VW Polo 5 2010 Brake Systems Eng

Service
Workshop Manual
Polo 2010 ➤
Brake systems
Edition 07.2013
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.
Polo 2010 ➤
Brake systems - Edition 07.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Test for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 General notes for anti-lock brake system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Bosch 8.2 and 9.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Bosch 8.2; 9.0 ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Assembly overview - hydraulic unit, brake booster/brake master cylinder . . . . . . . . . . . . . . 17
6.1 Bosch 8.2; 9.0 ABS, LHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Bosch 8.2; 9.0 ABS, RHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP, LHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP, RHD vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 56
7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2 Removing and installing parts of anti-lock brake system on rear axle (drum brakes) . . . . 57
7.3 Removing and installing parts of anti-lock brake system on rear axle (disc brakes) . . . . . . 59
8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.1 Removing and installing yaw rate sender G202 and lateral acceleration sender G200 . . 62
8.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Repairing front brakes, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing brake pads, brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.3 Removing and installing brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Repairing front brakes, FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.5 Removing and installing brake pads, brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.6 Removing and installing brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Repairing rear brakes (drum brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.1 Removing and installing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.2 Resetting brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.3 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.4 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Repairing rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.2 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents i
Polo 2010 ➤
4.1 Removing and installing handbrake cable (drum brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.2 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3 Removing and installing handbrake cable (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.4 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.1 Assembly overview - brake pedal, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2 Assembly overview - brake pedal, right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.1 Repairing FS III brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.2 Removing and installing brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.3 Repairing FN 3 brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.4 Removing and installing brake caliper piston FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2 Repairing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.1 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234 . . . . . . . . . . 114
4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5 Assembly overview - brake booster/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . 117
5.1 Assembly overview - brake booster/brake master cylinder (left-hand drive vehicle) . . . . . . 117
5.2 Assembly overview - brake booster/brake master cylinder (right-hand drive vehicle) . . . . 118
5.3 Vacuum pump for brake booster (vehicles with diesel engine) . . . . . . . . . . . . . . . . . . . . . . 120
5.4 Checking brake booster vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.5 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.6 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.7 Removing and installing brake booster pressure sensor G294 . . . . . . . . . . . . . . . . . . . . . . 126
5.8 Removing and installing brake light switch F , left-hand drive . . . . . . . . . . . . . . . . . . . . . . 127
5.9 Removing and installing brake light switch F , right-hand drive . . . . . . . . . . . . . . . . . . . . . . 127
6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.1 Removing and installing brake master cylinder, left-hand drive . . . . . . . . . . . . . . . . . . . . . . 129
6.2 Removing and installing brake master cylinder, right-hand drive vehicle . . . . . . . . . . . . . . 130
7 Removing and installing brake booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.1 Removing and installing brake booster, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.2 Removing and installing brake booster, right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . 137
8 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ii Contents
Polo 2010 ➤
00 – Technical data
1 Brake allocation via PR No.
(VRL005901; Edition 07.2013)
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.
Note
Information on the individual brake that is fitted is currently not

available on the vehicle data sticker.
– To find information about the brake, please search in ELSA/

Vehicle-specific notes.
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes - 1KU
♦ Arrow 2 - Front brakes - 1LJ
The vehicle data sticker can be found in the spare wheel well and
in the service schedule.
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) .
1.1 Front brakes

Engine PR No. Front brakes
1.2l - 44 kW 1LR / 1ZG FS III (14”)
1.2l - 51 kW
1.2l - 66 kW
1.2l - 77 kW TSI 1)
1.4l - 63 kW
1.2 l; 1.6 l - 55 kW TDI
1.6l - 66 kW TDI
1.6l - 77 kW TDI 1ZC FN3 (15”)
1.2l - 77 kW TSI 2)
1.4 l - 103 kW TSI
1.4l - 125; 132 3) kW 1ZD FN3 (15”)
TSI
1.4l - 132 kW TSI 4) 1ZR FN3 (16”)
2.0 l - 162 kW TSI 1ZP
1) Worldwide and Europe up to Week 22/2012
2) Europe as of Week 22/2012
3) up to CW 45/2012
4) from CW 45/2012
Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Brake allocation via PR No. 1

Polo 2010 ➤
1.2 Rear brakes
1.2.1 Disc brakes

Engine PR No. Rear brakes
1.2l - 66 kW 1KT C 38 (15”)
1.2l - 77 kW TSI
1.4 l - 63 kW1)
1.6l - 66 kW TDI
1.6l - 77 kW TDI
1.4 l - 103 kW TSI
1.4l - 125; 132 kW TSI 1KV C 38 (15”)
2.0 l - 162 kW TSI 1KD CI 38 (16”)
1) up to CW 22/2010, as of CW 22/2012
1.2.2 Drum brakes

Engine PR No. Rear brakes
1.2 I - 44 kW 1KM TB 200 X 40
1.2l - 51 kW
1.4 l - 63 kW1)
1.2 l; 1.6 l - 55 kW
TDI
1) as of CW 22/2010, up to CW 22/2012
2 Rep. gr.00 - Technical data

Polo 2010 ➤
2 Technical data for brakes
2.1 Brake master cylinder and brake boos‐

ter
Brake master cylinder ∅ in mm 22.22
Brake master cylinder ∅ in mm 23.81
16" brake
Brake booster (LHD) ∅ in inches 10
Brake booster (RHD) ∅ in inches 7/8
2.2 Front brakes

2.2.1 Front brakes FS III
Item PR No. 1LR / 1ZG
1 Brake caliper FS III (14”)
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 256
mm
Brake disc, mm 22
thickness
Brake disc, mm 19
wear limit
4 Brake caliper ∅ in 54
piston mm
2.2.2 Front brakes FN 3

Front brake FN3 15":
Item PR No. 1ZC / 1ZD
1 Brake caliper FN3 (15”)
2 Brake pad, mm 14
thickness
limit without
backplate
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
4 Brake caliper ∅ in 54
piston mm
2. Technical data for brakes 3

Polo 2010 ➤
Front brake FN3 16":

Item PR No. 1ZR / 1ZP
1 Brake caliper FN3 (16”)
2 Brake lining, mm 14
thickness
limit without
backplate
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
4 Brake caliper, ∅ in 54
piston mm
2.3 Rear brakes

2.3.1 Rear brake (drum brake)
Item PR No. 1KM
1 Wheel brake mm 19.05
cylinder
width
Brake pad, mm 5
thickness
Brake lining, mm 2.5
minimum thick‐
ness
3 Brake drum ∅ in 200
mm
Brake drum, ∅ in 201.5
wear limit mm

Polo 2010 ➤
2.3.2 Rear brakes (disc brakes)

Item PR No. 1KT / 1KV
1 Brake caliper C 38 (15”)
2 Brake pad, mm 12
thickness
Brake pad, mm 2
wear limit with‐
out backplate
3 Brake disc ∅ in mm 232
Thickness mm 9
Wear limit mm 7
4 Piston ∅ in mm 38
Item PR No. 1KD

1 Brake caliper CI 38 (16”)
thickness
Brake pad, mm 2
wear limit with‐
out backplate
3 Brake disc Diameter in 254
mm
Thickness mm 22
Wear limit mm 20
4 Piston Diameter in 38
mm
2. Technical data for brakes 5

Polo 2010 ➤
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 test, observe specifications provided by manufacturer of
roller dynamometer.
Note
The brake regulation systems do not function when ignition is off.
3.2 Test for vehicles with front-wheel drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.

Polo 2010 ➤
45 – Anti-lock brake system

1 General notes for anti-lock brake sys‐
tem (ABS)
1.1 Bosch 8.2 and 9.0

The following configurations are possible on vehicles with the
ABS Bosch 8.2 and 9.0:
♦ ABS
♦ ABS/EDL/TCS/ESP
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
ABS layout in left-hand drive vehicle:
1 - Hydraulic unit and control unit
2 - Brake booster
ABS layout in right-hand drive vehicle:

1 - Brake booster
2 - Hydraulic unit and control unit
1. General notes for anti-lock brake system (ABS) 7

Polo 2010 ➤
The hydraulic unit -2- and control unit -1- form one component.
Hydraulic pump -3- must not be separated from hydraulic unit.
8 Rep. gr.45 - Anti-lock brake system

Polo 2010 ➤
2 Notes for repair work on anti-lock

brake system
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault using “Guided Fault Finding”.
“Guided fault finding” is carried out on the vehicle diagnosis, test‐
ing and information system - VAS 5051- .
♦ Disconnect battery earth strap with ignition switched off.
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 114 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- or -V.A.G 1869- ⇒ page 114 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating control unit from hydraulic unit, use transport
protection for contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1 H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours). Ensure that no brake fluid enters connectors.
2. Notes for repair work on anti-lock brake system 9

Polo 2010 ➤
3 Connecting -VAS 5051- and select‐

ing functions
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system - VAS
5051-
♦ Diagnostic 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.
– Plug in connector of diagnostic cable -VAS 5051/1- or -

VAS 5051/3- at diagnostic connection -arrow-.

Polo 2010 ➤
– Switch on tester -arrow-.

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

Polo 2010 ➤
4 Electrical/electronic components and

locations
4.1 Bosch 8.2; 9.0 ABS
1 - ABS control unit - J104-

❑ Location: on the hy‐
draulic unit on right in
engine compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Removing and installing
⇒ page 17 .
2 - ABS hydraulic unit - N55-
The hydraulic unit consists of
the components:
❑ ABS return flow pump -
V39-
❑ Valve block (contains in‐
let and outlet valves).
V39- and valve block
should not be separated
from each other
⇒ page 17 .
3 - ABS warning lamp - K47-
❑ Location: in dash panel
insert.
Function: ⇒ page 15 .
4 - Brake system warning lamp

- K118-
insert.
5 - Diagnostic connection
❑ Location: Driver footwell cover.
6 - Brake light switch - F-
❑ Including brake pedal switch - F47- .
❑ Removing and installing ⇒ page 127 .
7 - Front right/left speed sensor -G45- / -G47-
8 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
9 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing (disc brakes) ⇒ page 61

Polo 2010 ➤
❑ Removing and installing (drum brakes) ⇒ page 59
4.2 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP

❑ Location: on the hy‐
draulic unit on right in
engine compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
The following components are
integrated into the control unit:
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
⇒ page 35 .
The hydraulic unit consists of
the components:
V39-
❑ Brake pressure sender -
G201-
❑ Valve block (contains in‐
let and outlet valves).
from each other
⇒ page 35 .
3 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
4 - ESP and TCS warning lamp - K155-

5 - Brake system warning lamp - K118-
4. Electrical/electronic components and locations 13

Polo 2010 ➤

7 - TCS and ESP button - E256-
8 - Diagnostic connection
❑ Location: Driver footwell cover.
9 - Steering angle sender - G85-
❑ Location: on steering column between steering wheel and steering column switch.
❑ Observe installation instructions.
⇒ page 62
10 - Front right/left speed sensor -G45- / -G47-
12 - Rear right/left speed sensor -G44- / -G46-

Polo 2010 ➤
5 Fault display via warning lamps

Warning lamps
Item Description
1 ABS warning lamp - K47-
2 ESP warning lamp - K155-
3 Brake system warning lamp - K118-
ABS warning lamp - K47-
♦ If the ABS warning lamp - K47- -1- does not go out after the
ignition has been switched on and test sequence has been
completed, then the fault may be:
-a- The voltage supply is below 10 volts.
-b- There is a fault in the ABS.
In the event of an ABS fault -b-, the anti-lock brake system re‐
mains switched off, but the brake system remains fully operation‐
al.
-c- A temporary speed sensor fault occurred since the vehicle was
last started.
In the event of a speed sensor fault -c-, the ABS warning lamp -
K47- will extinguish automatically after restarting the engine and
attaining a speed of above 2.75 km/h.
-d- The connection from dash panel insert to ABS control unit -
J104- is interrupted. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
ABS warning lamp - K47- and brake system warning lamp - K118-
♦ If the ABS warning lamp - K47- -1- goes out but the brake
system warning lamp - K118- -3- remains on, the causes of
the fault may be:
-a- The handbrake is applied.
-b- The brake fluid level is too low.
-c- There is a fault in the activation of the brake system warning
lamp - K118- . ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
♦ If the ABS warning lamp - K47- -1- and the brake system
warning lamp - K118- -3- light up, the anti-lock brake system
and the EBPD (electronic brake pressure distribution) system
have failed.
WARNING
After the ABS warning lamp - K47- and the brake system warn‐
ing lamp - K118- have lit up, it is possible that the rear wheels
will lock up earlier.
ESP warning lamp - K155-

Only in vehicles with ESP.
5. Fault display via warning lamps 15

Polo 2010 ➤
♦ If the ESP and TCS warning lamp - K155- -2- does not go out
after ignition is switched on and the test sequence has been
completed, then the fault may be:
-a- Short-circuit to positive in TCS and ESP button - E256- .
-b- There is a fault in the activation of the ESP and TCS warning
lamp - K155- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
-c- The TCS/ESP system was switched off by the TCS and ESP
button - E256- .
A fault in the system affecting only the TCS/ESP. The ABS/EDL
and EBD safety systems on the vehicle remain fully functional ⇒
Read fault memory.
If the ESP warning lamp - K155- flashes while the vehicle is in
motion, the TCS or ESP is in operation.

