VW Golf 5 Brake Systems Eng

Service
Workshop Manual
Eos 2006 ➤
Golf 2004 ➤
Golf Plus 2005 ➤
Touran 2003 ➤
Brake systems
Edition 05.2008
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Touran 2003 ➤
Brake systems - Edition 05.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Front brakes, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Front brakes, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Rear brakes, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Rear brakes, front-wheel drive Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Rear brakes, four-wheel drive Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Rear brakes, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Brake master cylinder and brake servo, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Brake master cylinder and brake servo, Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Test for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Test for vehicles with four-wheel drive via a Haldex coupling . . . . . . . . . . . . . . . . . . . . . . 9
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Electrical/electronic components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Assembly overview - hydraulic unit, brake servo/brake master cylinder . . . . . . . . . . . . . . 26
6.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 56
7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) . . 57
7.3 Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive) . . 58
8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1 Removing and installing ESP sensor unit G419 (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.2 Removing and installing ESP sensor unit G419 (Golf, Eos) . . . . . . . . . . . . . . . . . . . . . . . . 60
8.3 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.4 Removing and installing brake servo vacuum sender G483 . . . . . . . . . . . . . . . . . . . . . . . . 62
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Repairing front brakes, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.4 Repairing front brake, FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i

1.7 Repairing front brake, FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Repairing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Repairing rear brake CI 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Repairing rear brake CII 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.7 Repairing rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.10 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 Removing and installing handbrake cable up to model year 2007 . . . . . . . . . . . . . . . . . . . . 103
3.2 Removing and installing handbrake cable from model year 2008 . . . . . . . . . . . . . . . . . . . . 106
4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2 Removing and installing brake light switch F from week 45 of 2005 . . . . . . . . . . . . . . . . . . 110
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1 Repairing front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Repairing brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.2 Removing and installing piston for brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.3 Repairing brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.4 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.5 Repairing FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.6 Removing and installing piston for FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.3 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.1 Bleeding brake system using brake filling and bleeding equipment VAS 5234 or V.A.G 1869
...................................................................... 131
4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5 Brake servo and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle) . . . . . . . . 133
5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle) . . . . . . 134
5.3 Overview - exhauster pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . 136
5.4 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.5 Removing and installing brake servo pressure sensor G294 . . . . . . . . . . . . . . . . . . . . . . 137
5.6 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.7 Removing and installing brake light switch F as of week 45/05 . . . . . . . . . . . . . . . . . . . . . . 138
6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ii Contents
8 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

8.1 Separating point on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.2 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Contents iii
iv Contents
00 – Technical data
1 Brake allocation via PR No.
The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
Example of a vehicle data sticker:
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes -1KQ
♦ Arrow 2 - Front brakes -1ZE
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
♦ The following tables explain the PR numbers. These are rel‐
evant for the brake caliper/brake disc and brake pads.
1.1 Front brakes, Touran

Engine PR No. Front brake
1.6 l - 75 kW 1ZE FN3 (15”)
1.6 l - 85 kW FSI
1.4 l - 103 kW FSI
2.0 l -110 kW FSI
1.9 l - 66 kW TDI
1.9 l - 74, 77 kW TDI
2.0 l - 100, 103 kW TDI
1.4 l -125 kW FSI 1LJ FN3 (16”)
2.0 l - 125 kW TDI
Country-specific brake for Japan:
1.6 l - 85 kW FSI 1ZP FN3 (15”)
2.0 l -110 kW
1.2 Front brakes, Golf

1.4 l - 55, 59 kW 1ZF1) / 1ZM FS III (15”)
1.4 l -66 kW FSI
1.6 l - 75 kW
1.6 l - 85 kW FSI2)
2.0 l - 85 kW
1.9 l - 66 kW TDI
Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Brake allocation via PR No. 1

1.9 l - 77 kW TDI 3)
2.0 l -55 kW SDI
1.6 l - 85 kW FSI4) 1ZE FN3 (15”)
1.4 l - 88, 90 kW FSI
1.4 l - 103, 110 kW FSI
2.0 l -110 kW FSI
1.9 l - 77 kW TDI 5)
2.0 l - 100, 103 kW TDI
2.0 l -147 kW FSI 1LJ / 1LL FN3 (16”)
1.4 l -125 kW FSI 1LJ
2.0 l - 125 kW TDI
3.2 l -184 kW 1LM FNR-G (17”)
1) the 1ZE brake was installed at the start of series production.
2) Golf
3) with 5-speed manual gearbox 0A4.
4) Golf Plus
5) with Direct Shift Gearbox 02E - 6-speed or four-wheel drive.
Country specific brake for North America / Japan:
1.6 l -75 kW 1ZP FN3 (15”)
1.6 l - 85 kW FSI
2.0 l -110 kW
2.5 l -110 kW
1.9 l - 74 kW TDI
2.0 l -147 kW FSI 1ZD / 1LV FN3 (16”)
1.3 Front brakes, Eos

1.6 l - 85 kW FSI 1ZE FN3 (15”)
2.0 l -110 kW FSI
2.0 l -147 kW FSI 1LJ FN3 (16”)
2.0 l - 100, 103 kW TDI
3.2 l -184 kW
2.0 l -147 kW FSI 1ZD FN3 (16”)
3.2 l -184 kW
1.4 Rear brakes, Touran

Engine PR No. Rear brake
1.6 l - 75 kW 1KF CII 41 (15”)
1.6 l - 85 kW FSI
1.4 l -103 kW FSI
2.0 l -110 kW FSI
1.9 l - 66 kW TDI
2 Rep. Gr.00 - Technical data

1.9 l - 74, 77 kW TDI

2.0 l - 100, 103 kW TDI
1.4 l -125 kW FSI 1KJ 1) CII 41 (16”)
2.0 l - 125 kW TDI
1) Gradual switch to 1KF from the end of 2006
1.6 l - 85 kW FSI 1KE CII 41 (15”)
2.0 l -110 kW
1.5 Rear brakes, front-wheel drive Golf

Without Golf Variant:
1.4 l - 55, 59 kW 1KQ / 1KD CI 38 (15”)
1.4 l - 66 kW FSI
1.6 l - 75 kW
1.6 l - 85 kW FSI
2.0 l - 85 kW
1.4 l - 88, 90 kW FSI
1.4 l - 103, 110 kW FSI
2.0 l -110 kW FSI
2.0 l - 55 kW SDI
1.9 l - 66 kW TDI
1.9 l - 77 kW TDI
2.0 l - 100, 103 kW TDI
2.0 l - 147 kW FSI 1KY CII 38 (16”)
1.4 l - 125 kW FSI 1KZ 1)
2.0 l - 125 kW TDI

1) Gradual switch to 1KD from the end of 2006
Golf Variant only:
1.6 l - 75 kW 1KF CII 41 (15”)
1.6 l - 85 kW FSI
2.0 l - 110 kW FSI
1.9 l - 74, 77 kW TDI
2.0 l - 100, 103 kW TDI
1.6 l - 75 kW 1KE CII 41 (15”)
1.6 l - 85 kW FSI
2.0 l -110 kW
2.5 l - 110 kW
2.0 l - 147 kW FSI
1.9 l - 77 kW TDI
2.0 l - 100, 103 kW TDI
1. Brake allocation via PR No. 3

2.0 l - 147 kW FSI 1KV CII 38 (16”)
1.6 Rear brakes, four-wheel drive Golf

2.0 l - 110 kW FSI 1KF CII 41 (15”)
1.9 l - 77 kW TDI
2.0 l - 100, 103 kW TDI
3.2 l - 184 kW 2EL CII 41 (17”)
2.0 l - 110 kW 1KE CII 41 (15”)
1.7 Rear brakes, Eos

1.6 l - 85 kW FSI 1KD CI 38 (15”)
2.0 l - 110 kW FSI
2.0 l - 100, 103 kW TDI
2.0 l - 147 kW FSI 1KZ CII 38 (16”)
3.2 l - 184 kW
2.0 l - 147 kW FSI 1KJ CII 41 (16”)
3.2 l - 184 kW

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

Touran
Brake master cylinder ∅ in mm 22
Brake servo (LHD) ∅ in inches 11
Brake servo (RHD) ∅ in inches 7/8
2.2 Brake master cylinder and brake servo,

Golf, Eos
Brake master cylinder ∅ in mm 22
Brake servo (LHD) ∅ in inches 10
Brake servo (RHD) ∅ in inches 7/8
2.3 Front brakes

2.3.1 Front brakes FS III
Item PR No. 1ZF / 1ZM
1 Brake caliper FS III (15”)
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
back plate
3 Brake disc ∅ in 280
mm
Brake disc, mm 22
thickness
Brake disc, mm 19
wear limit
4 Brake caliper ∅ in 54
piston mm
2. Technical data for brakes 5

2.3.2 Front brakes FN 3

Item PR No. 1ZE / 1ZP
1 Brake caliper FN3 (15”)
2 Brake pad, mm 14
thickness
limit without
back plate
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
piston mm
Item PR No. 1LJ / 1LL / 1ZD / 1LV

1 Brake caliper FN3 (16”)
2 Brake pad, mm 14
thickness
limit without
back plate
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
piston mm
2.3.3 Front brakes FNR-G

Item PR No. 1LK / 1LM
1 Brake caliper FNR-G (17”)
2 Brake pad, mm 14
thickness
limit without
back plate
mm
Brake disc, mm 30
thickness
Brake disc, mm 27
wear limit
piston mm

2.4 Rear brakes (disc brakes)

2.4.1 Rear brakes CI 38
Item PR No. 1KQ / 1KD
1 Brake caliper CI 38 (15”)
2 Brake pad, mm 11
thickness
limit without
back plate
mm
Brake disc, mm 10
thickness
Brake disc, mm 8
wear limit
piston mm
2.4.2 Rear brakes CII 38

