VW t4 Sistema Frenante

Service
Workshop Manual
Transporter 1996 ➤
Brake systems asageof January 1996
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Service Department. Technical Information

Service
List of Workshop Manual Repairksw Groups
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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 00052708520

Brake systems as of January 1996 - Edition 09.2004
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Test for vehicles with front-wheel drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Test for vehicles with four-wheel drive via a viscous clutch. . . . . . . . . . . . . . . . . . . . . . . . . 7
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 General notes for anti-lock brake system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 ABS and ABS/EDL Bosch 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 ABS and ABS/EDL Bosch 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 ABS/EDL/TCS/ESP Bosch 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Notes for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Assembly overview - hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 ABS and ABS/EDL Bosch 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 ABS and ABS/EDL Bosch 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 ABS/EDL/TCS/ESP Bosch 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 23
4.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 24
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5 Removing and installing lks parts
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5.1 Removing andedinstalling yaw rate sender G202 andualateral
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5.2 Removinguthand
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5.3 Removing
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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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1.1 Front brake caliper distinguishing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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1.2 Repairing front brakes, 15" running gear, floating caliper brake Lucas C54 . . . . . . . . . . . . 31
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1.3 Removing and installing brake pads, 15" running gear, floating caliper brake Lucas C54
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........................................................................ 32
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1.4 Repairing front brakes, 15" running gear, floating frame caliper brake Lucas RC 54 . . . . 33
1.5 Removing and installing brake pads, 15" running gear, floating frame caliper brake Lucas RC
54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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1.6 Repairing front brakes, 15" running gear, floating caliper brake FN 3 . . . . . . . . . . . . . . . . 36
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1.7 Removing and installing brake pads, 15" running gear, floating caliper brake FN 3 . . . . . . 38
1.8 Repairing front brakes, 16" running gear, floating caliper brake FN 3 . . . . . . . . . . . . . . . . 40
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1.9 Removing and installing brake pads, 16" running gear, floating caliper brake FN 3 . . . . . . 42
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1.10 Repairing front brakes, 16" running gear, floating caliper brake FNR . . . . . . . . . . . . . . . . 44
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1.11 Removing and installing brake pads, 16" running gear, floating caliper brake FNR . . . . . . 46
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2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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2.1 Repairing rear brakes, 15" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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2.2 Removing and installing brake pads, 15" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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2.3 Repairing rear brakes, 16" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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2.4 Removing and installing brake pads, 16" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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3 Repairing handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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3.1 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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3.2 Removing and installing front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.3 Removing and installing pull rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.4 Removing and installing rear handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
3.5 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Repairing front brake calipers, 15" running gear, floating caliper brake Lucas C54 . . . . . . 66
1.2 Removing and installing pistons for front brake calipers, 15" running gear, floating caliper
brake Lucas C54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.3 Repairing front brake calipers, 15" running gear, floating frame caliper brake Lucas RC 54
........................................................................ 68
1.4 Removing and installing pistons for front brake calipers, 15" running gear, floating frame
caliper brake Lucas RC 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.5 Repairing front brake calipers, 15" running gear, floating caliper brake FN 3 . . . . . . . . . . 71
1.6 Removing and installing pistons for front brake caliper, 15" running gear, floating caliper brake
FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.7 Repairing front brake calipers, 16" running gear, floating caliper brake FN 3 . . . . . . . . . . 74
FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.9 Repairing front brake calipers, 16" running gear, floating caliper brake FNR . . . . . . . . . . 77
FNR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Removing and installing piston for rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.2 Pressure leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1 Bleeding brake system with brake filling and bleeding unit V.A.G 1869 . . . . . . . . . . . . . . 85
3.2 Bleeding brake system without brake filling and bleeding unit . . . . . . . . . . . . . . . . . . . . . . 86
4 Assembly overview - brake pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Adjusting the brake pressure regulator ........................................
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5 Assembly overview - brake olksservo/brake master cylinder
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5.1 Checking non-return edvalve . . . . . . . . . . . . . . . . . . . . . . .ua. ra. . . . . . . . . . . . . . . . . . . . . . . . . .
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5.2 Removing and installing
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5.3 Removing and ss installing brake servo . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . 96
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ii Contents
00 – Technical data
1 Brake allocation via PR No.
Depending on the brake caliper design, a different PR No. is en‐
tered on the vehicle data sticker.
Vehicle data sticker installation location -arrow-
LHD vehicles: Left A-pillar next to central electrics
RHD vehicles: Right A-pillar next to central electrics
Position of M equipment number (PR No.) on the vehicle data

sticker -arrow-
♦ 1LU = 15'' floating brake caliper FN3
♦ 1LP = 15'' floating brake caliper Lucas C54
♦ 1LE = 15'' floating frame brake caliper Lucas RC 54
♦ 1LB = 16'' floating brake caliper FN3
♦ 1LB = 16'' floating brake caliper FNR
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1. Brake allocation via PR No. 1

1.1 Front brakes

1.1.1 Vehicles with Lucas C54 brake calipers,
15'' running gear
Item M equipment No. (PR 1LP (floating caliper)
No.)1)
Brake ∅ in mm 23.8
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Brake ∅ in inch 9′′ +
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1 Brake caliper Lucas C54
2 Brake pad, thick‐ mm 13.5
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3 Brake disc ∅ in 282
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Brake disc, thick‐ mm 18
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4 Brake caliper pis‐ ∅ in 54
ton mm
1) M equipment number; explanation ⇒ page 1
1.1.2 Vehicles with Lucas RC54 brake cali‐

pers, 15'' running gear
Item M equipment No. (PR 1LE (floating frame caliper)
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2 Rep. Gr.00 - Technical data

1.1.3 Vehicles with FN3 brake calipers, 15''

running gear
Item M equipment No. (PR 1LU (floating caliper)
No.)3)
Brake ∅ in mm 25.4 agen
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1.1.5 Vehicles with FNR brake calipers, 16''

running gear
Item M equipment No. (PR No.)5) 1LB (floating caliper)
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1 Brake caliper FNR
2 Brake pad, thickness mm 14
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Brake disc, thickness mm 26
4 Brake caliper piston ∅ in 57
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1.2 Rear brakes

1.2.1 Vehicles with rear disc brake, 15'' run‐
ning gear
Item M equipment No. (PR 1LP (floating caliper)
No.)6) 1LE (floating frame caliper)
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2 Brake test
2.1 General
♦ The drive is provided by the test unit.
♦ For the test, ensure that for vehicles with a manual gearbox
the gearstick is in neutral and for vehicles with an automatic
gearbox the shift lever is in “N”.
♦ For test, observe guide lines provide by manufacturer of test
unit.
Note
The brake regulation systems do not function when ignition is off.
2.2 Test for vehicles with front-wheel drive.

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

via a viscous clutch.
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– Drive the vehicle onto the test rig counter to the direction of
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travel (backwards).
nform
ercia
WARNING
m
at
om
io
Before starting the rollers, briefly engage 1st gear. In vehicles

n
c
in t
or
with automatic gearbox, briefly shift to “D”. This switches off

his
te
the freewheel lock. Ensure that the front wheels are driven
a
do
riv
backwards.
p
cum
for
en
ng
t.
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Cop py
t.
– Carry out the brake test.
rig
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pyri by
Vo
o
by c
Rear wheels:
lksw
cted agen
Prote AG.
– Drive the vehicle onto the test rig in the direction of travel and
ensure that the rear wheels are driven forwards. Carry out the
brake test.
2. Brake test 7
WARNING
Do not engage reverse gear whilst the rollers are running.
AG. Volkswagen AG d
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nl
pt
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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
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Vo
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Prote AG.

45 – Anti-lock brake system

1 General notes for anti-lock brake sys‐
tem (ABS)
1.1 ABS and ABS/EDL Bosch 5

The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically, by the vacuum brake servo unit.
The hydraulic unit and control unit form one unit and must always
be removed and installed jointly.
1.2 ABS and ABS/EDL Bosch 5.3

AG. Volkswagen AG d
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agen oes
n ol ot g
yV u
Faults in the ABS influence
ed
b the brake system and servo assis‐
ara
nte
ris
tance. A changeutinh braking behaviour is to be reckoned with. After
o eo
the ABS warning
ss
a lamp comes on the rear wheels can lock earlyr ac
when braking!
ce
le
un
pt
an
d
ABS layout in left-hand drive vehicle.

itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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op
ABS layout in a right-hand drive vehicle. C py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. General notes for anti-lock brake system (ABS) 9

Hydraulic unit -a- and control unit -b- form one unit and must al‐
ways be renewed together in the event of complaints.
New control units supplied as replacement parts
agen
Aare
G. Vcoded.
olkswagen AG
do w es n
olks ot g
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ed ran
ris tee
tho or
au ac
ss
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nl
pt
du
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erm
ab
ility
ot p
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, is n
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hole
spec
1.3 ABS/EDL/TCS/ESP Bosch 5.3
es, in part or in w
t to the co
rrectness of i
Vehicles with ABS/EDL/TCS
l purpos
nform
ercia
Vehicles with ABS/EDL/TCS/ESP

m
at
Hydraulic unit and control unit are located separately in the vehi‐
om
ion
cle and can be removed and installed independently of each
c
in t
or
other.
his
ate
do
riv
Faults in the ABS influence the brake system and servo assis‐
p
cum
or
tance. A change in braking behaviour is to be reckoned with. After

f
en
ng
t.
yi
the ABS warning lamp comes on the rear wheels can lock early
Co
op py
when braking! t. C rig
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pyri by
ABS layout in left-hand drive vehicle.
co Vo
by lksw
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Prote AG.
10 Rep. Gr.45 - Anti-lock brake system

ABS layout in a right-hand drive vehicle.
Distinguishing features
1- Hydraulic unit
2- ABS return flow pump
olkswagen AG
en AG. V
3- Hydraulic pump for electronic stabilisation programme ksw with
ag does
not
Vol
brake pressure sender db
y gu
ara
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ris
tho eo
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c
ss
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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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
1. General notes for anti-lock brake system (ABS) 11

2 Notes for repair work on ABS

♦ Prior to carrying out repairs on the ABS determine the cause
of damage via self-diagnosis ⇒ Running gear self-diagnosis
for ABS as of January 1996; Rep. Gr. 01 ; Perform self-diag‐
nosis .
♦ Disconnect battery earth strap with ignition switched off. Ob‐
tain radio code on vehicles with coded radio.
♦ Before carrying out welding work with an electric welding unit
⇒ Special information; Body No. 19; Notes on safety .
♦ When working with brake fluid, observe the valid, relevant
safety precautions and notes ⇒ page 85 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
V.A.G 1869- ⇒ page 85 .
♦ During a concluding road test, ensure that a regulated brake
test takes place at least once (pulsations must be felt at the
brake pedal).
♦ When working on the anti-lock braking system, strict rules of
cleanliness should be adhered to. No products which contain
mineral oil, such as oils, greases, etc. should be used under
any circumstances.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or sealwaopen
gen AGcomponents
. Volkswagen AGif repairs cannot be
does
carried out immediately
yV
olks (use plug repair set -1H0 no698
t gu 311 A- ).
b ara
ed
♦ Only use lint-free
ho
ris cloths. nte
e
t or
au a
♦ Only unpack
ss replacement parts immediately prior to fitting. c
ce
le
un
pt
♦ Only use genuine packed parts.

an
d
itte
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♦ When the system is open do not work with compressed air and
rm
ab
pe
ility
do not move the vehicle.

ot
wit
, is n
♦ Ensure that no brake fluid enters electrical connections.

h re
hole
spec
♦ During painting operations, the electronic control unit can be

es, in part or in w
exposed to a maximum temperature of 95 °C for only a short

t to the co
period, and to a maximum of 85 °C for longer periods (approx.

2 hours).
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Assembly overview - hydraulic units
3.1 ABS and ABS/EDL Bosch 5 n AG. Volkswagen AG do

lkswage es n
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Note ir se tee
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ss
♦ Hydraulic unit is located on front left of engine compartment.
ce
le
un
pt
♦ When removing and installing brake lines, ensure that lines are marked and installed according to desig‐
an
d
itte
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nations on hydraulic unit.
rm
ab
pe
ility
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1 - Tandem brake master cyl‐
hole
spec
inder
es, in part or in w
t to the co
❑ With tandem brake ser‐
vo.
2 - Brake line
rrectness of i
❑ Master brake cylinder/
l purpos
secondary piston circuit

to hydraulic unit.
nform
ercia
3 - Brake line
m
❑ Brake master cylinder/
a
com
tio
primary piston circuit to
n in
r
hydraulic unit.
te o
thi
s
iva
do
4 - Brake line
r
rp
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fo
❑ Hydraulic unit to front
en
ng
t.
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left brake caliper.
Co
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5 - Brake line
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❑ Hydraulic unit to rear left
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brake caliper.
AG.
6 - Brake line
❑ Hydraulic unit to rear
right brake caliper.
7 - Brake line
8 - Hydraulic control unit ABS/
EDL
❑ Screwed onto control
unit
❑ The hydraulic control
unit can only be re‐
placed as a complete
unit if defective
9 - Buffer
10 - Hexagon nut
11 - Earth cable
❑ Ensure good contact.
12 - Bracket
3. Assembly overview - hydraulic units 13

Connecting brake lines from tandem brake master cylinder to hy‐

draulic unit
1- Primary piston circuit
2- Hydraulic unit to rear right brake caliper.
3- Hydraulic unit to front left brake caliper.
4- Secondary piston circuit
5- Hydraulic unit to rear left brake caliper.
6- Hydraulic unit to front right brake caliper.
3.1.1 Removing and installing control unit and

hydraulic unit
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
lkswage es n
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ir se tee
tho
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ss
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nl
pt
du
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ab
♦ Brake pedal depressor -V.A.G 1869/2-
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
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atio
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Location:
o
n in
or c
The control unit is bolted to the hydraulic unit and is located on

thi
te
sd
a
left in the engine compartment.

iv
o
r
rp
cu
o
m
f
en
ng
t.
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WARNING
Co
Cop py
t. rig
gh ht
yri
Do not bend the brake lines in the area of the hydraulic unit!
p by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Obtain radio code on vehicles with coded radio.
– Disconnect battery earth strap.

