Service: Touran 2003

Service
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Workshop Manual
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Touran 2003 ➤
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Brake systems
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Edition 07.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair
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00 - Technical data
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45 - Anti-lock brake system
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46 - Brakes - mechanism
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47 - Brakes - hydraulics
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E8030E5D9

Touran 2003 ➤
Brake systems - Edition 07.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Test for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to Week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from Week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 ABS Mark 60 EC (ABS/EDL/TCS/ESP) from Week 22/2008, LHD . . . . . . . . . . . . . . . . . . 16
5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Assembly overview - ABS hydraulic unit N55 , brake servo/brake master cylinder . . . . . . 21
6.1 ABS Mark 70 (ABS/TCS)
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6.2 ABS Mark yV
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not . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6.3 ABSrise Mark 60 (ABS/EDL/TCS/ESP) to Week nt22/2008,
ee LHD . . . . . . . . . . . . . . . . . . . . . . . . 36
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6.4 auABS
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Mark 60 EC (ABS/EDL/TCS/ESP) from Week
or
ac 22/2008, LHD . . . . . . . . . . . . . . . . . . 44
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6.5 ABS Mark 60 EC (ABS/EDL/TCS/ESP) (RHD vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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7 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 61
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7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 61

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7.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 62

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8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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8.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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8.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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1.1 Repairing front brakes, FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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1.2 Removing and installing brake pads, brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1.3 Removing and installing brake caliper, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . 72
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2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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2.1 Assembly overview - rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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2.2 Removing and installing brake pads, CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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2.3 Removing and installing brake caliper, CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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2.4 Assembly overview - Bosch rear wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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2.5 Removing and installing brake pads, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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2.6 Removing and installing brake caliper, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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3.1 Removing and installing handbrake cable up to model year 2007 . . . . . . . . . . . . . . . . . . . . 92
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3.2 Removing and installing handbrake cable from model year 2008 . . . . . . . . . . . . . . . . . . . . 94
3.3 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Contents i
Touran 2003 ➤
4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.1 Assembly overview - brake pedal, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2 Assembly overview - brake pedal, right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1 Repairing front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Repairing brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Assembly overview - brake caliper CII 41 . . . .k.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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2.2 Removing and installing piston forlkbrake s wage caliper CII 41 . d. o.e.s n ........................ 113
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2.3 Assembly overview - Bosch ebrake by V caliper . . . . . . . . . . . . . . . .t .gu. a. . . . . . . . . . . . . . . . . . . . 115
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2.4 Removing and installing tbrake
ho caliper piston, Bosch . . . . . . . . . . . . t.ee.o. . . . . . . . . . . . . . . . 117
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3 Pressurised leak test ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . 120
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3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234 . . . . . . . . 121
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4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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5 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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5.1 Assembly overview - brake servo/brake master cylinder to Week 22/2008, LHD . . . . . . . . 124
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5.2 Assembly overview - brake servo/brake master cylinder from Week 22/2008, LHD . . . . . . 126
5.3 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle) . . . . . . 128
5.4 Overview - vacuum pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 130
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5.5 Vacuum pump for brake servo (vehicles with 2.0 l petrol engine) . . . . . . . . . . . . . . . . . . . . 130
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5.6 Checking brake servo vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

5.7 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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5.8 Removing and installing vacuum sender G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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5.9 Removing and installing brake servo pressure sensor G294 . . . . . . . . . . . . . . . . . . . . . . 135
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5.10 Removing and installing brake servo vacuum sender G483 to Week 22/2008 . . . . . . . . . . 136
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5.11 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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5.12 Removing and installing brake light switch F from Week 45/2005, LHD . . . . . . . . . . . . . . 137
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5.13 Removing and installing brake light switch F , right-hand drive . . . . . . . . . . . . . . . . . . . . . . 138
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6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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6.1 Removing and installing brake master cylinder, left-hand drive . . . . . . . . . . . . . . . . . . . . . . 141
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6.2 Removing and installing brake master cylinder, right-hand drive . . . . . . . . . . . . . . . . . . . . 142
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7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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7.1 Removing and installing brake servo, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

7.2 Removing and installing brake servo, right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 150
8 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
ii Contents
Touran 2003 ➤
00 – Technical data
1 Brake allocation via PR No.
(VRL006022; Edition 07.2013)
The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
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 Awell
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♦ Allocation ⇒ Electronic Parts Catalogue
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♦ The following tables explain the PR
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1.1 Front brakes
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Engine PR No. Front brakes
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1.2l - 77 kW TSI 1ZE / 1ZP FN3 (15”)
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1.4l - 90 kW TSI
1.4l - 103 kW TSI
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1.6l - 66 kW TDI
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1.6l - 75 kW
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2.0l - 81 kW TDI
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2.0l - 100 kW TDI 1)

2.0l - 110 kW FSI
1.4l - 110 kW TSI 1LJ / 1ZA FN3 (16”)
1.4l - 118 kW TSI
1.4l - 125 kW TSI
2.0l - 103 kW TDI
2.0l - 125 kW TDI
1) For Belgium only
1. Brake allocation via PR No. 1

Touran 2003 ➤
Country-specific brake for Japan:

Engine PR No. Front brakes
1.6l - 85 kW FSI 1ZP FN3 (15”)
2.0l - 110 kW
1.2 Rear brakes

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1.4l - 90 kW TSI auth or
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1.4l - 103 kW TSI
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1.6l - 75 kW
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1.6l - 77 kW TDI
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1.9l - 66 kW TDI
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1.9l - 77 kW TDI
2.0l - 100 kW TDI 1)
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2.0l - 125 kW TDI
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1.6l - 75 kW 1KF CII 41 (15")
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1.4l - 103 kW FSI

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2.0l - 110 kW FSI

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2.0l - 100, 103 kW TDI
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1.4l - 125 kW FSI 1KJ 2) CII 41 (16")
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2.0l - 125 kW TDI

1) For Belgium only
2) Gradual switch to 1KF from the end of 2006
Country-specific brake for Japan:
Engine PR No. Rear brakes
1.6l - 85 kW FSI 1KE CII 41 (15")
2.0l - 110 kW
2 Rep. gr.00 - Technical data

Touran 2003 ➤
2 Technical data for brakes
2.1 Brake master cylinder and brake servo

Brake master cylinder ∅ in mm 23,81
Brake master cylinder ∅ in mm 22,22
(Japan)
Brake servo (LHD) ∅ in inches 10
Brake servo (RHD) ∅ in inches 7/8
2.2 Front brakes FN 3

Item PR No. 1ZE / 1ZP
1 Brake caliper FN3 (15”)
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
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backplate
3 Brake disc ∅ in 288
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
4 Brake caliper, ∅ in 54
piston mm
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2 Brake pad, mm aut 14 or
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Brake disc, mm 25
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Brake disc, mm 22
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2. Technical data for brakes 3

Touran 2003 ➤
2.3 Rear brakes (disc brakes)

2.3.1 Rear brakes CII 41
Item PR No. 1KF / 1KE
1 Brake caliper CII 41 (15")
2 Brake pad, mm 11
thickness
limit without
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3 Brake disc ∅ in 260 byV gu
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Brake disc, mm 12 ss a c
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Brake disc, mm 10
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Item PR No. 1KJ
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1 Brake caliper CII 41 (16")
2 Brake pad, mm 11
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Brake disc, mm 12
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2.3.2 Rear brakes, Bosch
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Item PR number 1KS

1 Brake caliper Bosch
2 Brake pad, mm 12
thickness with‐
out backplate
mm
Brake disc, mm 10
thickness
piston mm
4 Rep. gr.00 - Technical data

Touran 2003 ➤
3 Brake test
3.1 General
♦ The drive is provided by the test rig.
♦ For vehicles with a manual gearbox, ensure that the gear lever
is in neutral for the test. For vehicles with an automatic gear‐
box, ensure that the selector lever is in »N«.
♦ For 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‐
satelettronica
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
lkswage es n
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un
pt
an
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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cum
fo
en
ng
t.
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Cop py
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Vo
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by
cted agen
Prote AG.
3. Brake test 5
Touran 2003 ➤
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 ABS control unit -
J104- 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 - ABS hydraulic unit - N55- and ABS control unit - J104-
satelettronica
2 - Brake servo
lkswage es n
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a ac
ABS layout in right-hand drive vehicle
ss
ce
e
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pt

du
an
itte
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erm
2 - Brake servo
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
ABS control unit - J104- -1- and ABS hydraulic unit - N55- -2- are
incorporated in one device. They can be separated only when
nf
ercia
removed. ABS hydraulic pump - V64- -3- must not be separated

orm
from ABS hydraulic unit - N55- .

m
atio
om
n in
With ABS/EDL/TCS/ESP - separation is not possible in vehicles

or c
with hydraulic brake servo or hill hold assist.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 Rep. gr.45 - Anti-lock brake system

Touran 2003 ➤
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 .
. Volkswagen AG
wa gen AG d
♦ When working with brakeVfluid,
olks observe the valid, relevant
oes
not
gu
safety precautions and
ed notes
by ⇒ page 121 . ara
n is tee
or
♦ After work for which
au the brake system had to be opened, bleed
th or
ac
the brake system with brake filling and bleeding unit - VAS
ss
ce
e
5234- ⇒ page 121 .

nl
pt
du
an
itte
♦ During the final road test, ensure that a controlled brake test
y li
erm
satelettronica
ab
is performed at least once (pulsations must be felt at the brake
ility
ot p
pedal).
wit
, is n
h re
♦ Absolute cleanliness is required when working on the anti-lock
hole
spec
brake system.
es, in part or in w
t to the co
♦ Auxiliary items containing mineral oil, e.g. oils, greases, etc.
must never be used.
♦ Thoroughly clean all unions and the adjacent areas before
rrectness of i
loosening. Do not use aggressive cleaning agents such as
l purpos
brake cleanser, petrol, thinners or similar.

♦ Place removed parts on a clean surface and cover.
nf
ercia
♦ After separating ABS control unit - J104- / ABS hydraulic unit

rm
m
- N55- , use transport protection for contact pins.

atio
om
n in
c
♦ If repairs cannot be carried out immediately, carefully cover or

or
thi
e
seal open components. (Use sealing plugs from repair kit

t
sd
iva
1 H0 698 311 A).

o
r
rp
cu
o
m
f
♦ Only use lint-free cloths.

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ng
t.
yi Co
op py
♦ Only unpack replacement parts immediately prior to fitting. t. C rig
gh ht
pyri by
♦ Only use genuine packed parts.
co Vo
by lksw
cted agen
Prote AG.
♦ Do not work with compressed air if the system is open.
♦ Do not move vehicle when system is open.
♦ Make sure that none of the contact surfaces on the connector,
pressure sensor, ABS control unit - J104- or silicone gel are
touched by hand or any other objects.
♦ Ensure that no brake fluid enters connectors.
♦ During painting operations, the ABS control unit - J104- 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).
2. Notes for repair work on anti-lock brake system 7

Touran 2003 ➤
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-
lkswage es n
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byV ua
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pt
du
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
WARNING
♦ The vehicle diagnosis, testing and information system -

rrectness of i
VAS 5051- must always be secured on the back seat
l purpos
during road tests.

♦ These devices may be operated only by a passenger while
nf
ercia
the vehicle is in motion.

orm
m
atio
om
n in
c
– Fit connector of diagnostic cable -VAS 5051/1- or -

or
thi
e
VAS 5051/3- to diagnosis connection.

t
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Switch on tester -arrow-.

The tester is ready for operation when the touch panels of the
operating modes are shown.
– Switch on ignition.
– Touch Guided fault finding on screen.
– Select
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data input.
Wait until tester has interrogated all control units in vehicle.
– Press GoTo and select “Function/component selection” func‐
tion.
satelettronica
– Select “Running gear” shown on display.
– Select “Brake system” shown on display.
– Select “01 Systems capable of self-diagnosis” on display.
– Select “Anti-lock braking system” on display.
– Select “Function” on display.
All possible functions relating to anti-lock braking system installed
in vehicle will be displayed.
– Select desired function on display.
Volkswa AG. gen AG
agen does
olksw not
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db ara
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au ra
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ss
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Connecting VAS 5051 and selecting functions 9

Touran 2003 ➤
4 Electrical/electronic components and

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

❑ Location: on the ABS
hydraulic unit - N55- on
right in engine compart‐ n AG. Volkswagen AG do
swage es n
ment. byV
olk ot g
ua
ed ran
❑ Do not separate
horis con‐ tee
nectoraubefore success‐
t or
ac
fully completing self-di‐
ss
ce
e
agnosis. Switch ignition

nl
pt
du
an
off before separating
itte
y li
connector.
erm
ab
ility
ot p
❑ Removing and installing
wit
⇒ page 23
, is n
h re
satelettronica
hole
2 - ABS hydraulic unit - N55-
spec
es, in part or in w
❑ Location: on right in en‐

gine compartment. t to the co
The ABS hydraulic unit - N55-
rrectness of i
consists of the following com‐

ponents:
l purpos
❑ ABS hydraulic pump -

V64-
nform
ercia
❑ Valve block (includes in‐

m
at
let/outlet valves)
om
ion
c

in t
or
V64- and valve block

his
ate
do
riv
must not be separated

p
from one another.

um
for
en
ng
t.
yi Co
op
⇒ page 23
C py
t. rig
gh ht
yri by
3 - Brake pad warning lamp - cop Vo
by lksw
cted
K32-
agen
Prote AG.
❑ Location: in dash panel

insert.
❑ Function: ⇒ page 19 .
4 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
5 - Traction control system warning lamp - K86-
6 - Brake system warning lamp - K118-
7 - Brake light switch - F- up to Week 45/2005
❑ Including brake pedal switch - F47- .
❑ Location: on brake pedal.
❑ Removing, installing and adjusting ⇒ page 99 .

Touran 2003 ➤
8 - Brake light switch - F- from Week 45/2005

❑ Location: on brake master cylinder.
AG. Volkswagen AG d
❑ Removing and installing ⇒ page 137 ksw
agen oes
not
ol
yV gu
9 - TCS button - E256- ised b ara
nte
or
❑ Location: in centre console. aut
h eo
ra
ss c
10 - Diagnostic connection
ce
le
un
pt
❑ Location: driver side footwell cover.
an
d
itte
y li
rm
ab
11 - Front speed sensor
pe
ility
ot
❑ Removing and installing ⇒ page 61
wit
, is n
h re
12 - Wheel bearing housing
hole
spec
es, in part or in w
13 - Wheel bearing/hub unit
t to the co
❑ ABS sensor ring is installed in wheel bearing.
14 - Rear speed sensor
rrectness of i
l purpos
15 - Rear axle assembly with stub axle
satelettronica
16 - Wheel hub with wheel bearing
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Electrical/electronic components and locations 11

Touran 2003 ➤
4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to Week 22/2008

gine compartment.
❑ Do not separate con‐
nector before success‐
connector.
⇒ page 38
gine compartment.
ponents:
satelettronica
V64-
❑ Brake pressure sender -
G201-
let/outlet valves)
from one another. AG. Volkswagen AG d
agen oes
ksw
❑ Removing and installing by Vol not
gu
ara
⇒ page 38 ris
ed
nte
tho eo
3 - Brake pad warning
ss
au lamp - ra
c
K32-
ce
le
un
pt
❑ Location: in dash panel

an
d
itte
y li
insert.
rm
ab
pe
ility
ot
wit
, is n

h re
hole

spec
es, in part or in w
t to the co
5 - ESP and TCS warning lamp - K155-

❑ Only vehicles with ABS/EDL/TCS/ESP.
rrectness of i

l purpos
nform
ercia

m
a
com
ti
on in
r
te o
thi
7 - Brake light switch - F- up to Week 45/2005

s
iva
do

r
rp
cum
fo
❑ Location: on brake pedal.

en
ng
t.
yi Co
op
❑ Removing and installing ⇒ page 99 C py
t. rig
gh ht
yri by
8 - Brake light switch - F- from Week 45/2005 cop Vo
by lksw
cted agen
❑ Including brake pedal switch - F47- . Prote AG.

Touran 2003 ➤
9 - TCS and ESP button - E256-
❑ Location: in centre console.
10 - ESP sensor unit - G419-
❑ Behind glove compartment agen AG. Volkswagen AG do
w e n
olks sender - G200- , yaw srate
❑ Combined lateral acceleration ot gsender - G202- and longitudinal acceleration
byV ua
sender - G251- . rised ran
tee
ho
❑ Combined in one au housing.
t or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
12 - Steering angle sender - G85-
, is n
h re
❑ Location: on steering column between steering wheel and steering column switch.
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos

nform
ercia

m
a
com
tio
Figure for front-wheel drive n in
r
te o
thi

s
iva
do
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rp
cum

fo
en
ng
t.
yi Co
Figure for front-wheel drive t. Cop py
rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Figure for front-wheel drive
Prote AG.

Touran 2003 ➤
4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from Week 22/2008

gine compartment.
connector.
The following components are
integrated into the ABS control
unit - J104- :
♦ Lateral acceleration sender
- G200- n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Yaw rate sender - G202- d byV ua
ran
ir se tee
♦ Longitudinal acceleration autho
or
ac
sender - G251- (hill start) ss
ce
e
satelettronica
nl
pt
du
an
⇒ page 47
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
gine compartment.
hole
spec
es, in part or in w
t to the co
ponents:
rrectness of i
V64-
l purpos

G201-
nform
ercia

let/outlet valves)
m
at
om

ion
c

in t
or
his
e

at
do
riv
from one another.

p
cum
or

f
en
ng
t.
yi Co
op
3 - Brake pad warning lamp - K32- C py
t. rig
gh ht
yri
❑ Location: in dash panel insert. p by
co Vo
by lksw
cted agen
Prote AG.

7 - Brake light switch - F-

Touran 2003 ➤
Note
From Week 22/2008, vehicles

equipped with a 3rd generation
electromechanical power steering
system have the steering angle
sender - G85- in the steering rack
(for left-hand drive vehicles up to
Week 22/2010 ⇒ page 16 ).
❑ Location A: on steering column between steering wheel and steering column switch
satelettronica
❑ Location B: in steering rack.
. Volkswage n AG n AG d
wage oe
12 - Wheel bearing/hub
Vol
ks unit s no
t gu
d by a
❑ ABSorisensor
se ring is installed in wheel bearing.rante
h eo
ut ra
13 - Rear
ss
a speed sensor c
ce
e
nl

pt
du
an
itte
y li

erm
ab
ility
ot p

wit
, is n

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

Touran 2003 ➤
4.4 ABS Mark 60 EC (ABS/EDL/TCS/ESP) from Week 22/2008, LHD

gine compartment.
connector.
The following components are
integrated into the ABS control
unit - J104- :
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (hill start)
satelettronica
⇒ page 47
gine compartment. wage
es n
lks ot g
Vo
The ABS hydraulic unit - N55- ed by ua
ran
consists of the following com‐ hor is tee
ponents: aut or
ac
ss
ce
le
un
pt
V64-
an
d
itte
y li

rm
ab
pe
ility
G201-
ot
wit
, is n

h re
let/outlet valves)
hole
spec

es, in part or in w
t to the co

from one another.
rrectness of i

l purpos
3 - Brake pad warning lamp - K32-

nform
ercia
m

com
tion in

r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
❑ Only vehicles with ABS/EDL/TCS/ESP. t. Cop py
rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
6 - ESP and TCS warning lamp 2 - K216-
❑ ESP/TCS system has been switched off by the ESP and TCS button - E256- .

