D4B804B24F7 Brake System

Service
Repair Manual Volksw

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Service Department. Technical Information

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List of Workshop Manual Repair Groups
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Repair Group
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00 - General, Technical Data
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45 - Antilock Brake System
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46 - Mechanical Components
47 - Hydraulic Components
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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 D4B804B24F7

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Contents
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00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
, is n
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1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
spec
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1.1 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 1
t to the co
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Brake PR Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.1 Brakes Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Brakes Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2 Front Wheel Drive Vehicles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.3 AWD Vehicles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.4 Parking Brake, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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45 - Antilock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.1 ABS Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2 Component Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.1 Prote
Overview - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1 Overview - Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 , Removing and Installing . . . . . . . . 20
3.3 Control Module, Separating from Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Control Module, Attaching to Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.5 Brake Lines, Attaching to Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 Overview - Front Axle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Overview - Rear Axle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 ESP Sensor Unit G419 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.4 Right/Left Front ABS Wheel Speed Sensor G45 / G47 , Removing and Installing . . . . . . 49
4.5 Right/Left Rear ABS Wheel Speed Sensor G44 / G46 , Removing and Installing . . . . . . . . 49
4.6 ABS Sensor Ring, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
46 - Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Overview - Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2 Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.1 Overview - Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1 Overview - Parking Brake Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2 Electromechanical Parking Brake Control Module J540 , Removing and Installing . . . . . . 77
3.3 Left/Right Parking Brake Motor V282 / V283 , Removing and Installing . . . . . . . . . . . . . . 77
4 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Overview - Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2 Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3 Brake Pedal, Removing from Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Brake Pedal, Attaching to Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents i
Golf 2013 ➤ , Golf Variant 2014 ➤
Brake System - Edition 03.2015
4.5 Brake Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
47 - Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Overview - Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Brake Caliper Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.1 Overview - Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 Dust Cap, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 Brake Booster/Master Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1 Overview - Brake Booster/Master Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.2 Brake Lamp Switch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3 Brake Booster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.4 Brake Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.1 Overview - Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.2 Check Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.3 Vacuum Sensor G608 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.4 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5 Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.1 Brake Lines, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.1 Brake Fluid General Information . . . . . . . . . . . . . . . .. V.o.lk.sw. a. g. . . . . . . . . . . . . . . . . . . . . . . 146
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6.2 Hydraulic System, Standard Bleeding . . . o.lk.sw. a. g.e. . . . . . . . . . . . G . .do. e.s .no. . . . . . . . . . . . . . . 146
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6.3 Hydraulic System, Post-Bleeding . . .ed. . . . . . . . . . . . . . . . . . . . . . . . . . . g. u.a.ra. . . . . . . . . . .
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6.4 Checking for Leaks . . . . . . . . . . u.th.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . 147
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7 Special Tools . . . . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . 149
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8 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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ii Contents
00 – General, Technical Data

1 Safety Precautions
(Edition 03.2015)
⇒ “1.1 Safety Precautions during Road Test with Testing Equip‐
ment”, page 1
1.1 Safety Precautions during Road Test with Testing Equipment

There is a risk of injury caused by unsecured testing equipment.
If the front passenger airbag deploys during an accident, unse‐
cured testing equipment becomes a dangerous projectile.
– Secure the testing equipment to the rear seat.
or
– Have a second person operate testing equipment on the rear
seat.
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1. Safety Precautions 1
2 Identification
⇒ “2.1 Brake PR Numbers”, page 2
2.1 Brake PR Numbers

⇒ “2.1.1 Front Brakes”, page 2
⇒ “2.1.2 Rear Brakes”, page 2
2.1.1 Front Brakes

The PR number on the vehicle data label describes which brake
system is installed in the vehicle.
There is a vehicle data label in the spare wheel well and also one
in the customer Maintenance booklet.
– For information regarding each brake installed. Refer to ELSA/
vehicle-specific information.
In this example, the vehicle has “1KU” rear brakes.
♦ Allocation. Refer to the Parts Catalog.
♦ The following tables explain the PR numbers. These are im‐
portant for the combination brake caliper/brake rotor and
brake pad.
Engine PR Number Front Brakes
1.2L - 63; 77 kW TSI 1; 1ZF FS III (15”)
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2.0L - 110 kW TDI 1ZA/1ZD PC57 (16”)