– Pull connector off control unit.

– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using a suction bottle.
– Fit brake pedal depressor -V.A.G 1869/2- .
– Depress brake pedal with brake pedal depressor.
– Connect bleeder bottle hose to front left brake caliper bleed
screw and open bleed screw.
– Close front left bleeder screw.
– Unbolt earth cable from hydraulic unit.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
– Unscrew brake lines from hydraulic unit; seal brake lines and
threaded holes with plugs.
– Remove hydraulic unit together with control unit.
Installing
Note
♦ Do not remove sealing plugs from hydraulic unit until corre‐

sponding brake line is fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
– Installation is continued in reverse sequence

– Bleed brake system ⇒ page 85 .
Torque settings: n AG. Volkswagen AG do
lkswage es n
Brake lines to ABS unit: d byV
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se ran
Thread M10 x 1 tho
ir15 Nm tee
or
u
Thread M12 x 1 ss
a
15 Nm ac
ce
le
un
pt
an
d
3.2 ABS and ABS/EDL Bosch 5.3

itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec

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


inder
❑ With tandem brake ser‐
vo.
2 - Brake line
❑ Master brake cylinder/
secondary piston circuit
to hydraulic unit.
3 - Brake line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit.
4 - Brake line
5 - Brake line
❑ Hydraulic unit to rear
6 - Brake line
❑ Hydraulic unit to rear left
brake caliper.
7 - Brake line
left brake caliper.
8 - Hexagon nut, 8 Nm
9 - Protective cap
10 - Hydraulic control unit ABS/
EDL
❑ Screwed onto control AG. Volkswagen AG d
agen oes
ksw
unit by Vol not
gu
ara
d
❑ The hydraulic control rise nte
ho eo
unit can only be replaced as a complete unit
a if defective.
u t ra
c
ss
ce
le
un
pt
an
d
itte
12 - Bracket
y li
rm
ab
pe
13 - Bolt, 8 Nm
ility
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wit
, is n
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hole
spec
Connecting brake lines from tandem brake master cylinder to hy‐

es, in part or in w
draulic unit
t to the co
A - Secondary piston circuit

rrectness of i
B - Primary piston circuit

l purpos
1 - Hydraulic unit to rear left brake caliper.

2 - Hydraulic unit to rear right brake caliper.
nform
ercia
3 - Hydraulic unit to front right brake caliper.

m
a
com
ti
4 - Hydraulic unit to front left brake caliper.

on in
r
te o
thi
s
iva
do
r
rp

um
fo
en
ng
t.
hydraulic unit
yi Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required pyri by
Vo
co lksw
by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
Location:
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
WARNING
p
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Removing cted agen
Prote AG.
– Note or request radio code on vehicles with coded radio if

necessary.

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

-arrow 2-.
– Close front left bleeder screw. n AG. Volkswagen AG do
s wage es n
– Place sufficient lint-free cloths under the control by unit
Vo and hy‐
lk ot g
ua
draulic unit. ir se
d ran
tee
tho
or
– Unscrew brake lines from hydraulic unit; ss
au
seal brake lines and ac
ce
le
un
pt
an
– Remove hydraulic unit together with control unit.
d
itte
y li
rm
ab
Installing
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
Torque settings:
r
te o
thi
s
Brake lines to ABS unit:
iva
do
r
rp
c
Thread M10 x 1 15 Nm
um
fo
en
ng
t.
Thread M12 x 1 15 Nm
yi Co
Cop py
t. rig
gh ht
yri by
3.3 ABS/EDL/TCS/ESP Bosch 5.3
cop Vo
by lksw
cted agen
Prote AG.
Note


1 - Tandem brake servo

❑ On petrol engines the
vacuum required is tak‐
en from the intake mani‐
fold.
❑ On Diesel engines an
exhauster is installed to
generate vacuum.
❑ Functional check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust the vacuum in
the unit).
– Now depress brake
pedal with average foot
pressure, hold and start wage
es n
s
engine. If the servo unit yV
olk ot g
ua
is working properly, the ir se
d b ran
tee
pedal will be felt to give utho
or
slightly under foot (ser‐ ss
a ac
vo assistance becomes
ce
e
nl
pt
effective).
du
an
itte
y li
erm
ab
– If faulty, renew com‐
ility
ot p
plete.
wit
, is n
h re
❑ Non-return valve (in
hole
vacuum hose)
spec
es, in part or in w
⇒ page 95 .
t to the co
Functional check
⇒ page 95 .
rrectness of i
❑ Removing and installing
⇒ page 96 .
l purpos
2 - Brake fluid reservoir

nf
ercia
3 - Tandem brake master cyl‐ orm

m
inder
atio
om
n in
c
4 - Brake line
or
thi
e
❑ Master brake cylinder/secondary piston circuit to hydraulic unit.

t
sd
iva
o
r
rp
cu
❑ Marked on hydraulic unit with “HZ2”

o
m
f
en
ng
t.
yi
5 - Brake line
Co
Cop py
.
❑ Hydraulic unit to front left brake caliper.
t rig
gh ht
pyri by
Vo
❑ Marked on hydraulic unit with “VL”.
co lksw
by
cted agen
Prote AG.
6 - Brake line
❑ Hydraulic unit to front right brake caliper.
❑ Marked on hydraulic unit with “VR”.
8 - Protective cap
10 - Bolt, 8 Nm
11 - Bracket
12 - ABS hydraulic unit
❑ Screwed onto control unit
❑ The hydraulic control unit can only be replaced as a complete unit if defective.

Brake systems as of January
AG. Volks1996
wagen-AEdition 09.2004
n G do
wage es n
Volks ot g
13 - Brake line ed by ua
ran
ris tee
❑ Hydraulic uth unit to rear left brake caliper.
o
or
a ac
❑ Marked ss on hydraulic unit with “HL”.
ce
e
nl
pt
14 - Brake line
du
an
itte
y li
❑ Hydraulic unit to rear right brake caliper.
erm
ab
ility
ot p
❑ Marked on hydraulic unit with “HR”.
wit
, is n
h re
15 - Brake line
hole
spec
❑ Hydraulic unit to electronic stabilisation programme (ESP) hydraulic pump.
es, in part or in w
t to the co
❑ Marked on hydraulic unit with “VLP”.
❑ Marked with “HE” on electronic stabilisation programme (ESP) hydraulic pump.
rrectness of i
16 - Electronic stability programme hydraulic pump
l purpos
17 - Connection for brake fluid from brake fluid reservoir

18 - Brake pressure sender
nf
ercia
❑ Always renew together with electronic stabilisation programme hydraulic pump in the event of complaints.
orm
m
❑ Marked with “BA” on electronic stabilisation programme (ESP) hydraulic pump.
atio
om
n in
c
19 - Connector for electronic stabilisation programme hydraulic pump

or
thi
te
sd
a
20 - Brake line
iv
o
r
rp
cu
❑ Brake master cylinder/primary piston circuit to electronic stabilisation programme (ESP) hydraulic pump
o
m
f
en
ng
t.
yi
❑ Marked with “HZ” on electronic stabilisation programme (ESP) hydraulic pump.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Connecting brake lines from tandem brake master cylinder and Prote AG.
electronic stabilisation programme hydraulic pump to ABS/EDL/
TCS and ESP hydraulic unit
A - Hydraulic unit to electronic stabilisation programme (ESP) hy‐
draulic pump
- Marked on hydraulic unit with “VLP”.
- Marked with “HE” on electronic stabilisation programme (ESP)
hydraulic pump.
B - Hydraulic unit to brake master cylinder secondary piston cir‐
cuit.
- Marked on hydraulic unit with “HZ2”
1 - Hydraulic unit to front left brake caliper.
- Marked on hydraulic unit with “VL”.
2 - Hydraulic unit to front right brake caliper.
- Marked on hydraulic unit with “VR”.
3 - Hydraulic unit, rear right brake caliper.
- Marked on hydraulic unit with “HR”.
4 - Hydraulic unit, rear left brake caliper.
- Marked on hydraulic unit with “HL”.

hydraulic unit

lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
Location:
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

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

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

-arrow 2-.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
– Unscrew brake lines from hydraulic unit and electronic stabi‐
lisation programme hydraulic pump; seal brake lines and
– Remove hydraulic unit with control unit and ESP hydraulic
pump.
Installing
Note


AG. Volkswagen AG d
Torque settings: lksw
agen oes
not
Vo
Brake lines to ABS unit: d by gu
ara
rise nte
Thread M10 x 1 utho 15 Nm eo
ra
a c
Thread M12 x 1 ss
15 Nm
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote
22
AG.
Rep. Gr.45 - Anti-lock brake system
4 Removing and installing parts of ABS

system on front and rear axle
4.1 Removing and installing parts of ABS system on front axle
1 - Hexagon bolt
❑ Renew each time after
removal ⇒ Running
gear, axles, steering;
Rep. Gr. 40 ; Repairing
drive shaft .
2 - Hexagon Allen head bolt,
10 Nm
3 - Hexagon bolt
4 - Front right/left speed sensor
-G45- / -G47-
AG. Volkswagen AG d
❑ Before inserting sensor, agen oes
olksw not
clean fitting hole's inner ed by V gu
ara
surface and coat with lu‐ horis nte
eo
bricating paste -G 000 a ut ra
c
650- . ss
ce
le
un
❑ Observe assembly se‐
pt
an
d
itte
quence: Install sensor
y li
rm
ab
first and then clip line in‐
pe
ility
to the appropriate
ot
wit
bracket starting from the
, is n
h re
sensor using rubber
hole
spec
grommets.
es, in part or in w
❑ Line routing
⇒ page 23 . t to the co
5 - Bracket
rrectness of i
❑ A different bracket is in‐

l purpos
stalled in the 16' running

gear ⇒ page 24 .
nform
ercia
6 - Wheel bearing housing

m
7 - Drive shaft
com
tion in
❑ With rotor for speed

r
te o
thi
sensor
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
op
Speed sensor line routing on front axle C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Removing and installing parts of ABS system on front and rear axle 23
Transporter 1996 ➤ gen AG
. Volkswagen AG
does
swa
Brake systems as of January 1996 y- VEdition 09.2004
olk not
gu b ara
ed nte
ris
Speed sensor line routing on front axle,
au
th 16" running
o
gear e or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.1.1 Removing and installing speed sensor
l purpos
on front axle
nform
ercia
Removing
m
at
om
i
– Raise vehicle.
on
c
in t
or
– Remove bolt -1- from speed sensor.
his
ate
do
priv
– Pull ABS speed sensor out of wheel bearing housing.
cum
for
en
ng
t.
– Unclip line -2- from bracket -arrows-.
yi Co
Cop py
ht. rig
– Disconnect the speed sensor cable connector -3-. rig ht
py by
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by lksw
Installing Prote
cted AG.
agen
– Connect the speed sensor cable connector -3-.

Both lugs on the connector -3- plugs must point to one another.
– Clip cable -2- into bracket -arrows-.
– Before inserting speed sensor, clean inner surface of hole and
coat speed sensor around circumference with lubricating
paste -G 000 650- .
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt ⇒ page 23 .
– Turn steering to left and right lock and check clearance to
speed sensor line.
4.1.2 Checking or removing and installing ro‐

tor on front axle
– Raise vehicle.
– Check rotor is not damaged or dirty by rotating drive shaft.
– If rotor is damaged, remove drive shaft with rotor and renew
outer constant velocity joint ⇒ Running gear, axles, steering;
Rep. Gr. 40 ; Repairing drive shaft .
4.2 Removing and installing parts of ABS system on rear axle

AG. VolksBrake systems
wagen AG
as of January 1996 - Edition 09.2004
agen does
olksw not
y V gua
db
1 - Hexagon bolt rise
ran
tee
ho
❑ Renew each timeaut fol‐ or
ac
lowing removal ⇒ Run‐ ss
ce
e
ning gear, axles, steer‐
nl
pt
du
an
ing; Rep. Gr. 42 ;
itte
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Repairing wheel bear‐
erm
ab
ings (front and four-
ility
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wheel drive) .
wit
, is n
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hole
2 - Hub
spec
es, in part or in w
❑ Pressing out and in ⇒
t to the co
Running gear, axles,
steering; Rep. Gr. 42 ;
rrectness of i
wheel drive) .
l purpos
3 - Circlip
❑ Ensure proper seating.
nform
mercia
4 - Wheel bearing
at
om
io
❑ Pressing out and in ⇒
n
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in t
or
his
ate
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priv
c
um
for
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ng
t.
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wheel drive) .
Co
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gh
5 - Wishbone
ht
pyri by
Vo
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by
cted
6 - Bracket
agen
Prote AG.
❑ First attach to wishbone

on installation.
7 - Rivet
10 Nm
9 - Speed sensor
❑ Before inserting sensor,
clean fitting hole's inner surface and coat with lubricating paste -G 000 650- .
❑ Observe assembly sequence: Install sensor first and then clip line into the appropriate bracket starting
from the sensor using rubber grommets.
10 - Tensioning disc with rotor
❑ Only for vehicles with front-wheel drive.
11 - Self-locking hexagon nut
❑ Renew.
❑ Vehicles with front-wheel drive only ⇒ Running gear, axles, steering; Rep. Gr. 42 ; Repairing rear wheel
bearings (front and four-wheel drive) .
12 - Drive shaft
❑ With rotor for speed sensor
4.2.1 Removing and installing speed sensor

on rear axle
Removing
– Raise vehicle.
– Additionally in vehicles with brake pad wear indicator, rotate
brake pad wear indicator connector 90° and pull sideways out
of cable duct.
4. Removing and installing parts of ABS system on front and rear axle 25
– Separate connector for brake pad wear indicator.