Touran 2003 ➤
Note
From Week 22/2010, the steering

angle sender - G85- in LHD vehicles
with APA steering is again located
on the steering column between the
steering wheel and the steering col‐
satelettronica
umn switch.
❑ Location A: on steering column between steering wheel and steering column switch
❑ Removing and installing ⇒ page 65 wage
e ks s no
Vol t gu
12 - Front speed sensor db
y ara
rise nte
❑ Removing and installing ⇒ page 61 utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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Touran 2003 ➤ ed b ara
nte
ris
ut
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
5 Fault display via warning lamps

Warning lamps
AG. Volkswagen AG d
agen oes
Item Description
yV
olks
w not
gu
b ara
ed
1 Traction control system
oris warning lamp - K86- nte
eo
h
ut ra
ESP and TCSsswarning lamp - K155-
a c
ce
le
2 Brake pad warning lamp - K32-
un
pt
an
d
itte
3 ABS warning lamp - K47-
y li
erm
ab
4 Brake system warning lamp - K118-
ility
ot p
wit
is n
Brake pad warning lamp - K32-
h re
ole,
spec
♦ If the brake pad warning lamp - K32- -2- does not go out 3 sec‐
onds after the ignition is switched on, or it if comes on during
t to the co
vehicle operation, the fault may be:
-a- The brake pads are worn.
rrectne
Check brake pads/linings on front and rear axles. Renew worn
brake pads/linings.
ss o
satelettronica
-b- There is a wiring fault. ⇒ Current flow diagrams, Electrical fault
cial p
f in
finding and Fitting locations
form
mer
atio
ABS warning lamp - K47-
om
n
c
i
♦ If the ABS warning lamp - K47- -3- does not go out after the
or
n thi
e
ignition has been switched on and test sequence has been

t
sd
va
completed, then the fault may be:

i
o
pr
cum
r
fo
en
ng
-a- The voltage supply is below 10 volts.

t.
yi Co
Cop py
-b- There is a fault in the ABS.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING Prote AG.
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- Temporary speed sensor fault occurred after 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
system 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.
5. Fault display via warning lamps 19

Touran 2003 ➤
♦ If the ABS warning lamp - K47- -3- and the brake system wage
es n
warning lamp - K118- -4- light up, then the ABS is defective. yV
olks ot g
ua
A change in braking behaviour is to be reckoned with. ir se
d b ran
o te eo
th
au ra
c
WARNING ss
ce
e
nl
pt
du
an
After the ABS warning lamp - K47- and the brake system warn‐
itte
y li
erm
ing lamp - K118- have lit up, it is possible that the rear wheels
ab
ility
will lock up earlier.
ot p
wit
, is n
h re
hole
spec
Traction control system warning lamp - K86-
es, in part or in w
t to the co
♦ 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:
rrectness of i
There is a fault present which only affects the TCS. The ABS and
l purpos
EBD safety systems on the vehicle remain fully functional ⇒ Read

fault memory.
nform
ercia
-a- Short-circuit to positive in TCS button - E256- .

m
at
-b- There is a fault in the activation of the traction control system
om
satelettronica
o
warning lamp - K86- ⇒ Current flow diagrams, Electrical fault find‐
n
c
in t
or
ing and Fitting locations.
his
ate
do
riv
-c- The TSC system was shut off by the TCS button - E256- .
p
cum
for
en
g
If traction control system warning lamp - K86- flashes while the

n
t.
yi Co
op
vehicle is in motion, the TCS is in operation. C py
t. rig
gh ht
yri
♦ If the TCS warning lamp - K86- -1- does not light up during the
p by
co Vo
by lksw
self-test, the fault may be: Prote
cted AG.
agen
-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 the ignition has been switched on and the test sequence
has been 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 ⇒
Read 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 ve‐
hicle 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.

Touran 2003 ➤
6 Assembly overview - ABS hydraulic

unit - N55- , brake servo/brake mas‐
ter cylinder
lkswage es n
ot g
6.1 ABS Mark 70 (ABS/TCS) (LHD vehicle)
o
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
⇒ page 23
y li
erm
ab
ility
ot p
wit
, is n
h re
⇒ page 23
hole
spec
es, in part or in w
3 - Brake line
t to the co
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to ABS hydraulic
rrectness of i
satelettronica
unit - N55- .
l purpos
❑ Identification: union nut

with thread M10 x 1
nf
ercia
4 - Brake line
orm
m
atio
❑ Brake master cylinder/
om
secondary piston circuit
n in
or c
to ABS hydraulic unit -
thi
te
sd
N55- .
iva
o
r
rp
cu
o
m
f
en
ng
with thread M12 x 1

t.
yi Co
Cop py
5 - Brake line
t. rig
gh ht
yri by
❑ To front left brake cali‐ cop Vo
by lksw
cted
per.
agen
Prote AG.

with thread M12 x 1
6 - Brake line
❑ To front right brake cali‐
per.
with thread M10 x 1
7 - Brake line
❑ To rear left brake cali‐
per.
❑ Identification: union nut with thread M12 x 1
8 - Brake line
❑ To rear right brake caliper.
9 - Bolt
❑ 5.5 Nm
❑ Use new bolts.
10 - Bracket
11 - Bolt
❑ 8 Nm
6. Assembly overview - ABS hydraulic unit N55 , brake servo/brake master cylinder 21
Touran 2003 ➤
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 a vacuum pump to generate the necessary vacuum ⇒ page 130 .
❑ 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 completely (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.
satelettronica
16 - Nut
❑ 25 Nm
❑ Always renew after removing
17 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
AG. Volkswagen AG d
agen
18 - Brake fluid reservoir Volksw
oes
not
gu
d by ara
19 - Cap orise nte
eo
h
ut ra
20 - Sealing plug ss a c
ce
le
❑ Connection for vacuum hose.

un
pt
an
d
itte
y li
21 - Vacuum hose
rm
ab
pe
❑ Fit in brake servo.
ility
ot
wit
, is n
22 - Brake servo pressure sensor - G294-
h re
hole
❑ In vehicles with an FSI engine without HBV (hydraulic brake with vacuum servo)
spec
es, in part or in w
❑ Removing and installing ⇒ page 135 t to the co

rrectness of i
6.1.1 Connecting brake lines from brake mas‐

l purpos
ter cylinder to ABS hydraulic unit - N55-

On brake master cylinder:
nform
ercia
A - Primary piston circuit of brake master cylinder to ABS hy‐

m
draulic unit - N55- .

com
tion in
r
te o
- Identification: union nut with thread M10 x 1

thi
s
iva
do
B - Secondary piston circuit of brake master cylinder to ABS hy‐

r
rp
cum

fo
en
ng
t.
yi Co
- Identification: union nut with thread M12 x 1 Cop py
t. rig
gh ht
yri
1 - ABS hydraulic unit - N55- to front left brake caliper. p by
o Vo
by c lksw
cted agen
3 - ABS hydraulic unit - N55- to rear right brake caliper. Prote AG.
4 - ABS hydraulic unit - N55- to rear left brake caliper.

Touran 2003 ➤
To ABS hydraulic unit - N55-

A - ABS hydraulic unit - N55- to primary piston circuit of brake
master cylinder
B - ABS hydraulic unit - N55- to secondary piston circuit of brake
master cylinder
1 - ABS hydraulic unit - N55- to front left brake caliper.
2 - ABS hydraulic unit - N55- to front right brake caliper.
3 - ABS hydraulic unit - N55- to rear right brake caliper.
satelettronica
6.1.2 Removing ABS control unit - J104- and ABS hydraulic unit - N55-
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
1410-
♦ Brake pedal depressor -
V.A.G 1869/2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
23
agen
Prote AG.
6. Assembly overview - ABS hydraulic unit N55 , brake servo/brake master cylinder
Touran 2003 ➤
Sealing plugs repair kit, Part No. 1H0 698 311 A

Transport protection must be fitted after removal of ABS hydraulic
unit - N55- .
Without transport protection, the warranty for the ABS hydraulic
unit - N55- will not be recognised.
1 - Transport protection for contact pins (foam)
2 - Sealing plug M10
Removing
Location:
AG. Volkswagen AG d
ABS layout in left-hand drive vehicle. ksw
agen oes
not
Vol
by gu
d ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
erm
ab
satelettronica
N55- and is located on the right in the engine compartment.
ility
ot p
wit
is n
h re
ole,
2 - Brake servo
spec
t to the co
WARNING
rrectne
Do not bend the brake lines in the area of the ABS hydraulic
unit - N55-
ss o
cial p
f in
– Read out and note the existing control unit code ⇒ page 8 .
form
mer
– Note or request radio code on vehicles with coded radio if
atio
m
necessary.
o
n
c
i
or
n thi
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
te
sd
va
necting and reconnecting battery .

i
o
pr
cum
r
fo
– Remove engine cover.

en
ng
t.
yi Co
Cop py
t. rig
1.4l TSI engine
gh ht
pyri by
Vo
co lksw
by
– Remove engine cover -arrow A- and heat shield -arrow B-. Prote
cted AG.
agen
– Remove pressure pipe and intake connecting pipe with regu‐

lating flap control unit -2- ⇒ 4-cyl. injection engine (1.4l direct
injection engine, turbocharger and compressor); Rep. gr. 24 ;
Injection system; Part I - assembly overview - intake manifold .
– Remove charge air hose -1- ⇒ 4-cyl. injection engine (1.4l
direct injection engine, turbocharger and compressor); Rep.
gr. 21 ; Charge air system .
– Clamp off hose from coolant expansion tank and pull it off.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Touran 2003 ➤
s
s Brake systems - Edition 07.2013
ce
le
un
pt
an
d
itte
Vehicles with diesel engine
y li
erm
ab
– Pull off engine cover in -direction of arrow-.
ility
ot p
wit
is n
1.9l diesel engine
h re
ole,
spec
– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel
engine (2 valve); Rep. gr. 21 ; Removing and installing charge
t to the co
air system with turbocharger .
– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel
rrectne
engine (2 valve); Rep. gr. 23 ; Removing and installing mixture
preparation - injection .
ss o
cial p
f inform
mer
1.6l and 2.0l diesel engine
atio
m
– Remove upper part of timing belt guard by detaching clips

o
n
c
i
or
n
-arrows-.
thi
te
sd
va
– Remove plenum chamber middle bulkhead ⇒ General body

i
o
pr
cum
repairs, exterior; Rep. gr. 50 ; Assembly overview - plenum
r
fo
en
ng
chamber bulkhead .
t.
yi Co
Cop py
– Remove connecting pipe between intake hose and turbo‐
t. rig
satelettronica
gh ht
yri
charger.
p by
o Vo
by c lksw
cted agen
Prote AG.
All diesel engines with diesel particulate filter

– Unscrew exhaust gas pressure sensor , separate electrical
connectors, ⇒ Rep. gr. 26 ; Assembly overview - front exhaust
pipe with particulate filter .
– Remove clamp -1-.
– Unscrew bolts of particulate filter -2- to -5- ⇒ Exhaust system;
Rep. gr. 26 ; Removing and installing particulate filter with
front exhaust pipe .
– Lower particulate filter.
Continuation for all vehicles
– Release connector from ABS control unit - J104- in direction

of arrow -1- and pull it off -2-.
Touran 2003 ➤
– Apply brake pedal depressor - V.A.G 1869/2- .
– Connect bleed bottle bleed hose -1- to bleed valve of front left
brake caliper.
– Open bleed valve.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
satelettronica
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Connect bleed hose of bleed bottle -1- to bleed valve of rear

h re
left brake caliper.

hole
spec
es, in part or in w

t to the co
– Depress brake pedal at least 60mm using brake pedal de‐

pressor - V.A.G 1869/2- .
rrectness of i
– Close front left and rear left bleeder valves.

l purpos
– Place sufficiently lint-free cloths under ABS control unit - J104-

and ABS hydraulic unit - N55- .
nform
ercia
Ensure no brake fluid gets onto contacts.

m
a
com
tion in
r
te o
thi
– First mark the two brake master cylinder brake lines

s
iva
-A and B- and unscrew from ABS hydraulic unit - N55- .

do
r
rp
cum
fo
– Immediately seal brake lines and threaded holes with seal

en
ng
t.
yi
plugs from repair set Part No. 1H0 698 311 A.
Co
Cop py
t. rig
gh
– Mark brake lines (brake caliper) -1- to -4-, unscrew and im‐
ht
pyri by
Vo
mediately seal with plugs from repair kit Part No.
co lksw
by
cted agen
1H0 698 311 A. Prote AG.

Touran 2003 ➤
– Pull ABS hydraulic unit - N55- with ABS control unit - J104-
upwards in -direction of arrow- out of the dampers.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
6.1.3 Unbolting ABS control unit - J104- from ss au ra
c
ABS hydraulic unit - N55-
ce
le
un
pt
an
d
itte
y li
– Place ABS hydraulic unit - N55- with ABS control unit - J104-
rm
ab
upwards on a clean level surface.
pe
ility
ot
wit
, is n
– Remove bolts -arrows-.
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Pull off ABS control unit - J104- off ABS hydraulic unit - N55-
thi
s
iva
in -direction of arrow- without tilting ABS control unit.
do
r
rp
cum
fo
– Carefully pull all seals from contact pins of ABS hydraulic unit
en
ng
t.
- N55- .
yi Co
Cop py
t. rig
gh ht
pyri by
WARNING
co Vo
by lksw
cted agen
Prote AG.
♦ Printed circuit board becomes visible when ABS control

unit - J104- is removed.
♦ Make sure no moisture or particles of dirt find their way
inside the ABS control unit - J104- .
♦ ABS hydraulic pump - V64- may not be separated from
ABS hydraulic unit - N55- .
♦ Avoid electrostatic charge!
– Cover solenoids of ABS control unit - J104- with a lint-free

cloth.
After separating ABS control unit - J104- and ABS hydraulic unit
Touran 2003 ➤
6.1.4 Installing new ABS control unit - J104-
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ABS AG. Volkswagen AG d
control unit - J104- . The ABS control unit - J104- may then no agen oes
olksw not
longer be used. ed by
V gu
ara
ris nte
ho eo
aut ra
ss c
• Clean surfaces before assembling.
ce
le
un
pt
– Push all seals -A- over contact pins slightly.
an
d
itte
y li
erm
ab
– Place ABS control unit - J104- on ABS hydraulic unit - N55-
ility
ot p
without canting it.
wit
is n
h re
The seals are thus moved to end position.
ole,
spec
– Bolt ABS hydraulic unit - N55- and ABS control unit - J104-
t to the co
together with the new bolts provided.
rrectne
Note
satelettronica
s
♦ To ensure the elastic seal remains leak tight, a new ABS con‐
s o
trol unit - J104- may only be mounted on an existing ABS
cial p
f in
hydraulic unit - N55- a total of two times.
form
mer
♦ An ABS control unit - J104- which has already been operated
atio
m
in a vehicle must not be installed a second time.

o
n
c
i
or
n thi
te
sd
iva
o
r
6.1.5 Installing ABS control unit - J104- and

p
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh
Install in reverse order. Note the following points:
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Do not remove sealing plugs from new ABS hydraulic unit -

N55- until respective brake line is about to be installed.
♦ If sealing plugs are removed too early from the ABS hydraulic
unit - N55- , brake fluid can escape, and it can then no longer
be guaranteed that the unit can be sufficiently filled and bled.
♦ Ensure that rubber dampers are not pressed out of bracket.
– Remove brake pedal depressor - V.A.G 1869/2- .

– Bleed brake system ⇒ page 121 .
– Code radio.
– Code ABS control unit - J104- ⇒ page 8 .
Specified torque
Component Specified torque
ABS control unit - J104- to ABS hydraulic unit - N55- 5.5 Nm
♦ Use new bolts!
Hexagon bolt for ABS hydraulic unit - N55- to bracket 8 Nm

Brake lines on ABS hydraulic unit - N55- M 10 x 1 14 Nm
Particulate filter to bracket on engine block 25 Nm

Touran 2003 ➤

Clamping sleeve for exhaust system lkswage 25 Nm
es n
o ot g
byV u
Bracket to engine block ir se
d 25 Nm arant
o ee
h
Clamp between particulate filter and turbocharger
aut 7 Nm or
ac
ss
Exhaust system to subframe 25 Nm
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
6.2 ABS Mark 70 (ABS/TCS) (RHD vehicle)
wit
, is n
h re
hole
spec
6.2.1 Assembly overview
es, in part or in w
t to the co
1 - Brake line
rrectness of i
l purpos

N55- .
nf
ercia
o
rm
satelettronica
m
atio
with thread M12 x 1
om
n in
c
2 - Brake line
or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi
unit - N55- .
Co
Cop py
t. rig
gh ht
yri by
with thread M10 x 1
cop Vo
by lksw
cted agen
Prote AG.
3 - Brake servo
⇒ page 150
4 - Brake line
per.
with thread M10 x 1
5 - Brake line
❑ To front left brake cali‐
per.
with thread M12 x 1
⇒ page 31
7 - Bolt
❑ 5.5 Nm
❑ Use new bolts.
9 - Bracket
10 - Rubber damper
❑ Ensure that rubber dampers of retainer are not pressed out of bracket when installing.
Touran 2003 ➤
11 - Bracket
❑ Before installing, spray rubber dampers ⇒ Item 10 (page 29) with silicone lubricant spray - D 007 000
A2- .
❑ Check for secure seating after installing.
12 - Hexagon nut
❑ 20 Nm
13 - Bolt
❑ 8 Nm
14 - Brake line
❑ To rear left brake caliper.
15 - Brake line
6.2.2 Connecting brake lines from tandem
satelettronica
brake master cylinder to ABS hydraulic
unit - N55- agen
AG. Volkswagen AG d
w oes
olks not
On tandem brake master cylinder: byV gu
ara
ed nte
ris
A - Primary piston circuit of brake master cylinder thoto ABS hy‐ eo
au ra
draulic unit - N55- . ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
To ABS hydraulic unit - N55- : t to the co

rrectness of i
l purpos
master cylinder
- Identification: union nut with thread M12 x 1.
nform
ercia

m
a
com
ti
master cylinder
on in
r
te o
thi

s
iva
do
r

rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
2 - ABS hydraulic unit - N55- to rear left brake caliper. rig ht
py by
co Vo
by lksw
- Identification: union nut with thread M12 x 1 Prote
cted AG.
agen


Touran 2003 ➤

equipment required
1331-
1410-
V.A.G 1869/2-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos
unit - N55- .
nform

ercia

m
a
com
tio

n in
r
te o
thi

s
iva
do
r
rp

um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Touran 2003 ➤
Removing
Location:
N55- and is located on the left in the engine compartment.
1 - Brake servo with tandem brake master cylinder
2 - ABS control unit - J104- with ABS hydraulic unit - N55-
WARNING
unit - N55-
– Remove air filter ⇒ Rep. gr. 24
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing batteries .
satelettronica
– Remove battery tray -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes

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

Touran 2003 ➤
brake caliper. n AG. Volkswagen A G do
wage es n
– Open bleed valve. Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
left brake caliper.
rrectness of i
l purpos

nform
ercia
satelettronica
– Do not remove brake pedal depressor - V.A.G 1869/2- .
m
at
om
io
n
c
in t
or
his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
– First identify the two brake master cylinder brake lines -A- and Cop py
-B- and unscrew from ABS hydraulic unit - N55- . ht. rig
rig ht
py by
o Vo
– Seal brake lines and thread holes. by c lksw
cted agen
Prote AG.
– Mark brake lines (brake caliper) -1- to -4-, unscrew and im‐
1H0 698 311 A.
– Release connector from ABS control unit - J104- in

-direction of arrow 1- and pull off in -direction of arrow 2-.
upwards out of damper rubbers in bracket.
Touran 2003 ➤
6.2.4 Unbolting ABS control unit - J104- from

Sealing plug - 1H0 698 311 A-
unit - N55- .
1- Transport protection for contact pins (foam)
2- Sealing plug M10
3- Sealing plug M12
– Pull ABS hydraulic unit - N55- together with ABS control unit
- J104- upwards and place on a clean even surface.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Pull off ABS control unit - J104- from ABS hydraulic unit - N55-
h re
-arrow- without tilting ABS control unit.
hole
spec
es, in part or in w
– Carefully pull off all seals from contact pins of ABS hydraulic
t to the co
unit - N55- in -direction of arrow-.

rrectness of i
WARNING
l purpos

nf
ercia
♦ Make sure no moisture or particles of dirt make their way

orm

m
atio
om
n in
c
♦ ABS hydraulic pump - V64- may not be separated from

or
thi
ABS hydraulic unit - N55- .

te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t.
rig
gh ht
yri by
cloth. op Vo
by c lksw
cted agen
Prote
After separating control unit and ABS hydraulic unit - N55- , use
AG.
transport protection for contact pins.