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2.0L - 135 kW TDI 1ZA/1ZD/1ZB 2)
2.0L - 162 kW TSI 1ZB

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2.0L - 169 kW TSI 1LJ C60 (17”)

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2.0L - 206; 213; 221 kW 1LM

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system is installed in the vehicle.
There is a vehicle data label in the spare wheel well and also one
in the customer Maintenance booklet.
2 Rep. Gr.00 - General, Technical Data

– For information regarding each brake installed. Refer to ELSA/

vehicle-specific information.
In this example, the vehicle has “1KU” rear brakes.
♦ Allocation. Refer to the Parts Catalog.
♦ The following tables explain the PR numbers. These are im‐
portant for the combination brake caliper/brake rotor and
brake pad.
Engine PR number Rear Brakes
1.2L - 63 kW TSI 1KE FNc-M38 (15”)
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2.0L - 169 kW TSI 1KJ FNc-M42 (17”)
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2.0L - 206; 213; 221 1KY
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2. Identification 3
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⇒ “3.1.2 Front Brakes”, page 4
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3.1.1 Brake Master Cylinder and Brake Boos‐
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Brake master cylinder, diameter in mm 23.81 or 25.4
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Brake booster, depend‐ Diameter in in‐ 10 or 11
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Front brakes FS III (15”):
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thickness
Brake pad, wear mm 2
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backing plate
3 Brake Rotor diam‐ 276
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mm
Brake rotor, mm 24
thickness
Brake rotor, mm 21
wear limit
4 Brake caliper, diam‐ 57
piston eter in
mm

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Front brakes PC57th(15”):
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Item PR number s
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Brake rotor, mm 22
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Front brakes PC57 (16”):

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Item PR number 1ZA/1ZD/1ZB
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1 Brake caliper PC57 (16”)
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2 Brake pad, mm 14
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thickness
AG.

limit without
back plate
eter in
mm
Brake rotor, mm 25
thickness
Brake rotor, mm 22
wear limit
piston eter in
mm
3. Technical Data 5
Front brakes C60 (17”):

Item PR number 1LJ/1LM
1 Brake caliper C60 (17”)
2 Brake pad, mm 13
thickness
limit without
back plate
eter in
mm
Brake rotor, mm 30
thickness
Brake rotor, mm 27
wear limit
piston eter in
mm
AG. Volkswagen AG d
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3.1.3 Rear Brakes
oes
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Rear Brakes FNc-M38 (15”): hor eo
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Item PR number 1KE/1KV s
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1 Brake caliper FNc-M38 (15”)
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2 Brake pad, mm 11
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thickness
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spec
back plate
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eter in
mm
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Brake rotor, mm 10
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thickness
Brake rotor, mm 8
wear limit
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Rear brakes FNc-M42 (17”):

Item PR number 1KJ/1KY
1 Brake caliper FNc-M42 (17”)
2 Brake pad, mm 11
thickness agen
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eter in
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Brake rotor, mm 22
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Brake rotor, mm 20
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spec
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piston eter in
mm
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3. Technical Data 7
4 Brakes Inspection
⇒ “4.1 General Information”, page 8
⇒ “4.2 Front Wheel Drive Vehicles, Checking”, page 8
⇒ “4.3 AWD Vehicles, Checking”, page 8
⇒ “4.4 Parking Brake, Checking”, page 9
4.1 General Information

♦ The testing takes place on a test stand.
♦ When testing, manual transmission vehicles must be in idle
and automatic transmission vehicles must be in driving posi‐
tion N.
♦ Always follow the instructions provided by the test stand man‐
ufacturer.
Note
Brake regulation system does not function with ignition off.
4.2 Front Wheel Drive Vehicles, Checking

The brake test is to be performed on a one-axle roller test stand. AG. Volkswagen AG d
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Do not exceed a test speed of 6 km/h. d byV
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Volkswagen approved test stands meet these requirements.
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⇒ “4.3.1 Controlled Opposite-Running Test Stand ”, page 8
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⇒ “4.3.2 Without Test Stand ”, page 9
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4.3.1 Controlled Opposite-Running Test
h re
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spec
Stand
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Note
rrectness of i
With AWD, Testing with a Controlled Opposite-Running One-Axle
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Dynamometer
nform
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“Moving in opposite directions” means: The rollers on the one-

axle roller test stand turn forward on the one side and backward
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on the other side.