– Remove bolt from speed sensor.
– Pull speed sensor out of wishbone.
– Unclip line -arrow A- and -arrow B- from bracket on wishbone.
– Disconnect connectors -1- and -2-.

– Unclip line from bracket -3- in direction of arrow.
Installing
– Before inserting speed sensor, clean inner surface of hole and
coat speed sensor around circumference with lubricating
paste -G 000 650- .
– Insert speed sensor into hole in wishbone and tighten bolt
⇒ page 24 . AG. Volkswagen AG d
agen oes
ksw not
Further installation in reverse order. by
Vol
gu
ara
ed
ris nte
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aut ra
s c
s
ce
e
nl
pt
du
tor on rear axle (front-wheel drive)
an
itte
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erm
ab
– Raise vehicle.
ility
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wit
, is n
– Check rotor is not damaged or dirty.
h re
hole
– If rotor is damaged, remove tensioning disc and renew ⇒

Running gear, axles, steering; Rep. Gr. 42 ; Repairing wheel spec
es, in part or in w
t to the co
bearing (front and four-wheel drive) .

rrectness of i
tor on rear axle (four-wheel drive)

l purpos
– Raise vehicle.
– Check rotor is not damaged or dirty.
nf
ercia
orm
– If rotor is damaged, remove drive shaft with rotor and renew

m
atio
m
drive shaft with outer constant velocity joint ⇒ Running gear,

o
n in
c
axles, steering; Rep. Gr. 42 ; Repairing rear drive shaft .

or
thi
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sd
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f
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

5 Removing and installing parts of ESP

system
5.1 Removing and installing yaw rate send‐

er -G202- and lateral acceleration send‐ lksw
agen
AG. Volkswagen AG d
oes
not
er -G200-
o
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s n ri tee
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ac
ss
Note
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nl
pt
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Removal and installation of the yaw rate sender -G202- and the
y li
erm
ab
lateral acceleration sender -G200- are identical, as both are in‐
ility
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stalled in one housing.
wit
, is n
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hole
5.1.1 Removing
spec
es, in part or in w
t to the co
necessary.
– Disconnect battery.
rrectness of i
– Remove passenger side storage compartment ⇒ General
l purpos
body repairs, interior; Rep. Gr. 70 ; Dash panel 09.98 >; Re‐
moving and installing dash panel .
nf
ercia
o
– Fold back front right floor carpet until the yaw rate sender -
rm
m
atio
G202- and the lateral acceleration sender -G200- are freely
om
accessible.
n in
or c
thi
e
Installation location: The yaw rate sender -G202- -1- and the lat‐
t
sd
iva
eral acceleration sender -G200- are installed on the inner side of
o
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rp
cu
the wheel housing near the A-pillar.
o
m
f
en
ng
t.
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– Pull the plug -arrow- off the yaw rate sender -G202- and lateral Cop py
ht. rig
acceleration sender -G200- . opy
rig by
Vo
ht
c lksw
– Unscrew nuts and remove yaw rate sender -G202- and lateral
by
cted agen
Prote
acceleration sender -G200- .
AG.
5.1.2 Installing
WARNING
When renewing yaw rate sender -G202- and lateral accelera‐

tion sender -G200- , it must be ensured that wheel housing is
not damaged or deformed (accident) in area of senders.
Alignment of the senders is vital as regards their function.
– Install in reverse order.

– Enter radio code.
5. Removing and installing parts of ESP system 27

Brake systems as of January 1996 - Edition 09.2004 agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
5.2 Removing and installing control unit - ed
ris nte
ho eo
ut
J104- ss a ra
c
ce
le
un
pt
an
d
itte
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5.2.1 Removing
rm
ab
pe
ility
ot
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necessary.
h re
hole
spec
es, in part or in w
t to the co
– Remove passenger side storage compartment ⇒ General
body repairs, interior; Rep. Gr. 70 ; Dash panel 09.98 >; Re‐
moving and installing dash panel .
rrectness of i
Installation location: Control unit -J104- is located behind pas‐
senger side dash panel directly next to centre console. l purpos
– Fold foam mat forwards.
nform
ercia
– Pull connector from control unit -J104- , moving lever -1- in

m
a
direction of arrow.
com
tion in
r
2 - Centre console
te o
thi
s
iva
do
– Remove control unit -3-.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
5.2.2 Installing
– Enter radio code.
– Code control unit ⇒ Running gear self-diagnosis for ABS as
of January 1996; Rep. Gr. 01 ; Performing self-diagnosis;
Coding control unit .
– Introduce basic setting ⇒ Running gear self-diagnosis for ABS
as of January 1996; Rep. Gr. 01 ; Performing self-diagnosis;
Introducing basic setting .
5.3 Removing and installing steering angle

sender -G85-
– Turn wheels to straight-ahead position.
– Remove airbag unit and steering wheel ⇒ Running gear,
axles, steering as of January 1996; Rep. Gr. 48 ; Removing
and installing airbag; Removing and installing driver side air‐
bag unit .
– Remove trim below steering column switch.
– Remove trim above steering column switch.

– Pull off connectors -arrows-.
– Lift hooks -arrows A- carefully and pull off steering angle send‐
er -G85- .
-Arrow B- points towards the hole for the centre position marking.
This marking is required for installation.
5.3.1 Installing
The steering angle sender -G85- must be in its central
olks position
wage es n
ot g
before installing. db
y V ua
ran
e
ris tee
– Fit steering angle sender -G85- until thetho lugs -arrows A- en‐ or
au ac
gage. ss
ce
le
un
– A yellow dot must be visible in hole -arrow 1-.

pt
an
d
itte
y li
Ensure that the centred position is maintained.
erm
ab
ility
ot p
Further installation in reverse order. wit

is n
h re
– Install airbag unit and steering wheel ⇒ Running gear, axles,
ole,
spec
steering as of January 1996; Rep. Gr. 48 ; Removing and
installing airbag; Removing and installing driver side airbag

t to the co
unit .
– Code control unit ⇒ Running gear self-diagnosis for ABS as
rrectne
of January 1996; Rep. Gr. 01 ; Performing self-diagnosis;

Coding control unit .
ss
– Introduce basic setting ⇒ Running gear self-diagnosis for ABS

o
cial p
as of January 1996; Rep. Gr. 01 ; Performing self-diagnosis;

inform
Introducing basic setting .

mer
atio
om
n
c
i
or
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sd
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cum
r
fo
en
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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.
5. Removing and installing parts of ESP system 29

46 – Brakes - mechanism
1 Repairing front brakes
1.1 Front brake caliper distinguishing fea‐

tures wage
e
ks s no
Vol t gu
Position of the M equipment
ed
by number ⇒ page 1 ara
is nte
or
15'' floating brake
au
th caliper Lucas C54 (M equipment No. 1LP)e or a
⇒ page 31 ss c
ce
e
nl
pt
Distinguishing features:
du
an
itte
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♦ Balancer weight -A- symmetrical.
erm
ab
ility
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♦ VW logo -B- behind gate -C-.
wit
, is n
h re
♦ Continuous reinforcement ribs -D-.
hole
spec
es, in part or in w
♦ Further technical data ⇒ page 2 .
t to the co
15'' floating frame brake caliper Lucas RC54 (M equipment No. rrectness of i
l purpos
1LE) ⇒ page 33
nform
ercia
m
♦ Frame -A- closed.

at
om
ion
c
♦ Brake pads visible from above.

in t
or
his
ate

do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
15'' floating brake caliper FN 3 (M equipment No. 1LU)
⇒ page 36 .
♦ Insert retaining spring -A- into brake caliper housing.
30 Rep. Gr.46 - Brakes - mechanism

16'' floating brake caliper FN 3 (M equipment No. 1LB)

⇒ page 40 .
♦ Insert two-piece retaining spring -A- with additional damping
plate into brake caliper housing.
♦ With brake pad wear indicator -B-.
♦ 16'' is engraved on brake caliper -C-.
16'' floating brake caliper FNR (M equipment No. 1LB)

⇒ page 44 .
♦ Large, outer frame -A-.
♦ With brake pad wear indicator -B-.
♦ Retaining spring is inserted in outer brake pad.
AG. Volkswagen AG d
agen oes
1.2 Repairing front brakes, 15" running gear, floating caliper brake Lucas C54
by
Volksw not
gu
ara
ed
ris nte
ho eo
aut ra
Notess c
ce
le
un
pt
an
♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary, so that the
d
itte
y li
brake pads are properly seated in their normal operating position.

rm
ab
pe
ility
♦ Use a bleed bottle which is only used for brake fluid to extract fluid from brake fluid reservoir. Brake fluid is
ot
wit
, is n
poisonous and must on no account be sucked out by mouth using a hose!

h re
hole
spec
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal actuator -V.A.G 1869/2-
es, in part or in w
(release pressure in system).

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
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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.
1. Repairing front brakes 31

1 - Hexagon bolt, 280 Nm

2 - Brake carrier
3 - Brake pads
❑ Always renew both
sides.
❑ Pad thickness: 13.5
mm.
❑ Check thickness
⇒ Maintenance ; Book‐
let 19 .
❑ Wear limit: 2 mm without
backing plate (remain‐
ing pad thickness).
⇒ page 32 .
4 - Protective cap
5 - Guide pin
6 - Self-locking bolt, 35 Nm
❑ Renew.
7 - Brake caliper
❑ Repairing ⇒ page 66 .
❑ Distinguishing features
⇒ page 30 .
10 Nm
9 - Brake disc
sides.
❑ Remove brake caliper
prior to removing. agen
AG. Volkswagen AG d
oes
lksw not
❑ Non-ventilated brake byV
o gu
ara
disc: ∅ 282 mm. rised
nte
ho eo
❑ Brake disc thickness: 18 mm. s aut ra
c
s
❑ Wear limit: 15 mm.
ce
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nl
pt
du
an
itte
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erm
ab
11 - Cover plate
ility
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wit
, is n
12 - Brake pipe with connection nipple

h re
hole
spec
es, in part or in w
t to the co
14 - Bracket
15 - Brake hose
rrectness of i
l purpos
1.3 Removing and installing brake pads, 15"

running gear, floating caliper brake Lu‐
nf
ercia
cas C54
rm
m
atio
om
n in
or c
thi
e
1.3.1 Removing
t
sd
iva
o
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rp
cu
o
– Remove wheels.
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
32
cted agen
Prote AG.
Rep. Gr.46 - Brakes - mechanism
– Remove lower brake caliper housing securing bolt. Counter

hold on guide pin.
– Swing brake caliper housing upwards.
– Remove brake pads.
1.3.2 Installing
Note
Before inserting new brake pads, press piston back into the cyl‐
inder with resetting tool. Before pressing the piston back, draw off
brake fluid from the reservoir with a bleed bottle. Otherwise par‐
ticularly if reservoir has been topped up, fluid will overflow and
cause damage.
– Press piston back.

– Insert brake pads.
– Swivel the brake caliper housing down and tighten the secur‐
ing bolts to the prescribed tightening torque.
Note
olkswagen AG
en AG. V
♦ The repair kit includes two self-locking
olks hexagon bolts which s no
wag doe
must always be installed. db
yV t gu
ara
rise nte
♦ After replacing brake pads,au
thodepress brake pedal firmly several eo
ra
times with vehicle stationary,
ss so that the brake pads are prop‐ c
erly seated in their normal operating position.
ce
e
nl
pt
du
an
itte
y li
erm
ab
1.4 Repairing front brakes, 15" running gear, floating frame caliper brake Lucas
ility
ot p
wit
RC 54
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i

l purpos
nf
ercia
or

m
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
33
by lksw
cted agen
Prote AG.
1. Repairing front brakes
AG. Volkswagen AG d
agen oes
1 - Hexagon bolt, 280 Nm olksw not
y V gu
d b ara
2 - Brake carrier rise nte
tho eo
au ra
3 - Bridge ss c
ce
le
un
❑ Bolt to brake caliper
pt
an
d
housing ⇒ page 35 .
itte
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erm
ab
4 - Brake disc
ility
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wit
is n
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sides.
ole,
spec
❑ To remove, first un‐

screw lower brake carri‐
t to the co
er bolt and loosen upper
bolt.
rrectne
❑ Internally ventilated
brake disc: ∅ 280 mm.
s
❑ Brake disc thickness: 24
s o
mm.
cial p
f inform
mer
atio
m

o
n
c
10 Nm
i
or
n thi
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sd
a
6 - Outer brake pad

iv
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pr
cum
❑ With adhesive film on
r
fo
en
ng
backing plate.
t.
yi Co
op py
❑ Always renew both t. C rig
gh ht
sides. yri
p by
co Vo
by lksw
❑ Removing and installing cted agen
Prote AG.
⇒ page 35 .
❑ Pad thickness: 13 mm.
❑ Check thickness
let 19 .
❑ Wear limit: 2 mm without
backing plate (remain‐
ing pad thickness).
7 - Inner brake pad
❑ Always renew both sides.
❑ Removing and installing ⇒ page 35 .
❑ Pad thickness: 13 mm.
❑ Check thickness ⇒ Maintenance ; Booklet 19 .
❑ Wear limit: 2 mm without backing plate (remaining pad thickness).
8 - Brake pad retaining pins
9 - Securing spring
10 - Guide pin
11 - Metal ring
12 - Protective cap
❑ Check for damage.

