake shoes when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.
– Remove brake shoes ⇒ page 48 .
Note
If parking brake motor is to be reused, secure parking brake motor

in brake shoe mounting with a cable tie to prevent it turning.
4. Overview of electromechanical parking brake components 59

– Secure parking brake motor mounting with cable tie -2- to pre‐
vent it turning.
– Unscrew brake carrier plate.
– Release and disconnect connector -1- on parking brake motor.

– Remove parking brake motor electrical wiring from clip and
remove clip.
– Unscrew both multi-point socket head bolts -arrows- of parking

brake motor -1-.
– Remove parking brake motor.
Installing
brake.

5 Assembly overview - brake pedal

Illustration for automatic gearbox and hybrid model
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
1 - Pedal cluster mounting

bracket
2 - Bolt, 20 Nm
3 - Support
4 - Bolt, 3 Nm
5 - Pivot pin
❑ Only fits in one position,
recess in pivot pin to lug
on mounting bracket.
6 - Crash wedge
⇒ page 64
7 - Bolt, 3 Nm
8 - Sleeve bearing
9 - Support
❑ For ball head of brake
servo plunger rod.
10 - Sleeve bearing
11 - Brake pedal
⇒ page 63
❑ Separating brake pedal
from brake servo
⇒ page 62
❑ Clip brake pedal to
brake servo
⇒ page 63 .
KA) .
12 - Pedal cap
13 - Bracket with magnet
❑ Only with hybrid models.
❑ Securing bolt for bracket on brake pedal, 3.5 Nm.
❑ Adjusting, LHD vehicles ⇒ page 64 .
❑ Adjusting, RHD vehicles ⇒ page 66 .
14 - Brake pedal position sender - G100-
5. Assembly overview - brake pedal 61

15 - Brake pedal position sender - G100- retainer

16 - Bolt, 3 Nm
17 - Retaining ring
❑ For pivot pin.
5.1 Separating brake pedal from brake ser‐

vo
♦ Release tool - T10159 A-
– Remove footwell cover ⇒ General body repairs, interior; Rep.

gr. 68 ; Compartments, covers and trims .
– First press brake pedal in direction of brake servo and hold.
1 - Brake pedal
2 - Plunger rod
3 - Retaining lugs
– Insert release tool - T 10159- and pull in direction of driver seat.
When doing this, counterhold on brake pedal (at this stage,
brake 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 - T 10159- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).

5.1.1 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.
5.2 Removing and installing brake pedal
5.2.1 Removing
– Remove cover on side of dash panel ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments, covers and trims .
Left-hand drive (LHD)
Remove left dash panel cover, driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trims .
Remove right dash panel cover, front passenger side ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
– Remove knee airbag ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing knee airbag .
– Remove onboard supply control unit ⇒ Electrical system; Rep.
gr. 97 ; Control units .
– Remove accelerator.
Right-hand drive (RHD)
trims .
– Remove knee airbag ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing knee airbag .
– Remove onboard supply control unit ⇒ Electrical system; Rep.
gr. 97 ; Control units .
– Release wiring harness in right footwell and move it clear.

Continuation for both vehicles

– Unscrew bolts -arrows- and remove crash wedge -1- from
mounting bracket -2-.
– Separate brake pedal -3- from brake servo ⇒ page 62 .

– Pull split pin -arrow- off pivot pin -1-.
– Pull pivot pin -1- out of mounting.
– Remove brake pedal.
5.2.2 Installing
Note
Pivot pin fits in one position only.
– Clip brake pedal to brake servo ⇒ page 63 .

Specified torque
Component Specified torque
Crash wedge to mounting bracket 3 Nm
– Remove knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Airbag; Removing and installing
knee airbag .
5.3 Adjusting brake pedal position sender -

G100- , LHD vehicles
Remove cover on side of dash panel ⇒ General body repairs,
trims .