Item PR No. 1KY / 1KZ / 1KV
1 Brake caliper CII 38 (16")
2 Brake pad, mm 11
thickness
Brake pad, wear 2
limit without
back plate
mm
Brake disc, mm 12
thickness
Brake disc, 10
wear limit
piston mm
2. Technical data for brakes 7

2.4.3 Rear brakes CII 41

Item PR No. 1KF / 1KE
2 Brake pad, mm 11
thickness
limit without
back plate
mm
Brake disc, mm 12
thickness
Brake disc, mm 10
wear limit
piston mm
Item PR No. 1KJ

2 Brake pad, mm 11
thickness
limit without
back plate
mm
Brake disc, mm 12
thickness
Brake disc, mm 10
wear limit
piston mm
Item PR No. 2EL / 2EA

2 Brake pad, mm 11
thickness
limit without
back plate
mm
Brake disc, mm 22
thickness
Brake disc, mm 20
wear limit
piston mm

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

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

via a Haldex coupling
3.3.1 The brake test should be performed on

a single-axle roller dynamometer with
contra-rotating rollers for four-wheel
drive vehicles.
Contra-rotating means that the dynamometer rollers are driven
forwards on one side and backwards on the opposite side.
This prevents brake forces being transferred to the drive train.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
3.3.2 If no test rig is available for four-wheel

drive vehicles, the brake test can also be
carried out on a standard single-axle
roller dynamometer as follows:
– Drive vehicle forwards onto the rollers.
– Switch engine off and wait for 2 seconds.
– Carry out front brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
– Drive vehicle forwards until rear wheels are positioned on roll‐
ers.
3. Brake test 9
– Switch engine off and wait for 2 seconds.

– Carry out rear brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.

45 – Anti-lock brake system

1 General notes on anti-lock brake sys‐
tem
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking!
ABS layout in left-hand drive vehicle.
1 - Hydraulic unit and control unit
2 - Brake servo
The hydraulic unit -2- and control unit -1- form one component.
They can be separated only when removed. Hydraulic pump -3-
must not be separated from hydraulic unit.
With ABS/EDL/TCS/ESP - separation is not possible in vehicles
with hydraulic brake servo or hill hold assist.
1. General notes on anti-lock brake system 11

2 Notes for repair work on anti-lock

brake system
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using “Guided Fault Finding”.
“Guided Fault Finding” is carried out with the vehicle diagnostic,
testing and information system -VAS 5051- .
♦ Disconnect battery earth strap with ignition switched off.
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the valid, relevant
safety precautions and notes ⇒ page 130 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- or -V.A.G 1869- ⇒ page 130 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1 H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ 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.
12 Rep. Gr.45 - Anti-lock brake system

3 Connecting -VAS 5051- and select‐

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

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

VAS 5051/3- to diagnostic connection.
3. Connecting VAS 5051 and selecting functions 13

– 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.
– Select desired function on display.

4 Electrical/electronic components and

fitting locations
4.1 ABS Mark 70 (ABS/TCS)
1 - ABS control unit -J104-

❑ Fitting location: on the
hydraulic unit on right in
engine compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before disconnecting
connector.
❑ Removing and installing
⇒ page 28
2 - ABS hydraulic unit -N55-
❑ Fitting location: on right
in engine compartment.
The hydraulic unit consists of
the components:
❑ ABS hydraulic pump -
V64-
❑ Valve block (includes in‐
let/outlet valves)
V64- and valve block
must not be separated
from one another.
⇒ page 28
3 - Brake pad warning lamp -
K32-
❑ Fitting location: in dash
panel insert.
❑ Function: ⇒ page 23 .
4 - ABS warning lamp -K47-
panel insert.
5 - Traction control system warning lamp -K86-
❑ Fitting location: in dash panel insert.
6 - Brake system warning lamp -K118-
7 - Brake light switch -F- up to week 45/2005
❑ Including brake pedal switch -F47- .
❑ Fitting location: on brake pedal.
❑ Removing, installing and adjusting ⇒ page 110 .
4. Electrical/electronic components and fitting locations 15

8 - Brake light switch -F- from week 45/2005

❑ Fitting location: on brake master cylinder.
❑ Removing and installing ⇒ page 138
9 - TCS button -E256-
❑ Fitting location: in centre console.
10 - Diagnostic connection
❑ Fitting location: driver side footwell cover.
11 - Front right speed sensor -G45- / front left speed sensor -G47-
12 - Wheel bearing housing
13 - Wheel bearing/hub unit
❑ ABS sensor ring is installed in the wheel bearing.
14 - Rear right speed sensor -G44- / rear left speed sensor -G46-
❑ Removing and installing (front-wheel drive) ⇒ page 57
❑ Removing and installing (four-wheel drive) ⇒ page 58
15 - Rear axle assembly with stub axle
16 - Wheel hub with wheel bearing

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP)

engine compartment.
connector.
⇒ page 36
the components:
V64-
❑ Brake pressure sender -
G201-
let/outlet valves)
from one another.
⇒ page 36
K32-
panel insert.
5 - ESP and TCS warning lamp -K155-
❑ Only vehicles with ABS/EDL/TCS/ESP.

9 - TCS and ESP button -E256-
10 - ESP sensor unit -G419-
❑ Fitting location in Touran: behind glove box.
❑ Fitting location in Golf and Eos: under right front seat.
❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration
sender -G251-
❑ Combined in one housing.
❑ Removing and installing (Touran) ⇒ page 60
❑ Removing and installing (Golf, Eos) ⇒ page 60 .
12 - Steering angle sender -G85-
❑ Fitting location: on steering column between steering wheel and steering column switch.
13 - Front right/left speed sensor -G45- / -G47-
16 - Rear right/left speed sensor -G44- / -G46-
Figure for front-wheel drive


4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008

engine compartment.
connector.
⇒ page 42
the components:
V64-
G201-
let/outlet valves)
from one another.
⇒ page 42
K32-
panel insert.

10 - ESP sensor unit -G419-
❑ Fitting location in Touran: behind glove box.
❑ Fitting location in Golf and Eos: under right front seat.
❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration
sender -G251-
❑ Combined in one housing.
❑ Removing and installing (Touran) ⇒ page 60
❑ Removing and installing (Golf, Eos) ⇒ page 60 .
❑ Fitting location: on steering column between steering wheel and steering column switch.


4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008
1-
engine compartment.
connector.
The following components are
integrated into the control unit:
♦ Lateral acceleration sender
-G200-
♦ Yaw rate sender -G202-
♦ Longitudinal acceleration
sender -G251- (in vehicles
with four-wheel drive and
hill hold assist)
⇒ page 51
the components:
V64-
G201-
let/outlet valves)
must not be separated from one another.
3 - Brake pad warning lamp -K32-
7 - Brake light switch -F-

Note
❑ Fitting location A: on steering column between steering wheel and steering column switch.
❑ Fitting location B: in steering box.

5 Fault display via warning lamps

Warning lamps, Touran
5. Fault display via warning lamps 23

Warning lamps, Golf

Item Description
1 Traction control system warning lamp -K86-
ESP and TCS warning lamp -K155-
2 Brake pad warning lamp -K32-
3 ABS warning lamp -K47-
4 Brake system warning lamp -K118-
Brake pad warning lamp -K32-
♦ If the brake pad warning lamp -K32- -2- does not go out 3 sec‐
onds after the ignition is switched on, or it comes on during
vehicle operation, the fault may be:
-a- The brake pads are worn.
Check brake pads/linings on front and rear axles. Renew worn
brake pads/linings.
-b- There is a wiring fault. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
ABS warning lamp -K47-
♦ If the ABS warning lamp -K47- -3- does not go out after switch‐
ing ignition on and completion of test sequence then the fault
may be:
-a- The voltage supply is below 10 volts.
-b- There is a fault in the ABS.
WARNING
In the event of an ABS fault -b-, the anti-lock brake system

remains switched off, but the brake system remains fully op‐
erational.
-c- A temporary speed sensor fault occurred since the vehicle was
last started.
In this case, the ABS warning lamp will go out automatically after
the engine is restarted and the vehicle speed exceeds 20 km/h.
-d- The connection from dash panel insert to ABS control unit -
J104- is interrupted. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
-e- The dash panel insert is defective.
ABS warning lamp -K47- and brake system warning lamp -K118-
♦ If the ABS warning lamp -K47- -3- goes out but the brake sys‐
tem warning lamp -K118- -4- remains on, then the fault may
be:
-a- The handbrake is applied.
-b- The brake fluid level is too low (the warning lamp flashes).
Three warning tones are audible after ignition is switched on.
-c- There is a fault in the wiring to brake system warning lamp -
K118- . ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ If the ABS warning lamp -K47- -3- and the brake system warn‐
ing lamp -K118- -4- light up, then the ABS is defective. A
change in braking behaviour is to be reckoned with.

