D3E803BC25F-Brake System

Service
Workshop Manual
Golf Cabriolet 2012 ➤
Brake systems
Edition 04.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data autho eo
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45 - Anti-lock brake system s
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46 - Brakes - mechanism
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47 - Brakes - hydraulics
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E803BC25F

Brake systems - Edition 04.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Test for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP) n. A.G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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5 Assembly overview - hydraulic unit y Volks . . . . . . . . . . . . . . . . . . .s n. o.t .g . . . . . . . . . . . . . . . . . . . .
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5.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP)ris
ed . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . . . . . . 13
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6 Removing and installing auparts of ABS system on front and rear axle . . r.ac. . . . . . . . . . . . . 20
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6.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 20
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6.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 21
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7 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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7.1 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.1 Assembly overview - front brakes FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t to the co 24

1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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1.4 Assembly overview - front brakes FNR-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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1.5 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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2.1 Assembly overview - rear brakes C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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2.4 Assembly overview - rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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2.5 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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2.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.7 Assembly overview - Bosch rear wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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2.8 Removing and installing brake pads, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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2.9 Removing and installing brake calipers, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Removing and installing handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Contents i
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Assembly overview - brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.3 Assembly overview - brake caliper FNR-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.4 Removing and installing brake piston FNR-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Repairing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Assembly overview - brake caliper C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2 Assembly overview - brake caliper CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.3 Removing and installing piston for brake caliper C 38 and CII 41 . . . . . . . . . . . . . . . . . . . . 80
2.4 Assembly overview - Bosch brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.5 Removing and installing Bosch brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.6 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234 . . . . . . . . 88
4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5 Brake servo and brake master cylinder . . . . . . . . . . . . k.s. . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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5.2 Vacuum pump for brake servo (vehicles ed by with diesel engine) . . . . . . . . . g.ua. r. . . . . . . . . . . . .
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5.3 Vacuum pump for brake servo (vehicles ris with 2.0 l petrol engine) . . . . . . . . .te.e.o . . . . . . . . . 92
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5.4 Checking brake servo vacuumsssystem au r
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . 92
5.5 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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5.6 Removing and installing vacuum sender G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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5.7 Removing and installing brake light switch F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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8 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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8.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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ii Contents
00 – Technical data
1 Brake allocation via PR No.
(VRL005463; Edition 04.2013)
The type of brake system installed in the vehicle is indicated
among other things by the corresponding production control (PR)
number on the vehicle data sticker.
Example of a vehicle data sticker:
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes - 1KD
♦ Arrow 2 - Front brakes -1ZE agen
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In this example the rear brake “1KU” is installed in the vehicle. orm
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♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .

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♦ The following table explains the PR numbers. These are im‐

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1.1 Front brakes
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Engine PR No. Front brakes

1.2l - 77 kW FSI 1ZE FN3 (15")
1.4l - 90 kW TSI
1.6l - 77 kW TDI
2.0l - 103 kW TDI 1LJ / 1ZA / 1ZB FN3 (16")
1.4l - 118 kW TSI
2.0l - 155 kW TSI
2.0l - 188 kW T-FSI 1ZK FNR-G (17”)
2.0l - 195 kW T-FSI
1.2 Rear brakes

Engine PR No. Rear brakes
1. Brake allocation via PR No. 1

1.2l - 77 kW FSI 1KD C 38 (15”)

1.4l - 90 kW TSI
1.4l - 118 kW TSI
1.6l - 77 kW TDI
2.0l - 103 kW TDI
2.0l - 155 kW TSI 1KS/1KT Bosch ZOH 38
2.0l - 188 kW T-FSI 1KW CII 41 (17")
2.0l - 195 kW T-FSI
Country-specific brake for Japan:
Engine PR No. Rear brakes
All 1KS Bosch ZOH 38
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2 Rep. gr.00 - Technical data

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

Brake master cylinder ∅ in mm 23.81
Brake servo (LHD) ∅ in inches 10
Brake servo (RHD) ∅ in inches 7 /8
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Item PR No. 1ZE
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1 Brake caliper FN3 (15")
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2 Brake pad, mm 14
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Brake pad, wear mm 2
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3 Brake disc ∅ in 288
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Brake disc, mm 25
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Brake disc, mm 22
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4 Brake caliper ∅ in 54
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Item PR No. 1LJ / 1ZA / 1ZB

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1 Brake caliper FN3 (16")
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2 Brake pad, mm 14
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backplate
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Brake disc, mm 25
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Brake disc, mm 22
wear limit
piston mm
2. Technical data for brakes 3

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Brake systems - Edition 04.2013 aut
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2.2.2 Front brakes FNR-G
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Item PR No. 1ZK
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1 Brake caliper FNR-G (17”)
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2 Brake lining, mm 14
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Brake disc, mm 30
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Brake disc, mm 27
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4 Brake caliper, ∅ in 57
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2.3 Rear brakes (disc brakes)

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2.3.1 Rear brakes C 38

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Item PR No. 1KD
1 Brake caliper C 38 (15”)
2 Brake pad, mm 11
thickness
limit without
backplate
mm
Brake disc, mm 10
thickness
Brake disc, mm 8
wear limit
piston mm
2.3.2 Rear brakes Bosch ZOH 38

Item PR No. 1KS/1KT
1 Brake caliper Bosch ZOH 38 (16")
2 Brake pad, mm 12
thickness
limit without
backplate
mm
Brake disc, mm 10
thickness
Brake disc, mm 8
wear limit
piston mm

2.3.3 Rear brakes CII 41 (17")

Item PR No. 1KW
1 Brake caliper CII 41 (17")
2 Brake lining, mm 11
thickness
limit without
backplate
mm
Brake disc, mm 22
thickness
Brake disc, mm 20
wear limit
4 Brake caliper, ∅ in 41
piston mm
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2. Technical data for brakes 5

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♦ The drive is provided by the roller dynamometer.
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ab
♦ For the test ensure for vehicles with a manual gearbox that the
ility
ot p
gear lever is in neutral, and for vehicles with an automatic
wit
, is n
gearbox that the selector lever is in »N«.
h re
hole
spec
♦ For the test, observe the specifications provided by the man‐
es, in part or in w
ufacturer of the roller dynamometer.
t to the co
Note
rrectness of i
l purpos
The brake regulation systems do not function when ignition is off.
nf
ercia
3.2 Test for vehicles with front-wheel drive
orm
m
atio
m
The brake test must be performed on a single-axle roller dyna‐

o
n in
c
mometer.
or
thi
te
sd
The maximum test speed must not exceed 6 km/h.
iva
o
r
rp
cu
The test rigs authorised by Volkswagen fulfil these requirements.
o
m
f
en
ng
t.
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Cop py
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Vo
co lksw
by
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Prote AG.

45 – Anti-lock brake system

1 General notes on anti-lock brake sys‐
tem
On vehicles with ABS Mark 60 EC, the following version is instal‐
led:
♦ ABS/EDL/TCS/ESP with integrated ESP sensor unit
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
ABS layout in left-hand drive vehicle.
1 - Hydraulic unit and control unit
2 - Brake servo
. Volkswagen AG
gen AG does
The hydraulic unit -2- and control unit -1- form one component.
Vol
ksw
a
not
They can be separated only when removed. Hydraulic ed
by pump -3- gu
ara
must not be separated from hydraulic unit. thoris nte
eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
7
Prote AG.
1. General notes on anti-lock brake system
2 Notes for repair work on anti-lock

brake system
olkswagen AG
en AG. V
♦ Before carrying out repair work on the anti-lock brake
olks system,
wag does
not
determine the cause of the fault as well as theed
control
byV unit code gu
ara
using “Guided Fault Finding”. horis nte
eo
t
au ra
“Guided Fault Finding” is carried out withss the vehicle diagnostic, c
testing and information system - VAS 5051- .
ce
le
un
pt
an
d
♦ Disconnect battery earth strap with ignition switched off. itte
y li
erm
ab
♦ Before carrying out welding work with an electric welding unit,
ility
ot p
note ⇒ General Information; Body Repairs, General Body Re‐
wit
is n
h re
pairs .
ole,
spec
♦ When working with brake fluid, observe the relevant safety

precautions and notes ⇒ page 88 .
t to the co
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
rrectne
VAS 5234- ⇒ page 88 .
♦ During the final road test, ensure that a controlled brake test
ss
is performed at least once (pulsations must be felt at the brake
o
cial p
f i
pedal).
nform
mer
♦ Absolute cleanliness is required when working on the anti-lock
atio
m
brake system. It is not permitted to use any products which

o
n
c
contain mineral oil, such as oils, greases etc.
i
or
n thi
te
sd
a
♦ Thoroughly clean all unions and the adjacent areas before

iv
o
pr
c
loosening. Do not use aggressive cleaning agents such as
um
r
fo
en
ng
brake cleanser, petrol, thinners or similar. yi

t.
Co
op py
♦ Place removed parts on a clean surface and cover.
t. C rig
gh ht
pyri by
Vo
♦ After separating control unit from hydraulic unit, use transport
co lksw
by
cted agen
protection for contact pins. Prote AG.
♦ 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.
♦ Make sure not to touch any contact surfaces on the connector,
pressure sensor and control unit as well as the silicone gel by
hand or with objects.
♦ 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.
8 Rep. gr.45 - Anti-lock brake system

AG. Volkswagen AG d
agen oes
olksw not
3 Connecting -VAS 5051- and select‐
yV
b gu
d ara
ise nte
r
ing functions
ho eo
aut ra
ss c
ce
Special tools and workshop equipment required le
un
pt
an
d
itte
♦ Vehicle diagnosis, testing and information system - VAS 5051-
y li
rm
ab
pe
ility
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
WARNING
s
iva
do
r
rp
cum
♦ During a road test, you must always secure testing and
fo
en
g
measuring equipment on the back seat.

n
t.
yi Co
Cop py
♦ These devices may be operated only by a passenger while
ht. rig
rig ht
by
the vehicle is in motion. copy Vo
by lksw
cted agen
Prote AG.
– Connect connector of diagnosis cable -VAS 5051/1- or -

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

– Switch on tester -arrow-.