Polo 2010 ➤
6 Assembly overview - hydraulic unit,

brake booster/brake master cylinder
6.1 Bosch 8.2; 9.0 ABS, LHD vehicles

ABS hydraulic unit -
N55- with ABS control
unit - J104-
⇒ page 20 .
from each other
❑ When changing the hy‐
draulic unit, always seal
the old part with the
plugs from the repair set
Part No. 1H0 698 311 A.
unit - J104-
⇒ page 20 .
3 - Connection for brake line
❑ From hydraulic unit to
front right brake caliper.
❑ Marked on hydraulic
unit with -VR-.
❑ To rear left brake cali‐
per/wheel brake cylin‐
der
unit with -HL-.
❑ To rear right brake cali‐
der Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Marked on hydraulic unit with -HR-.
❑ From hydraulic unit to front left brake caliper.
❑ Marked on hydraulic unit with -VL-.
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
❑ Marked on hydraulic unit with -HZ1-.
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
6. Assembly overview - hydraulic unit, brake booster/brake master cylinder 17

Polo 2010 ➤
9 - Seal
❑ For brake booster.
10 - Brake booster
11 - Self-locking hexagon nut, 25 Nm
12 - Sealing ring
❑ Renew.
14 - Brake master cylinder
❑ Cannot be repaired. If faulty, renew as a complete unit.
15 - Securing pin for brake fluid reservoir
❑ Insert through brake master cylinder
16 - Sealing plug
❑ Moisten with brake fluid and press into brake master cylinder.
17 - Sealing plug
❑ Connection for vacuum hose.
18 - Brake fluid reservoir
19 - Cap
21 - Bracket
❑ For Bosch 8.2 ABS
❑ For bracket for Bosch 9.0 ABS refer to ⇒ Electronic Parts Catalogue “ETKA”
22 - Pin, 8 Nm
❑ Bolt and washer assembly for Bosch 9.0 ABS, 8 Nm
6.1.1 Connecting brake lines from brake mas‐

ter cylinder to hydraulic unit
On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
2 - Hydraulic unit to rear left brake caliper/wheel brake cylinder
3 - Hydraulic unit to rear right brake caliper/wheel brake cylinder
4 - From hydraulic unit to front left brake caliper.

Polo 2010 ➤
On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder
- Marked on hydraulic unit with -HZ1-.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
1 - From hydraulic unit to front right brake caliper.
- Marked on hydraulic unit with -VR-.
- Marked on hydraulic unit with -HL-.
- Marked on hydraulic unit with -HR-.
- Marked on hydraulic unit with -VL-.

Polo 2010 ➤
6.1.2 Removing control unit and hydraulic unit

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1331-
♦ Brake pedal depres‐

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

Part No. 1H0 698 311 A
Location:
The control unit is bolted
to the hydraulic unit and
is located on right in the
engine compartment.
WARNING
Do not bend the brake

lines in the area of the
hydraulic unit!
Removing:
– Read out and note
the existing control
unit code.
– Note or request radio
code on vehicles with
coded radio if neces‐
sary.
– Disconnect battery ⇒
Electrical system;
Rep. gr. 27 ; Discon‐
necting and recon‐
necting battery .

Polo 2010 ➤
Additional work on fol‐

lowing engines:
4-cyl. injection engine,
toothed belt drive:
– Pull hose off non-re‐
turn valve to cam‐
shaft housing.
– Remove intake hose
and pull air filter
housing upwards off
pivot pins ⇒ 4-cyl. in‐
jection engine, tooth‐
ed belt drive; Rep. gr.
24 .
– .
4-cylinder diesel engine
(1.6 l engine, common
rail):
– Remove wiper arms
⇒ Electrical system;
Rep. gr. 92 ; Window
wiper system; Re‐
moving and installing
window wiper sys‐
tem .
– Remove plenum
chamber cover ⇒
General body repairs,
exterior; Rep. gr. 50 .
– Pull engine cover
panel up out of brack‐
ets.
– Disconnect all connectors for electrical wires -1 to 4- to diesel

particulate filter and to lambda probe.
– Then remove bracket along with connectors from plenum
chamber bulkhead and lay to side.
– Remove intake hose and air filter housing.
– Take engine control unit out of bracket and lay to side.
– Remove bracket for engine control unit.
– Remove insulation from plenum chamber bulkhead.
– Remove plenum chamber bulkhead ⇒ General body repairs,
Continuation for all models:

Polo 2010 ➤
– Press red locking slide -arrow- down.
– Release control unit connector -arrow - and pull off forwards.
– 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.

Polo 2010 ➤
– Connect bleed bottle bleed hose -1- to bleed valve of rear left
brake caliper/wheel brake cylinder.
– Depress brake pedal at least 60 mm 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.
– Mark brake lines from hydraulic unit -A and B- to brake master
cylinder.
– Then unscrew brake lines from hydraulic unit and from brake
master cylinder, unclip from retainers and lay to side.
– Immediately seal brake lines and threaded holes with seal
plugs from repair set Part No. 1H0 698 311 A.
– Mark remaining brake lines (to brake calipers) -1 to 4-, un‐
screw from hydraulic unit and seal.
Bosch 8.2 ABS:
– Pull hydraulic unit with control unit upwards out of dampers.

– If necessary, loosen hexagon nuts -1- of bracket and remove
bracket.
Bosch 9.0 ABS:

Polo 2010 ➤
– Pull hydraulic unit and control unit -1- together with bracket
-2- upwards in -direction of arrow-.
– The rubber dampers -arrows- will be pulled off the studs of the
bracket -3-.
– Remove ABS unit from vehicle.
– If necessary, unbolt bracket -2- beforehand.
6.1.3 Unscrewing control unit from hydraulic

unit
♦ ESD workplace - VAS 6613-
♦ If a control unit is defective, the control unit must be discon‐
nected from the hydraulic unit and only the control unit re‐
newed.
♦ If the hydraulic unit is defective, the hydraulic unit must be re‐
newed together with the control unit.
WARNING
♦ Return flow pump must not be separated from hydraulic

unit.
♦ Printed circuit board becomes visible when control unit is
removed.
♦ No moisture or particles of dirt may enter control unit.
♦ Avoid electrostatic charge!
This electrostatic charge can cause malfunctions if you touch

electric components.
– Before working on electric components, touch an earthed ob‐
ject ESD workplace - VAS 6613- . Do not directly touch con‐
nector contacts or electronic components.
– Set hydraulic unit with control unit on top on ESD workplace -
VAS 6613- .
– Remove external Torx screws -arrows- from control unit.
– Taking care not to cant control unit, pull it off hydraulic unit.
– Cover solenoids of control unit with a lint-free cloth.
– Check cleanliness of hydraulic unit sealing surface; clean with
methylated spirits and a lint-free cloth if necessary.
Hydraulic unit sealing surface must not be processed with a file,
metal scraper, sandpaper or similar.
If hydraulic unit sealing surface is damaged (e.g. scoring, scratch‐
es), hydraulic unit must be renewed together with control unit.
After separating control unit and hydraulic unit, use transport pro‐
tection for contact pins.

Polo 2010 ➤
6.1.4 Installing new control unit

♦ Torque screwdriver - V.A.G 1624-
♦ External Torx bit E6
WARNING
Severe shocks (e.g. dropping, impact) may destroy control

unit. Control unit must not then be used.
• Clean surfaces before assembling.

– Without canting it, place control unit onto hydraulic unit.
– Tighten hydraulic unit and control unit diagonally in three
stages to specified torque with enclosed new Torx bolts.
The hydraulic unit's threads for securing the control unit must not
be recut. If the threads are damaged (bolts difficult to turn in by
hand or cannot be tightened to the specified torque), hydraulic
unit must be renewed.
Specified torque in three stages:
Use new bolts!
Stage 1: position and centre control unit; screw in -
Torx bolts until Torx bolts contact housing.
Stage 2: Seat sealing lugs evenly on all sides and 1.5 to
tighten initially. 2 Nm
Stage 3: Final tightening to specified torque. 3 Nm
Note
Max. 5 repeated bolting processes (hydraulic unit/control unit) are

permissible throughout the entire hydraulic unit's service life.

Polo 2010 ➤
6.1.5 Installing control unit and hydraulic unit
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ When installing, ensure that rubber dampers are not pressed
out of bracket.
– Continue installation in reverse order.

– Remove brake pedal depressor - V.A.G 1869/2- .
– Bleed brake system ⇒ page 114 .
– Code ABS control unit - J104- with ⇒ Vehicle diagnostic tester
in “Guided fault finding”.
– Code radio.
Specified torques:
Pin to hydraulic unit 8 Nm
Hexagon nut to body 20 Nm
Brake lines to ABS unit:
Thread M10 x 1 14 Nm
6.2 Bosch 8.2; 9.0 ABS, RHD vehicles

Polo 2010 ➤
1 - Brake booster
⇒ page 137 .
❑ In the case of petrol en‐
gines, the required vac‐
uum is taken from the
intake manifold.
gines with a dual clutch
gearbox, the necessary
vacuum is generated by
the vacuum pump for
brakes - V192- .
❑ Diesel engines are fitted
with a vacuum pump to
create the required vac‐
uum.
❑ Checking function
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust vacuum in unit).
– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake
booster is functioning
properly, the brake ped‐
al will be felt to go down
as the servo takes ef‐
fect.
❑ If faulty, renew com‐
pletely (check all vac‐
uum lines first).
❑ Non-return valve (in
vacuum hose) function‐
al check ⇒ page 124 .
❑ Separating from brake pedal ⇒ page 100
2 - Brake line
❑ ABS hydraulic unit - N55- to rear right brake caliper/wheel brake cylinder.
❑ Marked on hydraulic unit with -HR-.
❑ 14 Nm
3 - Brake line
❑ ABS hydraulic unit - N55- to rear left brake caliper/wheel brake cylinder.
❑ Marking on ABS hydraulic unit - N55- -HL-
❑ 14 Nm
4 - Brake line
❑ ABS hydraulic unit - N55- to front right brake caliper.
❑ Marking on ABS hydraulic unit - N55- -VR-
❑ 14 Nm
❑ Removing and installing ABS hydraulic unit - N55- with ABS control unit - J104- ⇒ page 30 .
❑ ABS return flow pump - V39- and valve block should not be separated from each other
❑ When replacing the hydraulic unit, always seal the old part with plugs - 1H0 698 311 A- .