WARNING
After the ABS warning lamp -K47- and the brake system warn‐
ing lamp -K118- have lit up, it is possible that the rear wheels
will lock up earlier.
Traction control system warning lamp -K86-

♦ If the traction control system warning lamp -K86- -1- does not
go out after switching ignition on and completion of test se‐
quence then the fault may be:
There is a fault present which only affects the TCS. The ABS and
EBD safety systems on the vehicle remain fully functional ⇒ In‐
terrogate fault memory.
-a- Short-circuit to positive in TCS button -E256- .
-b- There is a fault in the activation of the traction control system
warning lamp -K86- ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
-c- The TSC system was shut off by the TCS button -E256- .
If traction control system warning lamp -K86- flashes while the
vehicle is in motion, the TCS is regulating the system.
♦ If the TCS warning lamp -K86- -1- does not light up during the
self-test, the fault may be:
-a- The TCS warning lamp -K86- is defective ⇒ perform electrical
check.
ESP and TCS warning lamp -K155-
♦ If the ESP and TCS warning lamp -K155- -1- does not go out
after ignition is switched on and test sequence is completed,
then the fault may be:
A fault in the system affecting only the TCS/ESP. The ABS/EDL
and EBD safety systems on the vehicle remain fully functional ⇒
Interrogate fault memory.
-a- Short-circuit to positive in TCS and ESP button -E256- .
-b- There is a fault in the activation of the ESP and TCS warning
lamp -K155- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
-c- The TCS/ESP system was shut off by the TCS and ESP button
-E256- .
If the ESP and TCS warning lamp -K155- flashes while the vehicle
is in motion, the TCS or ESP system is regulating the system.
♦ If the ESP and TCS warning lamp -K155- -1- does not light up
during the self-test, the fault may be:
-a- The ESP and TCS warning lamp -K155- is defective ⇒ perform
electrical check.
5. Fault display via warning lamps 25

6 Assembly overview - hydraulic unit,

brake servo/brake master cylinder
6.1 ABS Mark 70 (ABS/TCS)

⇒ page 28
⇒ page 28
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit
❑ Identification: union nut
with thread M 10 x 1
4 - Brake line
❑ From secondary piston
circuit of brake master
cylinder to hydraulic unit
5 - Brake line
❑ To front left brake cali‐
per
6 - Brake line
❑ To front right brake cali‐
per
7 - Brake line
❑ To rear left brake caliper
8 - Brake line
❑ To rear right brake caliper
❑ Identification: union nut with thread M 10 x 1
9 - Torx socket head bolt, 5.5 Nm
❑ Use new bolts.
10 - Bracket
11 - Hexagon bolt, 8 Nm
12 - Seal
❑ For brake servo.
13 - Brake servo
❑ On petrol engines, the required vacuum is taken from the intake manifold.
❑ Diesel engines are fitted with an exhauster to create the required vacuum ⇒ page 136 .

❑ Functional check:
– With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the
unit.)
– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning
properly, the brake pedal will be felt to go down as the servo takes effect.
❑ If faulty renew complete (check all vacuum lines first).
14 - Sealing ring
15 - Brake master cylinder
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
❑ Cannot be repaired. If faulty, renew as a complete unit.
16 - Hexagon nut, 25 Nm
❑ Always renew after removing
17 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
18 - Brake fluid reservoir
19 - Cap
20 - Sealing plug
❑ Connection for vacuum hose
21 - Vacuum hose
❑ Fit in brake servo
22 - Brake servo pressure sensor -G294-
❑ On vehicles with FSI engine without HBV (Hydraulic Brake with Vacuum servo)
6.1.1 Connecting brake lines from brake mas‐

ter cylinder to hydraulic unit
On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: union nut with thread M 10 x 1
B - Secondary piston circuit of master brake cylinder to hydraulic
unit.
1 - From hydraulic unit to front left brake caliper.
3 - Hydraulic unit to rear right brake caliper.
4 - Hydraulic unit to rear left brake caliper.
6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 27

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
2 - From hydraulic unit to front right brake caliper.
6.1.2 Removing control unit and hydraulic unit
Special tools and workshop

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

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 pins (foam)
2 - Sealing plug M 10
Removing
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
right in the engine compartment.
WARNING
Do not bend the brake lines in the area of the hydraulic unit!
– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
connecting and reconnecting battery .
– Remove engine cover panel.
1.4 l TSI engine:
– Remove pressure pipe and intake connecting pipe with regu‐
lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct
injection engine, turbocharger and compressor); Rep. Gr. 24 ;
Injection system; Part I - assembly overview - intake manifold .
– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l
direct injection engine, turbocharger and compressor); Rep.
Gr. 21 ; Charge air system .
– Clamp off hose from coolant expansion tank and pull it off.
1.9 l diesel engine:
– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel
engine (2 valve); Rep. Gr. 21 ; Removing and installing charge
air system with turbocharger .
– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel
engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐
ture preparation - injection .
– Touran vehicles only: remove plenum chamber middle bulk‐
head ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assem‐
bly overview - plenum chamber bulkhead .
– Remove connecting pipe between intake hose and turbo‐
charger.
– Remove toothed belt guard upper part.

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 vehicles:
– 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.
– Pull hydraulic unit with control unit upwards out of dampers.
6.1.3 Unbolting control unit from hydraulic unit

– Place hydraulic unit with control unit upwards on a clean flat
level surface.

– Remove Torx socket head bolts -arrows-.
– Without canting it, pull control unit off from hydraulic unit
-arrow-.
– Carefully pull all seals from hydraulic unit contact pins.
WARNING
♦ The printed circuit board becomes visible when the control

unit is removed.
♦ No moisture or particles of dirt may enter the control unit.
♦ Hydraulic pump must not be separated from hydraulic unit.
♦ Avoid electrostatic charge!
– Cover control unit solenoids with a lint-free cloth.

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

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

– Push all seals -A- over contact pins slightly.
– Without canting it, place control unit onto hydraulic unit.
The seals are thus moved to end position.
– Bolt hydraulic unit and control unit with enclosed, new Torx
socket head bolts.
Note
♦ A new control unit may be mounted on an existing hydraulic

unit max. twice to guarantee impermeability of the elastic seal.
♦ A control unit which has already been operated in a vehicle
must not be installed a second time.

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

– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 130 .
– Code radio.
– Code control unit -J104- with ⇒ Vehicle diagnosis, testing and
information system VAS 5051 in ”Guided fault finding”.
Specified torques:
Control unit to hydraulic unit 5.5 Nm
♦ Use new bolts!
Hexagon bolt of hydraulic unit to bracket 8 Nm

Brake lines to ABS assembly:
Thread M 10 x 1 14 Nm

6.2 ABS Mark 60 (ABS/EDL/TCS/ESP)

Separation of the control unit
and hydraulic unit is not possi‐
ble in vehicles with hydraulic
brake servo or hill hold assist.
⇒ page 36
⇒ page 36
3 - Brake line
❑ Identification: ∅ 6.5 mm
and union nut with long
thread M 12x1.
4 - Brake line
thread M 12x1.
5 - Brake line
per
❑ Identification: ∅
5.25 mm and union nut
with short thread M 12x1.
6 - Brake line
❑ To front right brake caliper
❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.
7 - Brake line
❑ Identification: ∅ 5.25 mm and union nut with short thread M 12x1.
8 - Brake line
❑ Use new bolts.
10 - Bracket
12 - Seal
Volkswagen Technical Site: http://vwts.ru http://vwts.info

13 - Brake servo
❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump
⇒ page 137 .
❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 62 .
unit.)
14 - Sealing ring
15 - Brake servo vacuum sender -G483-
❑ Only on vehicles having HBV
17 - Heat shield
19 - Sealing plug
21 - Cap
22 - Sealing plug
23 - Vacuum hose

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.
unit.

On hydraulic unit:
cylinder.
- Identification: ∅ 6.5 mm and union nut with long thread M 12x1.
cylinder.
- Identification: ∅ 5.25 mm and union nut with short thread M
12x1.
12x1.


equipment required
1331-
1410-
V.A.G 1869/2-


protection.
Removing
Fitting location:
WARNING

necessary.
1.4 l TSI engine:
charger.



pull off -2-.
er valves.
draulic unit.

Note
Separation of the control unit and hydraulic unit is not possible in

vehicles with hydraulic brake servo or hill hold assist.
– Place hydraulic unit with control unit downwards on a clean

flat level surface.
– Remove Torx socket head bolts E5 -arrows- from hydraulic
pump.
WARNING
Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

– The hydraulic pump must therefore be secured onto the hy‐

draulic unit with the red retainer -1- from the repair kit and two
sealing plugs -2-.
– Carefully lift hydraulic unit with hydraulic pump at joint -1- up‐
wards off control unit.
When pulling off the control unit, ensure that the hydraulic unit
contact pins are not canted against the control unit solenoids.
Item 2 adapter for pump motor.
WARNING

♦ Before the new control unit can be installed, the pump motor
adapter must be inserted to stop and must engage. Make sure
not to damage the adapter guide.
♦ The adapter supplied as a spare part for the control unit can
only be engaged once and then cannot be removed.
♦ The white paste on the bottom of the control unit serves as
sealant and must not be removed.
♦ Make sure not to touch any contact surfaces on the adapter,
pressure sensor and control unit as well as the silicone gel and
the sealing components by hand or with objects to prevent
them from being dirty or damaged.

– Press adapter into adapter guide to stop; it must then be en‐

gaged.
– Bolt hydraulic unit and control unit with the new Torx bolts
which are enclosed.
Note

Note

– Code radio.
To do this, basic setting of the steering angle sender -G85- , the
lateral acceleration sender -G200- and the brake pressure sender
-G201- must be carried out.
Specified torques:
♦ Use new bolts!


6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008

⇒ page 42
⇒ page 42
3 - Brake line
thread M 12x1.
4 - Brake line
thread M 12x1.
5 - Brake line
per
with short thread M 12x1.
6 - Brake line
❑ To front right brake caliper
7 - Brake line
❑ Identification: ∅ 5.25 mm and union nut with short thread M 12x1.
8 - Brake line
❑ Use new bolts.
10 - Retainer
12 - Seal

13 - Brake servo
❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump
⇒ page 137 .
❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 62 .
unit.)
14 - Sealing ring
17 - Heat shield
19 - Sealing plug
21 - Cap
22 - Sealing plug
23 - Vacuum hose

unit.