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During this test, the wheels of one axle are driven in opposite
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directions, to prevent delivering power to the other axle.

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“Controlled” means: The speed of the test stand rollers must be

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the drive harness.
During testing, the wheel turning forward is measured, therefore
two braking test are necessary on each axle.
Do not exceed a test speed of 6 km/h.
Volkswagen approved test stands meet these requirements.

4.3.2 Without Test Stand
Note
With AWD, Testing with Standard One-Axle Dynamometer
– Drive the vehicle forward onto the rollers.

– Turn off the engine and wait 2 seconds.
– Perform the braking test.
– Start the engine and wait approximately 5 seconds until there
is enough vacuum.
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– Drive the vehicle forward
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the rear wheel are
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– Turn off theuthengine
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– Perform the braking test for the rear brakes.
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4.4 Parking Brake, Checking
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⇒ “4.4.2 Electromechanical Parking Brake, Checking, AWD Ve‐
spec
hicles”, page 10
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t to the co
⇒ “4.4.1 Electromechanical Parking Brake, Checking, FWD Ve‐
hicles”, page 9 rrectness of i
4.4.1 Electromechanical Parking Brake,

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Checking, FWD Vehicles

Activating »TÜV mode«:
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• The seat belt is on.

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• Rear axle in the one-axle roller test stand

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• The ignition remains on.

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• Auto Hold is off.

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• The rear wheel must rotate for at least 5 seconds non-stop
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between 2.5 and 9 km/h
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»TÜV mode« is indicated when the yellow Electric Parking/Hand
Brake Malfunction Indicator Lamp - K214- comes on.
Note
The electromechanical parking brake does not close completely

the first time the »TÜV mode« button is pressed.
Operating the Electric Parking/Hand Brake Malfunction Indicator

Lamp - E538- four times increases the tension.
Operating the Electromechanical Parking Brake Button - E538- a
fifth time releases the electromechanical parking brake.
Ending »TÜV mode«:
• Front wheels, speed greater than 0 km/h
• Rear wheels, speed less than 2.5 km/h or greater than 9 km/
h
4. Brakes Inspection 9
AG. Volkswagen AG d
• Ignition off. agen oes
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4.4.2 Electromechanical Parking Brake, ed
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Checking, AWD Vehicles ss a ra
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Activating »TÜV mode«:
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• The seat belt is on. erm
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• Rear axle in the one-axle roller test stand
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• The engine is off and the ignition is on.
hole
spec
• Auto Hold is off.
es, in part or in w
t to the co
• The front wheel must not be moving.
• The rear wheel must rotate for at least 5 seconds non-stop
rrectness of i
between 2.5 and 9 km/h
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»TÜV mode« is indicated when the yellow Electric Parking/Hand

Brake Malfunction Indicator Lamp - K214- comes on.
nform
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at
Note
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The electromechanical parking brake does not close completely
his
ate
the first time the »TÜV mode« button is pressed.
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Operating the Electric Parking/Hand Brake Malfunction Indicator

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op
Lamp - E538- four times increases the tension.
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Operating the Electromechanical Parking Brake Button - E538- a co Vo
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fifth time releases the electromechanical parking brake.
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is enough vacuum.
Ending »TÜV mode«:
• Front wheels, speed greater than 0 km/h
• Rear wheels, speed less than 2.5 km/h or greater than 9 km/
h
• Ignition off.

AG. Volkswagen AG d
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s Brake System - Edition 03.2015
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45 – Antilock Brake System
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1 General Information
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spec
es, in part or in w
⇒ “1.1 ABS Repair Instructions”, page 11
t to the co
1.1 ABS Repair Instructions
rrectness of i
The ABS brake system is divided diagonally (two circuits). The
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vacuum brake servo unit boosts the brakes pneumatically.