Polo 2010 ➤
7 - Brake line
❑ ABS hydraulic unit - N55- to front left brake caliper.
❑ Marking on ABS hydraulic unit - N55- -VL-
❑ 14 Nm
8 - Brake line
❑ ABS hydraulic unit - N55- to brake master cylinder/secondary piston circuit
❑ Marking on ABS hydraulic unit - N55- -HZ2-
❑ 14 Nm
9 - Brake line
❑ 14 Nm
10 - Rubber damper
❑ Qty. 3
❑ Do not push rubber dampers out of the bracket when installing the ABS hydraulic unit - N55-
11 - Bracket
❑ For bracket for Bosch 9.0 ABS refer to ⇒ Electronic Parts Catalogue “ETKA”
12 - Nut
❑ 20 Nm
❑ Qty. 3
❑ Always renew after removing.
13 - Pin
❑ For Bosch 8.2 ABS, 8 Nm
❑ Bolt and washer assembly for Bosch 9.0 ABS, 8 Nm

ter cylinder to ABS hydraulic unit - N55-
A - Primary piston circuit of brake master cylinder to ABS hy‐
draulic unit - N55- .
B - Secondary piston circuit of brake master cylinder to ABS hy‐
4 - ABS hydraulic unit - N55- to front right brake caliper.

Polo 2010 ➤
To ABS hydraulic unit - N55- :

A - ABS hydraulic unit - N55- to primary piston circuit of brake
master cylinder
- Marking on ABS hydraulic unit - N55- -HZ1-
B - ABS hydraulic unit - N55- to secondary piston circuit of brake
master cylinder
1 - ABS hydraulic unit - N55- to rear left brake caliper/wheel brake
cylinder.
- Marking on ABS hydraulic unit - N55- -HL-
2 - ABS hydraulic unit - N55- to rear right brake caliper/wheel
brake cylinder.
- Marking on ABS hydraulic unit - N55- -HR-
3 - ABS hydraulic unit - N55- to front left brake caliper.
- Marking on ABS hydraulic unit - N55- -VL-
- Marking on ABS hydraulic unit - N55- -VR-

Polo 2010 ➤

quired
♦ Torque wrench -
V.A.G 1331-

sor - V.A.G 1869/2-
Sealing plug - 1H0 698

311 A-
After removing ABS con‐
trol unit - J104- and ABS
hydraulic unit - N55- , fit
the transport protection.
Without transport protec‐
tion, the warranty for the
ABS hydraulic unit - N55-
will not be recognised.
1 - Transport protection
for contact pins (foam)
2 - M10 sealing plugs
Removing

Polo 2010 ➤
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
1 - Brake booster with tandem brake master cylinder
2 - ABS control unit - J104- with ABS hydraulic unit - N55-
WARNING
Do not bend the brake lines in the area of the ABS hydraulic
unit - N55-
– Read out and make a note of the code of ABS control unit -
J104- ⇒ page 10 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
– Remove air filter housing ⇒ Rep. gr. 24 ; Fuel mixture, elec‐
tronic injection, gas .
Vehicles with battery in engine compartment
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 .
Continuation for all vehicles
– Press locking slide -2- downwards in -direction of arrow-.

– Disengage locking clamp to -1- release connector -3- of ABS
control unit - J104- .
– To do this, press locking clamp -1- downwards in
-direction of arrow-.
– Pull connector -3- off forwards.

Polo 2010 ➤
brake caliper.
– Place sufficiently lint-free cloths under ABS control unit - J104-
and ABS hydraulic unit - N55- .
– First identify the two brake master cylinder brake lines -A- and
-B- and unscrew from ABS hydraulic unit - N55- .
– Immediately seal brake lines and threaded holes with sealing
plugs - 1H0 698 311 A- .
– Mark and unscrew brake lines -1- to -4-.
plugs - 1H0 698 311 A- .
Bosch 8.2 ABS:
– Pull ABS hydraulic unit - N55- -1- together with ABS control
unit - J104- upwards out of the -dampers- in
– If necessary, loosen hexagon nuts of bracket and remove
bracket.
Bosch 9.0 ABS:

Polo 2010 ➤
– Pull hydraulic unit and control unit -1- together with bracket
-2- upwards in -direction of arrow-.
– The rubber dampers -arrows- will be pulled off the studs of the
bracket -3-.
– Remove ABS unit from vehicle.
– If necessary, unbolt bracket -2- beforehand.

unit
newed.
WARNING

unit.
removed.

VAS 6613- .

Polo 2010 ➤

WARNING


Use new bolts!
Note


Install in reverse order. Note the following points:

Polo 2010 ➤
Note
♦ Do not remove sealing plugs from new ABS hydraulic unit -

N55- until respective brake line is about to be installed.
♦ If sealing plugs are removed too early from the ABS hydraulic
unit - N55- , brake fluid can escape, and it can then no longer
be guaranteed that the unit can be sufficiently filled and bled.
WARNING
When installing, ensure that rubber dampers are not pressed

out of bracket. After installation, check that the ABS hydraulic
unit - N55- is firmly seated, otherwise malfunctioning can oc‐
cur.

If a new ABS control unit - J104- has been installed, it must be
coded ⇒ page 10 .
Specified torque
Component Specified torque
Brake lines to ABS hydraulic unit - N55-
Bracket to body 20 Nm
6.3 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP, LHD vehicles

Polo 2010 ➤

unit - J104-
⇒ page 39 .
from each other
❑ When replacing the hy‐
draulic unit, always seal
the old part with plugs
from repair kit - 1H0 698
311 A- .
unit - J104-
⇒ page 39 .
❑ From hydraulic unit to
front right brake caliper.
unit with -VR-.
❑ With thread M10 x 1
❑ To rear right brake cali‐
der
unit with -HR-.
❑ From hydraulic unit to front left brake caliper.
❑ Marked on hydraulic unit with -VL-.
❑ To rear left brake caliper/wheel brake cylinder
❑ Marked on hydraulic unit with -HL-.
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
9 - Hexagon nut, 8 Nm
❑ For 3 rubber damper mountings
❑ 1 cap nut on side at top; it must be unscrewed to height of stud shoulder, otherwise removal and instal‐
lation are not possible.

Polo 2010 ➤
❑ 2 hexagon nuts with washer at bottom; turn back until rubber dampers can be turned.
10 - Seal
11 - Brake booster
13 - Sealing ring
❑ Renew.
16 - Securing pin for brake fluid reservoir
❑ Insert through brake master cylinder
17 - Sealing plug
18 - Sealing plug
❑ Connection for vacuum hose.
20 - Cap
22 - Stud
❑ Stud welded to body.
24 - Stud
❑ Stud welded to body.
25 - Bracket

ter cylinder to hydraulic unit
A - Primary piston circuit of brake master cylinder to hydraulic unit.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.

Polo 2010 ➤
On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
1 - From hydraulic unit to front right brake caliper.
- Marked on hydraulic unit with -VR-.
- Marked on hydraulic unit with -HL-.
- Marked on hydraulic unit with -HR-.
- Marked on hydraulic unit with -VL-.

Polo 2010 ➤

quired
♦ Torque wrench -
V.A.G 1331-

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

Part No. 1H0 698 311 A
Location:
The control unit is bolted
to the hydraulic unit and
is located on right in the
engine compartment.
WARNING
Do not bend the brake

lines in the area of the
hydraulic unit!
Removing:
– Read out and note
the existing control
unit code.
– Note or request radio
code on vehicles with
coded radio if neces‐
sary.
– Disconnect battery ⇒
Electrical system;
Rep. gr. 27 ; Discon‐
necting and recon‐
necting battery .

Polo 2010 ➤
Additional work on fol‐

lowing engines:
4-cyl. injection engine,
toothed belt drive:
– Pull hose off non-re‐
turn valve to cam‐
shaft housing.
– Remove intake hose
and pull air filter
housing upwards off
pivot pins ⇒ 4-cyl. in‐
jection engine, tooth‐
ed belt drive; Rep. gr.
24 .
– .
4-cylinder diesel engine
(1.6 l engine, common
rail):
– Remove wiper arms
⇒ Electrical system;
Rep. gr. 92 ; Window
wiper system; Re‐
moving and installing
window wiper sys‐
tem .
– Remove plenum
chamber cover ⇒
– Pull engine cover
panel up out of brack‐
ets.
– Disconnect all connectors for electrical wires -1 to 4- to diesel

particulate filter and to lambda probe.
– Then remove bracket along with connectors from plenum
chamber bulkhead and lay to side.
– Take engine control unit out of bracket and lay to side.
– Remove insulation from plenum chamber bulkhead.
– Remove plenum chamber bulkhead ⇒ General body repairs,
4-cylinder direct injection engines (2.0 l, 4 V, turbocharger, tooth‐
ed belt drive):

Polo 2010 ➤
♦ Set of plugs for engine - VAS 6122-
– Remove noise insulation -1- ⇒ General body repairs, exterior;

Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
– Unscrew bolt -arrow- for air pipe.

– Loosen hose clip -1-, and place air pipe on engine with hose
-2- connected.
– Remove intake hose between air pipe and turbocharger.
– Seal turbocharger with the sealing plug set for engine - VAS
6122/40- .
– Disconnect connector -1- for Lambda probe - G39- , and lay it

to one side.

Polo 2010 ➤
– Detach heat shield -1- in top area and pull it off slightly.
– Evacuate refrigerant circuit, e.g. with air conditioner service
station - VAS 6007A- ⇒ Air conditioning systems with refrig‐
erant R134a; Rep. gr. 00 ; Technical data , before opening
refrigerant circuit.
– Unbolt refrigerant lines -1 and 2- on expansion valve ⇒ Air

conditioning system; Rep. gr. 87 ; Refrigerant circuit; System
overview - refrigerant circuit .
– Unclip refrigerant lines, and lay them to one side.
– Disconnect vacuum line -1- and fuel supply line -2-, and unclip
them from coolant expansion tank. Separate plug-in connec‐
tors ⇒ Rep. gr. 20 ; Separating plug-in connectors .
– Place the fuel lines to one side.
– Release connector -2- and pull off.

– Undo screws -3-.
– Place coolant expansion tank -1- to one side.

Polo 2010 ➤
– Press red locking slide -arrow- down.
– Release control unit connector -arrow - and pull off forwards.
brake caliper.

Polo 2010 ➤
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
– Mark brake lines from hydraulic unit -A and B- to brake master
cylinder.
– Then unscrew brake lines from hydraulic unit and from brake
master cylinder, unclip from retainers and lay to side.
– Immediately seal brake lines and threaded holes with seal
plugs from repair set Part No. 1H0 698 311 A.
– Mark remaining brake lines (to brake calipers) -1 to 4-, un‐
screw from hydraulic unit and seal.
– Loosen 3 hexagon nuts -1- of rubber damper mountings.
– The cap nut (on side at top) must be unscrewed to height of

stud shoulder, otherwise the removal is not possible.
– Pull hydraulic unit with control unit upwards out of bracket.
– If necessary, loosen hexagon nuts of bracket and remove
bracket.

unit
newed.

Polo 2010 ➤
WARNING

unit.
removed.

VAS 6613- .

WARNING


Polo 2010 ➤

Use new bolts!
Note

Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ When installing, ensure that rubber dampers are seated cor‐
rectly in bracket.
– Continue installation in reverse order.