On hydraulic unit:
cylinder.
cylinder.
12x1.
12x1.


equipment required
1331-
1410-
V.A.G 1869/2-


protection.
Removing
Fitting location:
WARNING

necessary.
1.4 l TSI engine:
charger.



pull off -2-.
er valves.
draulic unit.

Note
Separation of the control unit and hydraulic unit is not possible in

vehicles with hydraulic brake servo or hill hold assist.
– Place hydraulic unit with control unit downwards on a clean

flat level surface.
– Remove Torx socket head bolts E5 -arrows- from hydraulic
pump.
WARNING
Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

– The hydraulic pump must therefore be secured onto the hy‐

draulic unit with the red retainer -1- from the repair kit and two
sealing plugs -2-.
– Carefully lift hydraulic unit with hydraulic pump at joint -1- up‐
wards off control unit.
When pulling off the control unit, ensure that the hydraulic unit
contact pins are not canted against the control unit solenoids.
Item 2 adapter for pump motor.
WARNING

♦ Before the new control unit can be installed, the pump motor
adapter must be inserted to stop and must engage. Make sure
not to damage the adapter guide.
♦ The adapter supplied as a spare part for the control unit can
only be engaged once and then cannot be removed.
♦ The white paste on the bottom of the control unit serves as
sealant and must not be removed.
♦ Make sure not to touch any contact surfaces on the adapter,
pressure sensor and control unit as well as the silicone gel and
the sealing components by hand or with objects to prevent
them from being dirty or damaged.

– Press adapter into adapter guide to stop; it must then be en‐

gaged.
– Bolt hydraulic unit and control unit with the new Torx bolts
which are enclosed.
Note

Note

– Code radio.
Specified torques:
♦ Use new bolts!


6.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008

⇒ page 51
2 - Torx socket head bolt, 2 Nm
+ 0.8 Nm
❑ Use new bolts.
⇒ page 51
4 - Brake line
and union nut with
thread M 12x1.
5 - Brake line
and union nut with
thread M 12x1.
6 - Brake line
per
with thread M 10x1.
7 - Brake line
❑ To front right brake cali‐
per
❑ Identification: ∅ 5.25
mm and union nut with thread M 12x1.
8 - Brake line
9 - Brake line
10 - Brake servo
❑ See ⇒ page 133 .
11 - Retainer
❑ Check for secure seating after installing.

12 - Torx bolt, 8 Nm
13 - Rubber damper
14 - Hexagon fitted bolt, 8 Nm
15 - Bracket
16 - Rubber damper
❑ Ensure that rubber dampers of retainer are not pressed out of bracket when installing.
18 - Heat shield

unit.
On hydraulic unit:
cylinder.
cylinder.


equipment required
1331-
1410-
V.A.G 1869/2-


protection.
Removing
Fitting location:
WARNING

necessary.
1.4 l TSI engine:
charger.


– Remove heat shield (if installed).

pull off -2-.
er valves.
draulic unit.

– Turn hexagon fitted bolt out of retainer.
– Pull hydraulic unit together with control unit and retainer side‐
ways out of rubber dampers of bracket and turn upside down.
– Unbolt retainer from hydraulic unit in engine compartment and
remove.
– Remove hydraulic unit together with control unit.
Note
– Place hydraulic unit with control unit upwards on a clean flat

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

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

unit is removed.
♦ No moisture or particles of dirt may enter the control unit.
♦ Avoid electrostatic charge!

WARNING

• Clean surfaces before assembling.

– Push all seals -A- over contact pins slightly.
The seals are thus moved to end position.
– Tighten hydraulic unit and control unit diagonally in stages to
specified torque with enclosed new Torx socket head bolts.
Note

Note

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.

– Code radio.
Specified torques:
Control unit to hydraulic unit 2 Nm + 0.8
♦ Use new bolts! Nm
Torx bolt of hydraulic unit to bracket 8 Nm

Hexagon fitted bolt, retainer to bracket 8 Nm

7 Removing and installing parts of ABS

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

❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
⇒ page 56
2 - Hexagon socket head bolt,
8 Nm
❑ ABS sensor ring is in‐
stalled in the wheel
bearing.
4 - Drive shaft
7.1.1 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle.

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

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

perature paste
G 052 112 A3.
⇒ page 58
8 Nm
bearing.
7. Removing and installing parts of ABS system on front and rear axle 57

on rear axle
Removing
– Raise vehicle.
speed sensor.
Installing
G 052 112 A3.
7.3 Removing and installing parts of anti-lock brake system on rear axle (four-
wheel drive)

perature paste
G 052 112 A3.
⇒ page 59
8 Nm
bearing.


on rear axle
Removing
– Raise vehicle.
speed sensor.
Installing
G 052 112 A3.
7. Removing and installing parts of ABS system on front and rear axle 59
8 Removing and installing parts of ESP

system
8.1 Removing and installing ESP sensor

unit -G419- (Touran)
The lateral acceleration sender -G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender -G251- are in‐
stalled together in one housing behind the glove compartment.
After exchanging the ESP sensor unit -G419- , perform basic set‐
ting for lateral acceleration sender -G200- .
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit -G419- . The ESP sensor unit -G419- may not then
be used any further.
Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trims .
– Pull connector -1- off ESP sensor unit -G419- .
– Remove the two securing nuts -arrows-.
– Remove ESP sensor unit -G419- .
Installing
When installing the ESP sensor unit -G419- , make sure it is cor‐
rectly seated in its bracket and is free of stress.
Note
Do not use the securing nuts to forcibly position the ESP sensor
unit -G419- .
– Tighten securing nuts to 9 Nm.

– Perform basic setting of lateral acceleration sender -G200- .
Connecting -VAS 5051- and selecting functions ⇒ page 13 .
8.2 Removing and installing ESP sensor

unit -G419- (Golf, Eos)
The lateral acceleration sender -G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender -G251- are in‐
stalled in a housing under the right front seat.
After exchanging the ESP sensor unit -G419- , perform basic set‐
ting for lateral acceleration sender -G200- .

WARNING
Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit -G419- . The ESP sensor unit -G419- may not then
be used any further.
Removing
– Remove right front seat together with seat frame ⇒ General
body repairs, interior; Rep. Gr. 72 .
– Remove sill panel trim ⇒ General body repairs, interior; Rep.
Gr. 68 ; Sill panel trims .
– Lift carpet and lay to the side.
– Remove coupling station -1-.
– Raise floor covering.
– Pull connector -1- off ESP sensor unit -G419- .

– Remove the two securing nuts -arrows-.
– Remove ESP sensor unit -G419- .
Installing
When installing the ESP sensor unit -G419- , make sure it is cor‐
rectly seated in its bracket and is free of stress.
Note
Do not use the securing nuts to forcibly position the ESP sensor
unit -G419- .
– Tighten securing nuts to 9 Nm.

– Perform basic setting of lateral acceleration sender -G200- .
8.3 Removing and installing steering angle

sender -G85-
The steering angle sender -G85- is located between the steering
wheel and steering column switch.
Removing and installing
⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - ex‐
terior; Steering column switch .
– Then perform basic setting of steering angle sender -G85- .
8. Removing and installing parts of ESP system 61

Note
In vehicles equipped with an electromechanical power steering of

the 3rd generation, the steering angle sender is located in the
steering box from week 22/2008.
8.4 Removing and installing brake servo

vacuum sender -G483-
Removing
– Removing and installing battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .
– Remove battery tray.
– Disconnect connector -1- from brake servo vacuum sender -
G483- -2-.
– Insert screwdriver into circlip groove between stop and one
end of circlip.
– Now press circlip -1- out of groove until brake servo vacuum
sender -G483- -2- can be pulled out of brake servo.
Installing

46 – Brakes - mechanism
1 Repairing front brakes
1.1 Repairing front brakes, FS III brake cal‐

iper
Note
♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment -VAS 5234- or
the extraction unit -V.A.G 1869/4- to draw off brake fluid from
the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor -V.A.G 1869/2- (when doing
this, release pressure in system).
1 - Hexagon bolt / Torx bolt,

12 Nm
❑ M6x10 hexagon bolt re‐
vised to M6x12 Torx bolt
❑ Replace hexagon bolt
with hexagon bolt and
Torx bolt with Torx bolt
2 - Brake disc
❑ Ventilated, ∅ 280 mm
❑ Thickness: 22 mm
❑ Wear limit: 19 mm
❑ Always renew on both
sides of an axle.
❑ Unscrew brake caliper
prior to removing.
3 - Cross head screw / Torx
screw, 4 Nm
4 - Brake pads
❑ Thickness: 14 mm with‐
out 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.
❑ Pad wear limit: 2 mm
without backplate
❑ Check thickness
⇒ Maintenance ; Book‐
let 18.1 .
sides of an axle.
1. Repairing front brakes 63

5 - Connector
❑ Brake pad wear indicator
6 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Repairing ⇒ page 113
7 - Guide pin, 30 Nm
8 - Cover cap
❑ Remove
9 - Brake hose with banjo union and banjo bolt, 35 Nm
11 - Cover cap
❑ Remove
12 - Bolt
13 - Bracket
❑ With integrated brake carrier.
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
16 - Hexagon socket head bolt, 8 Nm
18 - Splash plate
1.2 Removing and installing brake pads/lin‐

ings
♦ Torque wrench -V.A.G 1331-
64 Rep. Gr.46 - Brakes - mechanism

♦ Piston resetting tool -T 10145-
1.2.1 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.
– Disconnect connector -1- for brake pad wear indicator.
– Remove cover caps -arrows-.