The tester is ready for operation when the selector buttons for the
operating modes appear on the screen.
– Switch on ignition.
– Touch Guided Fault Finding on screen.
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data entered.
Wait until tester has interrogated all control units in vehicle.
– Press Go to and select function “Function/component selec‐
tion”.
– Select “Running gear” on display.
– Select “Brake systems” on display.
– Select “01 Self-diagnosis capable system …” shown on dis‐
play.
– Select “Anti-lock brake system …” shown on display.
– Select “Function” shown on display.
Now all possible functions from the anti-lock brake system instal‐
led in the vehicle will be displayed.
AG. Volkswagen AG d
agen
– Select desired function on display. Volksw
oes
not
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Electrical/electronic components and

locations
4.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP)
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‐ gen AG
. Volkswagen AG
does
swa
agnosis. Switch ignition yV
olk not
gu
off before separating
rised b ara
nte
connector. ut
ho eo
r
sa ac
The following components
s
are
ce
e
nl
integrated into the control unit:
pt
du
an
♦ Lateral acceleration sender
itte
y li
- G200-
erm
ab
ility
ot p
♦ Yaw rate sender - G202-
wit
, is n
h re
♦ Longitudinal acceleration
hole
spec
sender - G251- (depending
es, in part or in w
on equipment fitted)
t to the co
❑ Removing and installing
⇒ page 15
rrectness of i
2 - ABS hydraulic unit - N55-
l purpos
❑ Location: on right in en‐

gine compartment.
nform
ercia
The hydraulic unit consists of

the components:
m
at
om
♦ ABS hydraulic pump - V64-

ion
c
in t
or
♦ Brake pressure sender -

his
ate
G201-
do
priv
cum
or
♦ Valve block (contains inlet

f
en
ng
t.
yi
and outlet valves).
Co
Cop py
.
❑ ABS hydraulic pump -
ht rig
rig ht
by
V64- and valve block copy Vo
by lksw
must not be separated cted agen
Prote AG.
from one another.
❑ Removing and installing ⇒ page 15
3 - Brake pad warning lamp - K32-
❑ Location: in dash panel insert.
4 - ABS warning lamp - K47-
5 - ESP and TCS warning lamp - K155-
❑ Only vehicles with ABS/EDL/TCS/ESP.
6 - Brake system warning lamp - K118-
7 - Brake light switch - F-
❑ Including brake pedal switch - F47- .
4. Electrical/electronic components and locations 11

❑ Location: on brake master cylinder.
8 - TCS and ESP button - E256-
❑ Only vehicles with ABS/EDL/TCS/ESP.
❑ Location: in centre console.
9 - Diagnostic connection
❑ Location: Driver footwell cover.
10 - Steering angle sender - G85-
AG. Volkswagen AG d
agen oes
ksw not
Note by
Vol
gu
ara
ed
ris nte
o
In vehicles equipped with 3rd gen‐ aut
h eo
ra
eration electromechanical power ss c
steering, the steering angle sender
ce
e
nl
pt
du
is located in the steering box.
an
itte
y li
erm
ab
❑ Location: in steering box.
ility
ot p
wit
, is n
h re
hole
11 - Front right/left speed sensor -G45- / -G47-
spec
es, in part or in w
t to the co
12 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
rrectness of i
13 - Rear right/left speed sensor -G44- / -G46-
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5 Assembly overview - hydraulic unit
5.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP)
1 - ABS control unit - J104-

⇒ page 15
2 - Torx bolt, 2 Nm + 0.8 Nm
❑ Use new bolts.
3 - ABS hydraulic unit - N55-
⇒ page 15
4 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Identification: ∅ 6.5 mm
and union nut with
thread M12 x 1
AG. Volkswagen AG d
5 - Brake line ksw
agen oes
not
ol
❑ From secondary piston byV gu
ara
ed
circuit of brake master horis nte
eo
cylinder to hydraulic s aut ra
c
unit. s
ce
e
nl
pt
❑ Identification: ∅ 6.5 mm
du
an
itte
and union nut with
y li
erm
ab
thread M12 x 1
ility
ot p
wit
6 - Brake line
, is n
h re
❑ To front left brake cali‐
hole
spec
per.
es, in part or in w
t to the co
❑ Identification:
∅ 5.25 mm and union
nut with thread M10 x 1
rrectness of i
7 - Brake line
l purpos
❑ To front right brake cali‐

per. nform
ercia
❑ Identification: ∅ 5.25
mm and union nut with thread M12 x 1
m
at
om
io
8 - Brake line
n
c
in t
or
❑ To rear left brake caliper.

his
ate
do
riv
❑ Identification: ∅ 5.25 mm and union nut with thread M12 x 1

p
cum
for
en
g
9 - Brake line
n
t.
yi Co
op
❑ To rear right brake caliper.
C py
ht. rig
rig ht
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
py by
co Vo
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cted agen
10 - Brake servo
Prote AG.
❑ See ⇒ page 90 .
11 - Bracket
❑ Before installing, spray rubber dampers ⇒ Item 16 (page 14) with silicone lubricant D 007 000 A2.
❑ Check for secure seating after installing.
5. Assembly overview - hydraulic unit 13

12 - Torx bolt, 8 Nm
13 - Rubber damper
14 - Hexagon fitted bolt, 8 Nm
15 - Bracket AG. Volkswagen AG d
agen oes
olksw not
y V gu
16 - Rubber damper d b ara
rise nte
❑ Do not press rubber dampers out of console awhen
ut
ho
installing the bracket. eo
ra
ss c
17 - Hexagon nut, 20 Nm
ce
le
un
pt
an
d
18 - Heat shield
itte
y li
erm
ab
ility
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wit
is n
h re
ole,
spec
5.1.1 Connecting brake lines from brake mas‐
t to the co
ter cylinder to hydraulic unit
On brake master cylinder:
rrectne
A - Primary piston circuit of brake master cylinder to hydraulic unit.
s
- Identification: ∅ 6.5 mm and union nut with thread M12 x 1
s o
cial p
f i
B - Secondary piston circuit of brake master cylinder to hydraulic
nform
unit.
mer
atio
m

o
n
c
i
or
n thi
1 - From hydraulic unit to front left brake caliper.
te
sd
iva
o
r
3 - From hydraulic unit to rear right brake caliper.

p
cum
r
fo
en
ng
4 - From hydraulic unit to rear left brake caliper.

t.
yi Co
Cop py
t. rig
gh ht
yri
On hydraulic unit: p by
co Vo
by lksw
cted agen
A - From hydraulic unit to primary piston circuit of brake master Prote AG.
cylinder.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
1 - From hydraulic unit to front left brake caliper.
2 - From hydraulic unit to front right brake caliper.
3 - From hydraulic unit to rear right brake caliper.
4 - From hydraulic unit to rear left brake caliper.

5.1.2 Removing control unit and hydraulic unit
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1410-
♦ Brake pedal depressor -
V.A.G 1869/2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

The transport protection for the contact pins must always be
placed on the hydraulic unit after the control unit has been dis‐
connected from the hydraulic unit.
No warranty can be assumed for hydraulic units without transport
protection.
1 - Transport protection for contact
gen AG
pins
.Volksw(foam)
agen AG
a does
lksw not
2 - Sealing plug M10d by Vo gu
ara
e nte
ris
3 - Sealing plug
ut M12
ho eo
ra
a c
ss
Removing
ce
e
nl
pt
du
Location:
an
itte
y li
erm
ab
The control unit is bolted to the hydraulic unit and is located on
ility
ot p
right in the engine compartment.
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Do not bend the brake lines in the area of the hydraulic unit!
rrectness of i
– Read out and note the existing control unit code.
l purpos
– Note or request radio code on vehicles with coded radio if

necessary. nform
ercia
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

m
necting and reconnecting battery .

at
om
ion
c
– Remove engine cover.

in t
or
his
ate
1.4l TSI engine:

do
priv
cum
or
– Remove pressure pipe and intake connecting pipe with regu‐

f
en
ng
t.
yi
lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct
Co
op py
injection engine, turbocharger and compressor); Rep. gr. 24 ; t. C rig
gh ht
Injection system; Part I - assembly overview - intake manifold . pyri by
Vo
co lksw
by
cted agen
– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l Prote AG.
direct injection engine, turbocharger and compressor); Rep.
gr. 21 ; Charge air system .
– Clamp off hose from coolant expansion tank and pull it off.
2.0l TSI engine:
– Remove air pipe ⇒ 4-cylinder injection engine (1.8 and 2.0 l
engine, chain drive); Rep. gr. 21 ; Turbocharger .
– Seal off turbocharger using engine bung set -VAS 6122-.
Diesel engines with diesel particulate filter:
– Unscrew exhaust gas pressure sensor 1 - G450- , separate
electrical connectors, unscrew and lower diesel particulate fil‐
ter ⇒ Rep. gr. 26 ; Assembly overview - front exhaust pipe
with particulate filter .
Continuation for all models:
– Remove heat shield (if installed).