– Code ABS control unit - J104- with ⇒ Vehicle diagnostic tester
in “Guided fault finding”.
– Code radio.
Specified torques:
Hexagon nut for rubber damper mounting 8 Nm
Hexagon nut to body 20 Nm
Brake lines to ABS unit:
6.4 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP, RHD vehicles

Polo 2010 ➤
1 - Brake line
❑ ABS hydraulic unit -
N55- to front right brake
caliper.
❑ Marking on ABS hy‐
draulic unit - N55- -VR-
2 - Brake line
N55- to rear left brake
caliper/wheel brake cyl‐
inder.
draulic unit - N55- -HL-
3 - Brake line
N55- to rear right brake
caliper/wheel brake cyl‐
inder.
draulic unit - N55- -HR-
4 - Brake line
N55- to front left brake
caliper.
draulic unit - N55- -VL-
N55- with ABS control unit - J104- ⇒ page 50 .
6 - Nut
❑ 8 Nm
❑ For rubber damper mounting
❑ Qty. 3
❑ 1 cap nut on side at top; it must be unscrewed to height of stud shoulder, otherwise removal and instal‐
lation are not possible.
❑ 2 hexagon nuts with washer at bottom; turn back until rubber dampers can be turned.
❑ ABS return flow pump - V39- and valve block should not be separated from each other
❑ When replacing the ABS hydraulic unit - N55- , always seal the old part with plugs - 1H0 698 311 A- .
8 - Nut
❑ 25 Nm
❑ Qty. 3
9 - Bracket
10 - Brake booster

Polo 2010 ➤
11 - Brake line
12 - Brake line
13 - Brake line
❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .
14 - Brake line
❑ Brake master cylinder/secondary piston circuit to ABS hydraulic unit - N55- .

ter cylinder to ABS hydraulic unit - N55-
A - Primary piston circuit of brake master cylinder to ABS hy‐
B - Secondary piston circuit of brake master cylinder to ABS hy‐

Polo 2010 ➤
To ABS hydraulic unit - N55- :

A - ABS hydraulic unit - N55- to primary piston circuit of brake
master cylinder
B - ABS hydraulic unit - N55- to secondary piston circuit of brake
master cylinder
1 - ABS hydraulic unit - N55- to rear left brake caliper/wheel brake
cylinder.
- Marking on ABS hydraulic unit - N55- -HL-
2 - ABS hydraulic unit - N55- to rear right brake caliper/wheel
brake cylinder.
- Marking on ABS hydraulic unit - N55- -HR-
3 - ABS hydraulic unit - N55- to front left brake caliper.
- Marking on ABS hydraulic unit - N55- -VL-
- Marking on ABS hydraulic unit - N55- -VR-

Polo 2010 ➤

quired
♦ Torque wrench -
V.A.G 1331-

sor - V.A.G 1869/2-
Sealing plug - 1H0 698

311 A-
After removing ABS con‐
trol unit - J104- and ABS
hydraulic unit - N55- , fit
the transport protection.
Without transport protec‐
tion, the warranty for the
ABS hydraulic unit - N55-
will not be recognised.
1 - Transport protection
for contact pins (foam)
Removing

Polo 2010 ➤
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
1 - Brake booster with tandem brake master cylinder
2 - ABS control unit - J104- with ABS hydraulic unit - N55-
WARNING
Do not bend the brake lines in the area of the ABS hydraulic
unit - N55-
– Read out and make a note of the code of ABS control unit -
J104- ⇒ page 10 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
– Remove air filter housing ⇒ Rep. gr. 24 ; Fuel mixture, elec‐
tronic injection, gas .
Vehicles with battery in engine compartment
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 .
– Press locking slide -2- downwards in -direction of arrow-.

– Disengage locking clamp to -1- release connector -3- of ABS
control unit - J104- .
– To do this, press locking clamp -1- downwards in
– Pull connector -3- off forwards.

Polo 2010 ➤
brake caliper.

– Place sufficient lint-free cloths under the ABS hydraulic unit -
N55- .
– First identify the two brake master cylinder brake lines -A- and
-B- and unscrew from ABS hydraulic unit - N55- .
plugs - 1H0 698 311 A- .
– Mark and unscrew brake lines -1- to -4-.
plugs - 1H0 698 311 A- .
– Loosen the 3 nuts -arrows- of rubber damper mounting until

the rubber dampers can be turned.
– Undo upper nut on side as far as shoulder of the stud bolt.
– Pull ABS hydraulic unit - N55- -1- together with ABS control
unit - J104- upwards out of the bracket in -direction of arrow-.

unit

Polo 2010 ➤

newed.
WARNING

unit.
removed.

ject, ESD workplace - VAS 6613- . Do not directly touch
connector contacts or electronic components.
VAS 6613- .
newed.


Polo 2010 ➤
WARNING


Use new bolts!
Note


Note
♦ Do not remove sealing plugs from new ABS hydraulic unit -

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

Polo 2010 ➤
WARNING
When installing, ensure that rubber dampers are pressed into

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

After the ABS control unit - J104- and the ABS hydraulic unit -
N55- have been installed, the steering angle sender - G85- , the
lateral acceleration sender - G200- and the brake pressure send‐
er - G201- must be reset ⇒ page 10 .
If a new ABS control unit - J104- has been installed, it must be
coded ⇒ page 10 .
Specified torque
Bolt for ABS hydraulic unit - N55- to bracket. 8 Nm
Brake lines to ABS hydraulic unit - N55-

Polo 2010 ➤
7 Removing and installing parts of ABS

system on front and rear axle
7.1 Removing and installing parts of ABS system on front axle
1 - Wheel bearing housing

2 - Hexagon socket head bolt,
8 Nm
3 - Speed sensor
❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
⇒ page 57 .
4 - Splash plate
5 - Torx bolts, 12 Nm
6 - Wheel hub with wheel bear‐
ing
❑ The ABS sensor ring is
located in the wheel hub
⇒ page 56
❑ Pressing out and in ⇒
Running gear, axles,
steering; Rep. gr. 40 ; II
- Assembly overview -
wheel bearings .
7 - Brake disc
8 - Torx bolt, 4.5 Nm
ABS sensor ring -1-

Polo 2010 ➤
7.1.1 Removing and installing speed sensor

on front axle
Removing:
– Raise vehicle.
– 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.
Installing:
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.
– Turn steering to full left and right lock and check clearance to
speed sensor wire.
7.2 Removing and installing parts of anti-lock brake system on rear axle (drum
brakes)
7. Removing and installing parts of ABS system on front and rear axle 57
Polo 2010 ➤
1 - Axle beam
8 Nm
3 - ABS speed sensor
perature paste
G 052 112 A3.
⇒ page 59 .
4 - Brake line
5 - Stub axle
6 - Handbrake cable
7 - Hexagon bolt
❑ Specified torque ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. gr. 42 ; As‐
sembly overview: wheel
bearings, drum brakes .
8 - Torx bolt, 4 Nm
9 - Brake drum
❑ Reset brake before re‐
moving brake drum
⇒ page 77 .
10 - Cap
❑ Pressing off and driving
in ⇒ Running gear,
axles, steering; Rep. gr.
42 ; Assembly overview:
wheel bearings, drum
brakes .
11 - 12-point nut (self-locking)
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Assembly overview: wheel
❑ ABS sensor ring is installed in wheel bearing ⇒ page 58 .
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Assembly overview: wheel
13 - Brake backplate with brake shoes
❑ Reset brake before removing brake drum ⇒ page 77
ABS sensor ring -1-

Polo 2010 ➤

on rear axle (drum brakes)
Removing:
– Raise vehicle.
speed sensor.
– Remove bolt -2- from stub axle.
– Pull ABS speed sensor out of stub axle.
Installing:
G 052 112 A3.
– Insert speed sensor into hole in stub axle and tighten bolt to
8 Nm.
7.3 Removing and installing parts of anti-lock brake system on rear axle (disc
brakes)
Polo 2010 ➤
1 - Rear axle beam

2 - Brake line
3 - Handbrake cable
4 - Torx bolt, 4 Nm
5 - Brake disc
6 - Cap
❑ Pressing off and driving
in ⇒ Running gear,
axles, steering; Rep. gr.
42 ; Assembly overview:
wheel bearings, disc
brakes .
❑ Renew each time after
removal ⇒ Running
gear, axles, steering;
Rep. gr. 42 ; Assembly
overview: wheel bear‐
ings, disc brakes .
8 - Wheel hub with wheel bear‐
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing
⇒ page 60 .
⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Assembly overview:
brakes .
9 - Hexagon bolt
❑ Specified torque ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. gr. 42 ; As‐
sembly overview: wheel bearings, disc brakes .
10 - Splash plate
11 - Stub axle
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
13 - Hexagon socket head bolt, 8 Nm
ABS sensor ring -1-

Polo 2010 ➤

on rear axle
Removing:
– Raise vehicle.
speed sensor.
– Remove bolt -2- from stub axle.
– Pull ABS speed sensor out of stub axle.
Installing:
G 052 112 A3.
– Insert speed sensor into hole in stub axle and tighten bolt to
8 Nm.
Polo 2010 ➤
8 Removing and installing parts of ESP

system
8.1 Removing and installing yaw rate send‐

er - G202- and lateral acceleration send‐
er - G200-
In vehicles with the ABS Bosch 8.2i, the lateral acceleration send‐
er - G200- , the yaw rate sender - G202- and the longitudinal
acceleration sender - G251- (depending on the equipment fitted)
are installed in the control unit.
It is not possible to replace these parts separately.
– Removing and installing ABS control unit - J104- ⇒ page 35 .
8.2 Removing and installing steering angle

sender - G85-
The steering angle sender is located between the steering wheel
and steering column switch.
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- .
Connecting -VAS 5051- and selecting functions ⇒ page 10

Polo 2010 ➤
46 – Brakes - mechanism
1 Repairing front brakes
1.1 Repairing front brakes, FS III brake caliper
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.
♦ After work for which the brake system had to be opened, bleed the brake system with brake charge and
bleed system - VAS 5234- or extraction unit -V.A.G 1869/4- .
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).
1 - Brake disc
❑ Internally ventilated, ∅
256 mm
❑ Thickness: 22 mm
❑ Wear limit: 19 mm.
❑ Always renew on both
sides of an axle.
❑ Unscrew brake caliper
prior to removing.
❑ Never remove brake
discs from wheel hub by
force. If necessary use
penetrating fluid, be‐
cause otherwise brake
discs can be damaged.
3 - Brake pads
❑ Thickness: 14 mm not
including backplate.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake pads/linings:
Checking thickness .
sides of an axle.
⇒ page 64 .
4 - Brake caliper
❑ Do not disconnect brake
hose when changing
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Repairing front brakes 63

Polo 2010 ➤
pads.
❑ Repairing ⇒ page 103 .
5 - Guide pin, 30 Nm
6 - Cover cap
❑ Remove
7 - Spring pin
8 - Brake hose with banjo union and banjo bolt, 35 Nm
❑ Pressing out and in ⇒ Running gear, axles, steering; Rep. gr. 40 ; Assembly overview - wheel bearings .
11 - Splash plate
❑ With integrated brake carrier.
❑ Lightly grease brake pad guiding surfaces with lithium grease G 052150 A2.
1.2 Removing and installing brake pads,

brake caliper FS III
♦ Torque wrench - V.A.G 1331-
♦ Piston resetting appliance - T10145-
64 Rep. gr.46 - Brakes - mechanism

Polo 2010 ➤
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.
– Remove cover caps.
– Unscrew and remove both guide pins -arrows- from brake cal‐
iper.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pads out of brake caliper.
Cleaning:
WARNING
Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– 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.
– Lightly grease guiding surface for brake pads on brake carrier
with lithium grease G 052150 A2.
– Press piston back.
– Insert brake pads into brake caliper and piston.

Polo 2010 ➤
– Insert brake pad with “piston side” written on backing plate into
brake piston.
– Install brake caliper with brake pads on wheel bearing hous‐

ing.
– First position brake caliper at bottom -arrow- of brake carrier.
• Brake caliper stud must be positioned behind brake carrier
guide!
– Bolt brake caliper to brake carrier with both guide pins.
– Fit both cover caps.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .
Note
♦ Every time after changing pads, depress brake pedal firmly

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

FS III

Polo 2010 ➤
♦ 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 brake caliper bleeder valve and
open bleeder valve.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Pull both caps out of bearing bushes of brake caliper.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper off brake carrier.
– Remove brake pads from brake caliper.
1.3.2 Installing
• Piston is pressed back.
– Insert brake pads into brake caliper and piston.
– Insert brake pad with “piston side” written on backing plate into
brake piston.

Polo 2010 ➤
– Install brake caliper with brake pads on wheel bearing hous‐

ing.
– First position brake caliper with brake pads at bottom -arrow-

of brake carrier.
• Brake caliper stud must be positioned behind brake carrier
guide!
– Bolt brake hose to brake caliper.
– Fit wheels.
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torques:
Brake hose to brake caliper 35 Nm
1.4 Repairing front brakes, FN 3 brake caliper
Note
♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- or the upgrade kit and extraction unit - V.A.G
1869/4- to extract 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).