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

pads and remove corrosion.
– Clean brake caliper.
Use only methylated spirits for cleaning the brake caliper housing.
1.2.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press piston back.
– Insert inner brake pad (piston side) -1- and outer brake pad
-2- into brake caliper with retaining springs.
♦ Inner brake pad (piston side) with large 3-finger clip -1-.
♦ Outer brake pad with small 3-finger clip -2- (coloured black).

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

of brake carrier.
– Bolt brake caliper to brake carrier with both guide pins.

• Brake caliper stud must be positioned behind brake carrier
guide!
– Fit both cover caps.
– Reconnect connector for brake pad wear indicator.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .
Note

♦ Check brake fluid level after changing brake pads.
Specified torque:
Guide pin to brake carrier 30 Nm
1.3 Removing and installing brake caliper


♦ Brake pedal depressor -V.A.G 1869/2-
1.3.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Separate connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Pull both cover caps out of sleeve bearings of brake caliper.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper off brake carrier.
– Remove brake pads from brake caliper.
1.3.2 Installing
• Piston is pressed back.
– Insert inner brake pad (piston side) -1- and outer brake pad
-2- into brake caliper with retaining springs.
♦ Inner brake pad (piston side) with large 3-finger clip -1-.
♦ Outer brake pad with small 3-finger clip -2- (coloured black).

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

of brake carrier.

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

ary, so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torques:
Brake hose to brake caliper 35 Nm
1.4 Repairing front brake, FN 3 brake cali‐

per
Note

Assembly overview, FN3, 15 inches:

1 - Cross head screw / Torx

screw, 4 Nm
2 - Brake disc
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
3 - Brake pads
out backplate
dicator
insert comes on.
without backplate
❑ Check thickness
let 18.1 .
sides of an axle.
⇒ page 72
4 - Retaining spring
❑ Insert into both holes in
brake caliper.
5 - Brake carrier
❑ Bolt to wheel bearing housing.
6 - Brake caliper
8 - Cover cap
❑ Remove
10 - Ribbed bolt, 190 Nm
❑ Clean if reused.
11 - Bolt
12 - Bracket
❑ With bolted brake carrier.


16 - Splash plate
17 - Hexagon bolt / Torx bolt, 12 Nm
❑ M6x10 hexagon bolt revised to M6x12 Torx bolt
❑ Replace hexagon bolt with hexagon bolt and Torx bolt with Torx bolt
Assembly overview, FN3, 16 inches:
2 - Brake disc
sides of an axle.
removing.
3 - Torx bolt, 4 Nm
4 - Brake pads
out backplate
dicator
insert comes on.
without backplate
❑ Check thickness
let 18.1 .
sides of an axle.
⇒ page 72
❑ Insert into both holes in
brake caliper.
6 - Brake carrier
❑ Bolt to wheel bearing housing.
7 - Brake caliper

9 - Cover cap
❑ Remove
12 - Cover cap
❑ Remove
13 - Bolt
14 - Bracket
❑ With bolted brake carrier.
20 - Splash plate

ings

1.5.1 Removing
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper
-arrow- with a screwdriver and remove.

iper.
– Take brake pad out of brake caliper or from brake carrier.
Cleaning:
WARNING

– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.
1.5.2 Installing
damage.
– 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.


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

Specified torque:

1.6.1 Removing
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.


open bleeder valve.
1.6.2 Installing
• Outer brake pad is seated on brake carrier.
(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 hose to brake caliper.
– Insert retaining spring into brake caliper.
– Fit wheels.
Note

operating position.
Specified torques:
Brake hose to brake caliper 35 Nm

1.7 Repairing front brake, FNR-G brake cal‐

iper
Note

1 - Splash plate
3 - Brake disc
sides of an axle.
removing.
4 - Torx bolt, 4 Nm
5 - Brake carrier
❑ Bolt to wheel bearing
housing.
❑ Insert into brake pad re‐
taining spring and press
under brake carrier.
8 - Brake pads
out backplate
dicator
insert comes on.
without backplate
❑ Check thickness ⇒ Maintenance ; Booklet 18.1 .
❑ Always renew on both sides of an axle.

9 - Brake caliper
❑ Do not disconnect brake hose when changing brake pads.
❑ Must not be unbolted from one another.
11 - Cover cap
❑ Remove
12 - Washer
13 - Balance weight
14 - Bolt, 10 Nm
15 - Dust cap
16 - Retainer
17 - Bolt, 15 Nm
18 - Brake line, 14 Nm
19 - Brake hose
21 - Retainer
22 - Spring clip

ings

1.8.1 Removing
– Remove wheels.
– Lever brake caliper retaining spring out of brake pad retaining
spring using a screwdriver. To do this, position screwdriver
between the two retaining springs -enlargement-.
– Firmly hold brake caliper retaining spring with a cloth to pre‐
vent loss.

iper.
– Take brake pads out of brake caliper.
Cleaning:
WARNING

1.8.2 Installing
damage.
(piston).

– Insert outer brake pad -2- with retaining spring in caliper.

– Fit brake caliper with brake pads onto brake carrier.

– Insert brake caliper retaining spring into brake pad retaining
spring and press under brake carrier.
– Fit wheels.
Note

Specified torque:


1.9.1 Removing
– Remove wheels.
– Lever brake caliper retaining spring out of brake pad retaining
spring using a screwdriver. To do this, position screwdriver
between both retaining springs.
– Firmly hold brake caliper retaining spring with a cloth to pre‐
vent loss.
open bleeder valve.
1.9.2 Installing
(piston).
– Insert outer brake pad with retaining spring in brake caliper.
– Fit brake caliper with brake pads onto brake carrier.
– Connect brake hose to brake line from brake caliper.
– Insert brake caliper retaining spring into brake pad retaining
spring and press under brake carrier.
– Bleeding brake system
– Fit wheels.


Note

operating position.
Specified torques:
Brake hose to brake line 14 Nm

2 Repairing rear brake
2.1 Repairing rear brake CI 38
Note


perature paste
G 052 112 A3.
8 Nm
3 - Multi-point socket head bolt,
90 Nm and turn 90° further
❑ Always renew after re‐
moving
5 - Splash plate
6 - Hexagon bolt, 9 Nm / Torx
bolt, 12 Nm
8 - Brake disc
❑ ∅ 255 mm
❑ When worn, renew on
both sides of axle.
prior to removing.
9 - Cross-head screw, 4 Nm
10 - Bolt
11 - Brake pads
❑ Thickness: 11 mm without backplate
84 Rep. Gr.46 - Brakes - mechanism Volkswagen Technical Site: http://vwts.ru http://vwts.info

❑ Pad wear limit: 2 mm without backplate
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 replacement.
❑ Adjusting handbrake ⇒ page 101 .
14 - Hose retainer
16 - Self-locking hexagon bolt, 35 Nm
❑ Renew.
17 - Handbrake cable
18 - Spring clip
19 - Brake hose

ings
2. Repairing rear brake 85

♦ Resetting and removal tool -T 10165-
2.2.1 Removing
– Remove wheels.
– Remove securing bolts from brake caliper, to do this counter‐
hold on guide pins.
– Remove brake pads.
Cleaning:
WARNING

– Clean brake caliper, particularly the bonding surfaces for the
brake pads. These must be free of adhesive and grease res‐
idues.
2.2.2 Installing
Before pressing pistons back, draw off some brake fluid from res‐
ervoir with a bleeder bottle. Otherwise, particularly if reservoir has
been topped up, fluid will overflow and cause damage.
– Screw in piston by turning knurled wheel of resetting and re‐
moval tool - T 10165 - clockwise, do not damage protective
cap when doing this.

– To aid screwing in, use special tool T10165/1.

♦ If pistons are difficult to move, use a 13 mm open jaw spanner
on flats -arrow A- provided for this purpose.
– Pull protective foil off backing plates for brake pads.
– Insert brake pads into brake carrier.

When positioning the brake caliper, ensure that the brake pads
do not stick to the brake caliper before it is positioned correctly.
– Secure brake caliper with new self-locking bolts.
♦ The repair kit includes four self-locking hexagon bolts which
must always be installed.
– Fit wheels.
Note

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


2.3.1 Removing
– Remove wheels.
– Unclip brake cable from lever on brake caliper.
– Pull spring clip downwards and pull handbrake cable out of
retainer on brake caliper.
open bleeder valve.
– Unscrew brake line.
– Remove both securing bolts from brake caliper; to do this,
counterhold on guide pin.
2.3.2 Installing
• The brake pads are seated on the brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts.
– Screw brake line to brake caliper.
– Hook in handbrake cable and secure on retainer with spring
clip.
– Adjusting handbrake ⇒ page 101 .
– Fit wheels.

Note

operating position.
Specified torques:
♦ Use new bolts!
Brake line to brake caliper 14 Nm
2.4 Repairing rear brake CII 38
Note



perature paste
G 052 112 A3.
8 Nm
moving
5 - Splash plate
8 - Brake disc
❑ ∅ 286 mm
both sides of axle.
prior to removing.
10 - Bolt
❑ Front-wheel drive only
11 - Brake pads
out backplate
12 - Brake carrier with guide pin(s) and protective cap
guide pins.
13 - Pad retainer
❑ Always renew when changing pads.
14 - Brake caliper

15 - Hose retainer
❑ Renew.
19 - Spring clip
20 - Brake hose

ings
2.5.1 Removing
– Remove wheels.


hold on guide pins.
– Remove brake pads and pad retainers -arrows-.