– Release connector on control unit in direction of arrow -1- and

pull off -2-.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Connect bleeder bottle hose to front left brake caliper bleeder
valve and rear left brake caliper bleeder valve and open bleed‐
er valves.
– 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.
– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.
– Immediately seal brake lines and threaded holes with seal
plugs from repair set Part No. 1H0 698 311 A.
– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.
– Turn hexagon fitted bolt out of retainer.
– Pull hydraulic unit together with control unit and retainer side‐
ways out of rubber dampers of bracket
lksw
ageand turn upside down. es n
o ot g
yV ua
– Unbolt retainer from hydraulic
ris
ed unit in engine compartment and
b ran
tee
remove. ut
ho
or
sa ac
– Remove hydraulic unit
s
together with control unit.
ce
le
un
pt
an
d
itte
5.1.3 Unscrewing control unit from hydraulic

y li
erm
ab
ility
unit
ot p
wit
is n
h re
ole,
spec
Note
t to the co
– Place hydraulic unit with control unit upwards on a clean flat

rrectne
level surface.
– Unscrew Torx bolts -arrows- out of control unit.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

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

n AG. Volkswagen AG age does
ksw not
After separating control unit and hydraulic
yV
ol unit, use transport pro‐ gu
db ara
tection for contact pins. ris
e nte
tho eo
s au ra
c
s
ce
le
un
pt
5.1.4 Installing new control unit
an
d
itte
y li
rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
hole
Severe shocks (e.g. dropping, impact) may destroy control
spec
unit. Control unit must not then be used.
es, in part or in w
t to the co
• Clean surfaces before assembling.
– Push all seals -A- over contact pins slightly. rrectness of i
l purpos
– Place control unit on hydraulic unit, ensuring it is not canted

when doing so.
nform
ercia
The seals are thus moved to end position.

m
a
com
ti
– Tighten hydraulic unit and control unit diagonally in stages to

on in
specified torque with enclosed new Torx bolts.

r
te o
thi
s
iva
do
r
rp
cum
fo
Note
en
ng
t.
yi Co
op py
♦ A new control unit may be mounted on an existing hydraulic
. C rig
ht ht
rig
unit max. twice to guarantee impermeability of the elastic seal. py by
co Vo
by lksw
cted agen
♦ A control unit which has already been operated in a vehicle Prote AG.
must not be installed a second time.
5.1.5 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.
– Install in reverse order.

– Before installing bracket for ABS hydraulic unit - N55- in con‐

sole, spray rubber dampers with silicone lubricant
D 007 000 A2 to make installation easier.
WARNING
Ensure that rubber dampers of retainer are not pressed out of

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

– Bleed brake system ⇒ page 88 . . Volkswagen AG
gen AG does
swa
– Code radio. yV
olk not
gu
d b ara
e
– Code control unit -J104-horis
with ⇒ Vehicle diagnostic tester in nte
eo
aut
”Guided fault finding”. ra
ss c
ce
e
To do this, basic setting of the steering angle sender - G85- , the

nl
pt
du
lateral acceleration sender - G200- and the brake pressure send‐
an
itte
y li
er - G201- must be carried out.
erm
ab
ility
ot p
Specified torques:
wit
, is n
h re
Control unit to hydraulic unit 2 Nm + 0.8
hole
spec
♦ Use new bolts! Nm
es, in part or in w
t to the co
Torx bolt for hydraulic unit to bracket 8 Nm
Hexagon fitted bolt, retainer to bracket 8 Nm
rrectness of i
Brake lines to ABS unit:
Thread M10 x 1 14 Nm
l purpos
Thread M12 x 1 14 Nm
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6 Removing and installing parts of ABS

system on front and rear axle
wage es n
6.1 Removing and installing parts of ABS system on front axle
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
1 - ABS speed sensor
ss
ce
le
❑ Before inserting sensor,

un
pt
an
d
clean hole inner surface

itte
y li
and coat with high-tem‐
rm
ab
pe
ility
perature paste
ot
wit
G 052 112 A3.
, is n
h re
hole
spec
⇒ page 20
es, in part or in w
t to the co
2 - Hexagon socket head bolt,
8 Nm
rrectness of i
3 - Wheel hub with wheel bear‐
ing
l purpos
❑ ABS sensor ring is in‐

stalled in wheel bearing.
nform
ercia
4 - Drive shaft
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.1.1 Removing and installing ABS speed

sensor on front axle
Removing
– Raise vehicle.

– Disconnect connector -1- from ABS speed sensor.

– Unscrew bolt -2- from wheel bearing housing.
– Pull out ABS speed sensor from wheel bearing housing.
Installing
– Before inserting ABS speed sensor, clean inside of hole and
coat circumference of speed sensor with high temperature
paste G 052 112 A3.
– Insert ABS speed sensor in hole of wheel bearing housing and
tighten bolt to 8 Nm.
– Connect ABS speed sensor to speed sensor line.
6.2 Removing and installing parts of ABS system on rear axle

perature paste
G 052 112 A3.
⇒ page 21
8 Nm
ing
AG. Volkswagen AG d
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6.2.1 Removing and installing speed sensor

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on rear axle
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21
AG.
6. Removing and installing parts of ABS system on front and rear axle
– Disconnect connector -1- from ABS speed sensor.

– Unscrew bolt -2- from wheel bearing housing.
– Pull out ABS speed sensor from wheel bearing housing.
Installing
– Before inserting ABS speed sensor, clean inside of hole and
coat circumference of speed sensor with high temperature
paste G 052 112 A3.
– Insert ABS speed sensor in hole of wheel bearing housing and
tighten bolt to 8 Nm.
– Connect ABS speed sensor to speed sensor line.
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7 Removing and installing parts of ESP

system
In vehicles with the ABS Mark 60 EC, the lateral acceleration
sender - 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 15 .
7.1 Removing and installing steering angle

sender - G85-
In vehicles equipped with an electromechanical power steering of
the 3rd generation, the steering angle sender - G85- is located in
the steering box.
It is not possible to replace these parts separately.
Removing and installing steering ⇒ Running gear, axles, steer‐
ing; Rep. gr. 48 ; Electromechanical steering box .
– Then perform basic setting of steering angle sender - G85- .
Connecting -VAS 5051- and selecting functions ⇒ page 9 .
AG. Volkswagen AG d
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7. Removing and installing parts of ESP system 23

Golf Cabriolet 2012 ➤ AG. Volkswagen AG d
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Brake systems - Edition 04.2013 Volksw
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not
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46 – Brakes - mechanism aut ra
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1 Repairing front brakes
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1.1 Assembly overview - front brakes FN3
ole,
spec
t to the co
Note
rrectne
♦ 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.
ss o
cial p
f
♦ Use the brake filling and bleeding equipment - VAS 5234- to
inform
draw off brake fluid from the brake fluid reservoir.
mer
atio
m
♦ Before removing a brake caliper or disconnecting a brake

o
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c
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
i
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1 - Torx bolt, 4 Nm
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❑ Ventilated, ∅ 288 mm
❑ Thickness: 25 mm
❑ Wear limit: 22 mm.
❑ Always renew on both
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
3 - Brake pads
❑ Thickness: 14 mm not
including backplate.
❑ With break pad wear in‐
dicator.
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake discs and pads/
linings: Checking condi‐
tion of discs and thick‐
ness of pads/linings .
sides of an axle.
⇒ page 27
24 Rep. gr.46 - Brakes - mechanism

4 - Retaining spring
❑ Insert into both holes in brake caliper.
wage es n
5 - Brake carrier Vol
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❑ Bolt to wheel bearing housing. orise ran
tee
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ut or
6 - Brake caliper ss
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❑ Do not disconnect brake hose when changing pads.
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❑ Repairing ⇒ page 70 .
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7 - Guide pin, 30 Nm
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8 - Cover cap
spec
es, in part or in w
❑ Remove
t to the co
9 - Brake hose with banjo union and banjo bolt, 35 Nm
10 - Ribbed bolt, 190 Nm
rrectness of i
❑ Clean if reused.
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11 - Bolt
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12 - Bracket
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13 - Wheel bearing housing
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❑ With bolted brake carrier.
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❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
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15 - Hexagon socket head bolt, 8 Nm t. Cop py
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17 - Torx bolt, 12 Nm Prote AG.

Assembly overview, FN3, 16 inch:
1. Repairing front brakes 25

2 - Brake disc
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
3 - Torx bolt, 4 Nm AG. Volkswagen AG d
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4 - Brake pads d by Vo gu
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❑ Thickness:th14 o mm not
ri
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includings abackplate.
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insert comes on.
spec
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cluding backplate.
❑ Checking thickness
rrectness of i
let ; Front and rear

l purpos
brake discs and pads/

linings: Checking condi‐
tion of discs and thick‐
nform
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ness of pads/linings .
m

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sides of an axle.
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⇒ page 27
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❑ Insert into both holes in brake caliper. Cop py
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6 - Brake carrier p by
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❑ Bolt to wheel bearing housing.
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7 - Brake caliper
9 - Cover cap
❑ Remove
12 - Cover cap
❑ Remove

13 - Bolt
14 - Bracket
15 - Ribbed bolt, 190 Nm
❑ Clean if reused.
❑ With bolted brake carrier.
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
18 - Hexagon socket head bolt, 8 Nm
20 - Splash plate
1.2 Removing and installing brake pads/lin‐

ings
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
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Mark brake pads/linings when removing if they are to be reused.
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– Remove wheels.
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– Lever brake pad retaining spring out from brake caliper

-arrow- with a screwdriver and remove.
– Disconnect connector -1- for brake pad wear indicator.
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– Remove cover caps -arrows-.

t to the co
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– Unscrew both guide pins -arrows- and remove from brake cal‐
r
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– Take brake pad out of brake caliper or from brake carrier. Prote AG.
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, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.
Use only methylated spirits for cleaning the brake caliper housing.