Polo 2010 ➤
2 - Brake disc
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Internally ventilated
❑ FN3 (15”) ∅ 288 mm,
FN3 (16”) ∅ 310 mm
❑ Thickness: 25 mm
❑ Wear limit: 22 mm.
sides of an axle.
prior to removing.
4 - Brake pads
❑ Thickness: 14 mm not
including backplate.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake pads/linings:
Checking thickness .
sides of an axle.
⇒ page 70 .
5 - Retaining spring
❑ Insert into both holes in brake caliper.
6 - Brake carrier
❑ Bolt to wheel bearing housing.
7 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
9 - Cover cap
❑ Remove
10 - Brake hose with banjo union and banjo bolt, 35 Nm
12 - Cover cap
❑ Remove

Polo 2010 ➤
13 - Bolt
14 - Bracket
15 - Ribbed bolt, 124 Nm
❑ Clean if reused.
❑ With bolted-on brake carrier.
19 - Wheel bearing/hub unit
20 - Cover
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA” .
1.5 Removing and installing brake pads,

brake caliper FN 3
1.5.1 Removing
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.

Polo 2010 ➤
– Lever brake pad retaining spring out from brake caliper

-arrow- with a screwdriver and remove.
– Remove cover caps -arrows-.
– Unscrew both guide pins -arrows- and remove from brake cal‐
iper.
– Take brake pad out of brake caliper or from brake carrier.
Cleaning:
WARNING
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.

Polo 2010 ➤
1.5.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press piston back.
– Pull protective foil off outer brake pad backplate.
– Fit outer brake pad to brake carrier.
– Insert inner brake pad with retaining spring into brake caliper
(piston).
When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly.
Do not damage adhesive surface.
– Bolt brake caliper to brake carrier with both guide pins

-arrow-.
– Insert retaining spring into brake caliper.
– Fit wheels.
Note

Specified torque:

FN 3

Polo 2010 ➤
1.6.1 Removing
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.
open bleeder valve.
– Pull both caps out of bearing bushes of brake caliper.
– Loosen both guide pins and remove from brake caliper.
– Take brake pads out of brake caliper or from brake carrier.
1.6.2 Installing
• Outer brake pad is seated on brake carrier.
– Insert inner brake pad with retaining spring into brake caliper
(piston).
When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly.
Do not damage adhesive surface.

Polo 2010 ➤

– Bolt brake hose to brake caliper.
– Insert retaining spring into brake caliper.
– Fit wheels.
Note

operating position.
Specified torques:

Polo 2010 ➤
2 Repairing rear brakes (drum brakes)
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
1332-
1410-
♦ Brake pedal depressor -
V.A.G 1869/2-
2. Repairing rear brakes (drum brakes) 75

Polo 2010 ➤
2.1 Removing and installing rear brakes
Note
♦ After renewing wheel brake cylinder, brake backplate and brake shoes, depress brake pedal firmly several
times with vehicle stationary so that the brake shoes are properly seated in their normal operating position.
♦ After work for which the brake system had to be opened, bleed the brake system with brake charge and
bleed system - VAS 5234- or extraction unit -V.A.G 1869/4- .
♦ Before removing a wheel brake cylinder or brake backplate or disconnecting a brake line from the wheel
brake cylinder, fit brake pedal depressor - V.A.G 1869/2- (release pressure in system).
1 - Axle beam
8 Nm
perature paste
G 052 112 A3.
4 - Brake line, 14 Nm
5 - Stub axle
6 - Handbrake cable
❑ Adjusting handbrake
⇒ page 91 .
7 - Hexagon bolt
❑ ⇒ Running gear, axles,
Assembly overview -
wheel bearings, drum
brakes .
8 - Torx bolt, 4 Nm
9 - Brake drum
❑ Brake drum diameter:
200 mm
❑ Wear limit: 201.5 mm.
❑ Reset brake before re‐
moving brake drum
⇒ page 77
❑ Clean carefully and
check for wear, dam‐
age, dimensional accu‐
racy and flawless brake

Polo 2010 ➤
surface.
10 - Cap
❑ Pressing off and driving in ⇒ Running gear, axles, steering; Rep. gr. 42 ; Assembly overview - wheel
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Assembly overview -
wheel bearings, drum brakes .
13 - Brake backplate with brake shoes
❑ Minimal thickness of brake lining: 2.5 mm.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings: Checking thickness .
❑ Reset brake before removing brake drum ⇒ page 77
2.2 Resetting brake

– Insert a screwdriver through a wheel bolt threaded hole in the
brake drum and push the wedge upwards.
2.3 Repairing rear brakes

After working on rear wheel brakes:
♦ Release handbrake.
♦ Firmly depress brake pedal once.

Polo 2010 ➤
1 - Spring plate
❑ To remove, push
against compression
spring and turn through
90°.
2 - Compression spring
3 - Brake shoe with lever for
handbrake
⇒ page 79 .
⇒ page 91 .
4 - Upper return spring
❑ Unhook with special tool
3438
5 - Lower return spring
❑ Grease points of contact
with lubricating paste,
part No. G 000 650
6 - Spring
7 - Brake shoe
⇒ page 79 .
Brake linings can also be sup‐
plied without brake shoes.
8 - Cap
❑ Remove to check brake
lining thickness.
9 - Roll pin
10 - Brake carrier
8 Nm Volkswagen Technical Site: http://vwts.ru http://vwts.info
12 - Wheel brake cylinder
❑ Check for leaks ⇒ page 78 .
13 - Wedge
❑ To remove and install the brake drum, push upwards through a wheel bolt hole ⇒ page 77 .
14 - Plunger rod
❑ Grease points of contact with lubricating paste, part No. G 000 650
15 - Locating spring
❑ Unhook with special tool 3438
2.3.1 Checking wheel brake cylinder for leaks


Polo 2010 ➤
♦ Removal wedge - 3409-
– Lift off dust boot with removal wedge 3409.

– If brake fluid is found in the dust boot, renew wheel brake cyl‐
inder.
Ensure the dust boot is not damaged when lifting off.
2.4 Removing and installing brake shoes

♦ Hook - 3438-
2.4.1 Removing
– Remove wheels.
– Remove brake drum.
– Remove wheel hub with wheel bearing ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Assembly overview - wheel bearings,
drum brakes .
– Remove spring plate with spring.

Polo 2010 ➤
– Lever out brake shoes in direction of arrow with aid of a screw‐

driver behind support plate.
– Place brake shoe down on lower support plate.
– Unhook lower return spring.
– Unhook handbrake cable.
– Remove brake shoes.
– Clamp brake shoes in vice.
– Remove spring -1- for wedge -2-.

– Remove upper return spring -3- with special tool 3438.
– Unhook locating spring -1- with special tool 3438.

– Take push rod -2- and wedge -3- off brake shoe.
Cleaning:
WARNING
Use only methylated spirits for cleaning the brake system.
2.4.2 Installing
– Hook locating spring -1- into push rod -2- with special tool
3438.
– Insert wedge -3- at same time.
Installation position:
Raised portion -arrow- must remain visible when installing.
– Insert brake shoe with brake lever in push rod.

Polo 2010 ➤
– Connect return spring -3- with special tool 3438.

– Attach spring -1- for wedge -2-.
– Fit brake shoes onto wheel cylinder pistons.
– Attach handbrake cable to brake lever.
– Fit lower return spring and lift brake shoes behind lower sup‐
port.
– Fit spring and spring plate.
– Install wheel hub with wheel bearing ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Assembly overview - wheel bearings,
drum brakes .
– Install brake drum.
– Fit wheels.
– Firmly depress brake pedal once.
– Adjust handbrake ⇒ page 91 .

Polo 2010 ➤
3 Repairing rear brakes (disc brakes)
Note

♦ After work for which the brake system had to be opened, bleed
the brake system with brake charge and bleed system - VAS
5234- or extraction unit -V.A.G 1869/4- .
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
this, release pressure in system).
1 - Torx bolt, 4 Nm
2 - Brake disc
❑ Thickness ⇒ page 5
❑ Wear limit ⇒ page 5
sides of an axle.
prior to removing.
3 - Hexagon bolt
❑ ⇒ Running gear, axles,
Assembly overview:
brakes .
4 - Splash plate
5 - Handbrake cable
⇒ page 94 .
6 - Axle beam
30 Nm and turn 30° further
8 - Brake hose
❑ With banjo bolt and
seals
❑ Specified torque of ban‐
jo bolt to brake caliper:

Polo 2010 ➤
38 Nm
❑ Do not disconnect brake hose when changing pads.
9 - Self-locking hexagon bolt, 35 Nm
10 - Brake caliper
11 - Brake pads
❑ Thickness: 11.5 mm
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings: Checking thickness .
❑ Always renew on both sides of an axle.
12 - Brake carrier with guide pins and protective cap
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
❑ If protective cap or guide pins are damaged, install set of repair components. Use lubricant sachet sup‐
plied to lubricate guide pins.
3.1 Removing and installing brake pads/lin‐

ings
♦ Piston compressing tool - T20146-
3.1.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
– Remove wheels.
3. Repairing rear brakes (disc brakes) 83

Polo 2010 ➤
– Push handbrake lever in direction of -arrow- and unhook hand‐

brake cable from handbrake lever.
– Compress both locking lugs -arrows- together, then pull hand‐
brake cable out of bracket on brake caliper.
– Remove securing bolts from brake caliper, to do this counter‐

hold on guide pins.
– Remove brake pads.

Cleaning:
WARNING
– Thoroughly clean contact surface for brake pads on backplate

and remove corrosion.
– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.
3.1.2 Installing
Before turning piston back, draw off brake fluid from reservoir.
Otherwise, particularly if reservoir has been topped up, fluid will
overflow and cause damage.
– Turn piston to right into brake caliper with piston resetting ap‐
pliance - T20146- ; do not damage protective cap.

Polo 2010 ➤
– Thoroughly clean contact surfaces -arrows- of brake pads.
– Pull protective foil off brake pad backplate.

– Insert brake pads into brake carrier.
– Screw brake caliper to brake carrier with new securing bolts,

counter-holding at guide pin.
♦ The repair kit includes 4 self-locking hexagon bolts which must
always be installed.

Polo 2010 ➤
– Push handbrake cable into bracket on brake caliper until both

locking lugs -arrows- engage.
– Push handbrake lever in direction of -arrow- and attach hand‐
brake cable onto handbrake lever.
– Fit wheels.
Note

Specified torque:
Hexagon bolt, brake caliper to brake carrier 35 Nm
♦ Use new bolts.

3.2.1 Removing
– Remove wheels.
– Unclip brake cable from lever on brake caliper.

Polo 2010 ➤
– Compress both locking lugs together, then pull handbrake ca‐

ble out of bracket on brake caliper.
open bleeder valve.
– Remove both securing bolts from brake caliper; to do this,
counterhold on guide pin.
3.2.2 Installing
• The brake pads are seated on the brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts.
– Screw brake line to brake caliper.
locking lugs engage.
– Press down handbrake lever and attach handbrake cable onto
handbrake lever.
– Fit wheels.
Note

operating position.
Specified torques:
Hexagon bolt, brake caliper to brake carrier 35 Nm
♦ Use new bolts.

Polo 2010 ➤
4 Assembly overview - handbrake lever
1 - Push button
❑ Pulling off ⇒ page 89
❑ Will be destroyed when
pulling off; must be re‐
newed.
❑ Push onto handbrake
lever push rod and en‐
sure both locking lugs
are engaged by pulling
slightly.
2 - Handbrake lever trim
❑ First pull off push button
❑ Lever up release tab in
rear lower area of han‐
dle with a screwdriver.
❑ Then pull off forwards.
3 - Adjustment nut
❑ Adjusting handbrake:
❑ Vehicles with drum
brakes ⇒ page 91 .
❑ Vehicles with disc
brakes ⇒ page 94 .
4 - Compensator
5 - Handbrake lever
❑ Before removing, re‐
move centre console ⇒
interior; Rep. gr. 68 ;
Compartments, covers
and trims .
6 - Hexagon nut, 23 Nm
7 - Handbrake warning switch
8 - Rubber grommet
9 - Right guide tube
10 - Left guide tube
11 - Handbrake cables

Polo 2010 ➤
Removing push button
Note
Will be destroyed when removing; must be renewed.
4.1 Removing and installing handbrake ca‐

ble (drum brakes)
4.1.1 Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .
– Release handbrake.
– Loosen adjustment nut -arrow- until handbrake cable can be
unhooked from compensator.
– Raise vehicle.
– Unscrew hexagon nuts -arrows 1- and press underbody panel

-arrow- down until handbrake cable guide tube -arrow 2- be‐
comes visible.
– Remove wheel.
– Remove brake drum.
4. Assembly overview - handbrake lever 89

Polo 2010 ➤
– Unhook handbrake cable from handbrake lever.