Models with ABS do not have a mechanical brake pressure reg‐
nf
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ulator. A specially coordinated software program in the control
or
module determines brake pressure allocation at the rear axle.
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1. General Information 11
Note
ABS malfunctions do not affect the brake system and the booster.
Conventional brake system stays operative even without ABS. A
change in braking behavior should be checked. When the ABS
indicator lamp is lit up, the rear wheels may lock prematurely dur‐
ing braking!
ABS Layout
1 - Hydraulic unit and control module
2 - Brake Booster
The control module and hydraulic unit form one component. Sep‐
aration can only be performed when removed from vehicle. The
hydraulic pump must also not be separated from the hydraulic
unit.
♦ Before carrying out repair work on the anti-lock
olkswagbraking
en AG sys‐
en AG. V
tem, as well as the control module
lkswagcoding, determine dthe
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cause of the malfunction dusing gu
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Performs “Guided FaultutFinding”
ho using the -Vehicle diagnostic or
tester- . ss
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nl
♦ Turn off the ignition and disconnect the battery ground cable.
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♦ Carry out before welding with an electric welding tool. Refer to
erm
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⇒ General Information; Body Repairs, Body Collision Repair .
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♦ When working with brake fluid, observe relevant safety pre‐ h re

cautions and notes. Refer to
hole
spec
⇒ “6.1 Brake Fluid General Information”, page 146 .
es, in part or in w
t to the co
♦ After finishing any work that required opening the brake sys‐
tem, bleed the brake system using the Brake Charger/Bleeder
Unit - VAS5234- . Refer to
rrectness of i
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 146 .

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♦ During final road test, carry out at least one ABS-controlled

braking operation (appropriate pulsations must be felt at brake
pedal).
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♦ Absolute cleanliness is required when working on the anti-lock

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brake system. Do not use any products which contain mineral

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oil, such as oils, greases etc.

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♦ Thoroughly clean all unions and the adjacent areas before

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loosening. Do not use aggressive cleaning agents such as

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♦ Carefully cover or seal open components, if repairs are not
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carried out immediately. (Use plugs from repair set 1 H0 698
agen
Prote AG.
311 A)
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to installa‐
tion.
♦ Only use parts in their original packaging.
♦ If the system is open, do not work with compressed air and do
not move the vehicle.
♦ The valve coils inside the control module cannot be adjusted.
♦ The valve coils inside the control module cannot be replaced.
♦ The pressure sensor must be changed or damaged.
12 Rep. Gr.45 - Antilock Brake System

♦ The pressure sensor cannot be replaced.

♦ Do not place anything on the sensor housing.
♦ It is not possible to perform any measurements on the contacts
inside the control module.
♦ It is not possible to perform any measurements on the contacts
inside the hydraulic unit.
♦ The valve bodies inside the hydraulic unit must not be dam‐
aged or bent.
♦ The contacts cannot be replaced.
♦ Do not use contact spray on the contacts and pressure sensor.
♦ Make sure there are no foreign objects between the control
module and the hydraulic unit.
♦ When painting, electronic control module can be exposed to
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a maximum temperature of. 95 °C (203 °F) onlylksbriefly,
wage and to es n
a maximum of 85 °C (185 °F) for longer periods d by (approximately
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2 hours). For long periods (two hours) otheris control module can
e ran
tee
only be exposed to a maximum of 85 auth°C (185 °F). Make sure or
ac
that brake fluid does not enter harness
ss connectors.
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1. General Information 13
2 Component Location Overview

⇒ “2.1 Overview - ABS/ESP”, page 14
2.1 Overview - ABS/ESP
1 - ABS Control Module - J104-

❑ Component location: in
the hydraulic unit in the
motor compartment on
the front passenger
side.
❑ Do not disconnect con‐
nector before success‐
fully completing On
Board Diagnostic
(OBD). Turn off the igni‐
tion before disconnect‐
ing the connector.
The following components are
integrated inside the control
module:
♦ Electromechanical Parking
Brake Control Module -
J540-
♦ Transverse Acceleration
Sensor - G200- AG. Volkswagen AG d
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♦ Rotation Rate Sensor - d by V gu
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G202- orise nte
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♦ Longitudinal Acceleration ss a c
Sensor - G251- (depending
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on vehicle equipment)
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♦ The components cannot be

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replaced individually.
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❑ Removing and instal‐

h re
ling. Refer to
hole
spec
⇒ “3.2.1 ABS Control

es, in part or in w
Module and ABS Hy‐

t to the co
draulic Unit, Removing

and Installing, LHD,
Gasoline Engine”,
rrectness of i
page 20 .
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2 - ABS Hydraulic Unit - N55-