1.2.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Insert piston resetting tool - T 10145- into brake caliper -2- and
push back piston.
– 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.

– Fit both cover caps.
– Insert retaining spring into brake caliper.
– Connect brake pad wear indicator connector.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .
Perform basic setting of tyre pressure indicator ⇒ Running gear,
axles, steering; Rep. gr. 44 ; Tyre pressure indicator olkswage es n
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♦ Check brake fluid level after changing brake pads.
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Specified torque:
es, in part or in w
Guide pin to brake carrier 30 Nm t to the co
1.3 Removing and installing brake caliper

rrectness of i
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♦ Brake pedal depressor - V.A.G 1869/2-
1.3.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.
– Disconnect connector for brake pad wear indicator.
– Connect bleed bottle bleed hose -1- to bleed valve of brake
caliper.
– Open bleed valve.
AG. Volkswagen AG d
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– Apply brakeopedal
ris
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– Close bleed
ss a valve and remove bleed bottle. ra
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Rep. gr.46 - Brakes - mechanism
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– Unscrew brake hose -1- with banjo bolt -2-. byV
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– Pull both cover caps out of brake caliper bearing
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– Unscrew both guide pins -arrows- and remove from brake cal‐
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iper -1-.
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– Pull brake caliper from brake support plate.

– Take brake pads out of brake caliper.
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• Piston is pressed back.
• 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.
– Fit both cover caps.
– Bolt brake hose to brake caliper.
– Insert retaining spring into brake caliper.
– Connect brake pad wear indicator connector.
– Bleed brake system ⇒ page 88 .
– Fit wheels.
axles, steering; Rep. gr. 44 ; Tyre pressure indicator

Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torques:
Guide pin to brake carrier 30 Nm
Brake hose to brake caliper 35 Nm
1.4 Assembly overview - front brakes FNR-

G
Note
♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
the brake system with brake charge and bleed system - VAS
5234- or extraction unit -V.A.G 1869/4- .
AG. Volkswagen AG d
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1 - Splash plate
2 - Bolt
❑ Specified torque: 12 Nm
3 - Brake disc
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❑ Always replace on both agen oes
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4 - Bolt auth eo
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❑ Specified torque: 4 Nm s
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5 - Ribbed collar bolt
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bed bolts ⇒ page 34
h re
hole
spec
6 - Brake carrier
es, in part or in w
❑ Bolted to wheel bearing
t to the co
housing.
7 - Brake pads
rrectness of i
❑ Thickness: 14 mm not
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including backplate.
dicator.
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❑ Always replace on both sides

❑ Insert retaining spring into brake caliper and press under brake carrier.
9 - Brake caliper
❑ Do not disconnect brake hose when changing brake pads.
❑ Must not be unscrewed from one another.
10 - Guide bushes
❑ Guide bushes for guide pins.
11 - Guide pin
12 - Cover cap
❑ Remove
13 - Washer
14 - Balance weight
Allocation ⇒ Electronic Parts Catalogue (ETKA) .

15 - Bolt
16 - Dust cap
17 - Brake line
18 - Bolt
19 - Retainer
❑ Bracket for brake pipe/brake hose threaded connection.
20 - Brake hose
21 - Hexagon socket head bolt
22 - Retainer
23 - Spring clip
Specified torque for ribbed bolts
Note
Tightening of ribbed bolts is performed in 2 stages.
1. stage Tighten both ribbed bolts to brake carrier to 15 Nm

2. stage Tighten both ribbed bolts to brake carrier to 200 Nm
1.5 Removing and installing brake pads or

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34
agen
Prote AG.
Rep. gr.46 - Brakes - mechanism
Removing
Mark brake pads or linings when removing if they are to be
reused. Fit in same position when installing, or braking will be
uneven.
– Remove front wheels.
– Lever retaining spring -1- out of brake caliper using a screw‐
driver -2- in -direction of arrow B-. To do this, position screw‐
driver between the retaining spring and brake caliper
-arrow A-. en AG. V
olkswagen AG
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– Firmly hold brakey V caliper retaining spring -1- with
o ot g
uaa cloth to
db
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– Release both guide pins -arrows- and remove from brake cal‐
iper housing.
– Remove brake caliper -1- from brake carrier age-2-

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– Remove outer brake pad -3-
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t
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ac
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– Remove inner brake pad -4- from brake carrier -1-.
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Cleaning:
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– Thoroughly clean contact surfaces for brake pads on brake
rrectness of i
carrier and remove corrosion.
l purpos
– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing. nform
ercia
Installing
m
at
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ion
Before pressing piston back into cylinder with piston resetting tool,
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– Insert inner brake pad with retaining spring -4- into brake cal‐
iper (piston).
– Insert outer brake pad -3- into brake carrier -2-.
– Position brake caliper -1- on brake carrier -2-.
n AG. Volkswagen A
– Bolt brake caliper to brake carrier
olks
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– Insert brake caliper retaining spring -1- so that lower spring

bow is seated behind brake carrier -arrow A- and middle cen‐
rrectness of i
tring lug -arrow B- is located behind brake caliper housing

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-3-.
– Swivel upper spring bow behind brake carrier -2- -arrow C-.
nform
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– Reconnect connector for brake pad wear indicator.

m
at
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– Fit wheels.
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eral times with vehicle stationary, so that brake pads are Prote AG.
Specified torque:
Guide pin to brake carrier 30 Nm


AG. Volkswagen AG d
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Removing Volksw not
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This procedure applies only to exchanging or the followinghoris repair nte
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work on the brake caliper. s aut ra
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– Remove wheels.
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– Lever retaining spring out of brake caliper using a screwdriver.
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To do this, position screwdriver between retaining spring and
ility
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brake caliper -magnifying glass-.
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– Firmly hold brake caliper retaining spring with a cloth to pre‐
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vent loss.
spec
es, in part or in w
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– Apply brake pedal actuator - V.A.G 1869/2- .

– Close bleed valve and remove bleed bottle.
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8 - Brake disc
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❑ Unscrew brake caliper
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❑ Checking: Maintenance
booklet ⇒ Maintenance ;
Booklet ; Checking
thickness of brake pads
and condition of brake
discs at front and rear
❑ Never remove brake discs from wheel hub by force. If necessary use penetrating fluid, because otherwise
brake discs can be damaged.
9 - Torx bolt, 4 Nm
❑ For locating brake disc.

10 - Bolt
❑ Specified torque ⇒ Running gear, axles, steering; Rep. gr. 42 ; Assembly overview: wheel bearing
housing, trailing arm
11 - Brake pads
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
❑ Always renew on both sides of an axle.
12 - Brake carrier with guide pin(s) and protective cap
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.
13 - Brake caliper
❑ Adjust handbrake cable first after repairing or renewing.
❑ Adjusting handbrake ⇒ page 66 .
14 - Hose retainer
15 - Brake line, 14 Nm
16 - Self-locking hexagon bolt, 35 Nm
❑ Always renew after removing
17 - Handbrake cable
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2. Repairing rear brakes 45

♦ Resetting and removal tool - T 10165-
2.2.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
– Remove wheels.
– Unscrew both securing bolts from brake caliper; to do this,
counterhold on guide pin.
brake caliper does not strain or damage brake hose.
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– Use plate - T10165/1- for assistance when screwing in.

♦ If pistons are difficult to move, a 13 mm open-end spanner can
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– Insert brake pads into brake carrier.

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2.3.2 Installing
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2.4 Assembly overview - rear brake CII 41
Note
the brake system with brake charge and bleed system - VAS
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1 - Multi-point socket head bolt

❑ Always renew after re‐
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and turn 90° further
❑ Remove and install us‐
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T10035- ⇒ page 51 .
2 - Bolt
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❑ To remove, first remove brake caliper and brake carrier

10 - Bolt
11 - Brake pads
❑ Checking thickness: Maintenance Booklet ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings:
Checking thickness .
12 - Brake carrier
❑ If protective cap or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.
13 - Anti-rattle spring
❑ Always renew when changing pads.
14 - Brake caliper
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-arrows-.
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– Fit wheels.
Note
♦ Repair kit contains 4 self-locking hexagon bolts for securing

brake caliper. These must be installed under all circumstan‐
ces.
Specified torque:
Hexagon bolt, brake caliper to brakewcarrier
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Removing

– Unhook handbrake cable -1- from lever on brake caliper -2-.