Touran 2003 ➤
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ABS

control unit - J104- . The ABS control unit - J104- may then no
longer be used.

without canting it.
Note
satelettronica
♦ A new ABS control unit - J104- may be mounted on remaining
ABS hydraulic unit - N55- a maximum of two times in order to
guarantee impermeability of the elastic seal.
en AG. V
olkswagen AG
in a vehicle must not be installed a second time. ksw
ag does
not
y Vol gu
b ara
ed nte
oris eo
th
6.2.6 Installing ABS control unit
ss - J104- and
au ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
t to the co
rrectne
s
♦ When installing, ensure that rubber dampers are not pressed

s o
out of bracket.
cial p
f inform
mer

atio
om
n
c

i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
Specified torque
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
op Vo
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♦ Use new bolts! cted agen
Prote AG.

Brake lines on ABS hydraulic unit - N55- thread M 10 14 Nm
x1
Brake lines on ABS hydraulic unit - N55- thread M 12 14 Nm
x1
Touran 2003 ➤
6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) to Week 22/2008, LHD

On vehicles with hydraulic
brake servo or hill start feature,
it is not possible to separate
the ABS control unit - J104-
⇒ page 38
On vehicles with hydraulic
brake servo or hill start feature,
it is not possible to separate wage
es n
the ABS control unit - J104- y Vo lks ot g
and ABS hydraulic unit - N55-ise
d .
b ua
ran
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❑ Removing ands ainstalling
ut or
ac
satelettronica
⇒ page 38 s
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nl
pt
du
3 - Brake line
an
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unit - N55- .
hole
❑ Identification: ∅ 6.5 mm spec

es, in part or in w
and union nut with long

t to the co
thread M12 x 1
4 - Brake line
rrectness of i

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N55- .
nf
ercia
❑ Identification: ∅ 6.5 mm
rm
m
and union nut with long

atio
m
thread M12 x 1
o
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5 - Brake line
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❑ Identification: ∅ 5.25 mm and union nut with short thread M 12 x 1. t. Cop py
rig
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6 - Brake line pyri by
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❑ To front right brake caliper. cted agen
Prote AG.
❑ Identification: ∅ 5.25 mm and union nut with thread M 10 x 1
7 - Brake line
❑ Identification: ∅ 5.25 mm and union nut with short thread M 12 x 1.
8 - Brake line
9 - Bolt
❑ 5.5 Nm
❑ Use new bolts.

Touran 2003 ➤
10 - Bracket
11 - Bolt
❑ 8 Nm
12 - Seal
13 - Brake servo
❑ On petrol engines, the required vacuum is taken from the intake manifold.
❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump
⇒ page 136 .
❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 136 .
❑ Diesel engines are fitted with an vacuum pump to create the required vacuum ⇒ page 130 .
– With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the
unit.)
properly, the brake pedal will be felt to go down as the servo takes effect.
❑ If faulty, renew complete (check all vacuum lines first).
satelettronica
14 - Sealing ring agen
AG. Volkswagen AG d
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15 - Brake servo vacuum sender - G483- d by V gu
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❑ Only on vehicles having HBV uthor eo
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❑ Removing and installing ⇒ page 136 ss c
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17 - Heat shield
es, in part or in w
t to the co
18 - Nut
❑ 25 Nm
rrectness of i
19 - Sealing plug
l purpos
❑ Moisten with brake fluid and press into brake fluid reservoir. nform
ercia
20 - Brake fluid reservoir

m
21 - Cap
com
tion in
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22 - Sealing plug
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23 - Vacuum hose
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❑ Fit in brake servo. t. Cop py
rig
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pyri by
Vo
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by
cted agen
Prote AG.
Touran 2003 ➤

- Identification: ∅ 6.5 mm and union nut with thread M 12 x 1.
- Identification: ∅ 6.5 mm and union nut with thread M 12 x 1.
To ABS hydraulic unit - N55- :

master cylinder
satelettronica
- Identification: ∅ 6.5 mm and union nut with long thread M12 x 1
master cylinder
- Identification: ∅ 6.5 mm and union nut with long thread M12 x 1 wage
es n
lks ot g
Vo
1 - ABS hydraulic unit - N55- to front left brake caliper. d by ua
ran
ir se tee
o
- Identification: ∅ 5.25 mm and union nut with short thread M au 12
th or
ac
x 1. ss
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- Identification: ∅ 5.25 mm and union nut with thread M 10 x 1
erm
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- Identification: ∅ 5.25 mm and union nut with short thread M 12
x 1.
rrectne
ss o
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mer
atio
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n
c
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Cop py
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by
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Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
ksw
agen Brake
oes systems - Edition
not
07.2013
ol
byV gu
ara
d
Special tools and workshop orise nte
eo
equipment required aut
h
ra
ss c
ce
e
nl
pt
1331-
du
an
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erm
ab
ility
1410-
ot p
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♦ Brake pedal depressor - , is n
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hole
V.A.G 1869/2-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
satelettronica
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

unit - N55- .
Removing
Location:
Touran 2003 ➤
ABS layout in left-hand drive vehicle.

2 - Brake servo
WARNING
unit - N55-
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐ agen
AG. Volkswagen AG d
oes
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V gu
d by ara
e
– Remove engine cover. ho
ris nte
e t or
au ac
ss
1.4l TSI engine
ce
e
nl
pt
du
satelettronica
an
– Remove engine cover -arrow A- and heat shield -arrow B-.
itte
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spec
es, in part or in w
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nform
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– Pull off engine cover in -direction of arrow-.

m
at
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1.9l diesel engine

ion
c
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or

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ate

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for
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engine (2 valve); Rep. gr. 23 ; Removing and installing mixture t. C rig
gh ht
preparation - injection . pyri by
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chamber bulkhead .
charger.
– Remove upper part of timing belt guard by opening clips
-arrows-.

Touran 2003 ➤

connectors, ⇒ Rep. gr. 26 ;eAssembly overview
AG. Volkswagen AG - front exhaust
ag n
pipe with particulate ofilter
lksw .
does
no t gu
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– Remove clamp
ris -1-.
ed nte
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– Unscrewsbolts
sa of particulate filter -2- to -5- ⇒ Exhaust system; ra
c
ce
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un
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pe
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es, in part or in w
t to the co
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satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
brake caliper.
Touran 2003 ➤

left brake caliper.
– First identify the two brake master cylinder brake lines -A- and
-B- and unscrew from ABS hydraulic unit - N55- .
– Mark brake lines (brake caliper) -1- and -4-, unscrew and im‐
1H0 698 311 A.
satelettronica
upwards out of dampers.

Note
On vehicles with hydraulic brake servo or hill start feature, it is not

possible to separate the ABS Acontrol unit
G. Volkswagen- AJ104- and ABS hy‐
draulic unit - N55- . lkswagen G do
es n
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– Pull ABS thydraulic
hor unit - N55- with ABS control unit - J104-
eo
downwards
s au and place on a clean flat surface. ra
c
s
ce
e
– Unscrew bolts -arrows- from ABS hydraulic pump - V64- .

nl
pt
du
an
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erm
ab
WARNING
ility
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ABS hydraulic pump - V64- may not be separated from ABS

h re
hole
hydraulic unit - N55- .

spec
es, in part or in w
Avoid electrostatic charge!

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
ht. rig
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py by
42
co Vo
by lksw
cted
Rep. gr.45 - Anti-lock brake system
agen
Prote AG.
Touran 2003 ➤
– Therefore, secure ABS hydraulic pump - V64- with red bracket

-1- from replacement part set and 2 plugs -2- on ABS hydraulic
unit - N55- .
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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– Carefully separate ABS hydraulic unit - N55- with ABS hy‐
ce
le
un
pt
draulic pump - V64- upwards from ABS control unit - J104- at
an
d
itte
seam -1-.
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rm
ab
pe
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, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
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When pulling off ABS control unit - J104- ensure that contact pins
of ABS hydraulic unit - N55- do not cant with solenoid valves of
nform
ercia
ABS control unit - J104- .

m
a
com
ti
Item 2 adapter for pump motor.
on in
r
te o
thi
s
iva
cloth.
do
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cum
fo
en
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t.
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Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
WARNING

longer be used.
♦ Before the new ABS control unit - J104- can be installed, the
pump motor adapter must be inserted to stop and thereby en‐
gage. Make sure not to damage the adapter guide.
♦ The adapter supplied as a replacement part for the ABS con‐
trol unit - J104- can only be engaged once and thereafter
cannot be separated again.
♦ The white paste on the base of the ABS control unit - J104-
serves as a sealing compound and must not be removed.
♦ Ensure that none of the contact surfaces on the adapter, pres‐
sure sensor and ABS control unit - J104- , including silicon gel
and sealing elements, are touched, contaminated or damaged
either by hand or by any other object.
Touran 2003 ➤
– Clip adapter into adapter guide onto stop until it engages with
a click.
without canting it.
Note
♦ To ensure the elastic seal remains leak tight, a new ABS con‐
trol unit - J104- may only be mounted on an existing ABS
hydraulic unit - N55- a total of two times.

satelettronica
AG. Volkswagen AG d
agen oes
lksw not
Note d byV
o gu
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or e
h
♦ Do not removes aut sealing plugs from new ABS hydraulic unit - or a
c
N55- until respective
s brake line is about to be installed.
ce
le
un
pt
an
d
itte
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rm
ab

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ility
ot
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, is n
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hole
spec

es, in part or in w
t to the co
– Code radio.
rrectness of i
To do this, a basic setting of the steering angle sender - G85- ,

l purpos
the lateral acceleration sender - G200- and the brake pressure

sender - G201- must be carried out ⇒ page 8 .
nform
ercia
Specified torque
m
a
com

ion in
r

te o
thi
s
♦ Use new bolts!

iva
do
r
rp
cum
fo

en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
Clamping sleeve for exhaust system 25 Nm

Bracket to engine block 25 Nm
Clamp between particulate filter and turbocharger 7 Nm
6.4 ABS Mark 60 EC (ABS/EDL/TCS/ESP) from Week 22/2008, LHD

AG. Volkswagen AG d
ksw
agen oes
not
Touran 2003 ➤
ol
byV gu Brake systems - Edition 07.2013
d ara
ise nte
or eo
h
s aut ra
c
s
ce
e
nl
pt
⇒ page 47
du
an
itte
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2 - Bolt
erm
ab
ility
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❑ 2 Nm + 0.8 Nm
wit
, is n
❑ Use new bolts.
h re
hole
spec
es, in part or in w
t to the co
⇒ page 47
4 - Brake line
rrectness of i
l purpos

unit - N55- .
nform
ercia
m
at
and union nut with
om
ion
thread M 12 x 1.
c
in t
or
his
te
5 - Brake line
a
do
priv
satelettronica
um
for
en
g

n
t.
yi Co
to ABS hydraulic unit - Cop py
. rig
N55- .
ht ht
rig by
opy Vo
❑ Identification: ∅ 6.5 mm by c lksw
cted agen
and union nut with Prote AG.
thread M 12 x 1.
6 - Brake line
per.
❑ Identification:
∅ 5.25 mm and union
nut with thread M 10 x 1
7 - Brake line
per.
8 - Brake line
9 - Brake line
10 - Brake servo
❑ See ⇒ page 124 .
11 - Bracket
12 - Bolt
❑ 8 Nm
13 - Rubber damper
14 - Hexagon shoulder screw
❑ 8 Nm
Touran 2003 ➤
15 - Bracket
16 - Rubber damper
17 - Hexagon nut
❑ 20 Nm
18 - Heat shield
19 - Hexagon nut
❑ 8 Nm

satelettronica
AG. Volkswagen n AG do
wage es
olks to rear right brake caliper.
3 - ABS hydraulic unit y- VN55- not
gu b ara
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4 - ABS hydraulic
tho
runit
is - N55- to rear left brake caliper. e or
au ac
ss
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un
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d

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master cylinder
ab
pe
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wit
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master cylinder
es, in part or in w
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l purpos

nform
ercia

m
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com
tion in

r
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s

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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
6.4.2 Removing ABS controllksunit

wage - J104- and ABS
es n hydraulic unit - N55-
o ot g
yV ua
edb ran
ris tee
Special tools and workshop aut
ho or
ac
equipment required ss
ce
e
nl
pt
du
an
itte
1331-
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erm
ab
ility
ot p
1410-
wit
, is n
h re
hole
spec
V.A.G 1869/2-
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
satelettronica
o
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touran 2003 ➤

After removing ABS hydraulic unit - N55- , fit transport protection
for contact pins.
AG. Volkswagen AG d
1 - Transport protection for contact pins (foam) agen oes
olksw not
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b ara
2 - Sealing plug M10 rise
d
nte
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3 - Sealing plug M12 ss a ra
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Removing
nl
pt
du
an
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Location:
erm
ab
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wit
, is n
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spec
es, in part or in w
WARNING
t to the co
unit - N55-
rrectness of i
satelettronica
l purpos
nf
ercia
or
necessary.
m
m
atio
m

o
n in
or c
thi
te
sd
iva
o
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cu
1.4l TSI engine
o
m
f
en
ng
t.
– Remove engine cover -A- and heat shield -B-.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted
agen
Prote AG.

– Remove engine cover in -direction of arrow-.
1.9l diesel engine
engine (2 valve); Rep. gr. 23 ; Removing and installing mixture
preparation - injection .

Touran 2003 ➤

– Remove upper part of timing belt guard by detaching clasps
-arrows-.
chamber bulkhead .
charger.

connectors, ⇒ Rep. gr. 26 ; Assembly overview - front exhaust
pipe with particulate filter .
– Remove clamp -1-.
– Unscrew bolts of particulate filter -2- to -5- ⇒ Exhaust system;
satelettronica
– Remove heat shield (if installed). wage
es n
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Connect bleeder bottle hose to front left brake caliper bleeder

t to the co
valve and rear left brake caliper bleeder valve and open bleed‐
er valves.
– Depress brake pedal at least 60 mm using brake pedal de‐
rrectness of i

l purpos

nf

ercia
orm
m

atio
m

o
n in
or c
thi

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touran 2003 ➤
– First mark the two brake master cylinder brake glines

en AG. V
olkswagen AG
does
-A and B- and unscrew from ABS hydraulic Volkunit
swa - N55- . not
y gu
db ara
– Immediately seal brake lines and threaded
or
ise holes with seal nte
plugs from repair set Part No. 1H0
au 698 311 A.
th eo
ra
ss c
– Mark brake lines (brake caliper) -1 to 4-, unscrew and seal with
ce
e
nl
pt
plugs from repair kit Part No. 1H0 698 311 A.
du
an
itte
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– Turn hexagon fitted bolt out of retainer.
erm
ab
ility
ot p
– Pull off ABS hydraulic unit - N55- with ABS control unit - J104-
wit
, is n
and retainer sideways from damper rubbers of bracket and
h re
hole
turn upside down.
spec
es, in part or in w
– Unbolt bracket from ABS hydraulic unit - N55- in engine com‐
t to the co
partment and remove.
– Remove ABS hydraulic unit - N55- with ABS control unit -
rrectness of i
J104- .
l purpos

nf
ercia
orm
m
atio
Unbolt
satelettronica
om
n in
or c
thi
te
sd
iva
o
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rp
cu
unit - N55- .
o
m
f
en
ng
t.
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Without transport protection, the warranty for the ABS hydraulic Cop py
unit - N55- will not be recognised. ht. rig
rig ht
py by
o Vo
by c lksw
cted agen
Prote AG.
2- Sealing plug M10
3- Sealing plug M12

Touran 2003 ➤
- N55- .
WARNING

♦ Make sure no moisture or particles of dirt find their way

cloth.
satelettronica
WARNING

longer be used. gen AG
. Volkswagen AG
d wa oes
olks not
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ara
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• Clean surfaces before assembling. ris
tho eo
s au ra
c
– Push all seals -A- over contact pins sslightly.
ce
e
nl
pt
du

an
itte
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without canting it.
erm
ab
ility
ot p

wit
, is n
– Tighten ABS hydraulic unit - N55- and ABS control unit - J104- h re
hole
using new torx head bolts provided. Tighten in increments to

spec
specified torque in diagonal sequence.

es, in part or in w
t to the co
Note
rrectness of i
♦ To ensure the elastic seal maintains its leak tightness, a new

l purpos
ABS control unit - J104- may only be mounted on an existing

hydraulic unit a maximum of two times.
nf
ercia

rm
m

atio
om
n in
or c
thi
te
sd
a

iv
o
r
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cu

o
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f
en
ng
t.
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op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Touran 2003 ➤
Note

WARNING
Ensure that rubber dampers of retainer are not pressed out of

bracket when installing. After installing, check the ABS hy‐
draulic unit - N55- and ABS control unit - J104- are seated
properly as otherwise malfunctions may occur.

satelettronica
– Code radio.
– Code ABS control unit - J104- -J104- ⇒ page 8 .
To do this, a basic setting of the steering angle sender - G85- ,
the lateral acceleration sender - G200- and the brake pressure
sender - G201- must be carried out ⇒ page 8 .
Specified torque
Component AG. Volkswagen AG d Specified torque
agen oes
ksw
ABS control unit - J104- btoy VABS hydraulic unit - N55-
ol not
gu
ara
5.5 Nm
♦ Use new bolts! ris ed
nte
ho eo
aut ra
Hexagon bolt fors ABS hydraulic unit - N55- to bracket
s c 8 Nm
ce
e
nl

pt
du
an
itte
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erm
ab
ility

ot p
wit
, is n

h re
hole

spec
es, in part or in w

t to the co

rrectness of i
l purpos
6.5 ABS Mark 60 EC (ABS/EDL/TCS/ESP)

(RHD vehicle)
nf
ercia
orm
m
atio
om

n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
1 - Brake line agen oes
olksw not
y V gu
❑ Brake master cylinder/ rise
d b ara
nte
secondary piston circuit utho eo
ra
to ABS hydraulic unit - ss a c
N55- .
ce
e
nl
pt
du
an
itte
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and union nut with
erm
ab
thread M 12 x 1
ility
ot p
wit
, is n
2 - Brake line
h re
hole
spec
es, in part or in w
t to the co
unit - N55- .
rrectness of i
and union nut with
thread M 12 x 1
l purpos
3 - Brake servo
nf
ercia
❑ See ⇒ page 124 .
orm
m
atio
m
⇒ page 150
o
n in
satelettronica
or c
thi
4 - Brake line
te
sd
iva
o
r
rp
cu
per.
o
m
f
en
ng
t.
yi
❑ Identification: ∅ 5.25
Co
Cop py
mm and union nut with
t. rig
gh ht
yri
thread M 12 x 1 p by
co Vo
by lksw
cted agen
5 - Brake line Prote AG.

per.
❑ Identification: ∅ 5.25
mm and union nut with
thread M 10 x 1
7 - Bolt
❑ 2 Nm + 0.8 Nm
❑ Use new bolts.
8 - Rubber damper
9 - Bracket
10 - Nut
❑ 20 Nm
11 - Bolt
❑ 8 Nm
12 - Bracket
❑ Before installing, spray rubber dampers ⇒ Item 8 (page 53) with silicone lubricant D 007 000 A2.
13 - Rubber damper
14 - Hexagon shoulder screw
❑ 8 Nm
15 - Brake line
Touran 2003 ➤
16 - Brake line
17 - ABS hydraulic unit - N55- lkswage es n
o ot g
yV ua
❑ Removing and installing ⇒ page 55 ir se
d b ran
tee
tho
u or
a ac
ss
ce
le
6.5.2 Connecting brake lines from tandem
un
pt
an
d
itte
brake master cylinder to ABS hydraulic
y li
erm
ab
ility
unit - N55-
ot p
wit
is n
h re
On tandem brake master cylinder:
ole,
spec
t to the co
rrectne
satelettronica
ss
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r

fo
en
ng
master cylinder
t.
yi Co
Cop py
. rig
t
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pyri by
Vo
co
by lksw
cted agen
Prote
master cylinder
AG.