13 - Multi-point socket head bolt, 90 Nm

15 - Bleeder screw
17 - Bracket
19 - Bracket for brake hose
20 - Brake hose
21 - Brake caliper housing
❑ Bolt together with bridge ⇒ page 35 .
❑ Distinguishing features ⇒ page 30 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Bolt bridge and brake caliper housing horis
eo
aut ra
– Position bridge with multi-point socket head bolts and tighten. ss c
ce
le
un
pt
– Insert plate -1- (50 x 24 x 2 mm, produced internally) between
an
d
itte
face end of brake disc and lower side of bridge. This ensures
y li
erm
ab
sufficient clearance between bridge and brake disc.
ility
ot p
wit
– Press brake caliper housing/bridge against plates and tighten
is n
h re
guide pin hexagon nuts.
ole,
spec
– Remove plates and check unobstructed brake disc movement.
t to the co
Note
rrectne
♦ First tighten guide pin on inlet side.
ss
♦ To counter-hold at guide pin, roughen open jaw spanner if
o
cial p
f
necessary.
inform
mer
atio
Torque settings
om
n
c
i
or
Multi-point socket head bolt ⇒ page 33 n thi

te
sd
va
Nuts for guide pins ⇒ page 33

i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
running gear, floating frame caliper
gh ht
pyri by
Vo
o
by c
brake Lucas RC 54
lksw
cted agen
Prote AG.
1.5.1 Removing
– Remove wheels.
– Remove securing spring.

– Drive out brake pad retaining pins with drift -a-.

– Remove inner brake pad.
– Shift frame.
– Loosen outer brake pad from backing plate on bridge using a wage
es n
screwdriver or similar. yV
olks ot g
u b ara
ed
– Press piston back. oris nte
e
th or
au ac
Clean brake caliper housing, particularly the bonding surface
ss for
the brake pad. It must be free of adhesive residues and grease.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
1.5.2 Installing , is n
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
l purpos
cause damage.
nf
ercia
or
– Install inner brake pad.
m
m
atio
m
– Pre-assemble brake pad retaining pins so that inner pad is

o
n in
or c
held.
thi
te
sd
iva
– Pull protective film from outer brake pad.
o
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o
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f
en
ng
– Carefully insert outer brake pad. yi

t.
Co
op py
– Push brake pad retaining pins through fully and install securing
. C rig
ht ht
rig
spring. py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ When inserting the outer brake pad, ensure that it does not
stick to the brake caliper housing before it is in the correct in‐
stallation position.
♦ Do not damage adhesive surface.
♦ After installing new brake pads, forcibly depress brake pedal
two to three times and hold pedal for 5…10 s so that outer
pads stick to brake caliper housing.
♦ This achieves a reliable bond between the outer pad and
noise-free braking.
1.6 Repairing front brakes, 15" running gear, floating caliper brake FN 3
Note


. Volkswagen AG
10 Nm swa
gen AG does
k not
Vol gu
2 - Brakesdisc by ara
ed nte
ri
❑ autBrake
ho
disc thickness: 24 eo
ra
ss mm. c
ce
le

un
pt
an
d
itte
❑ When worn, always re‐
y li
erm
ab
new on both sides of
ility
ot p
axle.
wit
is n
❑ Never remove brake
h re
ole,
discs from hub by force.
spec
If necessary use pene‐
t to the co
trating fluid, because
otherwise brake discs
can be damaged.
rrectne
3 - Hexagon bolt
❑ Renew each time after
ss
removal ⇒ Running
o
cial p
f
gear, axles, steering;
inform
mer
drive shaft .
atio
om
n
c
4 - Wheel bolt
i
or
n thi
e
❑ Modified wheel bolt ⇒

t
sd
iva

pr
cum
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fo

en
ng
t.
Wheel bolt torque set‐
yi Co
op
tings .
C py
t. rig
gh ht
yri by
5 - Brake pads
cop Vo
by lksw
cted agen
Prote AG.
mm.
❑ Brake pad with retaining
spring is seated on pis‐
ton
❑ Brake pad with adhe‐
sive film on backing
plate is seated on outer side.
❑ Check thickness ⇒ Maintenance ; Booklet 19 .
6 - Retaining spring
❑ Insert in both brake caliper housing bore holes.
7 - Brake carrier
❑ Supplied as replacement part, assembled with sufficient grease on guide pins.
❑ Use repair set if protective caps are damaged
❑ Use supplied grease sachet to lubricate guide pins.
8 - Brake caliper
❑ Do not disconnect brake hose when changing brake pads.
❑ Removing:
– Remove brake pads ⇒ page 38 .
– Insert brake pedal actuator -V.A.G 1869/2- and relieve pressure.
– Unscrew brake hose ⇒ Item 14 (page 38) from brake caliper

❑ Installing:
– Installing brake pads ⇒ page 39 .

– Screw brake hose ⇒ Item 14 (page 38) to brake caliper.
– Remove brake pedal depressor -V.A.G 1869/2- .

9 - Guide pin, 25 Nm
10 - Cover plate
12 - Hexagon bolt, 10 Nm agen
AG. Volkswagen AG d
oes
olksw not
13 - Bracket byV gu
ara
ed
ris nte
o
14 - Brake hose aut
h eo
ra
ss c
15 - Drive shaft
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
18 - Bracket
spec
19 - ABS speed sensor
t to the co
❑ Before inserting sensor, clean fitting hole's inner surface and coat with lubricating paste -G 000 650- .
20 - Hexagon Allen head bolt, 10 Nm
rrectne
21 - Hexagon bolt
ss
22 - Cover plate
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi

te
sd
iva
running gear, floating caliper brake FN 3

pr
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r
fo
en
ng
t.
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Cop py
ht. rig
1.7.1 Removing rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Mark brake pads when removing if they are to be reused. Reinstall

in their original position to prevent uneven braking!
– Remove wheels.
– Remove protective caps -arrows-.

– Detach brake pad retaining spring from brake caliper housing

and remove.
Note
By pressing in direction of arrow (arrow stamped on retaining

spring), tilt retaining spring out of one housing bore hole -arrow-
and remove.
– Unbolt and remove both guide pins from brake caliper.

– Take off brake caliper housing and lay to one side so that the
weight of the brake caliper does not stress or damage the
brake hose.
– Take brake pad out of brake caliper housing or remove from
brake carrier.
Clean brake caliper housing, particularly the bonding surface for
the brake pad. It must be free of adhesive residues and grease.
1.7.2 Installing
Note
cause damage. AG. Volkswagen AG d
agen oes
lksw n o ot g
yV ua
edb ran
– Press piston back. ris tee
tho or
au ac
– Insert brake pad with retaining spring
ss in brake caliper housing
(piston).
ce
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un
pt
an
d
itte
– Fit outer brake pad on brake carrier.

y li
erm
ab
ility
– Secure brake caliper housing to brake carrier with both guide

ot p
pins and tighten to 25 Nm.

wit
is n
h re
ole,
– Fit both protective caps.

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
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fo
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ng
t.
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Cop py
t. rig
gh ht
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Vo
o
39
by c lksw
cted
1. Repairing front brakes
agen
Prote AG.
– Position one retaining spring AG.clip

Volkside
swagebelow
n AG d brake carrier and
insert one lug intoohousing
swagen bore hole -arrow oeA-.
s noTension sec‐
k
ond clip side belowy V l brake carrier and insert secondt gu lug into
d b ara
bore hole -arrow
or
ise
B-. nte
e
th or
s au ac
s
ce
e
Note
nl
pt
du
an
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
noise-free braking.
l purpos
nform
ercia
1.8 Repairing front brakes, 16" running gear, floating caliper brake FN 3
m
at
om
ion
c
in t
r
Note
o
his
ate
do
riv
p
cum
for

en
ng
t.
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op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
1 - Hexagon bolt agen oes
olksw not
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❑ Renew each time after ed b ara
nte
is
removal ⇒ Running hor eo
ut
gear, axles, steering; ss a ra
c
ce
le
un
drive shaft .
pt
an
d
itte
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erm
ab
10 Nm
ility
ot p
wit
is n
3 - Brake disc
h re
ole,
❑ Brake disc thickness: 26
spec
mm.
t to the co
rrectne
axle.
ss o
cial p
f i
nform
mer
atio
om
can be damaged.
n
c
i
or
n thi
e
4 - Brake pads
t
sd
iva
o
pr
c
um
r
fo
sides.
en
ng
t.
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op
❑ With wear indicator. C py
ht. rig
rig ht
❑ When wear reaches a py by
o Vo
predetermined limit (ap‐
by c lksw
cted agen
prox 2-3 mm), a warning
Prote AG.
lamp in dash panel in‐

sert comes on.
mm.
❑ Check thickness
let 19 .
❑ Wear limit: 8 mm (including backing plate).
❑ Brake pad with retaining spring is seated on piston
❑ Brake pad with adhesive film on backplate is seated on outer side
5 - Connector
❑ When changing pads, remove from bracket ⇒ Item 12 (page 42) .
❑ With additional damping plate.
❑ Insert in both brake caliper housing bore holes.
7 - Brake carrier
8 - Brake caliper
❑ Removing:

❑ Installing:
– Screw brake hose ⇒ Item 13 (page 42) to brake caliper.

10 - Cover plate
12 - Bracket
13 - Brake hose
16 - Drive shaft with rotor AG. Volkswagen AG d
agen oes
olksw not
17 - Wheel bearing housing d byV gu
ara
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r
18 - ABS speed sensor ut
ho eo
ra
a c
❑ Before inserting sensor, clean fitting hole's inner surface and coat with lubricating paste -G 000 650- . ss
ce
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un
pt
19 - Bracket
an
d
itte
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erm
ab
ility
ot p
21 - Cover plate
wit
is n
h re
ole,
spec
t to the co
rrectne
running gear, floating caliper brake FN 3
ss o
cial p
1.9.1 Removing
f inform
mer
atio
om
Note
n
c
i
or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
t.
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op
– Remove wheels. C py
ht. rig
rig ht
by
– Remove protective caps -arrows-. copy Vo
by lksw
cted agen
Prote AG.

– Detach brake pad retaining spring from brake caliper housing

and remove.
Note
By pressing in direction of arrow (arrow stamped on retaining AG. Volkswagen AG d

agen
spring), tilt retaining spring out of one housing bore hole -arrow- olksw
oes
not
and remove. ed
byV gu
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aut ra
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un
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erm
ab
– Disconnect connector -1- for brake pad wear indicator.
ility
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wit
– Lift up locking tab slightly on connector lower part -2- and then is n
h re
turn by 90° degrees.
ole,
spec
– Pull connector lower part out of bracket and unclip line from
t to the co
bleeder valve protective cap -3-.
rrectness o
cial p
f inform
mer
atio
– Unbolt and remove both guide pins from brake caliper.
om
n
c
i
or
n
thi
te
sd
iva
o
r
brake hose.
p
cum
r
fo
en
ng

t.
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op
brake carrier. C py
ht. rig
rig ht
by
Clean brake caliper housing, particularly the bonding surface for copy Vo
by lksw
the brake pad. It must be free of adhesive residues and grease. cted agen
Prote AG.
1.9.2 Installing
Note
cause damage.