– Remove convenience system central control unit -J393- with

retainer ⇒ Electrical system; Rep. gr. 97 ; Control units .
Brake pedal position sender - G100- retainer, guide ribs -A- and
bearing bracket -B- have slots to provide a sideways adjustment.
This also prevents twisting.
– Loosen bolts -2- until retainer -1- with brake pedal position
sender - G100- -3- can be moved back and forth in
-direction of arrow-.
– Set dimension -A- so that min. 4 mm to max. 5mm is between
brake pedal position sender - G100- -3- and magnet -4-.
– Tighten bolts -2- again.
– Loosen bolt -4- of magnet retainer -3- until magnet retainer

-3- can be pushed as far as possible in -direction arrow A-
against brake pedal -1-.
– Push stop tab -1- of retainer -2- downwards in

-direction of arrow- (figure section I) until stop tab -1- fasteners
engage on edge of retainer -2- (figure section II).
– Press magnet retainer -1- lightly in -direction of arrow- against
engaged stop tab -2-.

Both engaged fasteners -3- are shown on figure.

– Tighten bolt -4- of magnet retainer.
– Push stop tab -1- in -direction of arrow- until stop tab engages
on other side of retainer -2-.
– Install convenience system central control unit -J393- with re‐
tainer ⇒ Electrical system; Rep. gr. 97 ; Control units .
Install right dash panel cover on driver side ⇒ General body re‐
Install left dash panel cover on driver side ⇒ General body re‐
Install cover on side of dash panel ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Compartments, covers and trims .
– Install footwell cover ⇒ General body repairs, interior; Rep.
5.4 Adjusting brake pedal position sender -

G100- , RHD vehicles
Remove cover on side of dash panel ⇒ General body repairs,
trims .
– Remove convenience system central control unit -J393- with
retainer ⇒ Electrical system; Rep. gr. 97 ; Control units .

For adjustment purposes, the retainer -1- for the brake pedal po‐
sition sender - G100- is provided with two guides -A- on top, one
guide fin -B- on bottom and the mounting bracket is provided with
a slot -C-, which together allow for lateral adjustment. This also
prevents twisting.
– Loosen bolt -4- until retainer -3- with brake pedal position
sender - G100- -2- can be moved back and forth in
-direction of arrow-.
– Set dimension -A- so that min. 4 mm to max. 5mm is between
brake pedal position sender - G100- -2- and magnet -1-.
– Tighten bolt -4- again.
– Loosen bolt -1- of magnet retainer -2- until magnet retainer

-3- can be pushed as far as possible in -direction arrow A-
against brake pedal -3-.
– Unclip stop tab -1- in -direction of arrow A- from retainer -2-
(upper section of illustration).

– Then, fit stop tab from the side onto retainer and engage it in
-direction of arrow B- between stops -C- (lower section of il‐
lustration).
– Press magnet retainer -2- lightly in -direction of arrow- against

engaged stop tab -1-.
– Tighten bolt -3- of magnet retainer.
– Unclip stop tab -1- in -direction of arrow A- from retainer -2-.
– Then, fit stop tab -1- on retainer -2- and engage it in original
position in -direction of arrow B-.
– Install convenience system central control unit -J393- with re‐
tainer ⇒ Electrical system; Rep. gr. 97 ; Control units .
Install right dash panel cover on driver side ⇒ General body re‐
Install left dash panel cover on driver side ⇒ General body re‐
Install cover on side of dash panel ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Compartments, covers and trims .
– Install footwell cover ⇒ General body repairs, interior; Rep.

47 – Brakes - hydraulics
1 Repairing front brake calipers
1.1 Assembly overview - brake caliper,

Brembo 17"
♦ When carrying out repairs, install all parts supplied in repair
kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake
cylinder, piston and seal.
1 - Dust cap
❑ Secures brake pad wear
indicator wiring.
2 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread.
❑ 8 mm
3 - Brake caliper
4 - Sealing ring
⇒ page 70 .
5 - Piston, 46 mm
⇒ page 70 .
❑ Apply thin coat of as‐
sembly paste - G 052
150 A2- to piston before
inserting.
6 - Protective cap
❑ Take care not to dam‐
age when inserting pis‐
ton.