Touran 2003 ➤

equipment required
1331-
1410-
V.A.G 1869/2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr

um
r
fo
en
ng
t.
yi
Co
op py
unit - N55- .
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
unit - N55- will not be recognised. Prote AG.

Removing
Touran 2003 ➤
Location:
N55- and is located on the left in the engine compartment.
1 - Brake servo with tandem brake master cylinder
2 - ABS control unit - J104- with ABS hydraulic unit - N55-
WARNING
unit - N55-
– Remove air filter ⇒ Rep. gr. 24
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing batteries .
– Remove battery tray -arrows-. AG. Volkswagen AG d

agen oes
ksw
satelettronica
ol not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Apply brake pedal depressor - V.A.G 1869/2- . atio

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
brake caliper.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
left brake caliper.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
– First mark the two brake master cylinder brake lines

-A and B- and unscrew from ABS hydraulic unit - N55- .
m
at
om
ion
c
in t
or

his
ate
do
riv
– Mark brake lines (brake caliper) -1 to 4-, unscrew and seal with
p
cum
or
plugs from repair kit Part No. 1H0 698 311 A.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release connector from ABS control unit - J104- in

-direction of arrow 1- and pull off in -direction of arrow 2-.
– Turn hexagon fitted bolt -3- out of retainer.
and bracket sideways out of damper rubbers in bracket.
– Unbolt ABS control unit - J104- from ABS hydraulic unit - N55-
⇒ page 58 .
Touran 2003 ➤

Removing
unit - N55- .
2- Sealing plug M10
3- Sealing plug M12
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec

es, in part or in w
t to the co
- N55- .
rrectness of i
WARNING
l purpos

nf
ercia

orm
m
atio
♦ Make sure no moisture or particles of dirt enter ABS con‐

om
trol unit - J104- .

n in
or c
thi
e

t
sd
iva
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rp
cu
o
m
f
en
ng
t.
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Co
op py
cloth. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
- N55- , use transport protection for contact pins. Prote AG.

Touran 2003 ➤
WARNING

longer be used.

without canting it.
– Tighten ABS hydraulic unit - N55- and ABS control unit - J104-
using new torx head bolts provided. Tighten in increments to
specified torque in diagonal sequence.
satelettronica
Note
♦ A new ABS control unit - J104- may be mounted on remaining

ABS hydraulic unit - N55- a maximum of two times in order to
guarantee impermeability of the elastic seal. G. Volkswage
nA n AG d
wage oes
♦ An ABS control unit - J104- which has
yV
olalready
ks been operated not
gu
in a vehicle must not be installed
ise
a
d bsecond time. ara
nte
r
ho eo
aut ra
ss c
6.5.6 Installing ABS control unit - J104- and ce
le
un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co

rrectness of i
l purpos

nform
ercia
– Before installing bracket for ABS hydraulic unit - N55- , spray

damper rubbers with silicone lubricant - D 007 000 A2- to ease
m
a
com
installation.
ion in
r
te o
thi
s
iva
WARNING
do
r
rp
cum
fo
en
g
Ensure that rubber dampers of retainer are not pressed out of

n
t.
yi Co
bracket when installing. After installing, check the ABS hy‐ Cop py
t.
draulic unit - N55- and ABS control unit - J104- are seated
rig
gh ht
yri by
properly as otherwise malfunctions may occur. op Vo
by c lksw
cted agen
Prote AG.

– Code ABS control unit - J104- -J104- ⇒ page 8 .
Touran 2003 ➤
To do this, basic setting of the steering angle sender - G85- , the

lateral acceleration sender - G200- and the brake pressure send‐
er - G201- must be carried out.
Specified torque
ABS control unit - J104- to ABS hydraulic unit - N55- 2 Nm + 0.8 Nm
♦ Use new bolts!
Bolt for ABS hydraulic unit - N55- to bracket. 8 Nm

Hexagon fitted bolt, retainer to bracket 8 Nm
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
7 Removing and installing parts of ABS

system on front and rear axle
7.1 Removing and installing parts of ABS system

Volkswa
on front axle
AG. gen AG
agen does
olksw not
yV gu
1 - Front speed sensor rise
db ara
nte
❑ Before inserting sensor, tho eo
au ra
clean hole inner surface ss c
ce
le
and coat with high-tem‐
un
pt
perature paste
an
d
itte
y li
G 052 112 A3.
erm
ab
ility
ot p
wit
⇒ page 62
is n
h re
ole,
2 - Bolt
spec
❑ 8 Nm
t to the co
satelettronica
❑ ABS sensor ring is in‐
rrectne
stalled in wheel bearing.
4 - Drive shaft
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Removing and installing parts of ABS system on front and rear axle 61
Touran 2003 ➤
7.1.1 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle.
– Release connector -1- on speed sensor and pull off.
– Unscrew bolt -2- from wheel bearing housing.
– Pull out speed sensor from wheel bearing housing.
Installing
– Before inserting speed sensor , clean inside of hole and coat
speed sensor around circumference with high temperature
paste - G 052 112 A3- . . Volkswagen AG
gen AG does
swa
– Insert speed sensor in hole of wheel bearing housing and y V olk not
gu
tighten. risedb ara
nte
ho eo
– Fit connector on speed sensor . aut ra
ss c
satelettronica
ce
e
nl
pt
Specified torque
du
an
itte
y li
erm
ab
ility
ot p
Speed sensor to wheel housing bearing 8 Nm
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
7.2 Removing and installing parts of ABS system on rear axle
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
1 - Speed sensor
❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
⇒ page 63
2 - Hexagon socket head bolt
❑ 8 Nm
❑ ABS sensor ring is in‐
stalled in wheel bearing.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
7.2.1 Removing and installing speed sensor

on rear axle
rrectness of i
Removing
l purpos
– Raise vehicle.
– Release connector -1- from speed sensor and pull off.
nform
ercia
– Unscrew bolt -2- from wheel bearing housing.

m
at
om
ion
– Pull out speed sensor from wheel bearing housing.

c
in t
or
his
e
Installing
at
do
priv
cum
or

f
en
ng
t.
yi Co
– Before inserting speed sensor , clean inside of hole and coat Cop py
speed sensor around circumference with high temperature
t. rig
gh ht
yri
paste - G 052 112 A3- .
p by
co Vo
by lksw
cted agen
– Insert speed sensor in hole of wheel bearing housing and
Prote AG.
tighten.
– Fit connector on speed sensor .
7. Removing and installing parts of ABS system on front and rear axle 63
Touran 2003 ➤
Specified torque
Component n AG. VolkswSpecified
agen AG
doetorque
lkswage s no
o
Speed sensor to wheel housing bearing d by
V 8 Nm t guara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
satelettronica
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
8 Removing and installing parts of ESP

system
8.1 Removing and installing ESP sensor

unit - G419-
The lateral acceleration sender - G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender - G251- are in‐
stalled together in one housing behind the glove compartment.
After exchanging the ESP sensor unit - G419- , perform basic
setting 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.
satelettronica
AG. Volkswagen AG d
Removing agen oes
olksw not
y V gu
d b ara
– Remove gloveorise compartment ⇒ General body repairs, nteinterior;
Rep. gr.aut 68 ; Compartments, covers and trims .
h eo
ra
ss c
– Release connector -1- from ESP sensor unit - G419- and pull
ce
le
un
pt
off.
an
d
itte
y li
– Remove the two securing nuts -arrows-.

erm
ab
ility
ot p
– Remove ESP sensor unit - G419- .

wit
is n
h re
ole,
Installing
spec

t to the co
When installing the ESP sensor unit - G419- , make sure it is cor‐
rectly seated in its bracket and is free of stress.
rrectne
Note
ss o
cial p
f in
Do not use the securing nuts to forcibly position the ESP sensor
form
mer
unit - G419- .
atio
om
n
c
– Tighten securing nuts to 9 Nm.

i
or
n thi
te
sd
a
– Perform basic setting of lateral acceleration sender - G200- .

iv
o
pr
cum
r
fo
Connecting -VAS 5051- and selecting functions ⇒ page 8 .

en
ng
t.
yi Co
Cop py
t.
Specified torque
rig
gh ht
pyri by
Vo
co lksw
by
Component Prote
cted AG.
agen
Specified torque
ESP sensor unit - G419- 9 Nm
8.2 Removing and installing steering angle

sender - G85-
The steering angle sender - G85- is located between the steering
wheel and steering column switch (for exceptions, see notes).
8. Removing and installing parts of ESP system 65

Touran 2003 ➤
Note
From Week 22/2008, vehicles equipped with a 3rd generation

electromechanical power steering system have the steering angle
sender - G85- in the steering rack (for left-hand drive vehicles up
to Week 22/2010).
Removing and installing, location: steering column switch

– ⇒ Electrical system; Rep. gr. 94 ; Lights, bulbs, switches -
exterior; Steering column switch .
– Then perform basic setting of steering angle sender - G85- .
Removing and installing, location: steering rack
Removing and installing steering ⇒ Running gear, axles, steer‐
ing; Rep. gr. 48 ; Electromechanical steering rack .
– Then carry out basic setting of steering angle sender - G85- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
46 – Brakes - mechanism
1 Repairing front brakes
1.1 Repairing front brakes, FN 3 brake

en AG. V
olcaliper
kswagen AG
ag does
ksw not
y Vol gu
b ara
ed
Note thoris nte
eo
au ra
c
ss
♦ After every brake pad change, depress brake pedal firmly several times with vehicle stationary, so that brake
ce
le
un
pads are properly seated in their normal operating position.
pt
an
d
itte
y li
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
erm
ab
ility
ot p
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
wit
is n
(when doing this, release pressure in system).
h re
ole,
spec
Assembly overview, FN3, 15 inch:
t to the co
satelettronica
1 - Bolt
rrectne
❑ 4 Nm
2 - Brake disc
ss o
❑ Ventilated, ∅ 288 mm
cial p
f inform
❑ Thickness: 25 mm
mer
atio
❑ Wear limit: 22 mm.
om
n
c
❑ Renew on both sides.
i
or
n thi
te
❑ Remove brake caliper
sd
iva
o
r
and brake carrier prior to

p
cum
r
fo
removing. en
ng
t.
yi Co
op
3 - Brake pads C py
t. rig
gh ht
yri
❑ Thickness: 14 mm not p by
co Vo
including backplate.
by lksw
cted agen
Prote AG.
❑ With break pad wear in‐
dicator.
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Check thickness
⇒ Maintenance ; Book‐
let 18.1 .
⇒ page 70
4 - Retaining spring
❑ Insert into both holes in
brake caliper.
5 - Brake carrier
❑ Bolt to wheel bearing housing.
6 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
1. Repairing front brakes 67

Touran 2003 ➤
❑ Repairing ⇒ page 108
7 - Guide pin
❑ 30 Nm
8 - Cover cap
❑ Remove
9 - Brake hose with banjo union and banjo bolt
❑ 35 Nm
10 - Ribbed collar bolt
❑ 190 Nm
❑ Clean if reused.
11 - Bolt
12 - Bracket
❑ With bolted brake carrier.
satelettronica
❑ Before inserting sensor, clean inner surface of fitting hole and coat with hot bolt paste - G 052 112 A3-
15 - Hexagon socket head bolt, 8 Nm n AG. Volkswagen AG do
lkswage es n
o ot g
16 - Splash plate d byV ua
ran
ir se tee
17 - Bolt utho
or
a ac
❑ 12 Nm ss
ce
le
un
❑ M6x10 changed to M6x12
pt
an
d
itte
y li
❑ Replace hexagon bolt with hexagon bolt and Torx bolt with Torx bolt
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Assembly overview, FN3, 16 inch:
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
68 Rep. gr.46 - Brakes - mechanism

Touran 2003 ➤
1 - Bolt
❑ 12 Nm
2 - Brake disc
❑ Ventilated, ∅ 312 mm
❑ Remove brake caliper
and brake carriernprior
AG. Voto
lkswagen AG
wage does
removing.
Volks not
g
by ua
ed ran
3 - Bolt horis tee
ut or
❑ss a 4 Nm ac
ce
e
4 - Brake pads
nl
pt
du
an
itte
❑ Thickness: 14 mm not
y li
erm
ab
including backplate.
ility
ot p
❑ With break pad wear in‐
wit
, is n
dicator.
h re
hole
spec
❑ When wear reaches a
satelettronica
es, in part or in w
predetermined limit (ap‐
t to the co
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
rrectness of i
❑ Wear limit: 2 mm not in‐
l purpos
cluding backplate.
❑ Check thickness
⇒ Maintenance ; Book‐
nform
ercia
let 18.1 .
m
at

om
ion
c

in t
or
his
e
⇒ page 70
at
do
priv
um
for
en
ng
❑ Insert into both holes in

t.
yi Co
op
brake caliper.
C py
t. rig
gh ht
yri by
6 - Brake carrier cop Vo
by lksw
cted agen
❑ Bolt to wheel bearing housing. Prote AG.
7 - Brake caliper
❑ Repairing ⇒ page 108
8 - Guide pin
❑ 30 Nm
9 - Cover cap
❑ Remove
10 - Brake hose with banjo union and banjo bolt
❑ 35 Nm
11 - Guide pin
❑ 30 Nm
12 - Cover cap
❑ Remove

Touran 2003 ➤
13 - Bolt
14 - Bracket
15 - Ribbed collar bolt
❑ 190 Nm
❑ Clean if reused.
❑ With bolted brake carrier.
17 - ABS speed sensor
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
18 - Hexagon socket head bolt
❑ 8 Nm
20 - Splash plate
satelettronica
1.2 Removing and installing brake pads,
brake caliper FN 3
♦ Torque wrench - V.A.G 1331- agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Piston resetting appliance - T 10145-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
1.2.1 Removing
ht
pyri by
Vo
o
by c lksw
cted agen
Mark brake pads/linings when removing if they are to be reused.
Prote AG.
Fit in same position when installing, or braking will be uneven.

– Loosen wheel nuts/bolts.
– Raise vehicle.
– Remove wheels.

Touran 2003 ➤
– Lever brake pad retaining spring out from brake caliper

-arrow- with a screwdriver and remove.
– Release connector -1- for brake pad wear indicator and pull
off.
AG. Volkswagen AG d
agen oes
olksw not
V
satelettronica
by gu
d ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Remove cover caps -arrows-.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Unscrew both guide pins -arrows- and remove from brake cal‐
a
com
tio
iper.
n in
r
te o
thi
– Remove brake caliper and secure with wire so that weight of

s
iva
do
brake caliper does not strain or damage brake hose.

r
rp
cum
fo
en
g
– Take brake pad out of brake caliper or from brake carrier.

n
t.
yi Co
op py
Cleaning:
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING Prote AG.
Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!
– Thoroughly clean contact surfaces for brake pads on back‐

plate, and remove any corrosion.
– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.
Use only methylated spirits for cleaning the brake caliper housing.

Touran 2003 ➤
1.2.2 Installing
Before pressing piston back into cylinder with piston resetting tool
- T10145- , draw off brake fluid from brake fluid reservoir. Other‐
wise, particularly if reservoir has been topped up, fluid will over‐
flow and cause damage.
– Push back piston in brake caliper -2- using piston resetting tool
- T10145- -1-.
– 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
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– Bolt brake caliper to brake carrier with both guides pins.
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– Fit both cover caps.

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– Insert retaining spring into brake caliper.
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– Fit connector for brake pad wear indicator.
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– Fit wheels and tighten nuts/bolts ⇒ Running gear, axles,
h re
hole
steering; Rep. gr. 44 ; Specified torque for wheel installation .
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
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properly seated in their normal operating position.

♦ Check brake fluid level after changing brake pads.
nf
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Specified torque
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Guide pin to brake carrier 30 Nm

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FS III brake caliper
Prote AG.

Touran 2003 ➤
♦ Torque wrench - V.A.G 1331-
♦ Brake pedal depressor - V.A.G 1869/2-
satelettronica
Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
G. Volkswagen AG d
– Loosen wheel bolts.
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– Raise vehicle.
ise
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– Remove
s a wheel.
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– Lever brake pad retaining spring out from brake caliper

le
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-arrow- with a screwdriver and remove.

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– Remove cover caps -arrows-.

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Touran 2003 ➤
– Connect bleed bottle bleed hose -1- to bleed valve of brake

caliper.

– Close bleed valve and remove bleed bottle.
satelettronica
– Unscrew brake hose -1- on brake caliper. Loosen banjon Abolt
G. Volkswagen AG d
-2- to do this. olks
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– Immediately seal brake line and threadedrihole
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plugs - 1H0 698 311 A- . utho eo
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Prote AG.

Touran 2003 ➤
– Unscrew and remove guide pins -arrows- from brake caliper

-1-.
– Remove brake caliper from brake carrier.
Cleaning:
WARNING
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Use only methylated ed bspirits
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Note
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Before installing, clean carefully and check for wear and damage.
h re
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satelettronica
spec
es, in part or in w
– Thoroughly clean contact surfaces for brake pads on back‐
t to the co
plate, and remove any corrosion.
• Piston is pressed back.
rrectness of i
• Outer brake pad is seated on brake carrier.
l purpos
– Insert inner brake pad with retaining spring into brake caliper
(piston).
nform
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When positioning the brake caliper, ensure that the brake pad
m
does not stick to the brake caliper housing before it is positioned

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Do not damage adhesive surface.

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– Screw in brake caliper -1- guide pins -arrows- and tighten.

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– Fit both cover caps. C py
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Prote AG.

Touran 2003 ➤
– Screw on brake hose -1- with banjo bolt -2- and tighten.
– Remove brake pedal actuator - V.A.G 1869/2- .
– Insert retaining spring into brake caliper.
– Fit and tighten wheel ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Specified torques for mounting wheels .
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torque
satelettronica
Guide pin to brake carrier 30 Nm
Brake hose to brake caliper 35 Nm
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Touran 2003 ➤
2 Repairing rear brakes
2.1 Assembly overview - rear brake CII 41
Note
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
I - Assembly overview, front-wheel drive

II - Deviations, four-wheel drive
satelettronica
clean inner surface of
hole and coat with high
temperature paste - G
052 112 A3-
2 - Bolt
❑ 8 Nm
3 - Bolt
❑ 90 Nm + 90°
❑ Always renew after re‐
moving
❑ Remove and install us‐
ing socket insert
swag-e
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T10035-b⇒y Vpage 79 .
olk ot g
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4 - Wheelthbearing
or housing e or
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5- Splash
ss plate
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6 - Bolt
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❑ 12 Nm
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❑ Bolt M6x12
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7 - Wheel hub with wheel bear‐

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ing
spec
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8 - Brake disc
t to the co
Brake disc, 15 inches:

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❑ ∅ 256 mm
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❑ When worn, renew on

or
both sides of axle.