Cleaning:
WARNING
– Thoroughly clean contact surfaces for pad retainers (brake

pads) on brake carrier, and remove corrosion.
2.5.2 Installing

– Insert pad retainers -arrows- and brake pads into brake carrier.
– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Fit wheels.
Note

Specified torque:
♦ Use new bolts!


2.6.1 Removing
– Remove wheels.
open bleeder valve.
2.6.2 Installing
• The brake pads are seated in the retaining springs on the
brake carrier.
bolts.
clip.
– Fit wheels.


Note

operating position.
Specified torques:
♦ Use new bolts!
2.7 Repairing rear brake CII 41
Note

I - Assembly overview, front-wheel drive

II - Deviations, four-wheel drive


perature paste
G 052 112 A3.
8 Nm
moving
5 - Splash plate
6 - Hexagon bolt, 9 Nm / Torx
bolt, 12 Nm
8 - Brake disc
❑ 15 inches: ∅ 260 mm;
16 inches: ∅ 286 mm;
17 inches: ∅ 310 mm
❑ Thickness, 15 and
16 inches: 12 mm; 17 in‐
ches: 22 mm
❑ Wear limit, 15 and
16 inches: 10 mm; 17 in‐
ches: 20 mm
both sides of axle.
❑ Unscrew brake caliper prior to removing.
10 - Bolt
❑ Front-wheel drive only
11 - Brake pads
❑ Thickness: 11 mm without backplate
12 - Brake carrier with different guide pins and protective cap
guide pins.
❑ Installation instructions ⇒ page 97
13 - Pad retainer
❑ Always renew when changing pads.

14 - Brake caliper
15 - Hose retainer
❑ Renew.
19 - Spring clip
20 - Brake hose
Installation instructions for brake caliper CII 41, 15 inches, from

week 32/2004:
1- Shorter guide pins with steps -arrows-, leading side
2- Longer guide pins, phasing out
3- Balance weight, phasing out

ings

2.8.1 Removing
– Remove wheels.
hold on guide pins.
– Remove brake pads and pad retainers -arrows-.

Cleaning:
WARNING
– Thoroughly clean contact surfaces for pad retainers (brake

pads) on brake carrier, and remove corrosion.
2.8.2 Installing


– Insert pad retainers -arrows- and brake pads into brake carrier.
– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Fit wheels.
Note

Specified torque:
♦ Use new bolts!


2.9.1 Removing
– Remove wheels.
open bleeder valve.
2.9.2 Installing

• The brake pads are seated in the retaining springs on the

brake carrier.
bolts.
clip.
– Fit wheels.
Note

operating position.
Specified torques:
♦ Use new bolts!
2.10 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 .
– Depress foot brake hard at least three times.
– Firmly pull on and then release handbrake three times.
Below the first notch, the handbrake lever must return to its re‐
leased position.
• Handbrake lever in rest position.

– Tighten adjusting nut -arrow (enlargement)- until ...
– ... lever -1- lifts off the brake caliper stop -2-.
– 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.
Due to the automatic rear wheel brake adjustment there is no re‐
quirement to adjust the handbrake after making new/initial ad‐
justment.

3 Assembly overview - handbrake lev‐

er
The illustration shows the assembly overview for the Touran.
1 - Handbrake lever
❑ Before removing take
out centre console.
3 - Handbrake lever trim
❑ Pull off forwards.
❑ Lever up release tab in
rear, lower area of han‐
dle -arrow- with a screw‐
driver.
❑ If leather upholstery is
fitted, leather is cut in
area of locking mecha‐
nism.
4 - Pull rod
5 - Compensator
6 - Adjustment nut
❑ Adjusting handbrake
⇒ page 101 .
7 - Handbrake cables
up to model year 2007
⇒ page 103
from model year 2008
⇒ page 106
8 - Handbrake warning switch
3.1 Removing and installing handbrake ca‐

ble up to model year 2007
3.1.1 Removing
– Release handbrake
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
3. Assembly overview - handbrake lever 103

– Release adjustment nut -1- until relevant handbrake cable

-2- can be detached from compensator -3-.
– Lever spring clips off -1-.

– Press lever on brake caliper -2- in direction of arrow and de‐
tach handbrake cable -3-.
– Unscrew Torx bolt -1- and then release fastening clip from
handbrake cable -2-.
– Detach handbrake cable from bracket -1- and pull handbrake

cable out of guide tube -2-.

3.1.2 Installing
– Push handbrake cable into guide tube -2- and attach it into
bracket -1-.
– Press lever on brake caliper -2- in direction of arrow and attach

– Press spring clips -1- onto handbrake cable.
Handbrake cable -2- must be installed without tension between

brake caliper bracket and fastening clip.
– Therefore, fastening clip -1- should only now be screwed onto
trailing arm.
– Attach handbrake cable -2- into compensator -3-.

– Pretension handbrake cable with adjustment nut -1-.
– Adjust handbrake ⇒ page 101 .

3.2 Removing and installing handbrake ca‐

ble from model year 2008
3.2.1 Removing
– Release handbrake
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
– Release adjustment nut -1- until relevant handbrake cable
-2- can be detached from compensator -3-.
– Press lever on brake caliper -2- in direction of arrow and de‐

tach handbrake cable -3-.
– Compress locking lugs -1- together and pull handbrake cable
out of bracket on brake caliper.
– First pull handbrake cable -1- off locking lugs, then pull com‐
pletely out of bracket -2-.

– Detach handbrake cable from bracket -1- and pull handbrake

cable out of guide tube -2-.
3.2.2 Installing
– Push handbrake cable into guide tube -2- and attach it into
bracket -1-.
– Insert handbrake cable -1- through aperture, then clamp it to

bracket -2-.
– Push handbrake cable into bracket on brake caliper until both

locking lugs -1- engage.
– Press lever on brake caliper -2- in direction of arrow and attach
The handbrake cable must be installed without tension between
the brake caliper bracket and the bracket on the trailing arm.

– Attach handbrake cable -2- into compensator -3-.

– Pretension handbrake cable with adjustment nut -1-.
– Adjust handbrake ⇒ page 101 .

4 Assembly overview - brake pedal
WARNING
The brake pedal travel must not be restricted by additional floor

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

G 000 602.
1 - Mounting bracket
2 - Self-locking hexagon nut,
25 Nm
❑ Including brake pedal
switch -F47- .
❑ In vehicles from week
45/2005, the brake light
switch -F- is located on
the brake master cylin‐
der ⇒ page 133 .
❑ Before installing brake
light switch, connect
brake pedal to brake
servo push rod
⇒ page 110 .
❑ Grease head of push
rod with polycarbamide
grease G 052 142 A2.
brake light switch
⇒ page 110
4 - Hexagon bolt
5 - Brake pedal
6 - Cap
7 - Ball socket
8 - Mounting
❑ For ball head of brake
servo plunger rod.
25 Nm
10 - Sleeve bearing
11 - Pivot pin
4.1 Separating brake pedal from brake ser‐

vo
4. Assembly overview - brake pedal 109

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

Rep. Gr. 70 ; Dash panel
Vehicles with brake light switch on mounting bracket only:
– Pull connector off brake light switch.
– Remove brake light switch by turning 45° to left.
– 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).
4.1.1 Clipping brake pedal to brake servo

– Hold ball head of plunger rod in front of mounting and push
brake pedal in direction of brake servo, so that the ball head
clicks into place.
Continue installation in reverse order.
Vehicles with brake light switch on mounting bracket only:
– Install brake light switch ⇒ page 110 .
4.2 Removing and installing brake light

switch - F- from week 45 of 2005
Including brake pedal switch -F47-

In vehicles from week 45/2005, the brake light switch is located

on the brake master cylinder ⇒ page 133 .
4.2.1 Brake light switch, old version
Note
♦ After removing the old brake light switch (see figure

N46-0359), replace it with a new one (see figure N46-10145).
♦ Distinguishing features ⇒ page 112 .
Removing
– If necessary, remove footwell vent ⇒ Heater, air conditioning
system; Rep. Gr. 80 ; Repairing heater; Removing vent .
The brake light switch may be removed only while operating rod
is pressed in (brake pedal is not operated), or the locking mech‐
anism of the brake light switch will be damaged.
Installing, adjusting and locking
Because old brake light switches may no longer be used, the de‐
scription has been omitted.
Installing, adjusting and locking new brake light switch
⇒ page 112 .
4. Assembly overview - brake pedal 111

4.2.2 Brake light switch, new version
Note
♦ Use only new brake light switches.

♦ The most noticeable difference
to the old brake light switch is the new, bright tip of the plunger
-A-.
Removing
– If necessary, remove footwell vent ⇒ Heater, air conditioning
system; Rep. Gr. 80 ; Repairing heater; Removing vent .
The brake light switch may be removed only while operating rod
is pressed in (brake pedal is not operated), or the locking mech‐
anism of the brake light switch will be damaged.
Installing, adjusting and locking
Before assembling the brake light switch, grease the bright tip of
the plunger head with polycarbamide grease G 052 142 A2.
• The brake pedal must remain at rest position while the brake
light switch is being installed. The brake pedal must not be
touched by anything but the plunger head throughout the en‐
tire installation.
– Guide brake light switch through fitting hole -arrow 1- and

press it against pedal with head of plunger. Then turn brake
light switch 45° to right -arrow 2- until it can be felt to engage.
– Fit brake light switch connector.
– Check function of brake light.
– Install footwell vent ⇒ Heating and air conditioning system;
Rep. Gr. 80 ; Repairing heating; Removing vents .
– Install trim on driver's side ⇒ General body repairs, interior;

47 – Brakes - hydraulics
1 Repairing front brake caliper
1.1 Repairing brake caliper FS III

♦ 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 cyl‐
inder, piston and sealing ring.
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
5 - Sleeve bearing
❑ Insert into brake caliper.
6 - Brake caliper
7 - Protective cap
⇒ page 113
❑ Take care not to dam‐
age when inserting pis‐
ton.
8 - Piston
⇒ page 113
sembly paste
G 052 150 A2 to piston
before installing.
9 - Sealing ring
⇒ page 113
1.2 Removing and installing piston for brake

caliper FS III
1. Repairing front brake caliper 113

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

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

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

and seal before inserting.
– Insert seal into brake caliper.
– Place outer sealing lip of protective cap on the piston.
– Insert inner sealing lip into groove in cylinder using wedge
3409.
When doing this, hold piston in front of brake caliper.
– Press piston into brake caliper with piston resetting tool.