Brembo 18"
kit.
1. Repairing front brake calipers 69


paste - G 052 150 A2- to
thread.
❑ 11 mm
2 - Dust cap
3 - Brake caliper
5 - Piston seal
⇒ page 70 .
6 - Piston, 36 mm
⇒ page 70 .
inserting.
7 - Protective caps for piston
ton.
8 - Bracket
❑ For brake pad wear in‐
dicator wire.
9 - Connecting pipe, 17 Nm
1.3 Removing and installing piston for 17"

and 18" Brembo caliper
Removal and installation of pistons is identical though brake cal‐
ipers are different.
70 Rep. gr.47 - Brakes - hydraulics

♦ Wedge - 3409-
1.3.1 Removing
– Press pistons individually out of brake caliper using com‐
pressed air.
Only one piston can be pressed out at a time. Hold opposing pis‐
ton in brake caliper using piston resetting tool -a-. Block the other
pistons with, for example, a wooden block -b-. Additionally, place
a piece of wood -c- in front of piston resetting tool so that piston
is not damaged when being pressed out.
– Remove seal using wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
1.3.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of assembly paste - G 052 150 A2- to piston
and sealing ring before inserting.
1. Repairing front brake calipers 71

– Insert seal in brake caliper.
– Place protective cap on piston.
– Using equal pressure, push piston into brake caliper.

The protective cap should locate securely in the groove. If not,
use piston resetting tool to push piston in slightly.

2 Repairing rear brake calipers

Brembo 17"
kit.
1 - Dust cap
paste - G 052 150 A2- to
thread.
❑ 8 mm
3 - Brake caliper
4 - Sealing ring
⇒ page 73 .
5 - Piston, 46 mm
⇒ page 73 .
inserting.
6 - Protective cap
ton.
2.2 Removing and installing rear brake cal‐

iper piston
Removal and installation of pistons is identical though brake cal‐
ipers are different.
2. Repairing rear brake calipers 73

♦ Wedge - 3409-
2.2.1 Removing
– Press pistons individually out of brake caliper housing using
compressed air.
Only one piston can be pressed out at a time. When doing this,
hold the opposing piston in the caliper using the piston resetting
appliance -a-. Block the other pistons with, for example, a wooden
block -b-. Additionally, place a piece of wood -c- in front of piston
resetting tool so that piston is not damaged when being pressed
out.
– Remove seal using wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
2.2.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of assembly paste - G 052 150 A2- to piston
and sealing ring before inserting.

– Insert oil seal in brake caliper housing.
– Place protective cap on piston.
– Using equal pressure, push piston into brake caliper housing.

The protective cap should locate securely in the groove. If not,
use piston resetting tool to push piston in slightly.
2. Repairing rear brake calipers 75

3 Pressurised leak test

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

♦ or
♦ Adapter M8 - V.A.G 1310/13-
♦ or
♦ Adapter M7 - V.A.G 1310/1-
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 brake system tester - V.A.G 1310 A- with corre‐
sponding adapter 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.

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
♦ Do not under any circumstances allow brake fluid to come into

contact with fluids that contain mineral oils (e.g. oil, petrol,
cleaning agents). Mineral oils damage the seals and packings
in the brake system.
♦ 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.
♦ Do not reuse drained (used) brake fluid.
♦ Always observe the relevant environmental regulations for
disposal
A pre-pressure of 2 bar is required for bleeding the hydraulic unit.

Producing service flap to bleed brakes.
– Observe additional notes ⇒ Maintenance ; Booklet ; Changing
brake fluid .
– Clear plenum chamber cover so that the marked areas are
visible.
– Cut positions as marked -arrow-.
4.1 Bleeding brake system with brake filling

and bleeding equipment - VAS 5234-
4. Bleeding brake system 77

♦ Brake filling and bleeding equipment - VAS 5234-
♦ Tool set for brake bleeding - VAS 6564-
WARNING
Only use new brake fluid conforming to VW standard

(VW 501 14).
4.1.1 Bleeding (normal):