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❑ Unscrew brake caliper

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prior to removing.
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Brake disc, 17 inches:

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❑ Internally ventilated
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❑ Diameter: 310 mm. t. Cop py
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AG.
Touran 2003 ➤
❑ When worn, renew on both sides of axle.
❑ Unscrew brake caliper prior to removing.
9 - Bolt
❑ 4 Nm
❑ For locating brake disc.
10 - Flange bolt
❑ Front-wheel drive only
❑ Specified torque, see ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear wheel suspension, drive shaft .
11 - Brake pads
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness: Maintenance Booklet ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings:
AG. Volkswagen AG d
Checking thickness . swagen oes
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❑ Always replace on both esides yV gu
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12 - Backplate with different guide pins and protective caps
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❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
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❑ If protective cap or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
erm
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guide pins.
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❑ Assembly instructions, brake carrier for 15" brake system: ⇒ page 79 .
h re
ole,
❑ No different guide pins are installed in brake carrier for 17" brake system.
spec
13 - Anti-rattle spring t to the co

❑ Always renew when changing pads.
14 - Brake caliper
rrectne

s

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❑ Repairing ⇒ page 112 .

inform
❑ Adjust handbrake cable first after repairing or renewing.

mer
atio
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❑ Adjusting handbrake ⇒ page 96 .

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15 - Hose retainer
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16 - Brake line
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❑ Always renew after removing. Prote AG.
18 - Handbrake cable
❑ Both locking lugs must be engaged on brake caliper bracket.
19 - Brake hose

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t or
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ss
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Installation instructions for brake carrier CII 41, 15 inch:
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1- Shorter guide pin with steps -arrows-, leading side
erm
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2- Longer guide pins, phasing out
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3- Balance weight, phasing out
hole
spec
es, in part or in w
t to the co
rrectness of i
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Tool insert - T10035-
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2.2 Removing and installing brake pads, CII

41
2. Repairing rear brakes 79

Touran 2003 ➤
♦ Resetting and removal tool - T 10165-
2.2.1 Removing
AG. Volkswagen A
Mark brake pads when removing if they are ksw to be reused. Fit in
agen G do
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same position when installing, or braking ot g
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– Loosen rear wheel nuts/bolts.
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– Raise vehicle.
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pt
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– Remove rear wheels.
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erm
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– Remove securing bolts from brake caliper, to do this counter‐
ility
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hold on guide pins.
wit
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rrectness of i
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– Remove brake pads and anti-rattle springs -arrows-.

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Cleaning:
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WARNING
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Do not blow out brake system with compressed air; the result‐ t. C rig
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Prote AG.
– Thoroughly clean contact surfaces for anti-rattle springs

(brake pads) on brake carrier, and remove corrosion.
– Clean brake caliper.
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 piston compress‐
ing tool - T 10165 - clockwise, ensuring that protective cap is
not damaged in the process.

Touran 2003 ➤
Volkswagen AG
– To aid screwing in, use special tool T10165/1.
swa
gen AG
.
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♦ If pistons are difficult to move, ase13 d b mm open-end spanner can ara
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be used on intended flats -arrow hori
A-. eo
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un
pt
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ab
pe
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ot
wit
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hole
spec
es, in part or in w
t to the co
– Insert pad retainers -arrows- and brake pads into brake carrier.
rrectness of i
l purpos
nform
mercia
a
com
tio
satelettronica
n in
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te o
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Cop py
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– Ensure that brake pads are seated correctly in anti-rattle
rig
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– Secure brake caliper with new self-locking bolts.
AG.
– Fit and tighten wheels ⇒ Running gear, axles, steering; Rep.

gr. 44 ; Specified torques of wheel bolts .
Note
♦ Repair kit contains 4 self-locking hexagon bolts for securing

brake caliper. These must be installed under all circumstan‐
ces.
Specified torque
Brake caliper to brake carrier 35 Nm

CII 41

Touran 2003 ➤
satelettronica
2.3.1 Removing agen
AG. Volkswagen AG d
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This procedure applies only to exchanging or the following repairised b ara
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work on the brake caliper. hor eo
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– Remove rear wheels. s
ce
le
un
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– Unhook handbrake cable -1- from lever on brake caliper -2-.
an
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rm
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– Press locking lugs -3- together and remove handbrake cable
pe
ility
from bracket -4- on brake caliper.
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Connect bleed bottle bleed hose -1- to brake caliper bleed

valve and open bleed valve.
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tion in
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Prote AG.

Touran 2003 ➤

– Loosen threaded connection -3- between brake line and brake

hose -2-.
– Pull off retaining clip -1- and remove brake hose -2- from
bracket.
satelettronica
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– Unscrew both securing bolts fromir se
d brake caliper; to do this,
b ua
ran
counterhold on guide pin. th o tee
or
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ss
– Pull brake caliper from brake carrier.
ce
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nl
pt
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
2.3.2 Installing
l purpos

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

m
atio
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brake carrier.
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– Secure brake caliper to brake carrier with new self-locking

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bolts.
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Prote AG.

Touran 2003 ➤
– Screw brake pipe -3- to brake hose -2- and secure with re‐
taining clip -1-.
– Guide handbrake cable through bracket -4- on brake caliper
satelettronica
until locking lugs -3- engage.
– Attach handbrake cable -1- to lever -2- on brake caliper.
n AG. Volkswagen A ge G do
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– Bleed brake system
by
⇒olkpage 121 .
V ot g
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ri ⇒ page 96 . se
– Adjust handbrake
tho
tee
or
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– Fit and tighten
ss wheels ⇒ Running gear, axles, steering; Rep.
ce
e

nl
pt
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Note
ot p
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hole
spec
es, in part or in w
operating position.
t to the co

rrectness of i
Specified torque
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nform
ercia

♦ Use new bolts!
m
at
om
ion
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in t
Brake pipe to brake hose 14 Nm

or
his
ate
Brake line to brake caliper 14 Nm

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2.4 Assembly overview - Bosch rear wheel brake
ht. rig
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Prote AG.
Note
♦ After work for which the brake system had to be opened, bleed the brake system with brake charge and
bleed system - VAS 5234- or extraction unit -V.A.G 1869/4- .

Touran 2003 ➤
1 - ABS speed sensor

clean inner surface of
hole and coat with high-
temperature paste - G
052 112 A3- .
2 - Bolt
❑ 8 Nm
3 - Bolt
❑ 90 Nm and turn 90° fur‐
ther
moving
5 - Splash plate
6 - Bolt
❑ 12 Nm
❑ M6x12.
satelettronica
7 - Wheel hub with wheel bear‐
ing
❑ Different for front- and
four-wheel drive.
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel
suspension, drive shaft
8 - Bolt
❑ Different for front- and
four-wheel drive.
AG. Volkswagen AG d
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parts catalogue
d byV
o
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❑ ⇒ Running
thoris
gear, axles, steering; Rep. gr. 42 ; Repairing
eo rear wheel suspension, drive shaft
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9 - Dust scap
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❑ Front-wheel drive only

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10 - Brake disc
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❑ ∅ 272 mm
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spec
es, in part or in w
❑ When worn, renew on both sides of axle.

t to the co
❑ Unscrew brake caliper prior to removing.

❑ Checking: Maintenance Booklet ⇒ Maintenance ; Booklet ; Checking thickness of brake pads and con‐
rrectness of i
dition of brake discs at front and rear; Checking condition of brake discs
l purpos
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

❑ Never remove brake discs from wheel hub by force. If necessary use penetrating fluid, because otherwise
brake discs can be damaged.
nf
ercia
orm
11 - Bolt
m
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❑ 4 Nm
n in
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thi
❑ For locating brake disc.

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12 - Brake pads
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❑ Thickness: 12 mm not including backplate.

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Prote AG.
Touran 2003 ➤
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness: Maintenance Booklet ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings:
Checking thickness .
❑ Always replace on both sides
13 - Backplate with different guide pins and protective caps
❑ If protective cap or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.
14 - Anti-rattle spring
❑ Always renew when changing pads. AG. Volkswagen AG d
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15 - Anti-rattle spring d by V gu
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❑ Always renew when changing pads. thor eo
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16 - Brake caliper ss
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ility
❑ Repairing ⇒ page 117 .
ot p
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❑ Adjust handbrake cable first after repairing or renewing.
h re
hole
spec
es, in part or in w
17 - Bolt
t to the co
❑ 35 Nm
❑ Self-locking
rrectness of i
❑ Always renew after removing.
l purpos
18 - Handbrake cable
❑ Both locking lugs must be engaged on brake caliper bracket.
nform
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m
at
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ion
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19 - Brake hose
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ate
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❑ With banjo bolt and seals

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❑ 35 Nm
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2.5 Removing and installing brake pads,

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Prote AG.
Bosch

Touran 2003 ➤
♦ Piston compressing tool - T10165-
Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
– Loosen rear wheel nuts/bolts.
– Raise vehicle.
satelettronica
– Unscrew bolts -arrows- from brake caliper -1-; to do this coun‐
terhold on guide pin.
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o ot g
byV ua
d ran
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– Remove brake pads and anti-rattle
aut springs -arrows-. or
ac
ss
Cleaning:
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WARNING
ility
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is n
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ole,

spec
t to the co
– Thoroughly clean contact surfaces for anti-rattle springs

(brake pads) on brake carrier, and remove corrosion.
rrectne
– Clean brake caliper.

ss o
cial p
Installing
inform
mer

atio
om
Before pressing pistons back, draw off some brake fluid from res‐
n
c
i
or
ervoir with a bleeder bottle. Otherwise, particularly if reservoir has

thi
te
sd
a
been topped up, fluid will overflow and cause damage.

iv
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cum
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fo
en
ng
t.
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t. rig
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AG. Volkswagen AG d
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Touran 2003 ➤ d byV gu
ara
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Brake systems - Edition 07.2013 horis nte
eo
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ss c
– Screw in piston by turning thumb wheel on piston compressing
ce
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nl
tool - T10165- clockwise. Do not damage protective cover.
pt
du
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itte
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– Use plate - T10165/1- for assistance when screwing in.
erm
ab
ility
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♦ Insert piston compressing tool - T10165- so that collar rests
wit
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on plate - T10165/1- .
h re
hole
spec
♦ If pistons are difficult to move, a 13 mm open-end spanner can
es, in part or in w
be used on intended flats -arrow A-.
t to the co
rrectness of i
l purpos
– Insert anti-rattle springs -1- and -2- into brake carrier.
nform
mercia
at
Note om
ion
c
in t
or
Anti-rattle springs -1- and -2- are different. They can only be in‐
his
ate
stalled diagonally to each other.
do
priv
cum
for
en
g
satelettronica
n
t.
– Insert anti-rattle springs -1- and -2- so that guide lugs
yi Co
op
-arrows- on both sides of brake carrier point outwards.
C py
ht. rig
rig ht
py by
– Insert brake pads into brake carrier. co Vo
by lksw
cted agen
Prote AG.
– Ensure that brake pads are seated correctly in anti-rattle

springs -arrows-.
– Secure brake caliper with new self-locking bolts.
Note
♦ Repair kit contains 4 self-locking hexagon bolts for securing

brake caliper. These must be installed under all circumstan‐
ces.
Specified torque
♦ Use new bolts!

Bosch

Touran 2003 ➤
satelettronica
Removing
AG. Volkswagen
This procedure applies waonly
gen to exchanging or ethe
AG do
s no following repair
olks
work on the brake
d by caliper.
V t gu
a
e ran
ris tee
– Loosenuthrear
o wheel nuts/bolts. or
sa ac
– Raise
s
vehicle.
ce
le
un
pt

an
d
itte
y li
rm
ab
– Press level on brake caliper -2- in -direction of arrow-.

pe
ility
ot
wit
– Unhook handbrake cable -1- from lever on brake caliper -2-.

, is n
h re
hole
– Press locking lugs -3- together and remove handbrake cable

spec
-1- from bracket -4- on brake caliper.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Connect bleed bottle bleed hose -1- to brake caliper bleed

com
tion in
valve and open bleed valve.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤

– Release brake hose -1- connection with banjo bolt -2- on brake
caliper.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
satelettronica
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Unscrew bolts -arrows- from brake caliper -1-; to do this coun‐
t to the co
terhold on guide pin.
– Remove brake caliper from brake carrier. rrectness of i
Installing
l purpos

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

m
a
com
brake carrier.
ion in
r
te o
– Secure brake caliper to brake carrier with new self-locking

thi
s
iva
bolts.
do
r
rp
cum
fo
en
g
– Screw brake hose -1- with banjo bolt -2- on brake caliper.
n
t.
yi Co
Cop py
– Remove brake pedal actuator - V.A.G 1869/2- .
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
– Guide handbrake cable -1- through bracket -4- on brake cali‐

per until locking lugs -3- engage.
– Press level on brake caliper -2- in -direction of arrow-.
– Attach handbrake cable -1- to lever -2- on brake caliper.
– Adjust handbrake ⇒ page 96 .
Note

operating position.
Specified torque
satelettronica
♦ Use new bolts!
Brake hose with banjo bolt to brake caliper 35 Nm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
91
co Vo
by lksw
cted 2. Repairing rear brakes
agen
Prote AG.
Touran 2003 ➤
3 Assembly overview - handbrake lever
1 - Handbrake lever
❑ Before removing take
out centre console.
2 - Nut
❑ 15 Nm
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
satelettronica
5 - Compensator
6 - Adjustment nut
❑ Adjusting handbrake
⇒ page 96 . AG. Volkswagen AG d
agen oes
olksw not
y V gu
7 - Handbrake cables d b ara
rise nte
❑ Removing and installing autho eo
ra
up to model year 2007 ss c
⇒ page 92 ce
le
un
pt
an
d

itte
y li
from model year 2008
erm
ab
⇒ page 94
ility
ot p
wit
is n
8 - Handbrake warning switch

h re
ole,
spec
t to the co
rrectne
3.1 Removing and installing handbrake ca‐

ss
ble up to model year 2007

o
cial p
f inform
mer
atio
m
3.1.1 Removing
o
n
c
i
or
n thi
e
– Release handbrake.
t
sd
iva
o
pr
– Remove centre console ⇒ General body repairs, interior; Rep.

um
r
fo
en
gr. 68 ; Compartments, covers and trims .

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Release adjustment nut -1- enough so that relevant hand‐

brake cable -2- can be detached from compensator -3-.
– Lever off spring clip -1-.

– Push lever -2- on brake caliper in direction of arrow and un‐
hook handbrake cable -3-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Unscrew bolt -1- and detach securing clip from handbrake ca‐ s
ce
le
ble -2-.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unhook handbrake cable from retainer -1- and pull out hand‐
brake cable from guide tube -2-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.1.2 Installing
3. Assembly overview - handbrake lever 93

Touran 2003 ➤
– Push handbrake cable into guide tube -2- and hook onto re‐
tainer -1-.
– Push lever -2- on brake caliper in direction of arrow and hook

in handbrake cable -3-.
– Push spring clip -1- on handbrake cable.
satelettronica
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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
– Attach handbrake cable -2- to compensator -3-.

an
itte
y li
erm
– Pretension handbrake cable with adjustment nut -1-.

ab
ility
ot p

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
3.2 Removing and installing handbrake ca‐

m
at
ble from model year 2008

om
ion
c
in t
or
his
ate
do
riv
3.2.1 Removing
p
cum
for
en
ng
t.
– Release handbrake.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
94
Prote AG.
Rep. gr.46 - Brakes - mechanism
Touran 2003 ➤
– Remove centre console ⇒ General body repairs, interior; Rep.

gr. 68 ; Compartments, covers and trims .
– Release adjustment nut -1- enough so that relevant hand‐
brake cable -2- can be detached from compensator -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Push
ss lever on brake caliper -2- in direction of arrow and c un‐
hook handbrake cable -3-.
ce
le
un
pt
an
d
itte
– Press locking lugs -1- together and pull out handbrake cable
y li
erm
ab
from bracket on brake caliper.
ility
ot p
wit
is n
satelettronica
h re
ole,
spec
t to the co
rrectnes
– First pull off handbrake cable -1- from locking lugs, then pull
s o
cial p
out completely from bracket -2-.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unhook handbrake cable from retainer -1- and pull out hand‐
brake cable from guide tube -2-.
3.2.2 Installing

Touran 2003 ➤
– Push handbrake cable into guide tube -2- and hook onto re‐
tainer -1-.
– Push handbrake cable -1- through opening and attach to re‐

tainer -2- securely.
satelettronica
– Push handbrake cable into bracket on brake caliper enough
so that both locking lugs -1- engage.
– Push lever on brake caliper -2- in direction of arrow and hook
in handbrake cable -3-.
G. Volkswagen
The handbrake cable must lksw be installed without tension
agen
A AG do
es n between
the brake caliper bracket
by Vo and the bracket on the trailing
ot g
uaarm.
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Attach handbrake cable -2- to compensator -3-.

, is n
h re
hole
– Pretension handbrake cable with adjustment nut -1-.

spec
es, in part or in w

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
3.3 Adjusting handbrake

thi
te
sd
iva
o
r
rp
cu
New adjustment is only necessary after renewing handbrake ca‐

o
m
f
en
ng
bles and brake calipers. yi

t.
Co
op py
– Depending on equipment version of centre console, remove
t. C rig
gh ht
yri
only cup holder, rear cover or complete centre console ⇒ p by
co Vo
General body repairs, interior; Rep. gr. 68 ; Compartments,
by lksw
cted agen
Prote
covers and trims .
AG.

Touran 2003 ➤
– Firmly depress service brake pedal 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.
AG. Volkswagen AG d
agen
• Handbrake lever in rest position. Volksw
oes
not
gu
by ara
d
– Tighten adjusting nut -arrow (enlargement)- … orise nte
eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
– ... until lever -1- at brake calipers lift off stop (projection) -2-.
his
ate
do
riv
– The total distance -a- to stops -2- on left and right brake cali‐
p
cum
or
pers must not exceed 1.5 mm.

f
en
ng
t.
yi Co
op
– Check that both wheels turn freely.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Vehicles with Bosch rear wheel brake

– Tighten adjusting nut enough so that levers -1- on brake cali‐
pers lift off stop (projection) -2-.
– Distance -a- between lever -1- and stop -2- on left and right
brake calipers should be ≤ 1.5 mm in total.
– Check that both wheels turn freely.
Due to the automatic rear wheel brake adjustment there is no re‐
quirement to adjust the handbrake after making new/initial ad‐
justment.