❑ Component location: in the engine compartment on the front passenger side
nf
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or
The hydraulic unit consists of the components:

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atio
♦ ABS Hydraulic Pump - V64-

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♦ Brake Pressure Sensor 1 - G201-

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♦ Valve block (contains inlet and outlet valves)

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❑ The ABS Hydraulic Pump - V64- and valve block must not be separated from one another.
f
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❑ Removing and installing. Refer to Cop py
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⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Removing and Installing, LHD, Gasoline Engine”,
yri
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ht
page 20 . cop Vo
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3 - Brake Pad Wear Indicator Lamp - K32-
AG.
❑ Component location: inside the instrument cluster

4 - ABS Indicator Lamp - K47-

5 - ASR/ESP Indicator Lamp - K155-

6 - Brake System Indicator Lamp - K118-
7 - Brake Lamp Switch - F-
❑ Installed location: on the master brake cylinder
❑ Removing and installing. Refer to ⇒ “3.2.1 Brake Lamp Switch, Removing and Installing ”, page 102 .
8 - TASR/ESP Button - E256-
❑ Two versions, two component locations:
♦ As a button in the center console
♦ via the functioning surfaces in the Infotainment system menu
❑ ASR/ESP Button - E256- in the center console removing and installing. Refer to ⇒ Electrical Equipment;
Rep. Gr. 96 ; Controls; ASR/ESP Button - E256- , Removing and Installing .
9 - Diagnostic Connection
❑ Installed location: Driver side footwell cover
10 - Steering Angle Sensor - G85-
❑ Installed location: inside the steering gear
❑ The Steering Angle Sensor - G85- cannot be replaced separately.
❑ Steering removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Steering Gear;
Steering Gear, Removing and Installing .
11 - Right Front ABS Wheel Speed Sensor - G45- / Left Front ABS Wheel Speed Sensor - G47-
❑ Removing and installing. Refer to ⇒ “4.1 Overview - Front Axle Speed Sensor”, page 46 .
12 - Wheel Hub with Wheel Bearing
❑ The ABS sensor ring is installed in the wheel bearing
❑ Check the ABS sensor ring. Refer to ⇒ “4.6 ABS Sensor Ring, Checking”, page 51 .
13 - Right Rear ABS Wheel Speed Sensor - G44- / Left Rear ABS Wheel Speed Sensor - G46-
❑ Removing and installing (FWD). Refer to ⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 47 .
. Volkswagen AG
wa gen AG d
14 - Wheel Hub with Wheel Bearing olks
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❑ The ABS sensor ring is installed in the wheel
ris bearing
ed
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th ABS Sensor Ring, Checking”, page 51 . e or
❑ Check the ABS sensor ring. Refer to ⇒au“4.6 ac
ss
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nl
pt
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2. Component Location Overview
agen
Prote AG.
3 Control Module and Hydraulic Unit

⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
page 16
⇒ “3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 , Re‐
moving and Installing”, page 20
⇒ “3.5 Brake Lines, Attaching to Hydraulic Unit”, page 43
⇒ “3.3 Control Module, Separating from Hydraulic Unit”,
page 41
⇒ “3.4 Control Module, Attaching to Hydraulic Unit”, page 42
3.1 Overview - Control Module and Hydraul‐

ic Unit
⇒ “3.1.1 Overview - Control Module and Hydraulic Unit ”,
page 16
3.1.1 Overview - Control Module and Hydraulic Unit
1 - ABS Control Module - J104-

ling. Refer to
Gasoline Engine”,
page 20 .
2 - ABS Hydraulic Unit - N55-
ling. Refer to
Module and ABS Hy‐ AG. Volkswagen AG d
draulic Unit, Removing lksw
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and Installing, LHD, d by
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Gasoline Engine”, orise nte
page 20 . au
th eo
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3 - TORX® Screw
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un
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❑ Step 1: temporary tight‐

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ening specification: 1
rm
ab
Nm to 1.5 Nm (to install

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the seal)
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❑ Step 2: final tightening

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spec
specification: 2.5 Nm
es, in part or in w
❑ Install the new TORX®

t to the co
bolts in two steps

switching back and
forth.
rrectness of i
4 - Brake Line
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❑ 14 Nm
❑ To the right rear brake
nform
ercia
caliper
m
❑ Identification: 5.25 mm
com
tion in
diameter and tube fitting