– Press locking lugs -3- together and remove handbrake cable
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– Attach handbrake cable -1- to lever -2- on brake caliper.
– Adjust handbrake ⇒ page 66 .
– Fit wheels.
Note

operating position.
Specified torques:
♦ Use new bolts!
Brake pipe to brake hose 14 Nm

Brake line to brake caliper 14 Nm

2.7 Assembly overview - Bosch rear wheel brake
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- to draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).

clean inner surface of
hole and coat with high-
temperature paste - G
052 112 A3- .
8 Nm
3 - Multi-point socket head bolt,
90 Nm and turn 90° further
moving
5 - Splash plate
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❑ Checking thickness: Maintenance booklet ⇒ Maintenance ; Booklet ; Checking thickness of brake pads
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13 - Brake carrier with different guide pins and protective cap
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(brake pads) on brake carrier, and remove corrosion. Prote AG.
– Clean brake caliper.

Installing
Install in reverse order. Note the following points:

– Screw in piston by turning thumb wheel on piston compressing

tool - T10165- clockwise. Do not damage protective cover.
♦ Insert piston compressing tool - T10165- so that collar rests
on plate - T10165/1- .
– Insert anti-rattle springs -1- and -2- into brake carrier.
Note
Anti-rattle springs -1- and -2- are different. They can only be in‐
stalled diagonally to each other.
– Insert anti-rattle springs -1- and -2- so that

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♦ Repair kit contains 4 self-locking hexagon bolts for securing

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♦ Use new bolts!
2.9 Removing and installing brake calipers,

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– Release brake hose -1- connection with banjo bolt -2- on brake
caliper.
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3 Handbrake
3.1 Assembly overview - handbrake lever
1 - Handbrake lever
❑ Before removing take
out centre console.
3 - Handbrake lever trim
❑ Lever up release tab in
rear lower area of han‐
dle -enlargement- with a
screwdriver.
❑ Then pull off forwards.
❑ If leather upholstery is
fitted, leather is cut in
area of locking mecha‐
nism.
4 - Pull rod
❑ Riveted to handbrake
lever
5 - Compensator
6 - Adjustment nut
❑ Adjusting handbrake
⇒ page 66 .
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– Release handbrake.
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– Remove centre console ⇒ General body repairs, interior; Rep.

i
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gr. 68 ; Compartments, covers and trims .

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3. Handbrake 65
3.2.2 Installing
– Push handbrake cable into guide tube -2- and hook onto re‐
tainer -1-.
– Insert handbrake cable -1- through opening on retainer and

then clamp onto retainer -2-.
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– Pretension handbrake cable with adjustment nut -1-.

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3.3 Adjusting handbrake

New adjustment is only necessary after renewing handbrake ca‐
bles and brake calipers.
– 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 . wage
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Vehicles with C38 rear brakes:
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– ... until levers -1- on brake calipers lift off stops -2-. cted agen
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– The total distance -a- to stops -2- on left and right brake cali‐
pers must not exceed 1.5 mm.
– Check that both wheels turn freely.
Vehicles with Bosch rear brakes:

– Tighten adjusting nut enough so that levers -1- on brake cali‐
pers lift off stops -2-.
– Distance -a- between lever -1- and stop -2- on left and right
brake caliper must be ≤ 1.5 mm in total.
– Check that both wheels turn freely.
Due to the automatic rear wheel brake adjustment there is no re‐
quirement to adjust the handbrake after making new/initial ad‐
justment.
3. Handbrake 67
Golf Cabriolet 2012 ➤ agen
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Before installing, grease all mounting points with polycarbamide
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rrectness of i
1 - Mounting bracket
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2 - Self-locking hexagon nut,

25 Nm
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❑ For ball head of brake
servo plunger rod.
7 - Hexagon bolt
8 - Sleeve bearing
9 - Pivot pin
25 Nm
moving
4.1 Separating brake pedal from brake ser‐

vo

♦ Release tool - T 10159-
– Remove trim on driver's side ⇒ General body repairs, interior;

Rep. gr. 70 ; Dash panel
– First press brake pedal in direction of brake servo and hold.
2 - Push rod
3 - Retaining lugs
– Insert release tool - T 10159- and pull in direction of driver seat.
When doing this, counter-hold on brake pedal. (At this stage
the pedal must not be allowed to move backwards.) This action
will press retaining lugs -3- of mounting off ball head of plunger
rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool - T 10159- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).
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4. Assembly overview - brake pedal 69

47 – Brakes - hydraulics
1 Repairing front brake calipers
1.1 Assembly overview - brake caliper FN 3
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleed valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
5 - Sleeve bearing
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9 - Sealing ring
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⇒ page 70
10 - Piston
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⇒ page 70
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70 Rep. gr.47 - Brakes - hydraulics

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♦ Assembly tool for protective caps - T 10146/6-
1.2.1 Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.
1. Repairing front brake calipers 71

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

When removing ensure that the surface of the cylinder is not
damaged.
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Keep piston straight to prevent damage to sealing collar.
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– Blow air into protective cap using compressed air (max 3 bar)
-1-. During this step protective cap will spring on piston.
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1.3 Assembly overview - brake caliper FNR-G
Note
♦ When carrying out repairs, install all parts supplied in repair kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cylinder, piston and sealing ring.

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve
sembly paste
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
4 - Guide pin
5 - Bearing bush
❑ Insert into brake caliper.
6 - Brake caliper
❑ Must not be unscrewed
from one another.
7 - Brake carrier
❑ Bolt onto brake caliper.
8 - Sealing ring
⇒ page 74
9 - Piston
⇒ page 74
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1.4 Removing and installing brake piston

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♦ Assembly tool for protective caps - T 10146/6-
Removing
– Remove brake caliper ⇒ page 37 .
– Unscrew bleed valve.
Note
Place a piece of wood in brake caliper to prevent damage to pis‐

ton.

– Press piston out of brake caliper using compressed air gun

-arrow-.
– Lever off protective cap from brake caliper using removal
wedge - 3409- .
– Remove seal using removal wedge - 3409- .
Note
When removing ensure that the surface of the piston is not dam‐
aged.
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– Insert seal in brake caliper -arrow-.

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– Fit protective cap -A- in assembly tool - T10146/1- -1-.

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– Press protective cap onto brake caliper so that it lies on brake

caliper all around using assembly tool -1- and piston resetting
tool - T 10145- -2-.
Check seat of protective cap: n AG. Volkswagen A
ge G do
swa es
– At this stage it should
y V not be possible to remove protective
olk not
gu cap
from brake caliper
ed b by hand. ara
ris nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Gently press piston onto protective cap using an extension
hole
and a ratchet tool -1-. Hold piston in this position.
spec
es, in part or in w
t to the co
Note
rrectness of i
Keep piston straight to prevent damage to sealing collar.
l purpos
– Blow protective cap on over brake caliper with compressed air

(max. 3 bar) -2-. Protective cap will spring over the piston.
nform
ercia
– Press piston into brake caliper by hand. If necessary, gently

m
a
re-press using piston resetting tool - T 10145- .
com
tion in
r
te o
The outer sealing lip of the protective cap will then lock in the thi
s
groove on piston.
iva
do
r
rp
cum
– Screw in bleed valve.

fo
en
ng
t.
yi Co
– Install brake caliper ⇒ page 37 . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2 Repairing rear brake calipers
2.1 Assembly overview - brake caliper C 38
Note
♦ When carrying out repairs, install all parts supplied in repair

kit.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inder, piston and sealing ring.
♦ When repairs are performed, it is essential to appropriately
pre-bleed brake calipers (without brake pads) before installing
in vehicle ⇒ page 86 .
1 - Brake caliper with hand‐

brake cable lever
❑ If there is a leak at hand‐
brake cable lever, re‐
new brake caliper.
❑ Following repair work,
pre-bleed brake caliper swage
es n
⇒ page 86 . byV
olk ot g
ua
d ran
ir se
2 - Dust cap tho tee
or
au ac
3 - Bleed valve, 10 Nm ss
ce
le
un

pt
an
d
sembly paste
itte
y li
rm

ab
pe
ility
before screwing in.

ot
wit
, is n
4 - Self-locking hexagon bolt,

h re
hole
35 Nm
spec
es, in part or in w
❑ Always renew
t to the co
❑ When loosening and

tightening, counterhold
on guide pin.
rrectness of i
5 - Guide pin
l purpos
❑ Grease before fitting

protective cap.
nform
ercia
6 - Protective cap
m
a
com
ti
❑ Fit onto brake carrier

on in
and guide pin.

r
te o
thi
s
iva
do
7 - Brake carrier with guide pin

r
rp
cum
(s) and protective cap

fo
en
ng
t.
❑ Supplied as genuine
yi Co
op
part, assembled with
C py
t. rig
gh
sufficient grease on
ht
pyri by
Vo
o
guide pins.
c by lksw
cted agen
Prote AG.
❑ If protective caps or

guide pins are dam‐

aged, install repair kit. Use lubricant sachet supplied to lubricate guide pins.
8 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
9 - Piston with automatic adjustment
AG. Volkswagen AG d
agen oes
ksw
❑ Removing by
and installing ⇒ page 80
Vol not
gu
ara
ed
❑ Apply ho
risthin coat of assembly paste G 052 150 A2 nte to piston before installing.
e
t or
au ac
10 - Sealing
ss ring
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
2.2 Assembly overview - brake caliper CII
wit
, is n
h re
41
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ When carrying out repairs, install all parts supplied in repair
kit.
l purpos

nform
ercia
♦ New brake calipers are filled with brake fluid and are pre-bled.
m
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐

at
om
io
inder, piston and sealing ring.