. Volkswagen AG
does
swa
Brake systems as of January 1996 - Edition y09.2004
Volk not
gu b ara
ed nte
ris
– Press piston back. au
tho e or
ac
ss
– Insert brake pad with retaining spring in brake caliper housing
ce
e
nl
(piston).
pt
du
an
itte
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– Fit outer brake pad with brake wear indicator on brake carrier.
erm
ab
ility
ot p
– Secure brake caliper housing to brake carrier with both guide
wit
, is n
pins and tighten to 25 Nm.
h re
hole
spec
– Insert brake wear indicator connector lower part into bracket
on brake caliper. es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
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a
– Position one retaining spring clip side below brake carrier and
iv
o
r
insert one lug into housing bore hole -arrow A-. Tension sec‐
rp
cu
o
m
f
ond clip side below brake carrier and insert second lug into
en
ng
t.
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bore hole -arrow B-.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note Prote
cted AG.
agen
♦ When inserting retaining springs, do not damage or shift re‐

taining spring damping plate.
noise-free braking.
1.10 Repairing front brakes, 16" running gear, floating caliper brake FNR
Note
♦ Wheel bolt torque settings ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Wheel bolt torque settings


2 - Drive shaft
❑ With rotor for speed
sensor
4 - ABS speed sensor
❑ Before inserting sensor,
clean fitting hole's inner
surface and coat with lu‐
bricating paste -G 000
650- .
5 - Bracket
10 Nm
7 - Cover plate
8 - Hexagon bolt, 10 Nm AG. Volkswagen AG d
agen oes
lksw not
9 - Brake disc d by
Vo gu
ara
e nte
❑ Brake disc thickness: 26 horis
eo
mm. aut ra
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un
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an
❑ Internally ventilated
d
itte
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brake disc: ∅ 313 mm.
erm
ab
ility
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wit
is n
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axle.
ole,
spec

t to the co
rrectne
can be damaged.
s
10 - Hexagon bolt
s o
cial p
f
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft .
inform
mer

atio
om
12 - Connector
n
c
i
or
n thi
❑ When changing pads, remove from bracket ⇒ Item 22 (page 46) .

te
sd
iva
o
pr
13 - Brake pads
um
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fo
en
ng
❑ Thickness 14 mm.
t.
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op py
❑ Brake pad with retaining spring is seated on piston t. C rig
gh ht
yri by
❑ When wear reaches a predetermined limit (approx 2-3 mm), a warning lamp in dash panel insert comes op Vo
by c lksw
on. cted agen
Prote AG.
❑ Brake pad with adhesive film on backplate is seated on outer side
❑ Wear limit: 7 mm including backplate
❑ Checking thickness ⇒ Maintenance ; Booklet 19 ; Work sequences; Front and rear brake pads/linings:
Checking thickness .
15 - Brake carrier

16 - Brake caliper
❑ Removing:

❑ Installing: agen
AG. Volkswagen AG d
oes
olksw not
V
– Installing brake pads ⇒ page 47 . ed by gu
ara
ris nte
ho eo
– Screw brake hose ⇒ Item 23 (page
s aut 46) to brake caliper. ra
c
s
ce
le

un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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ole,
spec
t to the co
18 - Cover plate
19 - Bracket
rrectne
s
s o
cial p
f in
22 - Bracket
form
mer
23 - Brake hose
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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op
running gear, floating caliper brake FNR
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.11.1 Removing
Note

– Remove protective caps.

– Lever brake pad retaining spring out from brake caliper hous‐
ing -arrow- with a screwdriver and remove.

– Lift up locking tab slightly on connector lower part -1- and then
turn by 90° degrees.
– Pull connector lower part out of bracket in direction of arrow.
– Unscrew both guide pins -arrows- from brake caliper and re‐
move.
brake hose.
brake carrier.
Use methylated spirit only for cleaning the brake caliper housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
1.11.2 Installing
a ac
ss ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
cause damage.
– Press piston back.

rrectness of i
– Insert brake pad with retaining spring in brake caliper housing

l purpos
(piston).
– Fit outer brake pad on brake carrier.
nform
ercia
– Bolt brake caliper housing to brake carrier with both guide pins
m
at
om
⇒ page 44 .
on
c
in t
or

his
ate
do
priv
– Insert retaining spring into brake caliper housing.

cum
for
en
ng
t.
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Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ After changing brake pads, firmly depress brake pedal several
cted agen
Prote AG.
times with vehicle stationary, so that the brake pads are prop‐
♦ After changing brake pads check brake fluid level.

2 Repairing rear brakes
2.1 Repairing rear brakes, 15" running gear
1 - Hexagon bolt
❑ Renew each time fol‐
lowing removal ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. Gr. 42 ;
wheel drive) .
2 - Washer
10 Nm
4 - Brake disc
❑ Thickness 12 mm.
❑ Wear limit 10 mm.
new both sides. wage
es ks not
Vol gu
5 - Hexagon bolt, 10 eNm
db
y ara
nte
is
or eo
6 - Cover plate auth ra
ss c
7 - Hexagon bolt
ce
le
un
pt
an
d
8 - Spring for brake pressure

itte
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erm
regulator
ab
ility
ot p
❑ Adjusting the brake

wit
is n
pressure regulator
h re
ole,
⇒ page 89 .
spec
❑ Not fitted in vehicles

t to the co
with four-wheel drive,

ABS Bosch 5.3 and
closed body (van, Kom‐
rrectne
bi, Caravelle, Multivan).

ss o
10 - Mounting plate
cial p
f inform
❑ Mark installation posi‐

mer
tion before removing.

atio
om
11 - Bracket
c
i
or
n thi
te
sd
12 - Wishbone
iva
o
pr
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. Gr. 42 ; Repairing the rear wheel sus‐
um
r
fo
en
ng
pension .
t.
yi Co
Cop py
13 - Self-locking hexagon nut
t. rig
gh ht
yri by
❑ Renew.
op Vo
by c lksw
cted agen
❑ Vehicles with front-wheel drive only ⇒ Running gear, axles, steering; Rep. Gr. 42 ; Repairing rear wheel
Prote AG.
bearings (front and four-wheel drive) .

14 - Tensioning disc

AG. Volkswagen AG d
lksw
agen Brake oessystems as of
not January 1996 - Edition 09.2004
Vo gu
d by ara
e
15 - Speed sensor horis nte
eo
aut ra
16 - Hexagon Allen
ss head bolt, 10 Nm c
ce
le
un
pt
an
d
itte
y li
18 - Wheel bearing
rm
ab
pe
ility
19 - Circlip
ot
wit
, is n
h re
❑ Ensure proper seating.
hole
spec
20 - Hub
es, in part or in w
t to the co
21 - Brake carrier with guide pin and protective cap
❑ Vehicles up to chassis No. 70ZWH130 482 / 70ZWX121 939 without brake pad retaining springs.
rrectness of i
l purpos
❑ If protective caps or guide pins are damaged, install repair kit. Use grease sachet supplied to lubricate
guide pins.
nform
ercia
22 - Brake pads
❑ Thickness 11.5 mm without backing plate
m
a
com
tio
❑ Check thickness: ⇒ Maintenance ; Booklet 19 .
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
23 - Self-locking hexagon bolt, 35 Nm t. C rig
gh ht
yri by
❑ Renew. op Vo
by c lksw
cted agen
❑ When loosening and tightening, counter hold on guide pin.Prote AG.
24 - Guide pin
25 - Protective cap
26 - Brake caliper
❑ Modification: Adapted in vehicles as of chassis No. 70ZWH130 483 / 70ZWX121 940 on use of brake
pad retaining springs ⇒ Item 29 (page 49) and brake carrier ⇒ Item 30 (page 49) .
27 - Handbrake cable
❑ Adjust handbrake ⇒ page 63 .
28 - Spring clip
29 - Anti-rattle spring
❑ Installed in vehicles as of chassis No. 70ZWH130 483 / 70ZWX121 940.
❑ Install in conjunction with new brake carrier ⇒ Item 30 (page 49) only.
❑ Always renew when changing pads.
❑ Installed in vehicles as of chassis No. 70ZWH130 483 / 70ZWX121 940 on use of brake pad retaining
springs ⇒ Item 29 (page 49) .
guide pins.
2. Repairing rear brakes 49


running gear
2.2.1 Removing
Note

– Remove wheels. n AG. Volkswagen AG do

lkswage es n
– Remove handbrake cable from brake caliper. d byV
o ot g
ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove securing bolts -arrows- from brake caliper housing.
rrectne
s
s o
brake hose.
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
yri by
– Remove brake pads. cop Vo
by lksw
cted agen
Prote
– If fitted, remove brake pad retaining springs.
AG.

2.2.2 Installing
Note
Before pressing pistons back, draw off some brake fluid from res‐
ervoir. Use a bleed bottle or a plastic bottle which is only used for
brake fluid. Brake fluid is poisonous and must on no account be
sucked out by mouth through a hose.
– Brake caliper housing is attached to hook -arrow B-.

– Screw in piston by turning knurled wheel of resetting and re‐
moval tool -3272- clockwise, do not damage protective cap
when doing this.
Note
♦ Apply resetting and removal tool -3272- so that collar -arrow-

of tool rests on brake caliper.
♦ If piston is difficult to move, use a 13 mm open jaw spanner
on flats -arrow A- provided for this purpose.
♦ If the piston is pushed back with a piston resetting tool or by
operating the foot brake the automatic adjustment in the brake
caliper is destroyed.
In vehicles up to chassis No. 70ZWH130 482 / 70ZWX121 939:

– On brake carrier, thoroughly clean contact surfaces for brake
pads, remove corrosion.
– Insert brake pads into brake carrier.
– Use a feeler gauge -A- to check play between brake gpads

en AG. V
olkswagen AG
does
swa
-1- and brake pad contact surfaces -2- on brake
yV
olkcarrier. not
gu b ara
ed
Play: at least 0.4 mm to guarantee proper tbrake
ho
ris system function. nte
e or
au ac
If play is less than 0.4 mm, again clean scontact
s surfaces for brake
ce
pads on brake carrier.

e
nl
pt
du
an
itte
– Remove brake pads.

y li
erm
ab
ility
– Lightly coat brake pad contact surfaces with lubricating paste

ot p
wit
-G 000 650- .
, is n
h re
hole
– Insert brake pads into brake carrier.

spec
es, in part or in w
In vehicles as of chassis No. 70ZWH130 483 / 70ZWX121 940:

t to the co
– On brake carrier, thoroughly clean contact surfaces for pad

retaining springs, remove corrosion.
rrectness of i
– Insert brake pad retaining springs and brake pads into brake
l purpos
carrier.
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.

– Use a feeler gauge -A- to check play between brake pads

-1- and brake pad retaining springs -2- on brake carrier.
Play: at least 0.4 mm to guarantee proper brake system function.
If play is less than 0.4 mm, again clean contact surfaces for brake
pad retaining springs on brake carrier.
Continuation for all vehicles AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Secure brake caliper housing with new self-locking d b bolts. ara
rise nte
ho eo
♦ The repair kit includes four self-locking hexagon
aut bolts which ra
c
must always be installed. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Attach handbrake cable -arrow- to brake caliper housing.
ility
ot p
– Adjust handbrake ⇒ page 63 .
wit
, is n
h re
hole
Operate foot brake first after adjusting handbrake.
spec
es, in part or in w
– Install wheels.
t to the co
Note
rrectness of i
l purpos

times with vehicle stationary, so that the brake pads are prop‐
nf
ercia
or
♦ After changing brake pads check brake fluid level.
m
m
atio
om
n in
or c
thi
2.3 Repairing rear brakes, 16" running gear
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.


10 Nm
3 - ABS speed sensor wagen AG. Volkswagen AG does
olks not
❑ Before inserting db
y V sensor, gu
ara
clean fitting
oris hole's inner
e nte
eo
surfaceaut and coat with lu‐
h
ra
bricating
ss paste -G 000 c
ce
e
650- .
nl
pt
du
an
itte
4 - Connector
y li
erm
ab
❑ When changing pads,
ility
ot p
remove from bracket
wit
, is n
⇒ Item 7 (page 53) .
h re
hole
spec
5 - Wishbone
es, in part or in w
t to the co
6 - Self-locking hexagon bolt,
35 Nm
❑ Renew.
rrectness of i
❑ When loosening and
l purpos
tightening, counter hold

on guide pin.
nf
ercia
7 - Bracket
orm
m
atio
8 - Guide pin
om
n in
or c
9 - Protective cap
thi
te
sd
iva
10 - Brake pads
o
r
rp
cu
o
m
f

en
ng
t.
yi
sides.
Co
Cop py
ht. rig
❑ With wear indicator. rig ht
py by
o Vo
❑ Once wear limit is
by c lksw
cted agen
reached, warning light in
Prote AG.
dash panel insert comes

on.
❑ Thickness 13.5 mm.
❑ Wear limit: 8.5 mm including backplate
❑ Checking thickness: ⇒ Maintenance ; Booklet 19 ; Work sequences; Front and rear brake pads/linings:
Checking thickness .
11 - Anti-rattle spring
❑ Always renew when changing pads.
❑ Clip into brake caliper.
❑ Secures brake pad wear indicator wiring.
13 - Brake caliper
❑ Removing:
– Unscrew brake hose with brake caliper.

❑ Installing:
– Screw on brake hose with brake caliper.


❑ Adjust handbrake cable first after repairing or renewing.
14 - Spring clip
guide pins.
18 - Brake disc
❑ Thickness 13.5 mm.
❑ Wear limit 11.5 mm.
❑ When worn, always renew both sides.Volkswa
AG. gen AG
agen does
19 - Hexagon bolt, 10 Nm olksw not
yV gu
db ara
20 - Cover plate rise nte
tho eo
❑ Allocation ⇒ Electronic Parts Catalogue au “ETKA” . ra
c
ss
ce
e
21 - Cover plate
nl
pt
du
an
itte
❑ Drill out pop rivet ⇒ Item 22 (page 54) to remove.

y li
erm
ab
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA” .

ility
ot p
wit
, is n
22 - Pop rivet
h re
hole
❑ Qty. 4
spec
es, in part or in w
23 - Connecting strut
t to the co
rrectness of i

l purpos
running gear
nform
ercia
♦ Resetting and removal tool -3272-

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

Note

2.4.1 Removing
– Remove wheels.
– Unclip spring clip -1-.
– Remove handbrake cable -2- from brake caliper.
– Rotate brake pad wear indicator connector 90° and pull side‐
ways out of cable duct.
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
– Unclip retaining spring -A- for brake pad wear indicator cable wit
, is n
from brake caliper. h re

hole
spec
– Remove securing bolts -arrows- from brake caliper housing.

es, in part or in w
t to the co
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– Remove brake pads and pad retaining springs -arrows-.
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Before pressing pistons back, draw off some brake fluid from res‐
ervoir. Use a bleed bottle or a plastic bottle which is only used for
brake fluid. Brake fluid is poisonous and must on no account be
rrectness of i
sucked out by mouth through a hose.
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– Brake caliper housing is attached to hook -arrow B-.
nf
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– Screw in piston by turning knurled wheel of resetting and re‐
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moval tool -3272- clockwise, do not damage protective cap

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– On brake carrier, thoroughly clean contact surfaces for pad

retaining springs, remove corrosion.
– Insert brake pad retaining springs and brake pads into brake
carrier.
– Use a feeler gauge -A- to check play between brake pads

-1- and brake pad retaining springs -2- on brake carrier.
Play: at least 0.4 mm to guarantee proper brake system function.
If play is less than 0.4 mm, again clean contact surfaces for brake
pad retaining springs on brake carrier.