Touran 2003 ➤
4 Assembly overview - brake pedal
4.1 Assembly overview - brake pedal, left-

hand drive
4.1.1 Assembly overview - brake pedal to Week 45/2005
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
satelettronica
2 - Nut
❑ 25 Nm
moving
❑ Including brake pedal
switch - F47- .
❑ In vehicles from Week
45/2005, the brake light AG. Volkswagen AG d
agen oes
ksw not
switch - F- is located on byV
ol
gu
ara
the brake master cylin‐ rised
nte
der ⇒ page 124 . aut
ho eo
ra
s c
❑ Grease head of push s
ce
le
rod with polycarbamide

un
pt
an
d
grease G 052 142 A2.

itte
y li
rm
ab

pe
ility
brake light switch - F- to

ot
wit
, is n
Week 45/2005
h re
⇒ page 99
hole
spec
4 - Bolt
es, in part or in w
t to the co
5 - Brake pedal
6 - Cap
rrectness of i
7 - Bearing shell
l purpos
8 - Mounting
nform
ercia
❑ For ball head of brake

servo plunger rod.
m
a
com
tio
9 - Nut
n in
r
te o
❑ 25 Nm
thi
s
iva
do

r
rp
cum
moving
fo
en
ng
t.
yi Co
10 - Bearing bush ht. Cop py
rig
rig ht
11 - Pivot pin py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
4.1.2 Assembly overview - brake pedal from Week 45/2005
WARNING
AG. Volkswagen AG d
agen oes
olksw not
The brake pedal travel must notebe d b restricted by additional floor
yV gu
ara
coverings. horis nte
eo
aut ra
ss c
ce
e
nl
Grease all bearing points with polycarbamide grease - G 052 142
pt
du
an
A2- before installing.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
⇒ page 103
es, in part or in w
t to the co
2 - Nut
❑ 25 Nm
rrectness of i
moving
l purpos
❑ First tighten hexagon
satelettronica
nuts -A and B-.
nf
ercia
o
3 - Noise insulation on brake
rm
m
pedal
atio
om
n in
❑ Allocation ⇒Electronic
or c
thi
Parts Catalogue (ETKA)
te
sd
iva
o
r
4 - Lock washer
rp
cu
o
m
f
en
ng
5 - Brake pedal
t.
yi Co
op py
t. C rig
gh ht
yri
⇒ page 102 p by
o Vo
by c lksw
cted agen
6 - Nut Prote AG.
❑ 25 Nm
moving
7 - Cap
8 - Bearing shell
9 - Mounting
❑ For ball head of brake
servo plunger rod.
10 - Bolt
11 - Bearing bush
12 - Pivot pin
4.1.3 Removing and installing brake light

switch - F- to Week 45/2005
Including brake pedal switch - F47-
On vehicles from Week 45/2005, the brake light switch - F- is lo‐
cated on the brake master cylinder ⇒ page 124 .
4. Assembly overview - brake pedal 99

Touran 2003 ➤
4.1.4 Brake light switch - F- , old version
Note
♦ After removing the old brake light switch - F- (see figure

N46-0359), replace it with a new one (see figure N46-10145).
♦ Distinguishing features ⇒ page 101 .
Removing
– Remove trim on driver's side ⇒ General body repairs, interior;
Rep. gr. 70 ; Dash panel
– If necessary, remove footwell vent ⇒ Heater, air conditioning
system; Rep. gr. 80 ; Repairing heater; Removing lks wage .
vent es n
Vo ot g
by ua
ed ran
– Pull connector off brake light switch. oris tee
th or
au
Brake light switch - F- should only be operating removed
ss with the ac
rod pressed in (brake pedal not pressed), otherwise the locking
ce
e
nl
pt
mechanism of the brake light switch - F- will be damaged.
du
an
itte
y li
erm
satelettronica
– Remove brake light switch - F- by turning 45° to left.
ab
ility
ot p
Installing, adjusting and locking
wit
, is n
h re
hole
spec
es, in part or in w
Since the old brake light switch - F- may no longer be used, the
t to the co
description is not included here.
Install, adjust and lock new brake light switch - F- ⇒ page 101 .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
4.1.5 Brake light switch - F- , new version
Note
♦ Use only new brake light switches - F- .

♦ The most noticeable difference
to the old brake light switch - F- is the new, bright tip of the
plunger head -A-.
Removing
– Remove trim on driver's side ⇒ General body repairs, interior;
– If necessary, remove footwell vent ⇒ Heater, air conditioning
system; Rep. gr. 80 ; Repairing heater; Removing vent .
– Pull connector off brake light switch - F- .
Brake light switch - F- should only be removed with the operating
rod pressed in (brake pedal not pressed), otherwise the locking
mechanism of the brake light switch - F- will be damaged.
satelettronica
– Remove brake light switch - F- by turning 45° to left.
Installing, adjusting and locking
. Volkswagen AG
gen AG d
Install in reverse order.
Vol
ksNote
wa the following points:
oes
not
y gu
db a
Before installing
or
isbrake
e light switch - F- , grease bright tipraof
nteplung‐
eo
er head withaupolycarbamide grease G 052 142 A2.
th
ra
ss c
• The brake pedal must remain in the rest position while the
ce
e
nl
pt
brake light switch - F- is being installed. The brake pedal must

du
an
itte
not be touched by anything other than the plunger head of the

y li
erm
ab
brake light switch - F- throughout the entire installation.

ility
ot p
wit
, is n
– Guide brake light switch - F- through assembly opening

h re
hole
-arrow 1- and press plunger against pedal. Then turn brake

spec
light switch - F- 45° clockwise -arrow 2- until it can be felt to

es, in part or in w
t to the co
engage.
– Fit brake light switch - F- connector.
rrectness of i
– Check function of brake light.

l purpos
– Install footwell vent ⇒ Heating and air conditioning system;

Rep. gr. 80 ; Repairing heating; Removing vents .
nf
ercia
– Install trim on driver's side ⇒ General body repairs, interior;

orm

m
atio
om
n in
or c
thi
e
4.1.6 Separating brake pedal from, and clip‐

t
sd
iva
o
r
rp
cu
ping to, brake servo

o
m
f
en
ng
t.
yi Co
Special tools and workshop equipment required t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
♦ Release tool - T 10159-
Separating
– Pull out stowage compartment from mountings of left trim on
driver side.
– Remove knee airbag from bracket ⇒ General body repairs,
interior; Rep. gr. 69 ; Removing and installing knee airbag .
– Remove footwell vent ⇒ Heater, air conditioning system; Rep.
gr. 80 ; Repairing heater; Removing vent .
satelettronica
– First press brake pedal in direction of brake servo and hold.
2 - Push rod
wage
3- Retaining lugs yV
o lks es n
ot g
b ua
ed ran
– Insert release tool - T 10159-hoand
ris pull in direction of driver seat. tee
When doing this, counterholds aut
on brake pedal (at this stage, or
ac
brake pedal must not be allowed to move backwards). This
s
ce
le
action will press retaining lugs -3- of mounting off ball head of
un
pt
an
d
plunger rod -2-.

itte
y li
rm
ab
For the sake of clarity, separation of brake pedal from brake servo
pe
ility
is shown with pedal cluster removed.

ot
wit
, is n
h re
– Pull release tool - T 10159- and brake pedal together towards

hole
spec
driver seat. (This action will pull the brake pedal off the ball
es, in part or in w
head of the plunger rod).

t to the co
Clipping brake pedal to brake servo

rrectness of i
l purpos
– Hold ball head of plunger rod in front of mounting and push

nform
ercia
brake pedal in direction of brake servo, so that the ball head

clicks into place.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.1.7 Removing and installing brake pedal

Removing
driver side.

lkswage es n
o ot g
byV ua
d ran
o
ir se teTouran
eo 2003 ➤
th
au Brake systems - Edition
ra
c 07.2013
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– If fitted, remove noise insulation from brake pedal
spec
⇒ Item 3 (page 99) .
t to the co
– Separate brake pedal from brake servo ⇒ page 101 .
– Remove brake pedal.
rrectne
Installing
s
s o
cial p
f i
– Clip brake pedal to brake servo ⇒ page 101 .
nform
mer
4.1.8 Removing and installing mounting
atio
om
n
bracket
c
i
or
n thi
te
sd
va
Removing
i
o
pr
cum
r
fo
en
ng
t.
yi
driver side.
Co
op
satelettronica
C py
t. rig
gh
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
– Remove knee airbag retainer ⇒ General body repairs, interior;
Rep. gr. 69 ; Removing and installing knee airbag retainer .
– If fitted, remove noise insulation from brake pedal
⇒ Item 3 (page 99) .
– Remove mounting bracket.
Installing
4.2 Assembly overview - brake pedal, right-

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

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

A2- before installing.

Touran 2003 ➤
1 - Bolt
❑ 25 Nm
(RHD) ⇒ page 106
3 - Bolt
❑ 25 Nm
4 - Nut
❑ 25 Nm
moving
5 - Bearing bush
6 - Nut
❑ 25 Nm
moving
7 - Brake pedal
satelettronica
(RHD) ⇒ page 105
8 - Cap
9 - Pivot pin
10 - Bearing bush
11 - Bolt
AG. Volkswagen AG d
12 - Bearing shell agen oes
olksw not
V gu
by ara
13 - Mounting rised
nte
ho eo
❑ For ball head of brake aut ra
c
servo plunger rod. ss
ce
e
nl
❑ Separating and joining

pt
du
an
itte
(clips) brake pedal on

y li
erm
ab
brake servo ⇒ page 104

ility
ot p
wit
, is n
h re
hole
4.2.2 Separating brake pedal from, and clip‐

spec
es, in part or in w
ping to, brake servo

t to the co

rrectness of i
♦ Release tool - T 10159-

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
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Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d Brake systems - Edition 07.2013
agen oes
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Separating byV gu
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– First pressaut brake pedal in direction of brake servo and hold.
h eo
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2 - Push rod
ce
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un
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3 - Retaining lugs
itte
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erm
ab
– Insert release tool - T 10159- and pull in direction of driver seat.
ility
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When doing this, counterhold on brake pedal (at this stage,
wit
is n
brake pedal must not be allowed to move backwards). This
h re
ole,
action will press retaining lugs -3- of mounting off ball head of
spec
plunger rod -2-.
t to the co
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
rrectne
– 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).
ss o
cial p
f
Clipping brake pedal to brake servo
inform
mer
atio
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n
c
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satelettronica
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– Hold ball head of plunger rod in front of mounting and push

iv
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brake pedal in direction of brake servo, so that the ball head
um
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ng
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4.2.3 Removing and installing brake pedal

Removing
– Unscrew nut -1-.
– Pull out pin -2- and remove complete clip.
– Slide footwell trim -3- upwards in -direction of arrow- and re‐
move.

Touran 2003 ➤
– Remove bolt -1- for brake pedal anti-clockwise.

– Use nut -arrow- to counterhold.
– Remove brake pedal.
Installing
– Install in reverse order. Note the following points:
Specified torque AG. Volkswagen AG d

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Component rise
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th or
Brake pedal on mounting bracket
au ac25 Nm
♦ Use new nut ss
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4.2.4 Removing and installing mounting ility

ot
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bracket h re
hole
spec
es, in part or in w
Removing
t to the co
– Unscrew nut -1-.

– Pull out pin -2- and remove complete clip.
rrectness of i
– Slide footwell trim -3- upwards in -direction of arrow- and re‐

l purpos
move.
nform
ercia
– Remove brake pedal ⇒ page 105 .

m
a
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tion in
– Remove crash strut.

r
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– Remove bolt -1- from brake servo -2-. t. C rig
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Prote AG.

Touran 2003 ➤
– Unscrew bolt -1- on the right above the brake pedal support.
– Unscrew nut -2- on left beneath brake pedal support.
– Remove the mounting bracket.
Installing
AG. Volkswagen AG d
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Specified torque rise nte
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Component ss Specified torque c
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Brake servo to mounting bracket and bulkhead 25 Nm
pt
du
an
♦ Use new bolts
itte
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Mounting bracket to bulkhead 25 Nm
wit
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♦ Use new nut and bolt
h re
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spec
es, in part or in w
t to the co
rrectness of i
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ion
c
in t
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do
priv
cum
for
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t.
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Cop py
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by lksw
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Prote AG.

Touran 2003 ➤
Brake systems - Edition 07.2013 agen
AG. Volkswagen AG d
oes
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47 – Brakes - hydraulics
ris nte
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nl
pt
du
1 Repairing front brake caliper
an
itte
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wit
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1.1 Repairing brake caliper FN 3
h re
hole
spec
es, in part or in w
t to the co
1 - Dust cap
❑ Fit onto bleeder valve.
rrectness of i
2 - Bleeder valve
❑ 10 Nm
l purpos
❑ Before screwing in, ap‐

ply thin coat of assembly
nf
ercia
paste - G 052 150 A2- to
orm
thread.
m
atio
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n in
3 - Cover caps
or c
thi
e
❑ Insert into sleeve bear‐
satelettronica
t
sd
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ing.
o
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rp
cu
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f
en
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4 - Guide pin yi
t.
Co
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❑ 30 Nm
C py
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5 - Bearing bush co Vo
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❑ Insert into brake caliper. Prote AG.
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
⇒ page 108
10 - Piston
⇒ page 108
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to piston
before installing.
11 - Protective cap
❑ Take care not to damage when inserting piston.
1.2 Removing and installing piston for brake

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

Touran 2003 ➤
♦ Removal wedge - 3409-
♦ Piston resetting appliance - T 10145-
satelettronica
♦ Assembly tool for protective caps - T 10146/6-
lkswage es n
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Removing
wit
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hole
– Press piston out of brake caliper using compressed air.

spec
es, in part or in w
Place a piece of wood in the recess to prevent damage to the

t to the co
piston.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
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for
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Prote AG.
1. Repairing front brake caliper 109

Touran 2003 ➤
– Lever off protective cap from brake caliper using removal

wedge - 3409- .
– Remove seal using removal wedge - 3409- .

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

pe
ility
correctly all around using assembly tool -1- and piston reset‐
ot
wit
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ting appliance - T10145- -2-.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
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Prote AG.

Touran 2003 ➤
ag
Brake
en AG. Vsystems -
olkswagen A Edition
G do 07.2013
w es n
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Check seat of protective cap: ris
ed
b ran
tee
tho or
– At this stage it should not be possible to remove protective
au cap ac
ss
from brake caliper by hand.
ce
le
un
pt
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d
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rm
ab
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Press piston lightly onto protective seal and lock it in this po‐
sition using assembly wedge -2-, for example. l purpos
Keep piston straight to prevent damage to sealing collar.
nform
ercia
– Blow out protective cap using compressed air (max 3 bar)

-1-. During this step protective cap will spring on piston.
m
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tion in
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Cop py
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– Press piston into brake caliper using piston resetting tool -
by lksw
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T10145- -1-.
AG.
The outer sealing lip on the protective cap will then slip into the
piston groove.
1.2.1 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.
1. Repairing front brake caliper 111

Touran 2003 ➤
2 Repairing rear brake caliper
2.1 Assembly overview - brake caliper CII 41

15 inches from Week 32/2004:
1 - Brake caliper
❑ With handbrake cable
lever
❑ If there is a leak at hand‐
brake cable lever, re‐
new brake caliper.
❑ Following repair work, n AG. Volkswagen AG do
pre-bleed brake caliper olkswage es n
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⇒ page 115 . db
yV ua
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ris tee
2 - Dust cap tho or
au ac
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3 - Bleeder valve
ce
le
un
pt
satelettronica
❑ 10 Nm
an
d
itte
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rm
ab
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ility
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paste - G 052 150 A2- to
wit
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thread.
hole
spec
4 - Bolt
es, in part or in w
t to the co
❑ 35 Nm
moving
rrectness of i
❑ When loosening and

l purpos
tightening, counterhold
on guide pin.
nform
ercia
5 - Guide pin
m
❑ With steps
a
com
tion in
❑ Shorter than item 6

r
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❑ Grease before fitting

s
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protective cap.
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6 - Guide pin
n
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❑ Longer than item 5
C py
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❑ Grease before fitting p by
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Prote AG.

Touran 2003 ➤
protective cap.
AG. Volkswagen AG d
7 - Protective cap agen oes
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❑ Fit onto brake carrier and guide pin. rised ara
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8 - Brake carrier with balance weight aut ra
ss c
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an
❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
d
itte
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guide pins.
erm
ab
ility
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9 - Protective cap
wit
is n
h re
❑ Pull on so that outer sealing lip goes over piston.
ole,
spec
t to the co
10 - Piston with automatic adjustment
rrectne
❑ Apply thin coat of assembly paste - G 052 150 A2- to piston before inserting.
11 - Sealing ring
ss
o
cial p
f inform
mer
satelettronica
atio
m
2.2 Removing and installing piston for brake

o
n
c
i
or
n
caliper CII 41
thi
te
sd
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pr
c
um
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ng
t.
♦ Resetting and removal tool - T 10165-
yi Co
Cop py
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Prote AG.
2. Repairing rear brake caliper 113

Touran 2003 ➤
– Screw piston out of brake caliper by turning thumb wheel anti-

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

Installing
Install in reverse order. In the process, note the following:
G. Volkswagen AG d
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agen
A
oes
satelettronica
l not
and seal before installing. by
Vo gu
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th
au ra
c
ss
ce
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nl
pt
du
an
itte
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– Place protective cap with outer sealing lip onto piston.
erm
ab
ility
ot p
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
wit
, is n
inder groove.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
When doing this, hold piston in front of brake caliper.

m
at
om
io
– Screw in piston by turning thumb wheel clockwise.

n
c
in t
or
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ate
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for
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

Touran 2003 ➤
– Use plate of resetting tool - T10165/1- as an aid to screw in.

– Insert piston resetting tool - T10165- in such a way that collar
rests on piston.
If the piston is pushed back with piston resetting tool - T10145- or
by operating the foot brake, the automatic adjustment in the brake
caliper will be destroyed.

AG. Volkswagen AG d
– Open bleeder valve -arrow A- and, using a commerciallylkavail‐ wage
n oes
o s not
able bleeder bottle, fill with brake fluid until bubble-free by brake
V gu
ara
fluid flows from threaded hole of brake hose connection ed nte
oris eo
-arrow B-. Close bleeder valve. au
th ra
ss c
ce
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nl
pt
du
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satelettronica
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.3 Assembly overview - Bosch brake caliper
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
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for
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t.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.