n
c
in t
or
his
e
♦ When repairs are performed, it is essential to appropriately

at
do
riv
pre-bleed brake calipers (without brake pads) before installing

p
cum
or
in vehicle ⇒ page 86 .
f
en
ng
t.
yi Co
op py
Brake caliper CII 41 (17”)
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Repairing rear brake calipers 79


brake cable lever
brake cable lever, re‐ n AG. Volkswagen AG do
swage es n
new brake caliper. byV
olk ot g
ua
ed ran
horis tee
pre-bleed brakeau caliper
t or
ac
⇒ page 86 . ss
ce
le
un
pt
2 - Dust cap
an
d
itte
y li
erm
ab
3 - Bleeder valve
ility
ot p
wit
is n
h re
ole,
sembly paste
spec
t to the co
before screwing in.
4 - Hexagon bolt (self-locking)
rrectne
❑ Always renew
s
s o
cial p
on guide pin.
f inform
mer
atio
m
5 - Guide pin
o
n
c
i
or
n
thi
te
protective cap. sd
iva
o
pr
cum
r
6 - Deflector cap
fo
en
ng
t.
yi
Co
op py
and guide pin.
t. C rig
gh ht
pyri by
Vo
7 - Rear brake carrier
co lksw
by
cted agen
Prote
❑ Supplied as replace‐
AG.
ment part, assembled

with sufficient grease on
guide pins.
❑ If protective caps or
guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate guide pins.
8 - Deflector cap
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
10 - Sealing ring
2.3 Removing and installing piston for brake

caliper C 38 and CII 41

♦ Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Removing ut
ho eo
ra
s a c
– Remove brake caliper ⇒ page 54 . s
ce
le
un
pt
– Screw piston out of brake caliper by turning thumb wheel anti-
an
d
itte
y li
clockwise.
rm
ab
pe
ility
Apply resetting and removal tool so that collar of tool is resting on
ot
wit
, is n
piston.
h re
hole
spec
es, in part or in w

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove seal using wedge 3409.

r
te o
thi
s
Installing
iva
do
r
rp
cum
fo
en
ng
t.
methylated spirits and then dried. Cop
yi Co
py
t. rig
– Apply a thin coat of assembly paste G 052 150 A2 to piston gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

– Place protective cap with outer sealing lip on piston.

– Insert inner sealing lip into groove in cylinder using wedge
3409.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
When doing this, hold piston in front of brake caliper.
ole,
spec
– Screw in piston by turning thumb wheel clockwise.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
o
pr
c
♦ Apply resetting and removal tool so that collar of tool is resting
um
r
fo
en
ng
on brake caliper.
t.
yi Co
Cop py
♦ If the piston is pushed back with a piston resetting tool (e.g.
t. rig
gh ht
yri
T10145) or by operating the foot brake the automatic adjust‐ p by
co Vo
lksw
ment in the brake caliper is destroyed.
by
cted agen
Prote AG.
– Install brake caliper ⇒ page 54 .
2.4 Assembly overview - Bosch brake caliper


brake cable lever
brake cable lever, re‐
new brake caliper.
pre-bleed brake caliper
⇒ page 86
2 - Bleeder valve
❑ 10 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread. n AG. Volkswagen AG do
lkswage es n
3 - Dust cap d byV
o ot g
ua
ran
ir se tee
4 - Bolt utho
or
a ac
❑ 35 Nm ss
ce
le
un
❑ Self-locking
pt
an
d
itte
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❑ Renew.
erm
ab
ility
ot p
wit
is n
h re
on guide pin.
ole,
spec
5 - Upper guide pin
t to the co
protective cap.
❑ Allocation ⇒ Electronic
rrectne
parts catalogue “ETKA”
6 - Protective cap
ss o
cial p
f in
and guide pin.
form
mer
7 - Lower guide pin atio

om
n
c
❑ With recess.
i
or
n thi
te
❑ Grease before fitting protective cap.

sd
iva
o
pr
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

um
r
fo
en
ng
t.
yi
8 - Guide grommet
Co
Cop py
. rig
❑ On lower guide pin.
t
gh ht
pyri by
Vo
co lksw
9 - Brake carrier
by
cted agen
Prote AG.
❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
10 - Protective cap
❑ Apply thin coat of assembly paste - G 052 150 A2- to piston before inserting.
12 - Sealing ring

2.5 Removing and installing Boscholkbrake . Volkswagen AG

gen AG does
swa not
caliper piston y V gu
db ara
ise r nte
ho eo
sa
ut ra
c
s
♦ Piston compressing tool - T10165-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
♦ Removal wedge - 3409-
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
WARNING
It is only permissible to change the position of the brake piston

with the piston compressing tool - T10165- .
– Screw piston out of brake caliper by turning thumb wheel anti-

clockwise.
Insert piston compressing tool - T10165- so that collar rests on
piston.

– Remove seal using removal wedge - 3409- .

Installing
methylated spirits and then dried.
– Apply thin coat of assembly paste - G 052 150 A2- to piston
and seal before installing.
– Place protective cap with outer sealing lip on piston.
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove. en AG. V
olkswagen AG
ag does
lksw not
When doing this, hold piston in front of brake caliper.d by Vo gu
ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Screw in piston by turning thumb wheel on piston compressing
tool - T10165- clockwise. Do not damage protective cap.
rrectness of i
♦ Insert piston compressing tool - T10165- so that collar rests

l purpos
on plate - T10165/1- .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.6 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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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:

AG. Volkswagen AG d
agen oes
Brake system (hydraulic unit, brake hoses, brake lines and brake
yV
olks
w not
gu
calipers) operating properly and free of leaks. ise
d b ara
nte
r
ho eo
– Remove bleeder valve at one of front brake calipers.
au
t
Connect ra
c
pressure gauge -V.A.G 1310 A- and bleed. ss
ce
e
nl
pt
du
– Apply pressure to brake pedal until gauge indicates a pressure
an
itte
y li
of 50 bar. The pressure must not drop by more than 4 bar
erm
ab
within the test period of 45 seconds. Renew brake master cyl‐
ility
ot p
inder if drop in pressure exceeds specification.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Pressurised leak test 87

4 Bleeding brake system

Bleeding the brake system is described using brake filling and
bleeding equipment - VAS 5234- .
WARNING
Only use new brake fluid conforming to VW standard

(VW 501 14).
Note
♦ Brake fluid is poisonous. Also due to its corrosive effect brake

fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
4.1 Bleeding brake system with the brake

filling and bleeding equipment - VAS
5234-
♦ Brake filling and bleeding equipment - VAS 5234-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
♦ Tool set for brake bleeding - VAS 6564-

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
88
cted agen
Prote AG.
Rep. gr.47 - Brakes - hydraulics
WARNING
Only use new brake fluid conforming to VW standard

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

Adhere strictly to work sequence when bleeding brake system.
– Connect brake filling and bleeding equipment - VAS 5234- .
– Open bleed valves in prescribed sequence and bleed brake
calipers.
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
Use suitable bleeder hose. It must sit tightly on bleeder valve so
that no air can enter brake system.
– Leave bleeder valve of each brake caliper open with bleeder
hose fitted until brakeksw
fluid AG. Volkswagen AGof
agendischarges free doeair
s n bubbles.
Vol ot g
by ua
4.1.2 risSubsequent bleeding
ed ran
tee
utho or
Carry out subsequent
ss
a
bleeding when: ac
ce
e
nl
♦ brake pedal travel is too long or so-called »soft brake pedal«

pt
du
an
itte
y li
♦ in vehicles with EDL, EDL/TCS or EDL/TCD/ESP a chamber

erm
ab
in the brake fluid reservoir is completely empty. This occurs

ility
ot p
e.g. in the case of brake system leaks.

wit
, is n
h re
Subsequent bleeding requires the assistance of a second me‐

hole
spec
chanic:
es, in part or in w
t to the co
– Depress brake pedal firmly and hold.

– Open bleeder valve on brake caliper.
rrectness of i
– Fully depress brake pedal.

l purpos
– Close bleeder valve with pedal held down.

– Release brake pedal slowly.
nf
ercia
orm
This bleed sequence must be carried out 5 times per brake cali‐
m
atio
m
per.
o
n in
or c
thi
Bleeding sequence:
te
sd
iva
o
r
1 - Front left brake caliper

rp
cu
o
m
f
en
ng
2 - Front right brake caliper

t.
yi Co
Cop py
. rig
3 - Rear left brake caliper
t
gh ht
pyri by
Vo
co
4 - Rear right brake caliper
by lksw
cted agen
Prote AG.
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
4. Bleeding brake system 89

5 Brake servo and brake master cylin‐

der
5.1 Assembly overview: brake servo/brake

master cylinder (left-hand drive vehicle)
Note
Use only new brake fluid. Observe information on brake fluid res‐
ervoir!
1 - Pedal cluster
25 Nm
moving
3 - Seal agen
AG. Volkswagen AG d
oes
lksw not
❑ For brake servo. d by
Vo gu
ara
ise nte
r
4 - Brake servo ut
ho eo
ra
a
❑ On petrol engines, the ss c
ce
le
required vacuum is ei‐

un
pt
ther taken from the in‐
an
d
itte
y li
take manifold or gener‐
rm
ab
ated by a vacuum pump
pe
ility
ot
⇒ page 92 .
wit
, is n
❑ Diesel engines are fitted h re

hole
spec
with a vacuum pump to
es, in part or in w
generate the necessary

t to the co
vacuum pressure
⇒ page 91 .
❑ Functional check:
rrectness of i
– With engine switched

l purpos
off, depress brake pedal

firmly several times (to
nform
ercia
exhaust vacuum in unit).

m
– Now step on and hold

com
tio
brake pedal with medi‐

n in
r
te o
um pressure and start

thi
s
iva
engine. If the brake ser‐

do
r
rp
vo is functioning proper‐
um
fo
ly, the brake pedal will

en
ng
t.
yi
be felt to go down as the
Co
Cop py
servo takes effect.
t. rig
gh ht
pyri by
Vo
o
❑ Replace completely in by c lksw
cted agen
the event of a fault (be‐ Prote AG.
fore doing so, check

brake servo vacuum system) ⇒ page 92
5 - Sealing ring
6 - Brake master cylinder
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
❑ Cannot be repaired. If faulty, renew as a complete unit.