Adhere strictly to work sequence when bleeding brake system.
♦ Brembo brake calipers have two bleed valves. Always bleed
brake calipers at both bleed valves.
♦ Bleed outer bleed valve first.
– Connect brake filling and bleeding equipment - VAS 5234- .
– Open bleeder valves in specified order and bleed brake cali‐
pers.
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear right brake caliper
4 - Rear left brake caliper
Use suitable bleeder hose. It must sit tightly on bleeder valve so
that no air can enter brake system.
– Leave brake caliper bleed valves open until, with bleed hoses
still fitted, brake fluid discharges free of air bubbles.
4.1.2 Subsequent bleeding

Carry out subsequent bleeding when:
♦ brake pedal travel is too long or so-called »soft brake pedal«

♦ in vehicles with EDL, EDL/TCS or EDL/TCD/ESP a chamber

in the brake fluid reservoir is completely empty. This occurs
e.g. in the case of brake system leaks.
Subsequent bleeding requires the assistance of a second me‐
chanic:
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper.
– Fully depress brake pedal.
– Close bleed valve with pedal held down.
– 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 right brake caliper
4 - Rear left 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 ; Changing brake fluid
4. Bleeding brake system 79

5 Assembly overview - brake servo/brake master cylinder
Note
Use only new brake fluid. Observe information on brake fluid reservoir!
I - All models
II - Vacuum pump for brakes - V192- for hybrid models
⇒ page 84 .
1 - Brake pedal
⇒ page 63
❑ Separating brake pedal
from brake servo
⇒ page 62
❑ Clip brake pedal to
brake servo ⇒ page 63 .
KA) .
2 - Pedal cluster mounting
bracket
3 - Self-locking hexagon nut,
23 Nm
❑ Always renew after re‐
moving.
4 - Seal
❑ For brake servo.
5 - Brake servo
❑ On petrol engines, the
required vacuum is tak‐
en from the intake mani‐
fold.
❑ Hybrid vehicles with a
petrol engine are equip‐
ped with an electric vac‐
uum pump for the
brakes.
❑ 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 medium 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 88

6 - Sealing ring
7 - Torx bolt, 5 Nm
8 - Clip
9 - Brake light switch - F-
10 - Self-locking hexagon nut, 23 Nm
11 - Brake master cylinder
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Secondary piston circuit of brake master cylinder to hydraulic unit ⇒ page 14 .
❑ Primary piston circuit of brake master cylinder to hydraulic unit ⇒ page 14 .
14 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
15 - Brake fluid level warning contact - F34-
16 - Stud, 8 Nm
17 - Cap
18 - Brake fluid reservoir
19 - Pressure sensor
❑ Brake servo pressure sensor - G294- , hybrid.
❑ Vacuum sender - G608- V8 FSI
❑ Removing and installing on right-hand drive models ⇒ page 87
20 - Vacuum hose
❑ Fit in brake servo.
❑ Removing and installing on right-hand drive models ⇒ page 87
21 - Sealing plug
❑ Connection for vacuum hose.
5.1 Removing and installing brake light

switch - F- , left-hand drive
5.1.1 Removing
– Remove left plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50 ; Plenum chamber cover .
– Pull off engine compartment seal in vicinity of brake servo.
– Remove left plenum chamber bulkhead ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Plenum chamber bulkhead .
– Pull E-box out of retainer in plenum chamber and lay to side
⇒ Electrical system; Rep. gr. 97 ; E-boxes .
5. Assembly overview - brake servo/brake master cylinder 81

– Unscrew securing bolts -arrows- and remove cover of con‐

nection and distribution box 2 - SX2- .
– Disconnect all multi-pin connectors, depends on equipment
installed.
– Pull front wiring harness out of plenum chamber bulkhead and
place as far as possible to side together with E-box.
– Pull connector -2- off brake light switch - F- -1-.