– Insert brake pad retaining springs -arrows- and brake pads,

inner brake pad with cable for brake pad wear indicator, into
brake carrier.
– Secure brake caliper housing with new self-locking bolts.
Note
The repair kit includes four self-locking hexagon bolts which must
always be installed.
– Press brake lever -3- in direction of arrow and attach hand‐

brake cable -2-.
– Install spring clip -1-.
– Assemble the connection -5- for brake pad wear indicator and
press this into cable duct -4-.
– Turn connector 90° in cable duct.
Operate foot brake first after adjusting handbrake.
– Install wheels.
Note

times with vehicle stationary, so Vthat the brake pads are prop‐
erly seated in their normal
swageoperating
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3 Repairing handbrake
3.1 Removing and installing handbrake lever
1 - Handle
❑ Press down locking lugs
underneath handle and
pull off forwards.
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2 - Handbrake lever trim Volksw not
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3 - Trim horis nte
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4 - Push button ss c
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⇒ page 59 .
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6 - Spring sleeve
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⇒ page 59 .
es, in part or in w
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7 - Pawl rod
8 - Pawl
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9 - Circlip
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10 - Handbrake lever
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11 - Pin
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12 - Self-locking nut, 25 Nm
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❑ Not fitted in RHD.

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15 - Spreader rivet Prote
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❑ Renew.
17 - Toothed segment
❑ For RHD only.
18 - Pull rod
19 - Bracket
20 - Return spring
21 - Spring retainer
22 - Adjusting nut
23 - Pull cable
❑ Fitted in dropside only.

Spring sleeve installation position

1 - Pawl
2 - Spring sleeve
3 - Spring
- Dimension -a- approx. 126 mm
- On installation, push spring sleeve -2- onto spring -3-.
4 - Push button
- Screw on to stop.
5 - Pawl rod
6 - Handbrake lever
3.2 Removing and installing front hand‐

brake cable
3.2.1 Removing
– Release handbrake.
– Raise vehicle.
– Unscrew nut -arrow- from front handbrake cable.
– Lever the 2 retainers out from underbody.
AG. Volkswagen AG d
– Remove handbrake lever trim. agen oes
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– Raise brake lever to final position. rised
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– Detach front handbrake cable from pawl -1- -arrow-.

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– Guide handbrake cable through underbody into interior. t. Cop py
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– Raise brake lever to final position. yri
p by
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3. Repairing handbrake 59
– Attach front handbrake cable to pawl -1- -arrow-.

– Attach new cable ties to pawl in front of front handbrake cable.
– Install handbrake lever trim.
– Raise vehicle.
– Clip retainers into underbody.
– Screw nut -arrow- onto front handbrake cable.

AG. Volkswagen AG d
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3.3 Removing and installing pull rod

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3.3.1 Removing
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– Release handbrake.
t to the co
– Raise vehicle.
– Unscrew nut -arrow- from front handbrake cable.
rrectness of i
– Detach pull rod from compensator.

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– Remove pull rod -1- from rear handbrake cable -2-.
op Vo
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3.3.2 Installing
– Attach pull rod -1- to rear handbrake cable -2-.
– Attach pull rod to compensator.
– Screw nut -arrow- onto front handbrake cable.

3.4 Removingkswand agen installing rear

AG. Volkswagen AG d handbrake
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3.4.1 Removing
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– Unclip spring clip -1-.

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– Remove handbrake cable -2- from brake caliper.

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– Detach handbrake cable from retainer on wishbone

-arrow A-.
olkswagen AG
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– Unclip handbrake cable from retainer onolkunderbody
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3.4.2 Installing
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– Attach handbrake cable -1- to pull rod -2-.
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– Clip handbrake cable into retainer on underbody.
nform
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at
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ion
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– Attach handbrake cable to retainer on wishbone -arrow A-. Prote AG.

– Attach handbrake cable -2- to brake caliper.

– Clip spring clip -1- in.
AG. Volkswagen AG d
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3.5 Adjusting handbrake
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Note
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A new adjustment is only necessary after renewing, handbrake
es, in part or in w
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cables, brake calipers and brake discs.
rrectness of i
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– Handbrake lever in released position. Tighten adjusting nut in

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illustration V46-0819 until lever -arrow- lifts off the brake cali‐
at
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per stop.
n
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at
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– Pull on and then release handbrake.
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rig
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cted
Due to the automatic rear wheel brake adjustment there is no re‐
agen
Prote AG.
quirement to adjust the handbrake after making new/initial ad‐
justment.
– Check that both wheels turn freely.
4 Assembly overview - brake pedal
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
Note
Grease all bearing points withengrease

AG. Volks-G
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1 - Cap tho eo
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❑ Brake fluid warning indi‐
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3 - Sealing plug
spec
es, in part or in w
❑ Moisten with brake fluid t to the co

and press into expan‐
sion tank.
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inder
❑ Cannot be repaired. If
nform
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faulty, renew complete.

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❑ Bleed ⇒ page 85 .
com
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6 - Sealing ring
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❑ Ensure secure seating. t. Cop py
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8 - Pin p by
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❑ Grease with -G 000 cted agen
Prote AG.
602- .
❑ Renew.
10 - Push rod with brake servo
forked head
en from the intake manifold.
❑ On Diesel engines an exhauster is installed to generate vacuum.
– With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
– Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the pedal will be felt to give slightly under foot (servo assistance becomes effective).
– If faulty, renew complete.

❑ Non-return valve (in vacuum hose) ⇒ page 95 .
Functional check ⇒ page 95 .
12 - Gasket
❑ For tandem brake servo.
13 - Circlip
14 - Return spring for brake pedal
15 - Mounting bush for brake pedal
16 - Brake pedal
17 - Brake pedal pins n AG. Volkswagen AG do
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18 - Brake light switch byV
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❑ Before installing brake lighthoswitch,
ris secure brake pedal to brake servontpush ee rod.
ut or
❑ Before installing pull plunger
ss
a out fully. ac
❑ Guide switch through fitting hole and install by turning 90° to the right.
ce
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20 - Mounting bracket
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22 - Mounting plate
es, in part or in w
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23 - Bulkhead
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4.1 Removing and installing brake pedal
l purpos
nform
ercia
Note
m
at
om
♦ Lubricate all bearing and contact surfaces using MoS2 grease.

ion
c
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or
♦ Only the forked head connection to the brake pedal has to be

his
ate
removed to remove the brake servo.

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4.1.1 Removing
yi Co
Cop py
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– Remove covers before installing brake pedal. p by
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– Remove brake light switch. Prote AG.
– Remove circlip on pin for connecting fork head to brake pedal.

– Remove pin.
– Remove circlip for pivot pin for clutch and brake pedal.
– Remove clutch pedal ⇒ Rep. Gr. 30 ; Repairing clutch ac‐
tuation; Removing and installing clutch pedal .
– Remove pivot pin.
– Remove brake pedal.
4.1.2 Installing
– Adjust brake light switch ⇒ Item 18 (page 65) .
4. Assembly overview - brake pedal 65

47 – Brakes - hydraulics
1 Repairing front brake calipers
1.1 Repairing front brake calipers, 15" running gear, floating caliper brake Lucas
C54
Note
♦ When carrying out repairs install all parts supplied in repair kit.
♦ Apply thin coat of assembly paste -G 052 150 A2- to brake
swa
cylinders,
gen AG
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wagen AG
doesseals.
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1 - Brake caliper housing au ra
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2 - Sealing ring
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un
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an
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itte
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⇒ page 66 .
erm
ab
ility
ot p
3 - Protective cap
wit
is n
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❑ Do not damage when in‐
ole,
spec
serting piston.
t to the co
4 - Piston
⇒ page 66 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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t.
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Prote AG.
1.2 Removing and installing pistons for front

brake calipers, 15" running gear, floating
caliper brake Lucas C54
66 Rep. Gr.47 - Brakes - hydraulics

lkswage es n
o ot g
byV ua
ir se
d Transporter
ran
te 1996 ➤
t o
h Brake systems as of January 1996 - Editione o09.2004
au ra
ss c
ce
e
♦ Wedge -3409-
nl
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du
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ab
ility
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
♦ Piston resetting appliance -T10145-

m
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ate
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en
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
1.2.1 Removing
– Press piston out of brake caliper housing using compressed
air.
Note
Place a piece of wood in the recess to prevent damage to the

piston.
– Remove seal using wedge -3409- .
Note
When removing ensure that the surface of the cylinder is not

damaged.
1.2.2 Installing
– The surface of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Thinly coat piston and seal with assembly paste -G 052 150
A2- before inserting.
1. Repairing front brake calipers 67

– Insert oil seal in brake caliper housing.

– Place protective cap with outer sealing lip on piston.
– Using wedge -3409- , insert inner sealing lip into grove in cyl‐
inder.
Note
When doing this hold piston in front of brake caliper housing.
AG. Volkswagen AG d
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olksw not
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ara
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– Press piston into the brake caliper housing using piston reset‐
le
un
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ting tool.
an
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Note
wit
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The protective seal outer sealing lip will then locate in the piston
spec
es, in part or in w
groove.
t to the co
rrectness of i
l purpos
1.3 Repairing front brake calipers, 15" running gear, floating frame caliper brake
nform
ercia
Lucas RC 54
m
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tion in
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te o
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Note
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op
♦ Dismantling and assembling brake caliper ⇒ page 33 . C py
ht. rig
rig ht
♦ Apply thin coat of assembly paste -G 052 150 A2- to brake cylinders, pistons and seals.
py by
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by lksw
cted agen
Prote AG.

Brake systems as
en AG . of
Vo January
lkswagen 1996
AG - Edition 09.2004
ag does
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Vol gu
1 - Bleeder screw ed
by ara
nte
oris eo
2 - Brake caliper housing au
th
ra
ss c
3 - Sealing ring
ce
le
un
pt
an
d
itte
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⇒ page 69 .
erm
ab
ility
ot p
4 - Protective cap
wit
is n
h re
ole,
serting piston.
spec
5 - Piston
t to the co
⇒ page 69 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

brake calipers, 15" running gear, floating
frame caliper brake Lucas RC 54
♦ Wedge -3409-

1.4.1 Removing
air.
Note

piston.
lkswage es n
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byV ua
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ir se tee
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a ac
ss
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un
pt
an
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Note
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is n
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spec
damaged.
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cial p
1.4.2 Installing f inform

mer
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AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ut
ho eo
ra
a
ss Brake systems as cof January 1996 - Edition 09.2004
ce
le
un
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ility
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es, in part or in w
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nform
ercia
– Insert inner sealing lip into grove in cylinder.

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tion in
Note
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Cop py
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rig ht
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ting tool.
Note
groove.
1.5 Repairing front brake calipers, 15" running gear, floating caliper brake FN
3
Note

. Volkswagen AG
does
swa
Brake systems as of January
y V 1996 - Edition 09.2004
olk not
gu b ara
ed nte
ris
1 - Dust cap au
tho e or
ac
ss
❑ Fit onto bleed valve.
ce
le
un
pt
2 - Bleed valve
an
d
itte
y li
❑ Apply thin coat of as‐
erm
ab
ility
sembly paste -G 052
ot p
wit
150 A2- to the thread
is n
h re
before screwing in.
ole,
spec
3 - Cap
t to the co
❑ Insert into mounting
bush.
rrectne
5 - Mounting bush
ss
❑ Insert into brake caliper
o
cial p
f
housing.
inform
mer
atio
om
n
7 - Brake carrier
c
i
or
n thi
e

t
sd
va
housing.
i
o
pr
cum
r
fo
en
ng
8 - Retaining spring yi
t.
Co
op
❑ Insert with both ends in
C py
ht. rig
the bore holes in brake rig ht
py by
Vo
caliper housing.
co lksw
by
cted agen
Prote AG.
9 - Sealing ring
⇒ page 72 .
10 - Piston
⇒ page 72 .
11 - Protective cap
serting piston.

brake caliper, 15" running gear, floating
caliper brake FN 3
♦ Wedge -3409-

AG. Volkswagen AG d
agen oes
ksw
by
Vol not
gu Transporter 1996 ➤
d ara
orise Brake
nte systems as of January 1996 - Edition 09.2004
h eo
aut ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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ole,
spec
t to the co
rrectness o
1.6.1 Removing
cial p
f inform
mer
atio
air.
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng

t.
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op
piston. C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note

damaged.
1.6.2 Installing

inder.
Note
ting tool.
Note
groove. agen
AG. Volkswagen AG d
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olks ot g
byV ua
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ris tee
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1.7 Repairing front brake calipers, 16" running gear, floating caliper brake FN
rm
ab
pe
ility
3
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hole
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Note
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - Dust cap
❑ Secures brake pad wear
indicator wiring.
2 - Bleed valve
sembly paste -G 052
before screwing in.
3 - Cap
bush.
5 - Mounting bush
housing.
7 - Brake carrier
housing.
❑ Insert with both ends in
the bore holes in brake
caliper housing.
9 - Sealing ring
⇒ page 75 .
10 - Piston AG. Volkswagen AG d
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❑ Removing and installing olksw
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⇒ page 75 . byV gu
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11 - Protective cap aut
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1.8.1 Removing
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methylated spirits and then dried. Prote AG.