Touran 2003 ➤
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 119
2 - Bleeder valve
❑ 10 Nm
paste - G 052 150 A2- to
thread.
3 - Dust cap
4 - Bolt
❑ 35 Nm
❑ Self-locking
❑ Renew
satelettronica
❑ When loosening and
tightening, counterhold
on guide pin.
5 - Upper guide pin agen
AG. Volkswagen AG d
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❑ Grease before fitting d byV gu
ara
protective cap. orise nte
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ut
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parts catalogue “ETKA”
ce
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nl
pt
du
an
6 - Deflector cap
itte
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erm
ab
❑ Fit onto brake carrier

ility
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and guide pin.

wit
, is n
h re
7 - Lower guide pin

hole
spec
❑ With recess.
es, in part or in w
t to the co
❑ Grease before fitting protective cap.

rrectness of i
8 - Guide grommet
❑ On lower guide pin.
l purpos
9 - Brake carrier
nform
ercia

❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
m
at
om
guide pins.
on
c
in t
or

his
ate
do
riv
10 - Deflector cap
p
cum
for
❑ Pull on so that outer sealing lip goes over piston.

en
ng
t.
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op
❑ Removing and installing ⇒ page 117 C py
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11 - Piston with automatic adjustment
py by
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Prote AG.
❑ Apply thin coat of assembly paste - G 052 150 A2- to piston before inserting.
12 - Sealing ring

Touran 2003 ➤
2.4 Removing and installing brake caliper

piston, Bosch
♦ Piston compressing tool - T10165-
satelettronica
AG. Volkswagen AG d
agen oes
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Removing ed byV gu
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WARNING ss c
ce
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un
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It is only permissible to change the position of the brake piston

an
d
itte
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with the piston compressing tool - T10165- .

erm
ab
ility
ot p
wit
is n
h re
– Screw piston out of brake caliper by turning thumb wheel anti-

ole,
clockwise.
spec
t to the co
Insert piston compressing tool - T10165- so that collar rests on

piston.
rrectne

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

Touran 2003 ➤

Installing
and seal before installing.
– Place protective cap with outer sealing lip on piston.
satelettronica
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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– Screw in piston by turning thumb wheel on piston compressing

wit
, is n
tool - T10165- clockwise. Do not damage protective cap.

h re
hole
spec
– Use plate - T10165/1- for assistance when screwing in.

es, in part or in w
t to the co
♦ Insert piston compressing tool - T10165- so that collar rests

on plate - T10165/1- .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

Touran 2003 ➤

Carry out the following work:
– 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
nte
satelettronica
ris
ho eo
aut ra
ss c
ce
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un
pt
an
d
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rm
ab
pe
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

Touran 2003 ➤
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:
satelettronica
Brake system ( ABS hydraulic unit - N55- , brake hoses, brake
lines and brake calipers) working OK and not leaking.
– 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 Aby
G. Vmore
olkswathan 4dbar
gen AG
agen
within the test period of 45 seconds.
Volksw Renew brake master
oes
cyl‐
not
inder if drop in pressure exceeds
ed by specification. gu
ara
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
4 Bleeding brake system

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

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

fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
satelettronica
A pre-pressure of 2 bar is required for bleeding the ABS hydraulic
unit - N55- .
4.1 Bleeding brake system with the brake

filling and bleeding equipment - VAS
5234-
♦ Brake filling and bleeding equipment - VAS 5234- olkswage es n
ot g
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d ran
ir se tee
tho
u or
a ac
ss
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un
pt
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d
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
♦ Tool set for brake bleeding - VAS 6564-

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
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Prote AG.
4. Bleeding brake system 121

Touran 2003 ➤
WARNING
Only use new brake fluid conforming to VW standard

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

Adhere strictly to work sequence when bleeding brake system.
– Connect brake filling and bleeding equipment - VAS 5234- .
. Volkswagen AG
Use suitable bleeder hose. It must sit tightly on the bleeder valve wage
n AG does
so that no air can enter the brake system. Volks not
gu
by ara
ed nte
ris
– Connect bleeder bottle -1-. tho eo
au ra
c
– Open bleeder valves in specified order and bleed ss cali‐
brake
ce
le
pers. un
pt
an
d
itte
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1 - Front left brake caliper
erm
ab
ility
ot p
2 - Front right brake caliper
wit
is n
h re
satelettronica
3 - Rear left brake caliper
ole,
spec
4 - Rear right brake caliper
t to the co
– Leave bleeder valve of each brake caliper open with bleeder
hose fitted until brake fluid discharges free of air bubbles.
rrectne
4.1.2 Subsequent bleeding
ss
Carry out subsequent bleeding when:
o
cial p
f inform
♦ brake pedal travel is too long or so-called »soft brake pedal«
mer
atio
♦ if a chamber in the brake fluid reservoir in vehicles with EDL,
om
n
EDL/TCS or EDL/TCS/ESP is completely empty. This occurs
c
i
or
n thi
e.g. in the case of brake system leaks.
te
sd
iva
o
r
Subsequent bleeding requires the assistance of a second me‐

p
cum
r
fo
chanic:
en
ng
t.
yi Co
op
– Depress brake pedal firmly and hold.
C py
t. rig
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yri by
– Open bleeder valve on brake caliper. cop Vo
by lksw
cted agen
Prote
– Fully depress brake pedal.
AG.
– 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

Touran 2003 ➤
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 ⇒ Maintenance ; Booklet ; Brake and clutch
system: Changing brake fluid
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
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te
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iva
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Cop py
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rig ht
py by
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cted agen
Prote AG.
4. Bleeding brake system 123

Touran 2003 ➤
5 Brake servo and brake master cylin‐

der olkswage
es n
o
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ut
5.1 Assembly overview - brake servo/brake master cylinder to Week 22/2008,
ss
a ra
c
LHD
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
h re
Use only new brake fluid. Observe information on brake fluid reservoir!
hole
spec
es, in part or in w
t to the co
1 - Pedal cluster
2 - Nut
rrectness of i
❑ 25 Nm
l purpos

moving
nform
ercia
satelettronica
3 - Seal
m
a
com
t
ion in
r
te o
4 - Brake servo
thi
s
iva
❑ On petrol engines, the do

r
rp
cum
required vacuum is tak‐

fo
en
ng
en from the intake mani‐

t.
yi Co
op
fold. C py
t. rig
gh ht
yri
❑ Certain vehicles with a p by
co Vo
petrol engine and an au‐
by lksw
cted agen
Prote
tomatic gearbox are
AG.
equipped with a brake

vacuum pump - V192- .
⇒ page 136
❑ A vacuum sender is fit‐
ted in vehicles with HBV
⇒ page 136 .
❑ Diesel engines are fitted
with an vacuum pump to
create the required vac‐
uum ⇒ page 130 .
– 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.
❑ Replace completely in the event of a fault (before doing so, check brake servo vacuum system)
⇒ page 131
5 - Sealing ring
6 - Brake servo vacuum sender - G483-
❑ Only on vehicles having HBV

Touran 2003 ➤
7 - Brake master cylinder without brake light switch - F-
8 - Brake master cylinder with brake light switch - F-
AG. Volkswagen AG d
❑ Allocation ⇒ Electronic Parts Catalogue
lksw
agen(ETKA) . oes
not
Vo gu
❑ Cannot be repaired. If faulty,edrenew as a complete unit.
by ara
nte
ris
❑ Removing and installingut⇒ h page 141
o eo
r a ac
ss
ce
e
nl
pt
du
an
itte
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❑ In vehicles prior to Week 45/2005, the brake light switch - F- is located on the brake pedal ⇒ page 98 .
erm
ab
ility
ot p
wit
, is n
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10 - Bolt
hole
spec
❑ 5 Nm
es, in part or in w
t to the co
11 - Heat shield
satelettronica
12 - Nut
rrectness of i
❑ 25 Nm
l purpos

13 - Brake line
nf
ercia
❑ 14 Nm
orm
m
atio
❑ Brake master cylinder/secondary piston circuit to ABS hydraulic unit - N55- .
om
n in
c
14 - Brake line
or
thi
te
sd
a
❑ 14 Nm
iv
o
r
rp
cu
❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .
o
m
f
en
ng
t.
yi Co
15 - Sealing plug . Cop py
rig
ht
❑ Moisten with brake fluid and press into brake fluid reservoir. rig ht
py by
co Vo
by lksw
16 - Brake fluid reservoir cted agen
Prote AG.
17 - Cap with brake fluid level warning contact - F34-

18 - Sealing plug
19 - Vacuum hose
20 - Brake servo pressure sensor - G294-
❑ In vehicles with an FSI engine without HBV (hydraulic brake with vacuum servo)
5. Brake servo and brake master cylinder 125

AG. Volkswagen AG d
agen oes
Touran 2003 V➤ olks
w not
gu
by
Brake systems
ris
ed - Edition 07.2013 ara
nte
tho eo
au ra
5.2 ss
Assembly overview - brake servo/brake master cylinder from Week c
ce
e
nl
22/2008, LHD
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 - Pedal cluster
rrectness of i
2 - Nut
l purpos
❑ 25 Nm
moving
nf
ercia
orm
3 - Seal
m
atio
om
n in
or c
thi
e
4 - Brake servo
t
sd
iva
o
r
rp
cu
❑ On petrol engines, the
o
satelettronica
f
required vacuum is ei‐ en

ng
t.
yi
ther taken from the in‐
Co
Cop py
take manifold or gener‐
t. rig
gh ht
yri
ated by a mechanical p by
co Vo
lksw
vacuum pump.
by
cted agen
Prote AG.
❑ Some vehicles with a
petrol engine and a dual
clutch gearbox which
are not equipped with a
HBV (hydraulic brake
with vacuum servo)
have a vacuum pump
for brakes - V192-
⇒ page 136 .
with an vacuum pump to
create the required vac‐
uum ⇒ page 130 .
firmly several times (to
exhaust vacuum in unit).
– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake servo is functioning properly, the brake pedal will be felt to go down as the servo
takes effect.
⇒ page 131
5 - Sealing ring

Touran 2003 ➤
8 - Bolt
❑ 5 Nm
9 - Clip
10 - Heat shield
11 - Nut
❑ 25 Nm
12 - Brake line
❑ 14 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
13 - Brake line
❑ 14 Nm
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
14 - Sealing plug
satelettronica
17 - Vacuum hose
18 - Vacuum sender - G608-
AG. Volkswagen AG d
❑ Vehicles HBS agen oes
olksw not
y V gu
ris
ed b
⇒ page 135 ara
nt ee
tho or
au ac
Note ss
ce
e
nl
pt
du
On some vehicles with no HBV (hy‐

an
itte
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draulic brake with vacuum servo), a

erm
ab
brake servo pressure sensor -

ility
ot p
G294- is fitted.
wit
, is n
h re
hole
❑ Removing and installing brake servo pressure sensor - G294- ⇒ page 135 .
spec
es, in part or in w
19 - Sealing plug
t to the co

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

Touran 2003 ➤
5.3 Assembly overview - brake servo/brake master cylinder (right-hand drive

vehicle)
Note
1 - Pedal cluster
2 - Hexagon bolt
❑ 25 Nm
3 - Nut
❑ 25 Nm
moving
4 - Seal
satelettronica
5 - Brake servo
⇒ page 150
❑ On petrol engines, the
required vacuum is ei‐
ther taken from the in‐
take manifold or gener‐
ated by a mechanical
vacuum pump.
❑ Some vehicles with a
petrol engine and a dual
clutch gearbox, which agen
AG. Volkswagen AG d
oes
are not equipped with a olksw not
V gu
by
HBV (hydraulic brake ised ara
nte
with vacuum servo), ut
hor eo
have a vacuum pump ss a ra
c
for brakes - V192-
ce
le
un
pt
an
d
itte
y li
with a vacuum pump to
erm
create the required vac‐ ab

ility
ot p
uum wit
is n
h re
ole,
spec

t to the co

firmly several times.
(This will release the vacuum in the unit.)
rrectne
properly, the brake pedal will be felt to go down as the servo takes effect
ss o
cial p
f in
⇒ page 131
form
mer
atio
6 - Sealing ring
om
n
c
7 - Vacuum sender - G608-

or
n thi
te
sd
a
❑ Only on vehicles having HBV

iv
o
pr
cum
r

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
Note
On some vehicles with no HBV (hy‐

draulic brake with vacuum servo), a
brake servo pressure sensor -
G294- is fitted. AG. Volkswagen AG d
agen oes
o lksw not
byV gu
❑ Removing and installing brake servo pressure sensor
rised - G294- ⇒ page 135 . ara
nte
ho eo
ut
8 - Sealing plug ss a ra
c
ce
e
nl
pt
du
an
itte
9 - Vacuum hose
y li
erm
ab
ility
ot p
wit
10 - Brake master cylinder , is n
h re
hole
spec
es, in part or in w
t to the co
11 - Heat shield
rrectness of i
12 - Nut
satelettronica
l purpos
❑ 50 Nm
13 - Bolt
nf
ercia
or
❑ 25 Nm
m
m
atio
om
14 - Brake line
n in
or c
thi
❑ 14 Nm
te
sd
iva
o
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
r
rp
cu
o
m
f
en
ng
15 - Bolt
t.
yi Co
op py
❑ 5 Nm
. C rig
ht ht
rig by
py
16 - Clip
co Vo
by lksw
cted agen
Prote AG.
18 - Bolt
❑ 4 Nm
19 - Sealing plug
22 - Brake line
❑ 14 Nm
❑ From primary piston circuit of brake master cylinder to hydraulic unit.

Touran 2003 ➤
5.4 Overview - vacuum pump for brake ser‐

vo (diesel vehicles)
Exhauster pump for 4-cylinder diesel engine (2-valve):
Must not be dismantled.
Tandem pump -1- (vacuum 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):

Tandem pump -4- (vacuum pump and fuel pump)
satelettronica
Fuel lines -2 and 3-.
– Removing and installing tandem pump ⇒ 4-cyl. diesel engine AG. Volkswagen AG d
(4-valve); Rep. gr. 20 ; Removing and installing parts of fuel lksw
agen oes
not
supply system . d by Vo gu
ara
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Vacuum pump for 4-cyl. 2.0 l diesel engine (common rail) utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Vacuum pump -1-
wit
is n
h re
ole,
spec
– Removing and installing vacuum pump ⇒ 4-cylinder diesel
t to the co
engine (2.0 l engine, common rail); Rep. gr. 15 .
rrectness o
cial p
f inform
mer
5.5 Vacuum pump for brake servo (vehicles

atio
om
with 2.0 l petrol engine)

n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
Vacuum pump -1-

en
ng
t.
yi Co
op
Vacuum hose to brake servo -2- with non-return valve. C py
t. rig
gh ht
yri by
High-pressure pump -3-. cop Vo
by lksw
cted agen
Prote
– Removing and installing vacuum pump ⇒ Rep. gr. 15 .
AG.

Touran 2003 ➤
5.6 Checking brake servo vacuum system

The following instructions are intended to help you find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or in the event of a so-called »hard brake
pedal«.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if there is one)
Volkswa
When evaluating the measuring results, bear ain
gemind
n AG. that they willdoes
gen AG
ksw
be influenced by the geographical location.
by Vol The higher your lo‐ not
gu
ara
cation is above sea level, the lower
ris the air pressure will be.
ed
nte
tho eo
Before checking the vacuumsssystem,
au please take note of the fol‐ ra
c
lowing prerequisites for checking:
ce
e
nl
pt
du
an
satelettronica
♦ Visual inspection of all vacuum hoses for damage (e.g. cracks
itte
y li
or marten bite) and to check that they are correctly and firmly
erm
ab
attached
ility
ot p
wit
, is n
♦ Ensure cleanliness when working on vacuum system
h re
hole
spec
♦ Before starting work, clean engine compartment if necessary
es, in part or in w
t to the co
♦ Vacuum gauge for brake servo - VAS 6721-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
5.6.1 Connecting vacuum gauge for brake
p by
co Vo
by lksw
cted
servo - VAS 6721-
agen
Prote AG.
– Pull vacuum hose out of brake servo.

First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.

Touran 2003 ➤
– Place brake servo vacuum gauge - VAS 6721- between them

-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if there is one, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-
C Cut- In direction of brake servo

off
valve
– Push hose -A- of brake servo vacuum gauge - VAS 6721- onto
vacuum hose and press adapter -C- into brake servo.
satelettronica
lkswage es n
o ot g
5.6.2 Checking vacuum generation ir se
d byV ua
ran
tee
tho
u or
a ac
ss
Note
ce
le
un
pt
an
d
itte
y li
♦ The average air pressure of the earth's atmosphere at sea

erm
ab
level is 1013 mbar and decreases steeply as the altitude in‐

ility
ot p
creases (approx. 100 mbar/1,000 m altitude). Local and time

wit
is n
fluctuations also influence vacuum generation.

h re
ole,
spec
♦ A cold engine, a switched-on air-conditioning system as well

as engine idling have an adverse influence on generation of a

t to the co
vacuum.
rrectne
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
ss o
cial p
– Connect brake servo vacuum gauge - VAS 6721-

in
⇒ page 131 .
form
mer
atio
– Open cut-off valve -A-.

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Close cut-off valves -B+C-.

– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
– Read indicated measured value.
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for leaks. gen AG
. Volkswagen AG
a does
lksw n
– For comparison purposes,
db
yV
o
generate the vacuum with
ot g
uthe
ara man‐
ual vacuum pump
or
ise - VAS 6213- ⇒ page 135 . nte
h eo
ut r
Open cut-offssvalve
a -B- to facilitate removal of hose connectionsac
and adapter.
ce
e
nl
pt
du
an
itte
y li
5.6.3 Checking for leaks
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
satelettronica
es, in part or in w
♦ The average air pressure of the earth's atmosphere at sea
t to the co
level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
rrectness of i
♦ A cold engine, a switched-on air-conditioning system as well
l purpos
as engine idling have an adverse influence on generation of a

vacuum. nform
ercia
– Before starting work, check all vacuum hoses for damage (e.g.
m
at
om
cracks or marten bite) and to check that they are correctly and
on
c
in t
firmly attached
or
his
ate
– Connect brake servo vacuum gauge - VAS 6721-

do
priv
⇒ page 131 .
um
for
en
ng
t.
yi
– Open cut-off valve -A-.
Co
Cop py
ht. rig
– Close cut-off valves -B+C-. rig ht
py by
co Vo
by lksw
– Start warm engine (>60° C), press accelerator briefly (engine
cted agen
Prote AG.
speed greater than 2000/min).
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).

Touran 2003 ➤ agen
AG. Volkswagen AG d
oes
ksw not
Brake systems - Edition 07.2013 by Vol
gu
ara
d
rise nte
o eo
– Open cut-off valve -C- to evacuate brake servo. auth
ra
ss c
– Switch off engine.
ce
le
un
pt
an
d
– Read and make a note of measured value shown.
itte
y li
rm
ab
pe
A vacuum decrease of 400 mbar in 12 hours is permissible.
ility
ot
wit
, is n
If the vacuum decrease is greater, check for leaks in the vicinity
h re
of...
hole
spec
es, in part or in w
1- Brake servo
t to the co
or
2- non-return valve, vacuum hoses with connectors or vacuum
rrectness of i
pump/intake pipe
l purpos
.
If there are large leaks, the vacuum decreases steeply within a
nform
ercia
few seconds.
m
a
com
ti
Vacuum check in vicinity of brake servo:
on in
r
te o
thi
s
– After generation of vacuum, close cut-off valve -A- in order to
iva
do
r
check brake servo vacuum system.

rp
satelettronica
cum
fo
en
ng
Vacuum check in vicinity of non-return valve, vacuum hoses with

t.
yi Co
op
connectors and vacuum pump/intake pipe:
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– After generation of a vacuum, close cut-off valve -C- in order

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

Touran 2003 ➤
5.6.4 Vacuum generation with manual vac‐

uum pump - VAS 6213-
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump - VAS 6213- in certain cases.
– To do this, connect manual vacuum pump - VAS 6213- to vac‐
uum hose from connection -B- on brake servo vacuum gauge
- VAS 6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump - VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge - VAS 6721- .
– Then, carry out the corresponding
wage
n AG. Volkswachecks.
gen AG
doe
ks s no
Vol t gu
d by ara
5.7 Checking non-return valve
e nte
ris
utho eo
ra
a c
♦ Air must
ss pass through non-return valve -A- in direction of ar‐
ce
e
row.
nl
pt
du
an
itte
satelettronica
y li
♦ Non-return valve must remain closed in opposite direction.
erm
ab
ility
ot p
Observe correct installation position!
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
5.8 Removing and installing vacuum sender

l purpos
- G608-
nform
ercia
Only on vehicles having HBV (hydraulic brake with vacuum ser‐

vo).
m
at
om
io

n
c
in t
or
his
e
– Pull out vacuum hose with vacuum sender - G608- from brake
at
do
riv
servo.
p
cum
for
– Release clip with a pair of pliers -1-.

en
ng
t.
yi Co
op py
– Carefully lever out the vacuum sender - G608- -2-. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.9 Removing and installing brake servo

pressure sensor - G294-
– Pull out vacuum hose with brake servo pressure sender -
G294- from brake servo.

Touran 2003 ➤
– Release clip with a pair of pliers -1-.

– Carefully prise brake servo pressure sensor - G294- -2- off.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
5.10 Removing and installing brake servo
wit
, is n
h re
vacuum sender - G483- to Week
hole
spec
22/2008
es, in part or in w
t to the co
Removing
– Removing and installing battery ⇒ Electrical system; Rep. gr.
rrectness of i
27 ; Removing and installing battery .
satelettronica
l purpos
– Remove battery tray.

– Release connector -1- from vacuum sender in brake servo -
nf
ercia
o
G483- -2- and pull off.
rm
m
atio
m
– Insert screwdriver between stop and one end of circlip into

o
n in
c
groove of circlip.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Push circlip -1- out of groove enough so that vacuum sender

in brake servo - G483- -2- can be pulled out of brake servo.
Installing
– Ensure that vacuum sender in brake servo - G483- is seated
properly.
5.11 Vacuum pump for brakes - V192-

Location for vacuum pump for brakes - V192- is on automatic
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- .