– Unscrew Torx bolt from brake master cylinder.
– Pull brake light switch - F- -1- off top of brake master cylinder,
then from clip at bottom.
5.1.2 Installing
– Check function of brake light.
Specified torque:
Torx bolt to brake master cylinder 5 Nm
5.2 Removing and installing brake light

switch - F- , right-hand drive
5.2.1 Removing
– Remove right plenum chamber cover ⇒ General body repairs,
– Release and pull connector -2- off brake light switch - F- -1-.
– Unscrew bolt from brake master cylinder.
– Pull brake light switch - F- -1- off top of brake master cylinder,
then from clip at bottom.
5.2.2 Installing
– Install in reverse order. Note the following points:

– Insert brake light switch - F- -1- into clip on top of brake master
cylinder and fit bolt.
– Check function of brake light.
Specified torque
Component Specified torque
Brake light switch - F- to brake master cylinder 5 Nm
5. Assembly overview - brake servo/brake master cylinder 83

6 Brake servo vacuum supply
6.1 Overview - vacuum pump for brake ser‐

vo (diesel vehicles)
Vacuum pump for 6-cyl. diesel engine:
Must not be dismantled.
Vacuum pump -2-
Vacuum hose to brake servo -3- with non-return valve.
– Removing and installing vacuum pump ⇒ 6-cylinder diesel
engine (3.0 l engine, common rail); Rep. gr. 15 .
Vacuum pump for 8-cyl. diesel engine:
Must not be dismantled.
Vacuum pump is installed on right cylinder bank.
– Removing and installing vacuum pump ⇒ 8-cylinder diesel
engine (4.2 l engine, common rail); Rep. gr. 15 ; Cylinder
head, valve gear .
6.2 Assembly overview - vacuum pump for

brakes - V192-
For hybrid models

1 - Vacuum pump for brakes -

V192-
❑ Location ⇒ page 85
⇒ page 85 .
2 - Lower buffer
3 - Buffer
4 - Hexagon nut, 7 Nm
5 - Hose retainer
6 - Bracket
7 - Vent hose.
8 - Torx bolt, 8 Nm
❑ Coolant pipe to bracket.
9 - Torx bolt, 9 Nm
❑ Bracket to bracket.
10 - Clip
❑ Vent hose.
12 - Clip with cable tie
13 - Sleeve
14 - Vacuum hose
❑ To vacuum pump for
brakes - V192- .
15 - Brake servo pressure sen‐
sor - G294-
16 - Non-return valve
17 - Vacuum hose
❑ To brake servo.
18 - Brake servo relay - J569-
❑ Location: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
Location: vacuum pump for brakes -V192-

1- Vacuum pump for brakes - V192-
2- Bracket
6.2.1 Removing and installing vacuum pump

for brakes - V192-
No provision is made for repairs to vacuum pump for brakes -
V192- . If a fault occurs, the vacuum pump for brakes - V192- must
be renewed.
6. Brake servo vacuum supply 85

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Release vacuum hose -A- and pull off -arrow-.
– Unclip wiring harness from retainer -C- and lay to side.

– Release connector -B- from vacuum pump for brakes - V192-
and disconnect.
– Take lower part of connector out of retainer.
– Unscrew coolant pipe securing bolt -1- from retainer.

– Unscrew securing bolts from retainer -2- on bracket, move
coolant lines lightly back and forth for this.
– Remove vacuum pump for brakes - V192- together with brack‐
et.
Installing
Specified torques:
Torx bolt, bracket to bracket 9 Nm
Torx bolt, coolant pipe to bracket 8 Nm

6.3 Removing and installing vacuum line

with vacuum sender - G608- , right-hand
drive model
– Open clamp -1- and remove suction line.
– Remove bolts -arrows- for coolant expansion tank -1-.

retainer.
Note
– Remove nuts -arrows- and remove bracket -1-.

– Place bracket -1- with lines to one side.
– Remove star disc -arrow B-.

– Unclip coolant hose -1- from retainer -arrow A-.
– Remove right plenum chamber bulkhead ⇒ General body re‐

– Pull vacuum line off separating point -arrow- by pressing re‐

lease buttons.
– Pull vacuum line -1- out of brake servo unit.
– Cover engine compartment in area of engine control unit -

J623- , to prevent scratching of paintwork.
– Remove bolts -1- and remove engine control unit - J623- up‐
wards.
– Release and pull connector off vacuum sender - G608- .
– Guide vacuum line with vacuum sender - G608- out to right
Remove vacuum sender - G608- from vacuum line
– Release clip with a pair of pliers -1-.