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

kit.


1 - Dust cap
sembly paste
before screwing in.
3 - Cover caps
ing.
5 - Sleeve bearing
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
⇒ page 116
10 - Piston
⇒ page 116
sembly paste
before installing.
11 - Protective cap
❑ Take care not to damage when inserting piston.
1.4 Removing and installing piston for brake

caliper FN 3

♦ Assembly tool for protective caps -T 10146/6-
1.4.1 Removing
piston.

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

damaged.
1.4.2 Installing
– Fit protective cap -A- in assembly tool T10146/6 -1-.
– Press protective cap onto brake caliper so that seal is fitted

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

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

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

kit.


1 - Dust cap
sembly paste
before screwing in.
3 - Cover caps
ing.
5 - Sleeve bearing
6 - Brake caliper
❑ Must not be unbolted
from one another.
❑ Insert into brake pad re‐
taining spring and press
under brake carrier.
8 - Brake carrier
❑ Bolt onto brake caliper.
9 - Sealing ring
⇒ page 120
10 - Piston
⇒ page 120
sembly paste
before installing.
11 - Protective cap
❑ Take care not to damage when inserting piston.
1.6 Removing and installing piston for FNR-

G brake caliper

♦ Assembly tool for protective caps -T 10146/6-
1.6.1 Removing
piston.
– Lever off protective cap from brake caliper using wedge 3409.


damaged.
1.6.2 Installing
– Fit protective cap -A- in assembly tool T10146/1 -1-.
– Press protective cap onto brake caliper so that seal is fitted

correctly all round using assembly tool -1- and piston resetting
tool -2-.
Check seat of protective cap:
– At this stage it should not be possible to remove protective cap
from brake caliper by hand.

– Gently press piston onto protective seal using an extension

and ratchet insert -1- and then hold in this position.
Keep piston straight to prevent damage to sealing collar.
– Blow into protective cap using compressed air (max 3 bar)
-2-. During this step protective cap will spring on piston.
– Press piston into brake caliper by hand, subsequently press‐
ing with piston resetting tool if necessary.
piston groove.

2 Repairing rear brake caliper

kit.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ When repairs are performed, it is essential to appropriately
pre-bleed brake calipers (without brake pads) before installing
in vehicle ⇒ page 128 .
Assembly overview of brake calipers CI 38 and CII 38:
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
⇒ page 128 .
2 - Dust cap
sembly paste
before screwing in.
4 - Self-locking hexagon bolt,
35 Nm
❑ Renew.
❑ When loosening and
tightening, counterhold
on guide pin.
5 - Guide pin
❑ Grease before fitting
protective cap.
6 - Protective cap
❑ Fit onto brake carrier
and guide pin.
7 - Brake carrier with guide pin
(s) and protective cap
❑ Illustration for CII 38
brake
❑ Supplied as genuine
part, assembled with
sufficient grease on
guide pins.
guide pins.
8 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.

9 - Piston with automatic adjustment

❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
10 - Sealing ring
Assembly overview of brake caliper CII 41:

15 inches from week 32/2004:
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
⇒ page 128 .
2 - Dust cap
sembly paste
before screwing in.
4 - Self-locking hexagon bolt,
35 Nm
❑ Renew.
❑ When loosening and
tightening, counterhold
on guide pin.
5 - Guide pins with steps
❑ Shorter than item 6
protective cap.
6 - Guide pin
❑ Longer than item 5
protective cap.
7 - Protective cap
❑ Fit onto brake carrier
and guide pin.
8 - Brake carrier with balance
weight
guide pins.
9 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
10 - Piston with automatic adjustment
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
2. Repairing rear brake caliper 125

11 - Sealing ring
2.1 Removing
– Screw piston out of brake caliper by turning thumb wheel anti-

clockwise.
Apply resetting and removal tool so that collar of tool is resting on
piston.

2.2 Installing
– Place protective cap with outer sealing lip onto piston.
– Insert inner sealing lip into groove in cylinder using wedge
3409.
When doing this, hold piston in front of brake caliper.

– Screw in piston by turning thumb wheel clockwise.

♦ Apply resetting and removal tool so that collar of tool is resting
on brake caliper.
♦ If the piston is pushed back with a piston resetting tool (e.g.
T10145) or by operating the foot brake the automatic adjust‐
ment in the brake caliper is destroyed.
2. Repairing rear brake caliper 127

2.3 Pre-bleeding brake caliper

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

3 Pressurised leak test

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

Brake system (hydraulic unit, brake hoses, brake lines and brake
calipers) operating properly and free of leaks.
– Remove bleeder valve at one of front brake calipers. Connect
pressure gauge -V.A.G 1310 A- and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.
3. Pressurised leak test 129

4 Bleeding brake system

Bleeding the brake system is described for brake filling and bleed‐
ing equipment -VAS 5234- and -V.A.G 1869- .
Note
♦ Bleeding brake system on vehicles with ABS is performed in

the same way as on vehicles with a conventional brake sys‐
tem.
♦ Only use new brake fluid conforming to US standard
FMVSS 116 DOT 4.
♦ Genuine VW/Audi brake fluid conforms to this specification.
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air tight containers.
♦ Wash away spilt brake fluid using plenty of water.

A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
4.1 Bleeding brake system using brake fill‐

ing and bleeding equipment -VAS 5234-
or -V.A.G 1869-
Special tools and work‐
shop equipment re‐
quired
♦ Brake filling and
bleeding equipment -
VAS 5234-
♦ or
♦ Brake filling and
bleeding equipment -
V.A.G 1869-
♦ Upgrade kit and ex‐
traction unit -V.A.G
1869/4-
Commercially available
tool:
Note
If, in vehicles with EDL,

EDL/TCS or EDL/TCS/
ESP, a chamber in brake
fluid reservoir is com‐
pletely empty (e.g. brake
system leaking), brake
system must be pre-bled
first.
4.1.1 Pre-bleeding:
– Connect brake filling and bleeding equipment -VAS 5234- or
-V.A.G 1869- .
Bleeding sequence:
4. Bleeding brake system 131

1 - Bleed front left and front right brake calipers simultaneously.

2 - Bleed rear left and rear right brake calipers simultaneously.
– Leave bleeder valves open with brake fluid hoses connected
until brake fluid free from air bubbles flows out.
Then hydraulic unit must be bled again via function “Basic setting”
of tester -VAS 5051- .
Initiate basic setting (to bleed brake system):
– Then bleed brake system as normal.
4.1.2 Bleeding (normal):

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

This requires the assistance of a second mechanic:
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
– Release brake pedal slowly.
This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
A road test must be carried out after the brakes have been bled.
When doing this an ABS regulation must be performed at least
once!
4.2 Changing brake fluid
4.2.1 Changing brake fluid

⇒ Maintenance ; Booklet 18.1

5 Brake servo and master brake 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
4 - Brake servo
❑ On petrol engines, the
required vacuum is tak‐
en from the intake mani‐
fold.
❑ Certain vehicles with a
petrol engine and an au‐
tomatic gearbox are
equipped with a brake
vacuum pump -V192- .
⇒ page 137
❑ A vacuum sender is fit‐
ted in vehicles with HBV
⇒ page 62 .
❑ Diesel engines are fitted
with an exhauster to cre‐
ate the required vacuum
⇒ page 136 .
– With engine switched
off, depress brake pedal
firmly several times.
(This will release the
vacuum in the unit.)
– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning properly, the brake pedal will be felt to go down as the servo takes effect.
5 - Sealing ring
Volkswagen Technical Site: http://vwts.ru http://vwts.info
5. Brake servo and master brake cylinder 133

7 - Brake master cylinder without brake light switch
8 - Brake master cylinder with brake light switch
❑ In vehicles prior to week 45/2005, the brake light switch -F- is located on the brake pedal ⇒ page 109 .
11 - Heat shield
12 - 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
15 - Sealing plug
17 - Cap
18 - Sealing plug
19 - Vacuum hose
5.2 Assembly overview - brake servo/brake

master cylinder (right-hand drive vehi‐
cle)
Note
Use only new brake fluid. Observe information on brake fluid res‐
ervoir!