Touran 2003 ➤
5.11.1 Removing
– Pull vacuum hose -1- off vacuum pump for brakes - V192- .
– Release connector -2- for vacuum pump for brakes - V192-
and pull off.
– Remove wiring from bracket -3-.
– Unscrew bracket -arrows- -3- with vacuum pump for brakes -
V192- .
G. Volkswage
– Unscrew vacuum pump forlkbrakes
swa
gen A- V192- -1- nfrom
AG do
bracket
es n
-2- -arrows-. by Vo ot g
ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
satelettronica
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5.11.2 Installing
rrectness of i
l purpos
Specified torque
nform
ercia

m
Brake vacuum pump - V192- to bracket 8 Nm

a
com
tion in
Bracket to automatic gearbox 25 Nm

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5.12 Removing and installing brake light

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switch - F- from Week 45/2005, LHD
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On vehicles built before Week 45/2005, the brake light switch - F-
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is located on the brake pedal ⇒ page 98 .
AG.
Removing
– In certain vehicles, the intake hose must be removed.

Touran 2003 ➤
– Release and pull connector -1- off brake light switch - F- -3-.
– Remove bolt -2- from brake master cylinder.
– Remove brake light switch - F- -3- downwards from brake
master cylinder and pull out from retaining lug -4-.
Installing
– Install in reverse order. Note the following points:
– Insert brake light switch - F- properly in guide.
Specified torque
Bolt to brake master cylinder 5 Nm
5.13 Removing and installing brake light
satelettronica
switch - F- , right-hand drive
Removing
– Remove engine cover ⇒ Rep. gr. 15 .
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spec
– Remove heat shield -1- from diesel particulate filter by un‐

screwing nuts -arrows-.

t to the co
rrectness o
cial p
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mer
atio
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Cop py
t. rig
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Prote AG.

Touran 2003 ➤
– Remove upper timing belt guard by detaching clips -arrows-.
– Release connector -2- from differential pressure sender -

G505- and pull off.
– Remove bolt -4-.
– Remove differential pressure sender - G505- and place to one
side.
satelettronica
– Remove securing bolts -1- and take out bracket.
AG. Volkswagen AG d
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– Unclip heat shield and place to one side.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove heat shield -3- (if fitted) by unscrewing nuts -4-.

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Cop py
t. rig
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co lksw
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cted agen
Prote AG.

Touran 2003 ➤
– Separate connector -A- from brake light switch - F- and pull

off.
Note
The brake light switch - F- must then be removed from below.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .

– Pull brake light switch - F- -2- off the brake master cylinder n AG. Volkswagen AG do
underneath and out of the clip at the top -arrow-. olks
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Installing db ara
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– Insert brake light switch - F- properly in guide.

nl
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es, in part or in w
Specified torque
t to the co
Brake light switch - F- to brake master cylinder 5 Nm
rrectness of i
l purpos
nform
mercia
at
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ion
c
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ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
6 Removing and installing brake mas‐

ter cylinder
6.1 Removing and installing brake master

cylinder, left-hand drive
♦ Brake filling and bleeding equipment - VAS 5234-
AG. Volkswagen AG d
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es, in part or in w
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nform
mercia
a
com
tion in
6.1.1 Removing
r
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necessary.
fo
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– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Dis‐
Co
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connecting and reconnecting battery .
t. rig
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– Removing and installing ⇒ Electrical system; Rep. gr. 27 ; by c lksw
cted agen
Removing and installing battery
Prote AG.
– 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- .
6. Removing and installing brake master cylinder 141

Touran 2003 ➤
Vehicles with manual gearbox:

– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
Continuation for all models: AG. Volkswagen AG d
agen oes
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– Pull off connector -A- from sender d byfor brake fluid level warning
V gu
ara
contact - F34- . o rise nte
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– Release connector of brakess a
light switch - F- and pull it off. c
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– Remove brake fluid reservoir by pressing locking tabs on res‐
h re
ervoir outwards and, at the same time, pulling brake fluid
hole
spec
reservoir out of sealing plugs.
es, in part or in w
t to the co
– Disconnect brake lines -1- on brake master cylinder and seal
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Undo nuts -2- on brake master cylinder.
rrectness of i
satelettronica
– Remove heat shield (if installed).
l purpos
– Carefully take brake master cylinder out of brake servo.
nform
mercia
a
com
tion in
r
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6.1.2 Installing s
iva
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fo
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t.
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– When assembling brake master cylinder with brake servo,
Co
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make sure plunger rod is properly positioned in brake master
t. rig
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cylinder.
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Prote AG.
Specified torque
Brake master cylinder to brake servo 25 Nm
♦ Use new nuts.
Brake lines to brake master cylinder 14 Nm
6.2 Removing and installing brake master cylinder, right-hand drive

Touran 2003 ➤

equipment required
♦ Release tool - T10159 A-
♦ Sealing tool - T10249-
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-
satelettronica
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6.2.1 Removing
ut or
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– Place sufficient lint-free cloths in area of engine.

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hole
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Vehicle with diesel engine

t to the co
– Remove engine cover in -direction of arrow- ⇒ Rep. gr. 15 .

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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143
by lksw
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Prote 6. Removing and installing brake master cylinder
AG.
Touran 2003 ➤


lkswage es n
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G505- and pull off.
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nform
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side.
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c
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ate
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for
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t.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.

AG. Volkswagen AG d
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ise nte
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ho Brake e o systems
ra - Edition 07.2013
s a c
s
Vehicles with manual gearbox
ce
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un
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an
d
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– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
y li
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ab
reservoir -4-.
pe
ility
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– Seal return hose -2- for clutch sender cylinder -3- with sealing
, is n
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tool - T10249- -1-.
hole
spec
– Raise and tie return hose -2- in place.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Release and pull off connector -A- from brake fluid level warn‐
m
a
ing contact - F34- .
com
tion in
r
– Mark and unscrew brake lines -1- and -2- from brake master
te o
thi
cylinder.
s
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do
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– Seal brake lines using sealing plugs from repair kit - 1H0 698
fo
en
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311 A- .
n
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Co
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– Unscrew brake master cylinder nut -4-.
t. rig
gh ht
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by c
– Remove heat shield (if installed) -3-.
lksw
cted agen
Prote AG.
– Pull off connector -A- from brake light switch - F- .

– Unscrew nut -1- from brake master cylinder -2-.

– Pull brake light switch - F- -2- off the brake master cylinder
underneath and out of the clip at the top -arrow-.
– Carefully take brake master cylinder -2- out of brake servo.
6.2.2 Installing
– When assembling brake master cylinder with brake servo,
cylinder.
6. Removing and installing brake master cylinder 145

Touran 2003 ➤
. Volkswagen AG
swa
gen AG does
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Vehicles with manual gearboxesris
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– Bleed clutch ⇒ Clutchss controls; Rep.
a gr. 30 ; Bleeding clutch c
system .
ce
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pt
an
Specified torque d
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
satelettronica
iva
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
7 Removing and installing brake servo
7.1 Removing and installing brake servo,

left-hand drive
Note
If there are problems with the brake servo, first check the brake
. Volkswagen AG
servo vacuum system ⇒ page 131 sw agen AG does
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Special tools and workshop equipment ris required nte
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ss - VAS 5234- c
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at
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ion
c
in t
or
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ate
do
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for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7.1.1 Removing
necessary.
7. Removing and installing brake servo 147

Touran 2003 ➤
Vehicles with diesel engine:

– Release connector -1- and pull off.
– Detach spring-type clip -2- from intake hose.
– Pull off intake hose.
– Detach spring-type clip -arrow- and pull off hose from air intake
housing.
AG. Volkswagen AG d
agen oes
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spec
– Unscrew securing bolt -arrow- from air intake housing.

t to the co
– Pull out air intake housing upwards from brackets.

Continuation for all models:
rrectne
– Removing and installing battery ⇒ Electrical system; Rep. gr.

27 ; Removing and installing battery .
ss
– Remove battery tray.

o
cial p
f inform
– Place sufficient lint-free cloths in area of engine and gearbox.

mer
atio
m
o
n
c

i
or
n thi
te
sd
a

iv
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pr
cum
r
fo
en
ng
– Detach supply hose -B- for clutch master cylinder, lift clear and
t.
yi Co
op
tie in place, or clamp off supply hose -B- for clutch master cyl‐ C py
t. rig
inder with a commercially available tool, e.g. Hazet 4590, and gh ht
yri by
then pull off.
op Vo
by c lksw
cted agen
Prote AG.
– Pull off connector -A- from sender for brake fluid level warning
contact - F34- .
off.

Touran 2003 ➤
– Remove brake fluid reservoir by pressing locking tabs on res‐

ervoir outwards and, at the same time, pulling brake fluid
reservoir out of sealing plugs.
– Unscrew brake lines -1- from brake master cylinder.
311 A- .
– Undo nuts -2- on brake master cylinder.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
– Detach cables -1-. . Volkswagen AG

gen AG does
swa
– Unscrew support bracket -2- and y V place to one side ⇒ Rep. gr. t gua
olk no
34 ; Repairing gear selector ris
edmechanism .
b ran
tee
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ss
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satelettronica
nl
pt
– Remove trim on driver side ⇒ General body repairs, interior;
du
an
itte
Rep. gr. 70 ; Dash panel .
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ab
ility
Vehicles to Week 45/2005
ot p
wit
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From Week 45/2005, the brake light switch - F- is no longer lo‐
h re
hole
cated on the mounting bracket.
spec
es, in part or in w
t to the co
– Pull connector -1- off brake light switch - F- .
– Remove brake light switch - F- -2- by turning 45° anti-clock‐
rrectness of i
wise.
l purpos
– Remove air duct -3-.

– Remove cover -4-.
nform
ercia

m
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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op
– Unscrew nuts -1- from brake servo. C py
ht. rig
rig ht
by
– Remove both upper nuts -2- from mounting bracket. copy Vo
by lksw
cted agen
Prote
– Carefully remove brake servo from the vehicle.
AG.
7.1.2 Installing
Install in reverse order. In the process, note the following:
– After installing, bleed brake system ⇒ page 121 and clutch.

Touran 2003 ➤
Vehicles to Week 45/2005

– Installing brake light switch - F- ⇒ page 99 .
Specified torque
Component n AG. VolkSpecified
swagen AG torque
lkswage does
n
Brake servo to pedal cluster and bulkhead byV
o 25 Nm ot gua
♦ Use new nuts. ris
ed ran
tee
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Brake master cylinder to brake servo ss 25 Nm
ce
le
♦ Use new nuts.
un
pt
an
d
itte
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Brake lines to brake master cylinder erm 14 Nm
ab
ility
ot p
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is n
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ole,
7.2 Removing and installing brake servo,
spec
right-hand drive vehicle
t to the co
rrectne
Note
satelettronica
If there are problems with the brake servo, first check the brake
ss o
servo vacuum system ⇒ page 131
cial p
f inform
mer
atio
m

o
n
c
i
equipment required
or
n thi
te
sd
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♦ Support bracket - 10 - 222

i
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pr
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A-
r
fo
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ng
t.
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♦ Adapter - 10 - 222 A /3-
Co
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♦ Spindle - 10 - 222 A /11- yri
p by
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cted
♦ Shackle - 10 - 222 A /12-
agen
Prote AG.
♦ Adapter - 10 - 222 A /16-

Touran 2003 ➤
♦ Adjustment pin - T10060 A-
♦ Release tool - T10159 A-

♦ Sealing tool - T10249-
1331-
♦ Brake filling and bleeding
equipment - VAS 5234-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
satelettronica
th eo
au ra
ss c ce
e
nl
pt
du
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itte
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erm
ab
ility
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hole
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es, in part or in w
t to the co
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m
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n in
or c
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♦ Set of plugs for engine - VAS 6122-

o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
♦ Adapter - 10 - 222 A /26-
♦ Adapter - 10 - 222 A /30-
AG. Volkswagen AG d
satelettronica
agen oes
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♦ Hook - 10 - 222 A /2-

itte
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ab
ility
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spec
t to the co
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cial p
f inform
7.2.1 Removing
mer
atio
m
– Remove plenum chamber bulkhead ⇒ General body repairs;

o
n
c
i
or
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .

thi
te
sd
va
– Remove windscreen wiper system ⇒ Electrical system; Rep.

i
o
pr
cum
gr. 92 ; Windscreen wiper system (parallel wiper system) .

r
fo
en
ng
t.
yi Co
– Remove noise insulation and underbody protection ⇒ General Cop py
body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly
t. rig
gh ht
yri
overview - noise insulation .
p by
co Vo
by lksw
cted agen
– Place sufficient lint-free cloths in area of engine.
Prote AG.

Touran 2003 ➤
Vehicles with diesel engine and particulate filter

– Remove engine cover in -direction of arrow- ⇒ Rep. gr. 15 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

G505- and pull off.
side.

Touran 2003 ➤
– Unscrew bolts -1- to -3- and remove pendulum support.
lkswage es n
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d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Release connector -1- and pull off.
un
pt
an
d
itte
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– Unclip bracket -2- for electrical wiring to oil level and oil tem‐
rm
ab
perature sender - G266- on subframe.
pe
ility
ot
wit
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– Remove diesel particulate filter ⇒ Exhaust system; Rep. gr.
h re
26 ; Removing and installing particulate filter with front exhaust
hole
spec
pipe .
es, in part or in w
t to the co
– Seal turbocharger with sealing plug set for engine - VAS
satelettronica
6122- .
rrectness of i
l purpos
– Release connectors -1- and pull off.
nform
ercia
– Detach spring-type clip then pull off and remove intake hose
m
a
com
t
-2-.
ion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Vehicles to 11/2006

Touran 2003 ➤
– Place support bracket - 10 - 222 A- with adapters, as shown

in diagram, and take weight of engine.
Vehicles from 11/2006 to 5/2010
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du

an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Vehicles from 06/2010

nf
ercia
or

m
m
atio

om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Unscrew bolts -arrows- of engine/gearbox support on the en‐ spec

gine.
es, in part or in w
t to the co
– Lower engine/gearbox (first one side and then the other) via
the spindles and pull towards the front as far as possible.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
On the engine side, the distance -a- between the engine support
and the engine mounting must not be more than 11 cm.
Note
♦ Make absolutely sure that the drive shafts can move freely in
relation to the engine/gearbox support.
♦ In order to prevent damage, it must be ensured that the drive
shafts do not rest on the engine/gearbox support!
Vehicles with manual gearboxes
satelettronica
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch sender cylinder -3- with sealing
tool - T10249- -1-.
– Raise and tie return hose -2- in place.
AG. Volkswagen AG d
agen oes
olksw not
Continuation for all vehicles byV gu
ara
ed
ris nte
o eo
– Detach brake servo aut from brake pedal ⇒ page 101 .
h
ra
ss c
ce
e
nl
pt
du
an
itte
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– Release and pull off connector -A- from brake fluid level warn‐
ing contact - F34- .
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– Mark and unscrew brake lines -1- and -2- from brake master
cylinder.
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– Unscrew brake master cylinder nut -4-.

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– Remove heat shield (if installed) -3-.

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Touran 2003 ➤

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

– Carefully remove brake servo -2- from the vehicle.
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Vehicles with manual gearboxes

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– Bleed clutch ⇒ Clutch controls; Rep. gr. 30 ; Bleeding clutch

t to the co
system .
Specified torque
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Brake servo to mounting bracket and bulkhead 25 Nm

♦ Use new bolts!
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Steering column to steering rack 30 Nm
AG.
♦ Use new bolt!
Pendulum support to gearbox ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Front wheel suspension, drive
shaft

Touran 2003 ➤

Pendulum support to subframe ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Front wheel suspension, drive
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Subframe mountingsised bto engine ⇒ Power unit; Rep. gr. ara
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Touran 2003 ➤
8 Repairing brake lines

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

otherwise they will become kinked or deformed.
♦ If brake lines are bent more than 90°, the cross-section of the
brake line is changed in a manner which is not permitted.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
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♦ Do not grease spindle; merely clean y Vwith methylated spirits.
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Special tools and workshop equipment
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♦ Flanging tool for brake lines - VAS 6056-
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♦ Brake filling and bleeding equipment - VAS 5234-

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List of individual tools:

Touran 2003 ➤
1 - Flanging tool - VAS 6056/1-

❑ The 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 - Grip wrench with plastic
jaws - VAS 6056/4-
5 - Pipe bending tool - VAS
6056/5-
6 - Special wrench, 6 mm
7 - Flanging jaws - VAS
6056/7-
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8. Repairing brake lines 161

Touran 2003 ➤
8.1 Assembly overview - flanging tool
1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws .
2 - Fastening for handle
❑ Must be unscrewed to
access securing bolt for
upper part
3 - Securing bolt AG. Volkswagen AG d
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4 - Grub screws for flanging
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❑ Assembly instructions
⇒ page 162
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Flanging jaw assembly instructions:
♦ -VAS 6056/6- (dark) for black brake lines
♦ -VAS 6056/7- (light) for green brake lines
Note
♦ Arrow on rounded side of flanging jaws must point to edge of

housing.
♦ Straight side of flanging jaws must be installed to spindle, as
flanging head is not otherwise formed correctly.
8.2 Work instructions

– Unbolt brake line at brake caliper or wheel brake cylinder;
catch escaping brake fluid and dispose of this as per regula‐
tions.

Touran 2003 ➤
– 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.
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– Clamp brake line in grip wrench -4- so that rise approx. 50 mm
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– Clamp scraper -3- into a drill and position
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Length of scraping is determined by stop in scraper.
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– Remove scraper from brake line and remove scraping resi‐
dues.
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– Remove grip wrench and slide union bolt -D- onto brake line.
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– Slide brake line -B- 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.
– Pre-tension brake line in flanging tool until brake line can no

longer be moved. Fold up stop -A- and then tighten hexagon
socket head bolts diagonally in steps with angle screwdriver
-C-.
8. Repairing brake lines 163

Touran 2003 ➤
– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Release Allen head bolts diagonally.
– Remove brake line from flanging tool.
– Check and clean 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

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E8030E5D9

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 61

7.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 62

8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

1.1 Repairing front brakes, FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.2 Removing and installing brake pads, brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

2.1 Assembly overview - rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

2.2 Removing and installing brake pads, CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.3 Removing and installing brake caliper, CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.4 Assembly overview - Bosch rear wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.5 Removing and installing brake pads, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5.6 Checking brake servo vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

5.8 Removing and installing vacuum sender G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.11 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.1 Removing and installing brake servo, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1.2l - 77 kW TSI 1ZE / 1ZP FN3 (15”)

2.0l - 100 kW TDI 1)

1. Brake allocation via PR No. 1

Country-specific brake for Japan:

1.2 Rear brakes

1.4l - 125 kW TSI

1.6l - 75 kW 1KF CII 41 (15")

1.4l - 103 kW FSI

2.0l - 110 kW FSI

2.0l - 125 kW TDI

2 Rep. gr.00 - Technical data

2 Technical data for brakes

2.1 Brake master cylinder and brake servo

2.2 Front brakes FN 3

Brake pad, wear mm 2

3 Brake disc ∅ in 312

2. Technical data for brakes 3

2.3 Rear brakes (disc brakes)

3 Brake disc ∅ in 286

Item PR number 1KS

4 Rep. gr.00 - Technical data

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

3.2 Test for vehicles with front-wheel drive

45 – Anti-lock brake system

1 - ABS hydraulic unit - N55- and ABS control unit - J104-

removed. ABS hydraulic pump - V64- -3- must not be separated

from ABS hydraulic unit - N55- .

With ABS/EDL/TCS/ESP - separation is not possible in vehicles

with hydraulic brake servo or hill hold assist.

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

2 Notes for repair work on anti-lock