7 - Brake light switch - F-

❑ Including brake pedal switch - F47- .
8 - Torx socket head bolt, 5 Nm
9 - Clip
10 - Heat shield
11 - Self-locking hexagon nut, 25 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
14 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
15 - Brake fluid reservoir
16 - Cap
17 - Vacuum hose
❑ Fit in brake servo.
AG. Volkswagen AG d
18 - Vacuum sender - G608- ksw
agen oes
not
Vol gu
❑ Only on vehicles having HBV ed
by ara
nte
ris
❑ Removing and installingut ⇒ page 96
ho eo
ra
a c
ss
19 - Sealing plug ce
e
nl
pt
du
❑ Connection for vacuum hose. an

itte
y li
erm
ab
ility
ot p
wit
5.2 Vacuum pump for brake servo (vehicles

, is n
h re
hole
with diesel engine)

spec
es, in part or in w
t to the co
Must not be dismantled.

Vacuum pump -1-.
rrectness of i
Vacuum hose to brake servo -2- with non-return valve.

l purpos
– Removing and installing vacuum pump ⇒ 4-cylinder diesel

engine (1.6 l engine, common rail); Rep. gr. 15 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Brake servo and brake master cylinder 91

5.3 Vacuum pump for brake servo (vehicles

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

The following instructions are intended to help you find the causes
of problems effectively and objectively winagthe en Aevent
G. Volksof complaints
wagen AG
doe
about the brake servo or in the event y Volkof
s
a so-called »hard brakes not gu
pedal«. ris
ed
b ara
nt ee
tho or
This check relates to the sfollowing
au components: ac
s
ce
e
♦ Brake servo
nl
pt
du
an
itte
♦ Oil seal between brake master cylinder and brake servo.

y li
erm
ab
ility
♦ Non-return valve
ot p
wit
, is n
♦ Vacuum hoses with connectors h re

hole
spec
♦ Vacuum pump (if included)
es, in part or in w
t to the co
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.
rrectness of i
Before checking the vacuum system, please take note of the fol‐
l purpos
lowing prerequisites for checking:

♦ Visual inspection of all vacuum hoses for damage (e.g. cracks
nform
ercia
or marten bite) and to check that they are correctly and firmly
attached
m
at
om
ion
♦ Ensure cleanliness when working on vacuum system

c
in t
or
his
te
♦ Before starting work, clean engine compartment if necessary

a
do
priv
cum
or

f
en
ng
t.
yi Co
♦ Vacuum gauge for brake servo - VAS 6721- t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5.4.1 Connecting vacuum gauge for brake

servo - VAS 6721-
– Pull vacuum hose out of brake servo.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.
– Place brake servo vacuum gauge - VAS 6721- between them
-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if included, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721- swa
gen AG
. Volkswagen AG
does
valve Volk not
gu
♦ Open to simulate a fault source
sedb
y ara
n i tee
or
♦ Connection of manualau vacuum pump - VAS
th or
ac
6213- ss
ce
e
nl
pt
du
an
C Cut- In direction of brake servo
itte
y li
off
erm
ab
ility
valve
ot p
wit
, is n
h re
– Push hose -A- of brake servo vacuum gauge - VAS 6721- onto
hole
spec
vacuum hose and press adapter -C- into brake servo.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
5.4.2 Checking vacuum generation

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Note
t. C rig
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♦ The average air pressure of the earth's atmosphere at sea cted agen
Prote AG.
level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 93 .
– Open cut-off valve -A-.

– Close cut-off valves -B+C-.

– Start warm engine (>60 C), press accelerator briefly (engine
speed above 2000 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 96 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
5.4.3 Checking for leaks
Note lk swage es n
o ot g
byV ua
d ran
ir se
♦ The average air pressure of the earth's
tho atmosphere at sea tee
or
level is 1013 mbar and decreasesss
asteeply
u
as the altitude in‐ ac
creases (approx. 100 mbar/1,000 m altitude). Local and time
ce
le
fluctuations also influence vacuum generation.

un
pt
an
d
itte
y li
♦ A cold engine, a switched-on air-conditioning system as well
rm
ab
as engine idling have an adverse influence on generation of a
pe
ility
ot
vacuum.
wit
, is n
h re
hole
spec
– Before starting work, check all vacuum hoses for damage (e.g.
es, in part or in w
cracks or marten bite) and to check that they are correctly and
t to the co
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
rrectness of i
⇒ page 93 .
l purpos
– Open cut-off valve -A-.

– Close cut-off valves -B+C-.
nform
ercia
– Start warm engine (>60 C), press accelerator briefly (engine

m
speed above 2000 rpm).

a
com
tion in
Normally (see notes), the vacuum that is generated should be

r
te o
thi
between 600 and 950 mbar (depending on engine size).

s
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Cop py
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by
cted agen
Prote AG.

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

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

AG. Voclose
lkswagcut-off
en AG valve -A- in order to
check brake servo agen does
olkswvacuum system. not
V y gu
db a
Vacuum check
or
ise in vicinity of non-return valve, vacuumanhoses
r
tee with
connectors
au and vacuum pump/intake manifold:
th or
a
ss c
ce
le
un
pt
an
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
– Once vacuum pressure has been generated, close shut-off

valve -C- in order to check vacuum system using brake servo
rrectne
vacuum gauge - VAS 6721- up to intake manifold or vacuum

pump.
s
Open cut-off valve -B- to facilitate removal of hose connections

s o
cial p
and adapter.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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 servo vacuum gauge
- VAS 6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump - VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge - VAS 6721- .
– Then, carry out the corresponding checks.
AG. Volkswagen AG d
agen
5.5 Checking non-return valve
oes
olksw not
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d by ara
ise nte
♦ Air must pass through non-return valve -A- in tdirection
ho
r of ar‐ eo
row. ss au ra
c
ce
e
♦ Non-return valve must remain closed in opposite direction.

nl
pt
du
an
itte
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Observe correct installation position!
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5.6 Removing and installing vacuum sender
rrectness of i
- G608-
l purpos
nform
ercia
– Pull out vacuum hose with vacuum sender - G608- from brake
servo.
m
at
om
– Release clips using pliers -1-. ion

c
in t
or
his
e
– Carefully lever out the vacuum sender - G608- -2-.

at
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en
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cted agen
Prote AG.
5.7 Removing and installing brake light

switch - F-
Removing
– In certain vehicles, the intake hose must be removed.

– Separate connector -1- from brake light switch - F- .

– Unscrew bolt -2- from brake master cylinder.
– Pull off brake light switch - F- -3- from under brake master
cylinder and remove at top from clip -4-.
Installing
Specified torque:
Torx bolt to brake master cylinder 5 Nm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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en
ng
t.
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Cop py
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by
cted agen
Prote AG.

6 Removing and installing brake mas‐

ter cylinder AG. Volkswagen AG d
agen oes
ksw
Special tools and workshop equipment required by
Vol not
gu
ara
ed
is nte
♦ Brake filling and bleeding equipment - VAS 5234- hor eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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cted agen
Prote AG.
♦ Sealing tool - T10249-
6.1 Removing
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Dis‐
connecting and reconnecting battery .
– Removing and installing ⇒ Electrical system; Rep. gr. 27 ;
Removing and installing battery
– Remove battery tray.
– 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- .

Vehicles with manual gearbox:

– Pull off return hose -2- for clutch master cylinder -3- from brake
fluid reservoir.
– Seal return hose -2- using sealing tool - T10249/1- or elements
from engine bung set - VAS 6122- and then tie up.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Pull off connector -1- from brake fluid levels warning contact.
au ra
c
s
ce
e
– Disconnect brake line -2- on brake master cylinder and seal

nl
pt
du
using plugs from repair kit (part no. 1H0 698 311 A).
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove brake fluid reservoir -1-. To do this, force locking tabs

on brake fluid reservoir -arrows- outwards and, at the same
time, pull out brake fluid reservoir from sealing plugs in brake
nform
ercia
master cylinder -2-.

m
at
om
ion
c
in t
or
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ate
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cum
for
en
ng
t.
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Cop py
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rig ht
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cted agen
Prote AG.
– Pull off connector -1- from brake light switch - F- -2-.
6. Removing and installing brake master cylinder 99


– Unscrew nuts -arrows- from brake master cylinder -1-.
– Remove heat shield (if included).
– Carefully remove brake master cylinder from brake servo.
6.2 Installing
Observe the following important points when installing:
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
olksw
Specified torques: wage
n AG. V agen AG
does
olks not
Brake master cylinder to brake servoed by V
25 Nm gu
ara
♦ Use new nuts. horis nte
e
ut or
ac
sa
Brake lines to brake master cylinder
s 14 Nm
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
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cted agen
Prote AG.