– Carefully lever vacuum sender - G608- -2- downwards.
Installing
Install in reverse order. Note the following points:
– Make sure seals are correctly seated.
Specified torque
Components Specified torque
Coolant expansion tank to body 9 Nm
Engine control unit - J623- to body 9 Nm
6.4 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-
6.4.1 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.
6.4.2 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 89 .
– 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).
– 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 92 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

6.4.3 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 89 .
– 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).
– 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.
6.4.4 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.
6.5 Checking non-return valve

Air must pass through valve in direction of arrow.
Valve must remain closed in opposite direction.
Observe correct installation position.

7 Removing and installing brake mas‐

ter cylinder
7.1 Removing and installing brake master

cylinder, left-hand drive
7.1.1 Removing
– Pull connector off brake fluid level warning contact - F34- .
– Place sufficient lint-free cloths in plenum chamber in the area
of the brake master cylinder.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding unit - VAS 5234- or
extraction unit upgrade set - V.A.G 1869/4- .
– Pull brake line out of retainer in plenum chamber.
– Unscrew brake lines -A and B- from brake master cylinder.

– Seal brake lines and brake master cylinder using sealing plugs
- 1H0 698 311 A- from repair kit.
– Unscrew brake master cylinder nuts.
– Carefully take brake master cylinder out of brake servo.
7.1.2 Installing
7. Removing and installing brake master cylinder 93

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.
Sealing ring between brake master cylinder and brake servo is
fitted.
Specified torques:
Brake master cylinder to brake servo 23 Nm
♦ Use new nuts.
Brake lines to brake master cylinder 18 Nm
7.2 Removing and installing brake master cylinder, right-hand drive vehicle
Special tools and workshop

equipment required
♦ Sealing tool - T10249-
♦ Torque wrench - V.A.G
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-

7.2.1 Removing

retainer.
Note


ervoir using brake filling and bleeding equipment - VAS 5234- .

– Unclip brake line -1- from retainers -arrows-.
– Unscrew brake lines from brake master cylinder -A- and -B-.

– Release and pull off connector from brake fluid level warning
contact - F34- -2-.
– Unscrew nut -arrow- on brake servo.

– Remove bolt -arrow- and remove brake fluid reservoir -1- from
brake master cylinder -2-.
– Remove nut -arrow-.

– Carefully take brake master cylinder -1- off brake servo -2-.
7.2.2 Installing
cylinder.
Coat sealing plugs with brake fluid before pressing brake fluid
reservoir into brake master cylinder.
Specified torque
♦ Use new nuts.

Brake fluid reservoir to brake master cylinder 8 Nm

8 Removing and installing brake servo
8.1 Removing and installing brake servo,

left-hand drive
8.1.1 Removing
– Pull E-box out of retainer in plenum chamber and lay to side
⇒ Electrical system; Rep. gr. 97 ; E-boxes .
– Unscrew securing bolts -arrows- and remove cover of con‐
nection and distribution box 2 - SX2- .
– Disconnect all multi-pin connectors, depends on equipment
installed.
– Pull front wiring harness out of plenum chamber bulkhead and
place as far as possible to side together with E-box.
– Remove retaining pins in plenum chamber for E-box.

– Pull connector off brake fluid level warning contact - F34- .
ervoir using brake filling and bleeding equipment - VAS 5234-
or extraction unit - V.A.G 1869/4- .
– Pull brake line out of retainer in plenum chamber.

– Unscrew brake lines -A and B- from brake master cylinder.

– Pull vacuum hose out of brake servo.
– Separate brake pedal from brake servo ⇒ page 62 .
– Unscrew nuts -arrows- from brake servo.

– Carefully remove brake servo from plenum chamber.
– Unscrew brake master cylinder from brake servo.
8.1.2 Installing
Observe following points when installing:
Clip 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.
Specified torques:
Brake servo to pedal cluster and plenum chamber 23 Nm
bulkhead
♦ Use new nuts.