inder.
Note
AG. Volkswagen AG d
– Press piston into the brake caliper housing using piston wreset‐
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olks not
ting tool. db
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es, in part or in w
1.9 Repairing front brake calipers, 16" running gear, floating caliper brake FNR t to the co
rrectness of i
l purpos
Note
nform
ercia
m
♦ New brake calipers are filled with brake fluid and are pre-bled.
at
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ate
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Cop py
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by
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1 - Dust cap
❑ Secures brake pad wear
indicator wiring.
2 - Bleed valve
sembly paste -G 052
before screwing in.
3 - Cap
bush.
5 - Mounting bush
housing.
❑ Qty. 2
7 - Brake carrier
housing.
❑ Insert the two ends be‐
tween the outer and in‐
ner part of the brake
caliper housing.
❑ Insert in the centre into
the tab on the brake pad
9 - Sealing ring
AG. Volkswagen AG d
❑ Removing and installing ksw
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not
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⇒ page 78 . byV
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10 - Piston ut
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❑ Removing and installing ⇒ page 78 . ss c
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le
❑ First coat piston lightly with assembly paste -G 052 150 A2- .
un
pt
an
d
itte
❑ Piston diameter 57 mm.

y li
erm
ab
ility
11 - Protective cap
ot p
wit
is n
❑ Do not damage when inserting piston.

h re
ole,
spec
t to the co

rrectne
caliper brake FNR

s

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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78
Prote AG.
Rep. Gr.47 - Brakes - hydraulics
♦ Wedge -3409-
lkswage es n
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pt
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1.10.1 Removing
, is n
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spec
es, in part or in w
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t to the co
Note
rrectness of i
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piston. nf
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Cop py
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t. rig
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damaged.
1.10.2 Installing


inder.
Note
ting tool. agen
AG. Volkswagen AG d
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tee
or
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pt
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ility
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es, in part or in w
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nform
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c
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ate
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priv
cum
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en
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Cop py
t. rig
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Prote AG.

2 Repairing rear brake caliper
Note
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply thin coat of assembly paste -G 052 150 A2- to brake
cylinders, pistons and seals.
♦ When carrying out repairs it is essential to appropriately pre-
bleed the brake calipers (without brake pads) before installing
in the vehicle ⇒ page 84 .
1 - Self-locking hexagon bolt, agen

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35 Nm olksw not
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on guide pin.
pt
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2 - Sealing ring
erm
ab
ility
ot p
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⇒ page 82 .
, is n
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hole
3 - Piston with automatic ad‐
spec
justment
es, in part or in w
t to the co
⇒ page 82 .
rrectness of i
4 - Protective cap
❑ Pull outer sealing lip on‐
l purpos
to piston.
5 - Dust cap nform
mercia
6 - Bleed valve
at
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7 - Brake caliper housing with

in t
or
handbrake cable lever

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ate
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renew brake caliper
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bleed brake caliper Prote
cted AG.
agen
housing ⇒ page 84 .
8 - Guide pin
❑ Grease protective cap
before pulling on.
9 - Protective cap
❑ Pull onto brake carrier
and guide pin.
guide pins.
2. Repairing rear brake caliper 81

2.1 Removing and installing piston for rear

brake caliper
♦ Resetting and removal tool -3272-
AG. Volkswagen AG d
agen oes
olksw not
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♦ Wedge -3409-
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♦ Bleeder container C py
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rig ht
by
2.1.1 Removing copy Vo
by lksw
cted agen
Prote AG.
– Turn piston out of brake caliper housing by turning knurled
wheel to left, being careful not to damage protective cap.
Note

is in front of piston.

2.1.2 Installing
inder.
Note
lkswage es n
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byV ua
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ir se tee
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– Screw in piston by turning knurled wheel clockwise, taking

an
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care not to damage protective cap.

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erm
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ility
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Note
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spec

t to the co

rrectne
♦ If the piston is pushed back with a piston resetting tool or by

ss
o
cial p
f inform
mer
– Insert brake pads.

atio
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c
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Cop py
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Prote AG.
2. Repairing rear brake caliper 83

2.1.3 Pre-bleeding brake caliper

n AG bleed bottle, . Volkswage
– Open bleed valve -arrow A- and, using aksstandard
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fill with brake fluid until bubble-freebybrake fluid flows from gu
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-arrow B-. Close bleed nte
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pt
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Position brake caliper as illustrated to pre-bleed.
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2.2 Pressure leak test
rrectness of i
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♦ Brake pressure regulator tester -V.A.G 1310 A-
nform
mercia
at
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ion
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ate
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priv
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Prote AG.
Test prerequisites:
Brake system (hydraulic unit, brake hoses, brake lines and brake
calipers) operating properly and free of leaks.
– Remove bleed screw at one of front brake calipers. Connect
pressure gauge from -V.A.G 1310 A- and bleed.
– Apply pressure to brake pedal until the gauge indicates a
pressure of 50 bar. The pressure must not drop by more than
4 bar during the test period of 45 seconds. Renew brake mas‐
ter cylinder if pressure drops greatly.

3 Bleeding brake system

Bleeding the brake system is described using brake filling and
bleeding unit -V.A.G 1869- .
Note
♦ Bleeding the brake system on vehicles with ABS is performed

in same way as vehicles with a conventional brake system
♦ Use new brake fluid with part No. B 000 700 A . (enter con‐
tainer index for decimal point).
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
AG. Volkswagen AG d
agen oes
♦ Brake fluid is hygroscopic, which means
yV
olit
kswabsorbs moisture not
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from the ambient air and should therefore
ed
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air tight containers. oris eo
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♦ Rinse off spilled brake fluid using plenty of water.
ss c
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nl
pt
du
an
itte
Special point regarding vehicles with ABS/EDL
y li
erm
ab
ility
When one chamber in the brake fluid reservoir is completely emp‐
ot p
ty (e.g. leaks in brake system) the hydraulic unit must be bled with
wit
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fault reader -V.A.G 1551- in function “basic setting”.
hole
spec
Initiate basic (default) setting
es, in part or in w
t to the co
⇒ Running gear self-diagnosis for ABS; Rep. Gr. 01 ; Performing
self-diagnosis; Introducing basic settings .
rrectness of i
To bleed the hydraulic unit, a pre-pressure of at least 2 bar is
necessary.
l purpos
3.1 Bleeding brake system with brake filling
nform
ercia
and bleeding unit -V.A.G 1869-

m
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om

ion
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or
♦ Brake filling and bleeding unit -V.A.G 1869-

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Cop py
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pyri by
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Prote AG.
3. Bleeding brake system 85

Note
♦ Bleeding brake system on vehicles with ABS is performed in

same way as vehicles with a conventional brake system.
♦ Bleed brake system first if brake master cylinder has been re‐
moved or changed. Proceed as described in work sequence
for “Bleeding brake system without brake filling and bleeding
unit” ⇒ page 86 .
– Connect brake filling and bleeding unit -V.A.G 1869- .

– Open bleed screws in specified order and bleed brake cali‐
pers.
Use suitable bleed hose. It must sit tightly on bleed valve so that
no air can enter brake system.
– Leave brake caliper bleed screws open until, with bleeder bot‐
tle hose still fitted, brake fluid discharges free of air bubbles.
AG. Volkswagen AG d
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Bleeding sequence olksw
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1. Rear right brake caliper orise nte
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2. Rear left brake caliper ss a c
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3. Front right brake caliper

pt
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4. Front left brake caliper

erm
ab
ility
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Vehicles with ABS or ABS/EDL

wit
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With these vehicles a test drive must be carried out after bleeding
hole
spec
brakes. When doing this, an ABS regulation must occur at least

es, in part or in w
once!
t to the co
Note
rrectness of i
l purpos
On vehicles with a brake pressure regulator, move the regulator

lever when bleeding rear brakes.
nf
ercia
3.2 Bleeding brake system without brake fill‐

rm
m
atio
m
ing and bleeding unit

o
n in
or c
thi
e
– Build up pressure in brake system by actuating brake pedal

t
sd
iva
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ng
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– Pump brake fluid through system by pumping the brake pedal. py by
co Vo
by lksw
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AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Transporter 1996 ➤
e
horis Brake systems
nte
eo as of January 1996 - Edition 09.2004
aut ra
ss c
Ensure there is sufficient brake fluid in brake fluid reservoir.
ce
le
un
pt
an
– With brake pedal held down, close bleed screw.
d
itte
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rm
ab
– Repeat process until no further air escapes, but carry out at
pe
ility
least 3 times per brake caliper.
ot
wit
, is n
h re
Bleeding sequence ⇒ page 86 .
hole
spec
Changing brake fluid
es, in part or in w
t to the co
⇒ Maintenance ; Booklet 19 ; Work descriptions; Changing brake
fluid (every 2 years)
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.
3. Bleeding brake system 87

4 Assembly overview - brake pressure regulator
Note
Not fitted in vehicles with four-wheel drive, ABS Bosch 5.3 and closed body (van, Kombi, Caravelle, Multivan).
1 - Brake pressure regulator

❑ Adjusting ⇒ page 89 .
2 - Retaining clip
❑ Press onto threaded
stud and tighten 2 to 3
turns.
5 - Nut
6 - Spring holder
❑ Mark installation posi‐
tion before removing.
7 - Spring
❑ Observe installation po‐
sition.
❑ Note allocation ⇒ Run‐ agen
AG. Volkswagen AG d
ning gear, axles, steer‐ Volksw
oes
not
gu
ing; Rep. Gr. 42 ; Allo‐ d by ara
ise nte
cation of brake pressure thor eo
regulator coil springs s au ra
c
and springs . s
ce
le
un
pt
8 - Clip
an
d
itte
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rm
ab
9 - Horizontal beam
pe
ility
ot
❑ Slight inclination is per‐
wit
, is n
missible ⇒ page 92 .
h re
hole
spec
10 - Bump stop
es, in part or in w
t to the co
❑ Adjusting ⇒ page 92 .
11 - Wishbone
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.

4.1 Adjusting the brake pressure regulator
Special tools and workshop

equipment required
♦ Setting tool -3255-
♦ Socket, 27 mm -3257-
♦ Brake pressure regulator
tester -V.A.G 1310 A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an
itte
Brake pressure regulator basic setting

y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
♦ If e.g. one or both wishbones are renewed and there are no

es, in part or in w
t to the co
marks on the wishbone for the spring holder -2- installation

position, the following procedure is recommended during ba‐
sic setting.
rrectness of i
♦ If basic setting is not necessary, then brake pressure regulator

fine setting ⇒ page 90 .
l purpos
– Remove both shock absorbers ⇒ Running gear, axles, steer‐

nf
ercia
ing; Rep. Gr. 42 ; Repairing the rear wheel suspension;

rm
m
Removing and installing shock absorbers .

atio
om
n in
c
– Insert setting tool -3255- and pre-tension wishbone

or
thi
⇒ page 90 .
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
89
by lksw
cted agen
Prote AG.
4. Assembly overview - brake pressure regulator
– Visually set horizontal beam -4- to horizontal position by turn‐

ing both bump stops -1- up to stop on horizontal beam -4- (no
pre-tension at bump stop -1-).
– Push one of the spring retainers -2- down until the a gap
-arrow- of approx. 2 mm is created on opposite side between
bump stop -1- and horizontal beam -4-.
– Push second spring retainer -2- down until horizontal beam
-4- is horizontal again.
– Turn both bump stops -1- back completely so that maximum
possible gap is created between horizontal beam -4- and
bump stops -1-.
– Continue with brake pressure regulator fine setting
⇒ page 90 .
Brake pressure regulator fine setting
– Remove both shock absorbers ⇒ Running gear, axles, steer‐
ing; Rep. Gr. 42 ; Repairing the rear wheel suspension;
Removing and installing shock absorbers .
Volkswagen AG
– Push tubes -3255/1- onto setting
swa
gentool.
AG. does
k not
Vol gu
by ara
ed nte
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th
au ra
c
ss
ce
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un
pt
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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
– Insert setting tool -3255- with tubes -3255/1- as shown in il‐

lustration.
rrectness of i
l purpos
Note
nform
ercia
♦ Grease spindle threads, face end of nut and surface of washer

with MoS2 grease.
m
a
com
tion in
♦ To tension wishbone, place a shock absorber rubber bush be‐

r
te o
thi
tween washer -arrow- and wishbone.

s
iva
do
r
rp
♦ Use of an impact screwdriver is not permitted.

um
fo
en
ng
t.
♦ In the event of complaints - rear brakes too severe or weak -
yi Co
op py
first check bump stop setting ⇒ page 92 . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pre-tension wishbone with setting tool -3255- to dimension