– Pull handbrake cable out of brake backplate.
– Unclip handbrake cable from retainer on rear axle beam

-arrow A- and unhook from retainers -arrows-.
– Pull handbrake cable out from guide tube -1- in direction of

arrow.
4.1.2 Installing
– Slide handbrake cable into guide tube on underbody.
– Insert handbrake cable into brake backplate.

Polo 2010 ➤
– Engage handbrake cable onto handbrake lever.

– Install brake drum.
– Clip handbrake cable into retainer on rear axle beam

-arrow A-.
– Handbrake cable clamping ring must lie in the middle of the
clip.
– Hook handbrake cable into retainers -arrows-.
– Attach handbrake cable to compensator.
– Pretension the handbrake cable with adjustment nut -arrow-.

– Fit wheels.
– Secure underbody panel.
– Install centre console ⇒ General body repairs, interior; Rep.
4.2 Adjusting handbrake

A new adjustment is only necessary when the handbrake cables,
brake backplate or brake linings are renewed.
– Remove centre console extension, ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments, covers and trims .
– The foot brake must be functional and bled.
– Firmly depress brake pedal three times.
– Pull handbrake lever on 4 notches.

Polo 2010 ➤
– Tighten adjusting nut -A- until both wheels are difficult to turn
by hand.
Adjustment nut -A- must be screwed over end of pull rod -1-.
– Release handbrake and check that both wheels turn freely. If
required turn adjustment nuts back slightly.
– Install centre console extension. ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments, covers and trims .
Due to the automatic rear wheel brake adjustment there is no re‐
quirement to adjust the handbrake after making new/initial ad‐
justment.
4.3 Removing and installing handbrake ca‐

ble (disc brakes)
4.3.1 Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
– Loosen adjustment nut -arrow- until handbrake cable can be
unhooked from compensator.
– Raise vehicle.
– Unscrew hexagon nuts -arrows 1- and press underbody panel

-arrow- down until handbrake cable guide tube -arrow 2- be‐
comes visible.

Polo 2010 ➤
– Push handbrake lever in direction of -arrow- and unhook hand‐

brake cable from handbrake lever.
– Compress both locking lugs -arrows- together, then pull hand‐
brake cable out of bracket on brake caliper.
– Unclip handbrake cable from retainer on rear axle beam

-arrow A- and unhook from retainers -arrows-.
– Pull handbrake cable out from guide tube -1- in direction of

arrow.
4.3.2 Installing
– Slide handbrake cable into guide tube on underbody.
locking lugs -arrows- engage.
– Push handbrake lever in direction of -arrow- and attach hand‐
brake cable onto handbrake lever.

Polo 2010 ➤
– Clip handbrake cable into retainer on rear axle beam

-arrow A-.
– Handbrake cable clamping ring must lie in the middle of the
clip.
– Hook handbrake cable into retainers -arrows-.
– Attach handbrake cable to compensator.
– Pretension the handbrake cable with adjustment nut -arrow-.

– Secure underbody panel.
– Install centre console ⇒ General body repairs, interior; Rep.
4.4 Adjusting handbrake

A new adjustment is only necessary after renewing, handbrake
cables, brake calipers and brake discs.
– Depending on equipment version of centre console, remove
only cup holder, rear cover or complete centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims .
– The foot brake must be functional and bled.
– Firmly depress brake pedal three times.
– Handbrake lever in rest position. Tighten adjusting nut
-arrow A- until levers -arrow B- on brake calipers lift off stop.
Adjustment nut -A- must be screwed over end of pull rod -1-.

Polo 2010 ➤
– The total distance -a- of level -1- to stops -2- on left and right
brake calipers must not exceed 1.5 mm.
– Firmly pull on and then release handbrake.
– Check that both wheels turn freely.
– Install centre console extension. ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments, covers and trims .
Due to the automatic rear wheel brake adjustment there is no re‐
quirement to adjust the handbrake after making new/initial ad‐
justment.

Polo 2010 ➤
5 Assembly overview - brake pedal
5.1 Assembly overview - brake pedal, left-

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

coverings.
The brake light switch is located on the brake master cylinder.
1 - Pedal cluster
⇒ page 98 .
2 - Self-locking hexagon nut,
25 Nm
❑ Always renew after re‐
moving.
3 - Sleeve bearing
4 - Brake pedal
⇒ page 98 .
5 - Cap
6 - Ball socket
7 - Support
❑ For ball head of brake
booster plunger rod.
8 - Pivot pin
❑ May be fitted only once
because the tabs will
break off when disman‐
tled.
9 - Sleeve bearing
5.1.1 Separating brake pedal from brake

booster

Polo 2010 ➤
♦ Release tool - T 10159A-
– First press brake pedal in direction of brake booster and hold.

2 - Plunger rod
3 - Retaining lugs
– Insert release tool - T 10159A- and pull in direction of driver
seat. When doing this, counter-hold on brake pedal. (At this
stage the brake pedal must not be allowed to move back‐
wards.) 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
booster is shown with pedal cluster removed.
– Pull release tool - T 10159A- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).
5.1.2 Clipping brake pedal to brake booster

– Hold ball head of plunger rod in front of mounting and push
brake pedal in direction of brake booster, so that the ball head
clicks into place.
– Pull brake pedal briefly to ensure parts are engaged correctly.
5. Assembly overview - brake pedal 97

Polo 2010 ➤
5.1.3 Removing pedal cluster

– Remove fuse box cover ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling fuse box cover .
– Unbolt fuse box and lay to side.
– Remove crash bar ⇒ Running gear, axles, steering; Rep. gr.
48 .
– Remove footwell vent ⇒ Heater, air conditioning system; Rep.
gr. 80 ; Repairing heater; Removing vent .
– Pull connector off accelerator pedal position sender.
– Separate brake pedal from brake booster ⇒ page 96 .
– Remove hexagon nuts -arrows- from pedal cluster.

– Remove foot pedal cluster.
5.1.4 Installing pedal cluster

Install in reverse order.
– Clip brake pedal to brake booster ⇒ page 97 .
5.1.5 Removing brake pedal

– Remove foot pedal cluster ⇒ page 98 .
– Turn pivot pin to left -movement arrow- using a 10 mm hexa‐
gon key; tabs -arrows 1- will then break off.
– Pull pivot pin out.
– Remove brake pedal.
5.1.6 Installing brake pedal

Install in reverse order.

Polo 2010 ➤
– Insert pivot pin and turn clockwise -movement arrow- with a

10 mm hexagon key until tabs -arrow 2- come to stop.
– Install foot pedal cluster ⇒ page 98 .
5.2 Assembly overview - brake pedal, right-hand drive
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
The brake light switch is located on the brake master cylinder.
1 - Bolt
2 - Sleeve bearing
3 - Brake pedal
⇒ page 101 .
4 - Pedal cluster
⇒ page 101 .
5 - Nut
❑ 25 Nm
moving.
6 - Nut
❑ 25 Nm
moving.
7 - Pedal cap
8 - Ball socket
9 - Support
❑ For ball head of brake
booster plunger rod.
❑ Detach ball head from
mounting ⇒ page 100
❑ Clip ball head to mount‐
ing ⇒ page 100

Polo 2010 ➤
5.2.1 Separating brake pedal from brake

booster
♦ Release tool - T 10159A-
– First press brake pedal in direction of brake booster and hold.

2 - Plunger rod
3 - Retaining lugs
– Insert release tool - T10159A- and pull towards driver seat,
counter holding on brake pedal.
Note
♦ Pedal cluster must not move backwards at this moment.

♦ This action will press retaining lugs -3- of mounting off ball
head of plunger rod -2-.
– Pull release tool - T10159A- and brake pedal together towards

driver seat.
As a result, the brake pedal is pulled off.
5.2.2 Clipping brake pedal to brake booster

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

Polo 2010 ➤
5.2.3 Removing pedal cluster

Removing
– Undo bolted connection -arrow A- of trim -1- for the foot sup‐
port.
– Pull trim -1- for foot support upwards out of the lower guide in
– Remove trim -1- for foot support.
– Twist out snap fastener -arrow B- and remove trim -2- of steer‐
ing column.
– Release connector of accelerator pedal position sender - G79-
and pull it off.
– Unscrew bolts -arrows- of pedal cluster.

– Remove foot pedal cluster.
5.2.4 Installing pedal cluster

Specified torque
Pedal cluster to brake booster and plenum chamber 25 Nm
bulkhead
♦ Use new nuts
Foot support cover to plenum chamber bulkhead 5 Nm
5.2.5 Removing brake pedal

♦ Release tool - T 10159-

Polo 2010 ➤
Carry out the following work:

Removing
– Remove foot pedal cluster ⇒ page 100 .
– Loosen nut -2- whilst counterholding with bolt -1-.
– Remove brake pedal.
5.2.6 Installing brake pedal

Specified torque
Brake pedal to pedal cluster 25 Nm
♦ Use new nuts
Pedal cluster to brake booster and plenum chamber 25 Nm

bulkhead
♦ Use new nuts

Polo 2010 ➤
47 – Brakes - hydraulics
1 Repairing front brake calipers
1.1 Repairing FS III brake calipers
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Sleeve bearing
❑ Insert into brake caliper.
5 - Cover caps
❑ Insert into sleeve bear‐
ing.
6 - Brake caliper
7 - Sealing ring
⇒ page 103 .
8 - Piston
sembly paste
G 052 150 A2 to piston
before installing.
⇒ page 103 .
9 - Sealing ring
⇒ page 103 .

FS III
1. Repairing front brake calipers 103

Polo 2010 ➤
1.2.1 Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.
– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
1.2.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
104 Rep. gr.47 - Brakes - hydraulics

Polo 2010 ➤
– Apply a thin coat of assembly paste G 052 150 A2 to piston

and seal before inserting.
– Insert seal into brake caliper.
– Place protective cap with outer sealing lip on piston.
– Insert inner sealing lip into groove in cylinder using wedge

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

The outer sealing lip on the protective cap will then slip into the
piston groove.
1.3 Repairing FN 3 brake calipers

Polo 2010 ➤
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
5 - Sleeve bearing
❑ Insert into brake caliper.
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
8 - Retaining spring
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
⇒ page 106 .
10 - Piston
⇒ page 106 .
sembly paste - G 052
150 A2- to piston before
inserting.
11 - Deflector cap
❑ Take care not to damage when inserting piston.

piston FN 3

Polo 2010 ➤
♦ Piston resetting appliance - T 10145-
♦ Assembly tool for protective caps - T 10146/6-
1.4.1 Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.
– Lever off protective cap from brake caliper using removal

wedge - 3409- .

Polo 2010 ➤
– Remove seal using removal wedge - 3409- .

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

correctly all round using assembly tool - T10146/6- -1- and
piston resetting tool - T10145- -2-.
Check seat of protective cap:
– At this stage, it should not be possible to remove protective

cap from brake caliper by hand.

Polo 2010 ➤
– Press piston lightly onto protective cap and lock it in this po‐
sition with, for example, an removal wedge - 3409- -2-.
Keep piston straight to prevent damage to sealing collar.
– Blow compressed air (max 3 bar) -1- into protective seal. The
protective cap then springs onto piston.
– Press piston into brake caliper with piston resetting appliance

- T10145- -1-.
The outer sealing lip on the protective cap will then slip into the
piston groove.