7 Removing and installing brake servo
Note
If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 92


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Sealing tool - T10249- rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
7.1 Removing
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
necessary.
AG.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Dis‐

connecting and reconnecting battery .
7. Removing and installing brake servo 101

– Disconnect wiring connector -1- and loosen rear spring-type

clip on intake hose.
– Detach spring-type clip -arrow- and pull off hose from air filter
housing.
– Unscrew securing bolt from air filter housing -arrow-.

– Pull out air filter housing upwards from retainers and then re‐
move.
– Removing and installing ⇒ Electrical system; Rep. gr. 27 ;
Removing and installing battery
– Remove battery tray.
– Place sufficient lint-free cloths in. Varea
olkswof
ag
engine and gearbox.
AG en AG
w agen doe
– Draw off as much brake yV
olks fluid as possible from brake
s no fluid res‐
t gu
ervoir using brake
ised bfilling and bleeding equipment - VAS ara5234-
nte
or extractionthunit
or -V.A.G 1869/4- . eo
u ra
sa c
Vehicles withs manual gearbox:
ce
e
nl
pt
du
– Pull off return hose -2- for clutch master cylinder -3- from brake
an
itte
y li
fluid reservoir.
erm
ab
ility
ot p
– Seal return hose -2- using sealing tool - T10249/1- or elements

wit
, is n
h re
from engine bung set - VAS 6122- and then tie up.
hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
102
c by lksw
cted agen
Rep. gr.47 - Brakes - hydraulics Prote AG.
– Pull off connector -1- from brake fluid level warning contact.
– Remove brake fluid reservoir -1-. To do this, force locking tabs

on brake fluid reservoir -arrows- outwards and, at the same
time, pull out brake fluid reservoir from sealing plugs in brake
master cylinder -2-.
– Pull off connector -1- from brake light switch - F- -2-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

– Unscrew nuts -arrows- from brake master cylinder -1-.
rrectne
– Remove heat shield (if included).

ss
– Carefully remove brake master cylinder from brake servo.

o
cial p
f in
– Pull out vacuum hose from brake servo.

form
mer
atio
– Remove trim on driver side ⇒ General body repairs, interior;

om
Rep. gr. 70 ; Dash panel

n
c
i
or
n thi
e
– Separate brake pedal from brake servo ⇒ page 68 .

t
sd
iva
o
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cum
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en
ng
t.
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Cop py
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cted agen
Prote AG.
7. Removing and installing brake servo 103

– Unscrew nuts -1- from brake servo.

– Loosen two upper nuts -2- of mounting bracket slightly only if
brake servo is difficult to pull out.
– Carefully remove brake servo from the vehicle.
7.2 Installing
Observe following points when installing:
– Clip brake pedal to brake servo ⇒ page 69 .
– After installing, bleed brake system ⇒ page 88 and clutch.
Specified torques:
AG. Volkswagen AG d
agen
Brake servo to pedal cluster and bulkhead Volksw 25 Nm oes
not
gu
♦ Use new nuts. ed by ara
n
ris tee
tho or
Brake master cylinder to brakessservo
au
25 Nm ac
♦ Use new nuts.
ce
le
un
pt
an
d
itte
Brake lines to brake master cylinder 14 Nm

y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

. Volkswagen AG
gen AG
8 Repairing brake linesby Volkswa
does
not
gu
d ara
e nte
The flanging tool for brake lines - VAStho6056- can be used to flange
ris
eo
brake lines with an outer pipe diameter
s au of 5 mm without damaging ra
c
the coating. In certain cases, this allows sections of brake lines
s
ce
le
to be renewed at less expense.
un
pt
an
d
itte
y li
The use of flanging tool V.A.G. 1356 is not permitted due to the
rm
ab
coating and the diameter of the black brake lines.
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ 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.
rrectness of i
♦ Preferably separate brake lines at vehicle floor.
l purpos
♦ The positions of the intermediate pieces must be selected so

that they cannot chafe on moving parts.
nform
ercia
♦ Do not grease spindle; merely clean with methylated spirits.

m
a
com
tion in
r
te o
thi
s
iva
♦ Flanging tool for brake lines - VAS 6056-
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cum
fo
en
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Cop py
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cted agen
Prote AG.

List of individual tools:
8. Repairing brake lines 105

AG. Volkswagen AG d
agen oes
olksw not
1 - Flanging tool - VAS 6056/1- d by V gu
ara
ise nte
❑ Flanging tool - VAS thor eo
6056/1- contains flang‐ ss au ra
c
ing jaws - VAS 6056/6-
ce
le
un
pt
an
2 - Pipe cutter - VAS 6056/2-
d
itte
y li
rm
ab
3 - Brake line scraper - VAS
pe
ility
6056/3-
ot
wit
, is n
h re
❑ Grub screws (in shaft
hole
and at side) are adjus‐
spec
ted and must not be
es, in part or in w
t to the co
readjusted!
4 - Set of grips with plastic jaws
- VAS 6056/4-
rrectness of i
5 - Pipe bending tool - VAS
l purpos
6056/5-
6 - Special wrench, 6 mm
nform
ercia
7 - Flanging jaws - VAS

m
a
com
ti
6056/7-
on in
r
te o
thi
s
iva
do
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cum
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en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

8.1 Assembly overview - flanging tool
1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws
2 - Fastening for handle
❑ Must be removed to ac‐
cess retaining screw for
upper part
3 - Retaining screw
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ For centring and holding
flanging jaws
❑ Hexagon socket head
bolt, 2 mm
5 - Flanging jaws
❑ Various
❑ Assembly instructions
⇒ page 107
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Flanging jaw assembly instructions:
l purpos
♦ VAS 6056/6 (dark) for black brake lines

♦ VAS 6056/7 (light) for green brake lines
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
The arrow on the rounded side of the flanging jaws must point to
do
priv
the edge of the housing, and the straight side of the flanging jaws
um
for
must be installed towards the spindle, or the flange will not be

en
ng
t.
yi
formed correctly.
Co
Cop py
t. rig
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pyri by
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by
8.2 Work instructions
cted agen
Prote AG.
– Unbolt relevant brake line at brake caliper or wheel brake cyl‐

inder; catch escaping brake fluid and dispose of this as per
regulations.

Volkswagen AG
– Cut through brake line at a suitable point (straight, freely ac‐ agen
AG. does
ksw
cessible section) with pipe cutter -2-. by
Vol not
gu
ara
ed nte
– Remove section to be renewed. oris eo
th
au ra
c
– Degrease brake line surface. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Clamp brake line tightly in grip wrench with plastic jaws - VAS
om
6056/4- so that approx. 50 mm project from plastic jaws.
n in
or c
thi
e
– Clamp brake line scraper - VAS 6056/3- in a drill and position

t
sd
iva
on brake line.
o
r
rp
cu
o
m
f
en
ng
– At slow drill speed and with gentle pressure on brake line,

t.
yi Co
scrape coating off brake line. Cop py
t. rig
gh ht
yri
Length of scraping is determined by stop in scraper. p by
o Vo
by c lksw
cted agen
– Withdraw scraper from brake line and remove residue from Prote AG.
scraping.
– Remove grip wrench and slide union bolt onto brake line.

– Push brake line into flanging tool - VAS 6056/1- to stop 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 - VAS 6056/1- until brake

line can no longer be moved. Fold up stop and now tighten
hexagon socket head bolts diagonally using special wrench.
– Turn spindle to stop in flanging tool - VAS 6056/1- .

– 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
gen AG
Volbe
kswinserted
agen AG with compressed air.
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Join brake lines using connector.

ility
ot p
wit
– Install brake line.

, is n
h re
hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

D3E803BC25F-Brake System

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E803BC25F

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

6.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 21

7.1 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.1 Assembly overview - front brakes FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t to the co 24

1.4 Assembly overview - front brakes FNR-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.5 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.1 Assembly overview - rear brakes C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.4 Assembly overview - rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.5 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.7 Removing and installing brake light switch F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

installed can also be called up via ELSA/vehicle-specific

♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .

♦ The following table explains the PR numbers. These are im‐

portant for the brake caliper/brake disc and brake pads.

Engine PR No. Front brakes

1.2 Rear brakes

1. Brake allocation via PR No. 1

1.2l - 77 kW FSI 1KD C 38 (15”)

2 Rep. gr.00 - Technical data

2 Technical data for brakes

2.1 Brake master cylinder and brake servo

Brake pad, wear mm 2

Item PR No. 1LJ / 1ZA / 1ZB

2. Technical data for brakes 3

2.3 Rear brakes (disc brakes)

2.3.1 Rear brakes C 38

2.3.2 Rear brakes Bosch ZOH 38

4 Rep. gr.00 - Technical data

2.3.3 Rear brakes CII 41 (17")

2. Technical data for brakes 5

ufacturer of the roller dynamometer.

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‐

6 Rep. gr.00 - Technical data

45 – Anti-lock brake system

2 Notes for repair work on anti-lock

note ⇒ General Information; Body Repairs, General Body Re‐

♦ When working with brake fluid, observe the relevant safety

♦ 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

brake cleanser, petrol, thinners or similar. yi

♦ If repairs cannot be carried out immediately, carefully cover or

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

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

measuring equipment on the back seat.

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