♦ Use new nuts.
8.2 Removing and installing brake servo, right-hand drive vehicle
8. Removing and installing brake servo 99

Special tools and workshop

equipment required
♦ Sealing tool - T10249-
♦ Torque wrench - V.A.G
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-
8.2.1 Removing


retainer.
Note


ervoir using brake filling and bleeding equipment - VAS 5234- .
– Unclip brake line -1- from retainers -arrows-.

– Unscrew brake lines from brake master cylinder -A- and -B-.

– Release and pull off connector from brake fluid level warning
contact - F34- -2-.
– Unscrew nut -arrow- on brake servo.
– Remove bolt -arrow- and remove brake fluid reservoir -1- from
brake master cylinder.

– Remove nut -arrow-.

– Carefully take brake master cylinder -1- off brake servo -2-.
– Detach brake servo from brake pedal ⇒ page 62 .
– Unscrew nuts -arrows- from brake servo.

– Carefully remove brake servo from plenum chamber.
8.2.2 Installing
– Carefully insert brake servo and tighten nuts.
– Clip brake pedal to brake servo ⇒ page 63 .
cylinder.
Coat sealing plugs with brake fluid before pressing brake fluid
reservoir into brake master cylinder.
Specified torque
Brake servo to pedal cluster and plenum chamber 23 Nm
bulkhead
♦ Use new nuts.

♦ Use new nuts.

Brake fluid reservoir to brake master cylinder 8 Nm

9 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 vehicle floor.
♦ 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:
Item Tool Tool number
1 Flanging tool (incl. flanging jaws VAS 6056/1
VAS 6056/6)
2 Pipe cutter VAS 6056/2
3 Brake line scraper1) VAS 6056/3
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
1) Grub screws (in shaft and at side) are adjusted and must not be readjusted!
9.1 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 105
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.
9.2 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.
9. Repairing brake lines 105

– 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 position 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.
– Withdraw scraper from brake line and remove residue from
scraping.
– 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-.

– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Loosen hexagon socket head bolts diagonally.
– Remove brake line from flanging tool, clean and check brake
line and flange.
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.
9. Repairing brake lines 107

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Service

Service Department. Technical Information

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

5.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 Example of a vehicle data sticker

1.2 Front brakes

3.0l - 235; 245 kW FSI 1LG / 1LW Brembo (18")

1.3 Rear brakes

1. Brake allocation via PR No. 1

3.0l - 235; 245 kW FSI

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

2 Rep. gr.00 - Technical data

2.1 Brake master cylinder and brake servo

2.2 Front brakes

2.2.2 Front brake, Brembo (18")

2.3 Rear brakes

2.3.2 Parking brake (17" brake drum)

4 Rep. gr.00 - Technical data

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

3.2 Testing vehicles with no electric differ‐

3.3 Testing vehicles with electric differential

3.4 Testing the electromechanical parking

3.4.1 Vehicles with no electric differential lock:

Entering »TÜV mode« is indicated by the yellow electric parking

6 Rep. gr.00 - Technical data

45 – Anti-lock brake system

1. General notes for anti-lock brake system (ABS) 7

2 Notes for repair work on the ABS

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

3 Connecting -VAS 5051- and select‐

♦ Diagnosis cable - VAS 5051/1- or -VAS 5051/3-

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

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

3. Connecting VAS 5051 and selecting functions 9

– Switch on tester -arrow-.

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

4 Electrical/electronic components and locations

1 - ABS control unit - J104-

4. Electrical/electronic components and locations 11

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

5 Assembly overview - hydraulic unit

1 - ABS control unit - J104-

5. Assembly overview - hydraulic unit 13

Connecting brake lines from brake master cylinder to hydraulic

5.1.1 Removing and installing control unit

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

♦ Torque wrench - V.A.G 1783-

– Unscrew fuel filter -arrows-, do not disconnect fuel lines, place

– Disconnect connector for air suspension, unscrew securing

5. Assembly overview - hydraulic unit 15

Continuation for all vehicles

Do not pull off coolant hoses.

– Thoroughly clean control unit, hydraulic unit and surrounding

– Release control unit connector -arrow 1- and pull off

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

♦ Do not use aggressive cleaning agents (use enclosed clean‐

No moisture or particles of dirt may enter control unit.

♦ Use new bolts.