Polo 2010 ➤
2 Repairing rear brake calipers
1 - Self-locking hexagon bolt,

35 Nm
❑ Renew.
❑ When loosening and
tightening, counterhold
on guide pin.
2 - Bleeder valve
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Dust cap
4 - Guide pin
❑ Grease before fitting
protective cap.
5 - Deflector cap
❑ Fit onto brake carrier
and guide pin.
6 - Brake carrier with guide
pins and protective cap
❑ Supplied as genuine
part, assembled with
sufficient grease on
guide pins.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Deflector cap
❑ Pull on so that outer
sealing lip goes over
piston.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
8 - Piston with automatic adjustment
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
9 - Sealing ring
10 - Brake caliper with handbrake cable lever
❑ If there is a leak at handbrake cable lever, renew brake caliper.
❑ Following repair work, pre-bleed brake caliper ⇒ page 112 .
2.1 Removing and installing rear brake cal‐

iper piston

Polo 2010 ➤
♦ Piston compressing tool - T20146-
♦ Bleeder bottle
2.1.1 Removing
– Twist piston anti-clockwise out of brake caliper with piston re‐
setting appliance - T20146- .
– Remove seal using wedge 3409.
2. Repairing rear brake calipers 111

Polo 2010 ➤
2.1.2 Installing
The surfaces of the piston and seal must be cleaned only with
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Place protective cap with outer sealing lip on piston.
– Insert inner sealing lip into groove in cylinder using wedge

3409.
When doing this, hold piston in front of brake caliper.
– Turn piston to right into brake caliper with piston resetting ap‐
pliance - T20146- ; do not damage protective cap.
2.1.3 Pre-bleeding brake caliper

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

Polo 2010 ➤
3 Pressurised leak test

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

Brake system ( ABS hydraulic unit - N55- , brake hoses, brake
lines and brake calipers) is working properly and is not leaking.
– Remove bleeder valve at one of front brake calipers. Connect
brake system tester - V.A.G 1310A- with corresponding adapt‐
er and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.
3. Pressurised leak test 113

Polo 2010 ➤
4 Bleeding brake system

Bleeding the brake system is described using brake filling and
bleeding equipment - VAS 5234- .
Note
♦ Bleeding brake system on vehicles with ABS is performed in

same way as vehicles with a conventional brake system.
♦ Only use new brake fluid conforming to US standard
FMVSS 116 DOT 4.
♦ Genuine VW/Audi brake fluid conforms to this specification.
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
4.1 Bleeding brake system with brake filling

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

Polo 2010 ➤
Note
If, in vehicles with EDL, EDL/TCS or EDL/TCS/ESP, a chamber

in brake fluid reservoir is completely empty (e.g. brake system
leaking), brake system must be pre-bled first.
4.1.1 Pre-bleeding:
Carry out pre-bleeding:
♦ if a chamber in the brake fluid reservoir in vehicles with EDL,
EDL/TCS or EDL/TCS/ESP is completely empty. This occurs
e.g. in the case of brake system leaks.
– Connect brake filling and bleeding equipment - VAS 5234- or
-V.A.G 1869- .
Bleeding sequence:
1 - Bleed front left and front right brake calipers simultaneously.
2 - Bleed rear left and rear right brake calipers simultaneously.
– Leave bleeder valves open with brake fluid hoses connected
until brake fluid free from air bubbles flows out.
Then hydraulic unit must be bled again via function “Basic setting”
of tester -VAS 5051- .
Initiate basic setting (to bleed brake system):
Connecting -VAS 5051- and selecting functions ⇒ page 10
– Then bleed brake system as normal.
4.1.2 Bleeding (normal):

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

Carry out subsequent bleeding when:
♦ brake pedal travel is too long or so-called »soft brake pedal«
Subsequent bleeding requires the assistance of a second me‐
chanic.
– Depress brake pedal firmly and hold.
– Open bleeder valve on wheel brake cylinder/brake caliper.
– Fully depress brake pedal.
4. Bleeding brake system 115

Polo 2010 ➤
– Close bleeder 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- Rear left wheel brake cylinder/ brake caliper
2- Front left brake caliper
3- Front right brake caliper
4- Rear right wheel brake cylinder/ 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 ⇒ Maintenance ; Booklet ; Brake and clutch
system: Changing brake fluid

Polo 2010 ➤
5 Assembly overview - brake booster/

brake master cylinder
5.1 Assembly overview - brake booster/brake master cylinder (left-hand drive

vehicle)
Complete brake master cylinders and brake boosters can be re‐
newed independently of each other.
1 - Cap
2 - Brake fluid level warning
contact - F34-
4 - Sealing plug
5 - Brake booster
❑ On petrol engines, the
required vacuum is ob‐
tained at the intake con‐
necting piece.
uum.

fect.
❑ Replace completely in
the event of a fault (be‐
fore doing so, check
brake booster vacuum
system) ⇒ page 120
vacuum hose) functional check ⇒ page 124 .
6 - Seal
8 - Sealing ring
❑ Renew.
5. Assembly overview - brake booster/brake master cylinder 117

Polo 2010 ➤

11 - Torx bolt, 7 Nm
13 - Pin
14 - Sealing plug
5.2 Assembly overview - brake booster/brake master cylinder (right-hand drive

vehicle)
1 - Brake booster
gines, the required vac‐
uum is taken from the
intake manifold.
gines with a dual clutch
gearbox, the necessary
vacuum is generated by
the vacuum pump for
brakes - V192- .
uum.

fect.
❑ Replace completely in
the event of a fault (be‐
fore doing so, check
brake booster vacuum
system) ⇒ page 120
vacuum hose) function‐
al check ⇒ page 124 .

Polo 2010 ➤
2 - Seal
3 - Vacuum line
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
4 - Self-locking hexagon nut
❑ 25 Nm
❑ Qty. 4
5 - Pedal cluster
6 - Sealing ring
❑ Renew.
8 - Bolt
❑ 7 Nm
10 - Nut
❑ 25 Nm
11 - Brake line
12 - Brake line
❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .
13 - Sealing plug
❑ With brake fluid level warning contact - F34-
15 - Cap
16 - Bolt
❑ 4 Nm

Polo 2010 ➤
5.3 Vacuum pump for brake booster (vehi‐

cles with diesel engine)
5.3.1 Vacuum pump for diesel engines

Must not be dismantled.
1 - Exhauster pump
2 - Vacuum hose to brake booster with non-return valve.
– Installing and removing vacuum pump ⇒ 3-cylinder diesel en‐
gine (1.2 l engine, common rail); Rep. gr. 15 ; Cylinder head;
Installing and removing vacuum pump .
– Installing and removing vacuum pump ⇒ 4-cylinder diesel en‐
gine (1.6 l engine, common rail); Rep. gr. 15 ; Cylinder head;
Installing and removing vacuum pump .
5.4 Checking brake booster 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 booster or in the event of a so-called »hard brake
pedal«.
This check relates to the following components:
♦ Brake booster
♦ Oil seal between brake master cylinder and brake booster.
♦ 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 booster - VAS 6721-

Polo 2010 ➤
5.4.1 Connecting vacuum gauge for brake

booster - VAS 6721-
– Pull vacuum hose out of brake booster.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.
– Place brake booster 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 booster
off vacuum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-
C Cut- In direction of brake booster

off
valve
– Push hose -A- of brake booster vacuum gauge - VAS 6721-

onto vacuum hose and press adapter -C- into brake booster.
5.4.2 Checking vacuum generation
Note
♦ The average air pressure of the earth's atmosphere at sea

level is 1,013 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 booster vacuum gauge - VAS 6721-
⇒ page 121 .
– Open cut-off valve -A-.

Polo 2010 ➤
– Close cut-off valves -B+C-.

– Start warm engine (>60°C), press accelerator briefly (engine
speed greater than 2,000 rpm).
– 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 124 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
5.4.3 Checking for leaks
Note
♦ The average air pressure of the earth's atmosphere at sea

level is 1,013 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 booster vacuum gauge - VAS 6721-
⇒ page 121 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine (>60°C), press accelerator briefly (engine
speed greater than 2,000 rpm).
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).

Polo 2010 ➤
– Open cut-off valve -C- to evacuate brake booster.

– 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 booster
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 booster:
– After generation of vacuum, close cut-off valve -A- in order to

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

Polo 2010 ➤
5.4.4 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 booster 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 booster vacuum
gauge - VAS 6721- .
– Then, carry out the corresponding checks.
5.5 Checking non-return valve

♦ Air must pass through non-return valve -A- in direction of ar‐
row.
♦ Non-return valve must remain closed in opposite direction.
Observe correct installation position!
5.6 Vacuum pump for brakes - V192-

Only in vehicles with petrol engine and dual clutch gearbox.
Vacuum pump for brakes - V192- is located on the front right-hand
side in engine compartment.
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.
5.6.1 Assembly overview - vacuum pump for brakes - V192-

Polo 2010 ➤
1 - Bolt
❑ 8 Nm
❑ Qty. 2
2 - Bracket
3 - Vacuum pump for brakes -
V192-
⇒ page 125 .
4 - Brake booster pressure
sensor - G294-
⇒ page 126 .
5 - Vacuum line
6 - Rubber damper
7 - Bolt
❑ 25 Nm
❑ Qty. 3
8 - Rubber damper
❑ Qty. 2
9 - Bracket
5.6.2 Removing
The vacuum pump for brakes - V192- is located on the front right-
hand side in engine compartment.
– Pull vacuum hose -2- off vacuum pump for brakes - V192-
-1-.

Polo 2010 ➤
– Pull vacuum pump for brakes - V192- -1- out of rubber damp‐
ers -arrows A-.
– Remove vacuum pump for brakes - V192- -1- upwards in
-direction of arrow B-.
– Place vacuum pump for brakes - V192- -1- somewhere safe

together with the bracket -2-.
– Undo bolts -arrows- and take bracket -2- off the vacuum pump
for brakes - V192- -1-.
5.6.3 Installing
When installing, ensure that rubber dampers are not pressed out
of bracket.
Specified torque
Vacuum pump for brakes - V192- to bracket 8 Nm
5.7 Removing and installing brake booster

pressure sensor - G294-
Only in vehicles with petrol engine and dual clutch gearbox.
Removing
Note
The vacuum line does not have to be removed.

Polo 2010 ➤
– Release connector -2- at brake booster pressure sensor -

G294- -1- and pull connector off.
– Release clip with a pair of pliers -1-.

– Carefully prise brake booster pressure sensor - G294- -2- off.
Installing
– Carefully connect brake booster pressure sensor - G294- to
vacuum line so that sensor engages correctly.
5.8 Removing and installing brake light

switch - F- , left-hand drive
Removing
– Remove air filter housing (except 4-cylinder injection engine,
1.4 l).
– Separate connector -1- from brake light switch - F- .
– Remove bolt -2- from brake master cylinder.
– Pull brake light switch - F- -3- from brake master cylinder and
remove it from locking lug on brake master cylinder.
Installing
– Install in reverse order.
Specified torque:
Torx bolt to brake master cylinder 7 Nm
5.9 Removing and installing brake light

switch - F- , right-hand drive
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Front of body .

Polo 2010 ➤
– Undo bolt -arrow B- of brake light switch - F- -1- from brake

master cylinder.
– Pull brake light switch - F- -1- out of brake master cylinder
upwards.
– Pull brake light switch - F- -1- out of brake master cylinder
locking lug -arrow A-.
– Remove brake light switch - F- together with wiring.
– Release connector of brake light switch - F- and pull it off.
Installing
– Insert brake light switch - F- -1- into brake master cylinder

locking lug -arrow A-.
– Screw in bolt -arrow B- and tighten.
Specified torque
Brake light switch - F- to brake master cylinder 7 Nm

Polo 2010 ➤
6 Removing and installing brake mas‐

ter cylinder
6.1 Removing and installing brake master

cylinder, left-hand drive
6.1.1 Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Dis‐
connecting and reconnecting battery .
6. Removing and installing brake master cylinder 129

Polo 2010 ➤
– Remove air filter housing (except 4-cylinder injection engine,

1.4 l).
– Disconnect connector -A- from brake fluid level warning con‐
tact - F34- .
– Separate connector -C- from brake light switch - F- .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234-
or extraction unit -V.A.G 1869/4- .
Additional work for vehicles with manual gearbox:
– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
– Push brake fluid reservoir pin through fastening tab and brake
master cylinder.
– Then pull brake fluid reservoir out of brake master cylinder.
– Mark and unscrew brake lines from brake master cylinder -1-
and immediately seal brake lines with plugs from repair kit Part
No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
– Carefully take brake master cylinder out of brake booster.
– Remove brake light switch - F- .
6.1.2 Installing
Observe the following important points when installing:
– When assembling brake master cylinder with brake booster,
make sure plunger rod is properly positioned in brake master
cylinder.
Specified torques:
Brake master cylinder to brake booster 25 Nm
♦ Use new nuts!
Brake lines to brake master cylinder 14 Nm

Torx bolt for brake light switch to brake master cyl‐ 7 Nm
inder
6.2 Removing and installing brake master cylinder, right-hand drive vehicle

Polo 2010 ➤

equipment required
♦ Sealing tool - T10249-
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-
6.2.1 Removing
– Undo and remove bolted joint -3-.