1 - Pedal cluster
25 Nm
moving
4 - Seal
5 - Brake servo
❑ On petrol engines, the
required vacuum is tak‐
en from the intake mani‐
fold.
❑ Certain vehicles with a
petrol engine and an au‐
tomatic gearbox are
equipped with a brake
vacuum pump -V192- .
⇒ page 137
❑ A vacuum sender is fit‐
ted in vehicles with HBV
⇒ page 62 .
❑ Diesel engines are fitted
with an exhauster to cre‐
ate the required vacuum
⇒ page 136 .
– With engine switched
off, depress brake pedal
firmly several times.
(This will release the
vacuum in the unit.)
– Now step on and hold

brake pedal with medi‐
um pressure and start engine. If the brake servo is functioning properly, the brake pedal will be felt to go
down as the servo takes effect.
6 - Sealing ring
8 - Sealing plug
9 - Vacuum hose
❑ With brake light switch -F- from week 45/2005

12 - Heat shield
14 - Twelve point bolt, 25 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit
18 - Sealing plug
❑ From primary piston circuit of brake master cylinder to hydraulic unit
21 - Cap
5.3 Overview - exhauster pump for brake

servo (diesel vehicles)
Exhauster pump for 4-cylinder diesel engine (2-valve):
Must not be dismantled.
Tandem pump -1- (exhauster pump and fuel pump)
Vacuum hose to brake servo -2- with non-return valve.
Fuel lines -3 and 4-.
– Removing and installing tandem pump ⇒ 4-cylinder diesel
engine (2-valve); Rep. Gr. 20 ; Removing and installing parts
of fuel supply system .
Exhauster pump for 4-cylinder diesel engine (4-valve):
Must not be dismantled.

Tandem pump -4- (exhauster pump and fuel pump)
Vacuum hose to brake servo -1- with non-return valve.
Fuel lines -2 and 3-.
– Removing and installing tandem pump ⇒ 4-cylinder diesel
engine (4-valve); Rep. Gr. 20 ; Removing and installing parts
of fuel supply system .

5.4 Checking non-return valve

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

pressure sensor -G294-
– Pull vacuum hose together with brake servo pressure sensor
-G294- out of brake servo.
– Release clips with pliers -1-.
– Carefully lever off brake servo pressure sensor -G294- -2-.
5.6 Vacuum pump for brakes -V192-

Installation location for vacuum pump for brakes -V192- is on au‐
tomatic gearbox at front in direction of travel.
No provision is made for repairs to vacuum pump for brakes -
V192- . If a fault occurs, the vacuum pump for brakes -V192- must
be renewed.
Can be tested in “Guided fault finding” using -VAS 5051- .
5.6.1 Removing
– Pull vacuum hose -1- off vacuum pump for brakes -V192- .
– Disconnect connector -2- for vacuum pump for brakes -V192- .
– Remove remaining connectors and lines from bracket -3-.
– Unscrew -arrows- bracket -3- together with vacuum pump for
brakes -V192- .

– Then unscrew -arrows- vacuum pump for brakes -V192- -1-

from bracket -2-.
5.6.2 Installing
Install in reverse order.
Specified torques:
Brake vacuum pump -V192- to bracket 8 Nm
Bracket to automatic gearbox 25 Nm
5.7 Removing and installing brake light

switch -F- as of week 45/05
In vehicles prior to week 45/05, brake light switch was located on
brake pedal.
Removing
– In certain vehicles, the intake hose must be removed.
– Separate connector -1- from brake light switch -F- .
– Remove bolt -2- from brake master cylinder.
– Pull brake light switch -F- -3- from brake master cylinder at
bottom and remove from locking lug at top -4-.
Installing
Specified torque:
Torx bolt on brake master cylinder 5 Nm

6 Removing and installing brake mas‐

ter cylinder
♦ Brake filling and bleeding equipment -VAS 5234-
6.1 Removing
necessary.
Except for Eos V6; in this case, remove air filter housing.
– Remove battery trim.
– 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- .
6. Removing and installing brake master cylinder 139

Vehicles with manual gearbox:

– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
– Pull connector -A- off float warning indicator sender.
– Separate connector from brake light switch -F- (vehicles from
week 45/2005 only).
– Remove brake fluid reservoir. To do this press locking tabs on

reservoir outwards and simultaneously pull brake fluid reser‐
voir out of sealing plugs.
– Disconnect brake lines -1- on brake master cylinder and seal
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
– Carefully take brake master cylinder out of 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.
Specified torques:
Brake master cylinder to brake servo 25 Nm
♦ Use new nuts!
Brake lines to brake master cylinder 14 Nm

7 Removing and installing brake servo

7.1 Removing
necessary.
Vehicles with diesel engine:
– Disconnect wiring connector -1- and loosen rear spring-type
clip on intake hose.
7. Removing and installing brake servo 141

– Loosen spring-type clip -arrow- and pull hose off air cleaner
housing
– Remove securing bolt from air cleaner housing -arrow-.

– Pull air filter housing upwards out of brackets and remove it.
– 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- .
– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
– Pull connector -A- off float warning indicator sender.
– Separate connector from brake light switch -F- (vehicles from
week 45/2005 only).
– Remove brake fluid reservoir. To do this press locking tabs on

reservoir outwards and simultaneously pull brake fluid reser‐
voir out of sealing plugs.
– Disconnect brake lines -1- on brake master cylinder and seal
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
– Carefully take brake master cylinder out of brake servo.
– Pull vacuum hose out of brake servo.

– Release cables -1-, unbolt support bracket -2- and place it to

side ⇒ Rep. Gr. 34 ; Repairing selector mechanism .
– Remove trim on driver side ⇒ General body repairs, interior;
From week 45/2005, the brake light switch is no longer located
on the mounting bracket.
– Pull connector -1- off brake light switch.

– Remove brake light switch -2- by turning 45° to left.
– Remove air duct -3-.
– Remove cover -4-.
– Separate brake pedal from brake servo ⇒ page 109 .
– Unscrew nuts -1- from brake servo.

– Remove both upper nuts -2- from mounting bracket.
– Carefully remove brake servo from vehicle.
7.2 Installing
Observe following points when installing:
– Clip brake pedal to brake servo ⇒ page 110 .
– After installing, bleed brake system ⇒ page 130 and clutch.
Vehicles up to week 45/2005 only:
– Install brake light switch ⇒ page 110 .
Specified torques:
Brake servo to pedal cluster and bulkhead 25 Nm
♦ Use new nuts!
Brake master cylinder to brake servo 25 Nm

♦ Use new nuts!
Brake lines to brake master cylinder 14 Nm
7. Removing and installing brake servo 143

8 Brake lines
8.1 Separating point on underbody
Old connection:
1- Union nut, 14 Nm
2- T-piece, counterhold when tightening.
New connection:
1- Union nut, 14 Nm
2- Ring
3- Flange F
4- Flange E, cannot be pinched
5- Nut, counterhold when tightening.
8.2 Repairing brake lines

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

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

♦ Flanging tool for brake lines -VAS 6056-

List of individual tools:
1 - Flanging tool -VAS 6056/1-

❑ Flanging tool -VAS
6056/1- contains flang‐
ing jaws -VAS 6056/6-
2 - Pipe cutter -VAS 6056/2-
3 - Brake line scraper -VAS
6056/3-
❑ Grub screws (in shaft
and at side) are adjus‐
ted and must not be
readjusted!
4 - Set of grips with plastic jaws
-VAS 6056/4-
5 - Pipe bending tool -VAS
6056/5-
6 - Special wrench, 6 mm
7 - Flanging jaws -VAS 6056/7-
8. Brake lines 145

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

❑ Unbolt to change flang‐
ing jaws
2 - Fastening for handle
❑ Must be removed to ac‐
cess retaining screw for
upper part
3 - Retaining screw
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ For centring and holding
flanging jaws
❑ Hexagon socket head
bolt, 2 mm
5 - Flanging jaws
❑ Various
❑ Assembly instructions
⇒ page 146
Flanging jaw assembly instructions:

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

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

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

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

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

socket head bolts are tightened, or the flange will not be formed
correctly.
– Tighten brake line in flanging tool until brake line can no longer
be moved. Fold up stop -A- and now tighten hexagon socket
head bolts diagonally using special wrench -C-.
8. Brake lines 147

– Turn spindle to stop in flanging tool.

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

– Install brake line.

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Service

Service Department. Technical Information

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

8 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1 Front brakes, Touran

1.2 Front brakes, Golf

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

1.3 Front brakes, Eos

1.4 Rear brakes, Touran

2 Rep. Gr.00 - Technical data

1.9 l - 74, 77 kW TDI

1.5 Rear brakes, front-wheel drive Golf

2.0 l - 125 kW TDI

1. Brake allocation via PR No. 3

2.0 l - 147 kW FSI 1KV CII 38 (16”)

1.6 Rear brakes, four-wheel drive Golf

1.7 Rear brakes, Eos

4 Rep. Gr.00 - Technical data

2 Technical data for brakes

2.1 Brake master cylinder and brake servo,

2.2 Brake master cylinder and brake servo,

2.3 Front brakes

2. Technical data for brakes 5

2.3.2 Front brakes FN 3

Item PR No. 1LJ / 1LL / 1ZD / 1LV

2.3.3 Front brakes FNR-G

6 Rep. Gr.00 - Technical data

2.4 Rear brakes (disc brakes)

2.4.2 Rear brakes CII 38

2. Technical data for brakes 7

2.4.3 Rear brakes CII 41

Item PR No. 1KJ

Item PR No. 2EL / 2EA

8 Rep. Gr.00 - Technical data

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

3.2 Test for vehicles with front-wheel drive

3.3 Test for vehicles with four-wheel drive

3.3.1 The brake test should be performed on

3.3.2 If no test rig is available for four-wheel

– Switch engine off and wait for 2 seconds.

10 Rep. Gr.00 - Technical data

45 – Anti-lock brake system

1. General notes on anti-lock brake system 11

2 Notes for repair work on anti-lock

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

3 Connecting -VAS 5051- and select‐

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

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

3. Connecting VAS 5051 and selecting functions 13

– Switch on tester -arrow-.

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

4 Electrical/electronic components and

4.1 ABS Mark 70 (ABS/TCS)

1 - ABS control unit -J104-

4. Electrical/electronic components and fitting locations 15

8 - Brake light switch -F- from week 45/2005

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