-x-.
1- Backing plate
2- Spring
3- Wishbone
Note
wage es n
♦ Measurement is carried out from y V edge of plate in spring re‐
olks ot g
ua
tainer -arrow a- to upper edgeir se of assembly hole in wishbone
d b ran
tee
-arrow b-. utho
or
a ac
ss
♦ Set dimension -x- according to table ⇒ page 92 .
ce
e
nl
pt
du
♦ Coil springs may be removed to set wishbone to dimension
an
itte
y li
-x-.
erm
ab
ility
ot p
wit
– Continue with checking brake pressure ⇒ page 91 .
, is n
h re
hole
spec
4.1.1 Checking brake pressure
es, in part or in w
t to the co
– Connect tester for brake pressure regulator -V.A.G 1310 A- to
brake caliper (front left wheel) and brake caliper (rear left
wheel).
rrectness of i
– Bleed both pressure gauges (bleeding brake system
l purpos
⇒ page 85 ).
– Depress brake pedal and measure pressures.
nform
mercia
Front axle pressure 50 bar
at
om
ion
c
Rear axle pressure 20 ± 2 bar in t

or
his
ate
– Adjust if necessary ⇒ page 91 .

do
priv
cum
or
– Continue with setting bump stops ⇒ page 92 .

f
en
ng
t.
yi Co
op
4.1.2 Setting brake pressure
C py
t. rig
gh ht
pyri by
Vo
– Turn both bump stops -1- back to stop (down).
co lksw
by
cted agen
Prote AG.
– Mark position of spring retainer -2- on wishbone with felt-tip
pen or adhesive tape.
– Loosen bolt -3- and shift retainer -2-.
Push spring retainer -2- down - increase in pressure.
Push spring retainer -2- up - reduction in pressure.
4. Assembly overview - brake pressure regulator 91

wage es n
Transporter 1996 ➤ yV
olks ot g
b ua
Brake systems as of January ir se 1996 - Edition 09.2004
d ran
tee
tho
u or
a ac
♦ Second spring retainer -2-sonly
s has to be adjusted if horizontal
beam -4- is excessively inclined (more than 4 mm ⇒
ce
e
nl
pt
du
-arrows-).
an
itte
y li
erm
ab
♦ 1 mm spring retainer -2- adjustment travel corresponds to ap‐
ility
prox. 4 bar change in pressure on rear axle. ot p
wit
, is n
h re
– Slight horizontal beam -4- inclination is permissible (max. 4
hole
mm between left and right ⇒ -arrows-).
spec
es, in part or in w
t to the co
– Tighten bolt -3-, counter-holding whilst tightening.
– Correct brake pressure regulator setting at second spring re‐
tainer -2- if necessary.
rrectness of i
– Continue with setting bump stops ⇒ page 92 .
l purpos
4.1.3 Setting bump stops
nf
ercia
orm
Check whether retaining clip ⇒ Item 2 (page 88) is firmly seated.
m
atio
om
n in
– Check brake pressure (if not already done) ⇒ page 91 .
or c
thi
te
sd
– If setting is OK, insert pedal support.
iva
o
r
rp
cu
– Maintain brake pressure of at least 50 bar on front axle.
o
m
f
en
ng
t.
yi Co
– Turn both bump stops -1- up with 6 mm Allen key (illustration Cop py
. rig
shows only one bump stop) until a gap of 0.5 mm is measured
t
gh ht
yri by
simultaneously on both sides between bump stop -1- and hor‐ cop Vo
by lksw
izontal beam -4- with feeler gauge -5-.
cted agen
Prote AG.
– Remove -V.A.G 1310 A- and bleed brake system ⇒ page 85 .

– Remove setting tool -3255- .
– Install shock absorbers ⇒ Running gear, axles, steering; Rep.
Gr. 42 ; Repairing the rear wheel suspension; Removing and
installing shock absorbers .
4.1.4 Brake pressure regulator setting table

Rear axle spring Colour code Dimension x
± 1 mm
701 511 105 L Grey 238 mm
701 511 105 A/C White 258 mm
701 511 105 M Pink 268 mm
701 511 105 H/J Orange 270 mm
701 511 105 P Light blue 270 mm
701 511 105 Violet 280 mm
701 511 105 F Opal green 281 mm
701 511 105 K Yellow 284 mm
701 511 105 B Red brown 292 mm
4.1.5 Testing rear brakes on rolling road

General
A brake test on the rolling road cannot be transposed 100% to the
real conditions which occur when braking on the road.
Due to the relatively high differences in weight between the front
and rear axle, measuring a higher value on the front axle is nor‐
mal. However, vehicles with low rear axle loads only achieve low
rear axle brake pressures.

In addition, influences on braking during vehicle operation such

as shifts in weight, friction conditions, road characteristics, etc.
cannot be reproduced on the rolling road.
The following table shows the minimum brake pressure at the rear
axle depending on the actual axle load when the vehicle is sta‐
tionary.
The lower limit values, which must be achieved, are specified in
the table. These are always achieved or exceeded if the brake
system is functioning correctly.
Minimum rear axle brake pressure test values
Rear axle load (weighted) Minimum rear axle brake pressure
(both rear wheels)
Less than 600 kg 900 N
700 kg 1200 N
800 kg 1500 N
900 kgo lkswage es n
ot g
1800 N
yV
1000
ir se
d b kg ua
ran 2200 N
o tee
th 1100 kg or 2500 N
au ac
ss
1200 kg 2800 N
ce
le
un
pt
1300 kg 3100 N
an
d
itte
y li
rm
1400 kg 3300 N
ab
pe
ility
1500 kg 3700 N
ot
wit
, is n
h re
1800 kg 4000 N
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.
4. Assembly overview - brake pressure regulator 93

5 Assembly overview - brake servo/brake master cylinder
Note
Complete master cylinders and brake servos can be renewed independently of each other.

en from the intake mani‐
fold.
❑ On Diesel engines an
exhauster is installed to
generate vacuum.
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust the vacuum in
the unit).
– Now depress brake

pedal with average foot
pressure, hold and start
engine. If the servo unit
is working properly, the
pedal will be felt to give
slightly under foot (ser‐
vo assistance becomes
effective).
AG. Volkswagen AG d
– If faulty, renew com‐ agen oes
olksw not
plete. d byV gu
ara
ise nte
r
❑ Non-return valve (in ut
ho eo
ra
vacuum hose) ss a c
⇒ page 95 .
ce
le
un
pt
an
d
Functional check
itte
y li
rm
⇒ page 95 .
ab
pe
ility
ot

wit
, is n
⇒ page 96 .
h re
hole
spec
2 - Sealing ring
es, in part or in w
t to the co
❑ Renew.
rrectness of i
4 - Cap
l purpos
5 - Sealing plug
❑ Moisten with brake fluid and press into expansion tank.
nform
ercia
6 - Retainer pin
m
a
com
❑ Insert through brake master cylinder.

ion in
r
te o
7 - Tandem brake master cylinder

thi
s
iva
do
❑ Cannot be repaired. If faulty, renew complete.

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.

9 - Bracket
5.1 Checking non-return valve

– Check non-return valve -A-.
Air must pass through valve in direction of arrow.
Valve must remain closed in opposite direction.
Observe correct installation position.
The illustration shows the vacuum line of the 111 kW TDI engine.
The vacuum line differs depending on the engine design; allocate
as per ⇒ Electronic Part Catalogue “ETKA” .
5.2 Removing and installing brake master

cylinder
olkswage
es n
o
V t gu
by
Special toolsrisand
ed workshop equipment required
ara
nte
tho eo
♦ Hosess aclamps
u
to Ø 25 mm -3094- ra
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
5.2.1 Removing
nform
ercia

necessary.
m
a
com
tion in
r
te o
thi
s
– Lay out sufficient lint free clothes in area of engine and gear‐
iva
do
r
box.
rp
cum
fo
en
ng
– Fit bleeder hose to the front left brake caliper bleed screw and
t.
yi Co
op
open bleed screw. C py
t. rig
gh ht
yri by
– Operate brake pedal until sufficient brake fluid has been pum‐
cop Vo
by lksw
ped out for the brake fluid level in the brake fluid reservoir to
cted agen
Prote AG.
have sunk below the supply hose.
– Clamp off clutch master cylinder supply hose using hose
clamp -3094- .
– Pull off clutch master cylinder supply hose.
– Pull connector off brake fluid level warning contact.
5. Assembly overview - brake servo/brake master cylinder 95

– Unscrew brake lines from brake master cylinder and seal

brake lines with plugs from repair kit Part No. -1H0 698 311
A- .
– Unscrew brake master cylinder nuts.
– Carefully take brake master cylinder out of brake servo unit.
5.2.2 Installing
– Install in reverse order. . Volkswagen AG
gen AG does
swa
Observe the following points when installing:y V olk not
gu
d b ara
e nte
– When fitting together the brake master
thoris
cylinder and brake ser‐ eo
vo unit, ensure that the push rods is correctly located in the
a u ra
c
brake master cylinder. s
ce
e
nl
pt
du
– After installing, bleed brake system ⇒ page 85 and clutch ⇒
an
itte
y li
Rep. Gr. 30 ; Repairing clutch actuation; Bleeding clutch sys‐
erm
ab
tem .
ility
ot p
wit
, is n
Specified torque settings:
h re
hole
spec
Brake master cylinder and brake servo ⇒ page 94
es, in part or in w
t to the co
5.3 Removing and installing brake servo
rrectness of i
♦ Hose clamps to Ø 25 mm -3094-
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
5.3.1 Removing
AG.

necessary.
– Lay out sufficient lint free clothes in area of engine and gear‐
box.
– Fit bleeder hose to the front left brake caliper bleed screw and
open bleed screw.
– Operate brake pedal until sufficient brake fluid has been pum‐
ped out for the brake fluid level in the brake fluid reservoir to
have sunk below the supply hose.
– Clamp off clutch master cylinder supply hose using hose
clamp -3094- .
– Pull off clutch master cylinder supply hose.
– Pull connector off brake fluid level warning contact.
– Unscrew brake lines from brake master cylinder and seal
brake lines with plugs from repair kit Part No. -1H0 698 311
A- .

– Separate brake line unions -arrows-.

– Detach line -1- from bracket -2-.
AG. Volkswagen AG d
– Unbolt cooling system expansion tank and lay to side without
ksw
agen oes
not
opening cooling system. y Vol gu
db e
ara
ris nte
– Disconnect vacuum hose from brake servo. utho eo
ra
sa c
– Cover on driver's side must be removed. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove circlip -1- on pin for connecting fork head to brake
es, in part or in w
pedal.
t to the co
– Remove pin.
– Unbolt brake servo -arrows-.
rrectness of i
– Guide brake servo with brake master cylinder out forwards and
l purpos
remove.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
5.3.2 Installing
p
cum
for
en
ng
t.
yi
Install in reverse order.
Co
Cop py
t. rig
gh
– After installing, bleed brake system ⇒ page 85 and clutch ⇒
ht
pyri by
Vo
o
Rep. Gr. 30 ; Repairing clutch actuation; Bleeding clutch sys‐ by c lksw
cted agen
tem . Prote AG.
Specified torque settings:

Brake servo to bulkhead ⇒ page 94
5. Assembly overview - brake servo/brake master cylinder 97

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg 00052708520

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.1 Front brake caliper distinguishing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.1 Repairing rear brakes, 15" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.2 Removing and installing brake pads, 15" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.2 Removing and installing front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.5 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Position of M equipment number (PR No.) on the vehicle data

The brake caliper code may beswinagdifferent

1. Brake allocation via PR No. 1

1.1 Front brakes

1.1.2 Vehicles with Lucas RC54 brake cali‐

Brake ∅ in inch 9′′ +

1 Brake caliper Lucas RC54

2 Brake pad, thick‐ mm 13

3 Brake disc ∅ in 280

2) M equipment number; explanation ⇒ page 1

2 Rep. Gr.00 - Technical data

1.1.3 Vehicles with FN3 brake calipers, 15''

1. Brake allocation via PR No. 3

1.1.5 Vehicles with FNR brake calipers, 16''

4 Rep. Gr.00 - Technical data

1.2 Rear brakes

2 Brake pad, thick‐ mm 11.5

3 Brake caliper pis‐ ∅ in 38

7) M equipment number; explanation ⇒ page 1

1. Brake allocation via PR No. 5

3 Brake caliper pis‐ ∅ in 38

8) M equipment number; explanation ⇒ page 1 cum

6 Rep. Gr.00 - Technical data

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

2.2 Test for vehicles with front-wheel drive.

2.3 Test for vehicles with four-wheel drive

The forward rotating wheel is measured during the test, which

The maximum test speed must not exceed 6 km/h.

Before starting the rollers, briefly engage 1st gear. In vehicles

with automatic gearbox, briefly shift to “D”. This switches off

Do not engage reverse gear whilst the rollers are running.

8 Rep. Gr.00 - Technical data

45 – Anti-lock brake system

1.1 ABS and ABS/EDL Bosch 5

1.2 ABS and ABS/EDL Bosch 5.3

ABS layout in left-hand drive vehicle.

1. General notes for anti-lock brake system (ABS) 9

Vehicles with ABS/EDL/TCS/ESP

tance. A change in braking behaviour is to be reckoned with. After

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

ABS layout in a right-hand drive vehicle.

1. General notes for anti-lock brake system (ABS) 11

2 Notes for repair work on ABS

♦ Only use genuine packed parts.

do not move the vehicle.

♦ Ensure that no brake fluid enters electrical connections.

♦ During painting operations, the electronic control unit can be

exposed to a maximum temperature of 95 °C for only a short

period, and to a maximum of 85 °C for longer periods (approx.

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

3 Assembly overview - hydraulic units