Polo 2010 ➤
– Detach fuel lines -arrows- at separating point on wheel hous‐

ing on right and place to one side.
– Place sufficient lint-free cloths in area of engine.
Vehicles with manual gearboxes:
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch sender cylinder -3- with sealing
tool - T10249- -1-.
– Tie return hose -2- in place above.

– Release and pull connector -1- off brake fluid level warning
contact - F34- .
– Unscrew bolt -arrows- from brake fluid reservoir -1-.

– Carefully pull brake fluid reservoir out of sealing plugs of brake
master cylinder.

Polo 2010 ➤
– Mark and unscrew brake lines -1- from brake master cylinder
-2- .
– Seal brake lines with sealing plugs - 1H0 698 311 A- .
– Pull vacuum line -3- out of brake booster unit and put it down
somewhere.
– Unscrew nuts -arrows- from brake master cylinder -1-.

– Carefully remove brake master cylinder together with brake
light switch - F- from brake booster.
– Release and pull connector off brake light switch - F- .
– Remove brake light switch - F- .
6.2.2 Installing
cylinder.
Coat sealing plugs with brake fluid before pressing brake fluid
reservoir into brake master cylinder.
Specified torque
Brake fluid reservoir to brake master cylinder 4 Nm
Brake light switch to brake master cylinder 7 Nm
Coolant expansion tank to body 5 Nm

Polo 2010 ➤
7 Removing and installing brake boos‐

ter
7.1 Removing and installing brake booster,

left-hand drive
Note
If there are problems with the brake booster, first check the brake
booster vacuum system ⇒ page 120

7.1.1 Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Dis‐
connecting and reconnecting battery .
– Remove engine control unit ⇒ Rep. gr. 24 .

Polo 2010 ➤
– Unbolt fastening tab for air filter.

– Disconnect connector -A- from brake fluid level warning con‐
tact - F34- .
– Separate connector -C- from brake light switch - F- .
– Place sufficient lint-free cloths in area of engine and gearbox.
Additional work on following engines and gearboxes:
3-cyl. injection engine (4-valve):
– Remove throttle valve module - J338- ⇒ 3-cyl. injection engine
(4-valve); Rep. gr. 24 ; Injection system; Assembly overview
- intake manifold .
4-cyl. injection engine, toothed belt drive:
– Removing and installing ⇒ Electrical system; Rep. gr. 27 ;
Removing and installing battery
4-cylinder direct injection engines (2.0 l, 4 V, turbocharger, tooth‐
ed belt drive):
– Remove air filter housing -1- with air hose ⇒ Rep. gr. 24 ; Air
filter; Removing and installing air filter housing .
– Remove engine control unit -2-, and lay it to one side ⇒ Rep.
gr. 23 ; Engine control unit; Removing and installing engine
control unit .
– Remove bracket for engine control unit from bulkhead.
– Remove rear bracket for air filter housing ⇒ Rep. gr. 24 ; Air
filter; Assembly overview - air filter housing .
4-cylinder injection engine (1.4 l and 1.6 l engine, BiFuel):
– Remove natural gas vaporizer ⇒ Rep. gr. 24 ; Removing and
installing vaporizer for vehicles with liquefied petroleum gas
drive .
3-cylinder diesel engine (1.2 l engine, common rail):
7. Removing and installing brake booster 135

Polo 2010 ➤
– Loosen charge air pipe and screw-type clip -1- on connecting

hose leading to turbocharger ⇒ 3-cylinder diesel engine (1.2 l
engine, common rail); Rep. gr. 21 .
– Then unbolt pulsation damper from turbocharger and remove

along with connecting hose.
4-cylinder diesel engine (1.6 l engine, common rail):
– Loosen charge air pipe and screw-type clip to turbocharger ⇒
4-cylinder diesel engine (1.6 l engine, common rail); Rep. gr.
21 .
– Then unbolt pulsation damper from turbocharger and remove

along with connecting hose.
Manual gearbox:
– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
Dual clutch gearbox:
– Remove gear selector cable from ball head and cable support
⇒ 7-speed dual clutch gearbox 0AM; Rep. gr. 34 ; Selector
mechanism .
– Remove selector lever from selector shaft on gearbox ⇒ 7-
speed dual clutch gearbox 0AM; Rep. gr. 34 ; .
– Push brake fluid reservoir pin through fastening tab and brake
master cylinder.
– Then pull brake fluid reservoir out of brake master cylinder.

Polo 2010 ➤
– Mark and unscrew brake lines from brake master cylinder -1-
and immediately seal brake lines with plugs from repair kit Part
No. 1H0 698 311 A.
– Pull vacuum hose out of brake booster.
– Remove hexagon nuts -arrows-.

– Carefully remove brake booster from vehicle.
– If brake booster sticks in holes, loosen both remaining nuts on
mounting bracket.
– Unscrew brake master cylinder from brake booster.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake booster.
7.1.2 Installing
Observe following points when installing:
Specified torques:
Brake booster to pedal cluster and plenum chamber 25 Nm
bulkhead
♦ Use new nuts!

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

right-hand drive vehicle
Note
If there are problems with the brake booster, first check the brake
booster vacuum system ⇒ page 120

Polo 2010 ➤

equipment required
♦ Release tool - T10159 A-
♦ Sealing tool - T10249-
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-
7.2.1 Removing
Vehicles with a 1.4 l 125 kW petrol engine
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Front of body .
– Remove front right wheel housing ⇒ Body; Rep. gr. 66 ; Ex‐
terior equipment .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Front wheel suspension, drive shaft .
– Remove engine cover panel -arrow A- and heat shield
-arrow B- ⇒ Rep. gr. 21 ; Charge air pressure system .
– Remove charge air pressure pipes -1- and -2- ⇒ Rep. gr. 21 ;
Charge air pressure system .

Polo 2010 ➤
– Remove air cowling -1- ⇒ Rep. gr. 19 ; Removing and instal‐

ling parts of the cooling system .
– Remove noise insulation from compressor ⇒ Rep. gr. 21 ;
Removing and installing compressor and place to one side.
– Remove throttle valve module - J338- ⇒ Rep. gr. 24 ; Re‐
moving and installing throttle valve module J338 .
Vehicles with manual gearboxes
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch sender cylinder -3- with sealing
tool - T10249- -1-.
– Tie return hose -2- in place above.
– Detach brake booster from brake pedal ⇒ page 100 .
– Open holder -2- carefully at the locking lug -arrow-.

– Unclip coolant line -1-.
– Detach fuel lines -arrows- at connecting point in engine com‐

partment on right.
– Place the fuel lines to one side.

Polo 2010 ➤
– Unclip wiring harness from holders -arrow-.

– Undo screws -3-.
ervoir using brake filling and bleeding equipment - VAS 5234- .

– Release and pull connector -1- off brake fluid level warning
contact - F34- .
– Unscrew bolt -arrows- from brake fluid reservoir -1-.

– Carefully pull brake fluid reservoir out of sealing plugs of brake
master cylinder.

Polo 2010 ➤
– Mark and unscrew brake lines -1- from brake master cylinder
-2- .
– Seal brake lines with sealing plugs - 1H0 698 311 A- .
– Pull vacuum line -3- out of brake booster.
Vehicles with petrol engine and dual clutch gearbox

– Release connector -2- at brake booster pressure sensor -
G294- -1- and pull connector off.
– Pull vacuum hose -2- off vacuum pump for brakes - V192-
-1- and place to one side.

– Unscrew nuts -arrows- from brake master cylinder -1-.
– Release connector of brake light switch - F- and pull it off.
– Carefully remove brake master cylinder together with brake
light switch - F- from brake booster.

Polo 2010 ➤
– Unclip brake hoses from bracket -arrow-.
– Remove nuts -arrows-.
– Remove bolts -1- to -4- of engine mounting.

– Pull engine 3.5 cm forwards in -direction of arrow- by the en‐
gine mounting.
– Carefully remove brake booster from the vehicle.
7.2.2 Installing
– Carefully insert brake booster and tighten nuts.
cylinder.
Coat sealing plugs with brake fluid before pressing brake fluid
reservoir into brake master cylinder.
Specified torque
Brake booster to pedal cluster and plenum chamber 25 Nm
bulkhead
♦ Use new nuts

Polo 2010 ➤

♦ Use new nuts

Brake fluid reservoir to brake master cylinder 4 Nm
Coolant expansion tank to body 5 Nm

Polo 2010 ➤
8 Repairing brake lines

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

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

♦ Flanging tool for brake lines - VAS 6056-

List of individual tools:
Item Tool Tool number
1 Flanging tool (including flanging VAS 6056/1
jaws 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!
8.1 Assembly overview - flanging tool

Polo 2010 ➤
1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws.
2 - Fastening for handle
❑ Must be unscrewed to
access securing bolt for
upper part.
3 - Securing bolt
❑ 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 145
Flanging jaw assembly instructions:

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

– Unbolt relevant brake line at brake caliper or wheel brake cyl‐
inder; catch escaping brake fluid and dispose of this as per
regulations.
8. Repairing brake lines 145

Polo 2010 ➤
– 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-.

Polo 2010 ➤
– 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.
8. Repairing brake lines 147

VW Polo 5 2010 Brake Systems Eng

Uploaded by

Copyright:

Available Formats

VW Polo 5 2010 Brake Systems Eng

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VW Polo 5 2010 Brake Systems Eng

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

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

4.1 Removing and installing handbrake cable (drum brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . 89

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Information on the individual brake that is fitted is currently not

– To find information about the brake, please search in ELSA/

1.1 Front brakes

Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Brake allocation via PR No. 1

1.2 Rear brakes

1.2.1 Disc brakes

1.2.2 Drum brakes

2 Rep. gr.00 - Technical data

2 Technical data for brakes

2.1 Brake master cylinder and brake boos‐

2.2 Front brakes

2.2.2 Front brakes FN 3

2. Technical data for brakes 3

Front brake FN3 16":

2.3 Rear brakes

4 Rep. gr.00 - Technical data

2.3.2 Rear brakes (disc brakes)

Item PR No. 1KD

2. Technical data for brakes 5

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

3.2 Test for vehicles with front-wheel drive

6 Rep. gr.00 - Technical data

45 – Anti-lock brake system

1.1 Bosch 8.2 and 9.0

ABS layout in right-hand drive vehicle:

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

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

2 Notes for repair work on anti-lock

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

3 Connecting -VAS 5051- and select‐

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

– Plug in connector of diagnostic cable -VAS 5051/1- or -

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

– Switch on tester -arrow-.

3. Connecting VAS 5051 and selecting functions 11

4 Electrical/electronic components and

4.1 Bosch 8.2; 9.0 ABS

1 - ABS control unit - J104-

4 - Brake system warning lamp

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

4.2 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP

1 - ABS control unit - J104-

4 - ESP and TCS warning lamp - K155-

4. Electrical/electronic components and locations 13

6 - Brake light switch - F-

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

5 Fault display via warning lamps

ESP warning lamp - K155-

5. Fault display via warning lamps 15

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

6 Assembly overview - hydraulic unit,

6.1 Bosch 8.2; 9.0 ABS, LHD vehicles

1 - ABS control unit - J104-

6. Assembly overview - hydraulic unit, brake booster/brake master cylinder 17