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with thread M 12 x 1
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5 - Brake Line
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❑ 14 Nm
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Rep. Gr.45 - Antilock Brake System
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Prote AG.
❑ To the left front brake caliper
❑ Identification: 5.25 mm diameter and tube fitting with thread M 10 x 1
6 - Brake Line
❑ 14 Nm
❑ To the right front brake caliper
❑ Identification: 5.25 mm diameter and tube fitting with thread M 12 x 1
7 - Brake Line
❑ 14 Nm agen
AG. Volkswagen AG d
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❑ To the left d byrear
Vo
brake caliper gu
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❑ Identification:
thori 5.25 mm diameter and tube fitting with
e o thread M 10 x 1
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8 - Brake
ss Line c
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❑ 14 Nm
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❑ Master brake cylinder/primary piston circuit to hydraulic control unit
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❑ Identification: Diameter 6 mm and tube fitting with thread M 12 x 1
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9 - Brake Line
h re
ole,
❑ 14 Nm
spec
❑ Master brake cylinder/secondary piston circuit to hydraulic unit
t to the co
❑ Identification: Diameter 6 mm and tube fitting with thread M 12 x 1
10 - Brake Booster
rrectne
❑ Removing and installing. Refer to ⇒ “3.3.1 Brake Booster, Removing and Installing ”, page 105 .
ss
11 - Bracket
o
cial p
f in
12 - TORX® Screw
form
mer
❑ 8 Nm
atio
om
13 - Rubber Insulation
c
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or
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❑ When installing the mount, make sure the rubber bushing does not push out of the bracket. Make sure
t
sd
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the ABS Hydraulic Unit - N55- is secure after installing it otherwise malfunctions can occur.
i
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14 - Heat Shield
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Allocation. Refer to the Parts Catalog.
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15 - Nut
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Prote AG.
❑ 20 Nm
16 - Bracket
17 - Nut
❑ 20 Nm
3. Control Module and Hydraulic Unit 17

3.1.2 Overview - Control Module and Hydraulic Unit, RHD
1 - Brake Line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ Identification: 6 mm di‐
ameter and tube fitting
with a M12 x 1 thread
❑ Repairing the brake
lines. Refer to
⇒ “5.1 Brake Lines, Re‐
pairing”, page 142 .
❑ 14 Nm
2 - Brake Line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit
❑ Identification: 6 mm di‐
ameter and tube fitting
with a M12 x 1 thread
❑ Repairing the brake
lines. Refer to
⇒ “5.1 Brake Lines, Re‐
❑ 14 Nm
3 - Brake Line
❑ To the right rear brake
caliper
❑ Identification: 5.25 mm
diameter and tube fitting AG. Volkswagen AG d
with a M12 x 1 thread agen oes
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❑ Repairing the brake d b ara
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lines. Refer to thor eo
⇒ “5.1 Brake Lines, Re‐ ss au ra
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pt
❑ 14 Nm
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4 - Brake Line
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❑ To the left front brake caliper

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❑ Identification: 5.25 mm diameter and tube fitting with a M10 x 1 thread

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spec
❑ Repairing the brake lines. Refer to ⇒ “5.1 Brake Lines, Repairing”, page 142 .
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❑ 14 Nm
5 - Brake Line
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❑ To the right front brake caliper

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⇒ “3.4 Control Module, Attaching to Hydraulic Unit”, page 42 . ot p
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8 - Bracket
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❑ after installing, make sure it fits properly
9 - Screw
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❑ 8 Nm
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10 - Rubber Bushing
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the ABS Hydraulic Unit - N55- is secure after installing it otherwise malfunctions can occur.
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11 - Nut
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⇒ “3.1 Overview - Brake Booster/Master Brake Cylinder”, page 98 .
❑ Checking the brake booster. Refer to ⇒ “4.4 Vacuum System, Checking”, page 137 .
❑ Brake booster, removing and installing on vehicles with diesel engine. Refer to
⇒ “3.3.2 Brake Booster, Removing and Installing, RHD with Diesel Engine”, page 110 .
❑ Brake booster removing and Installing on vehicles with 1.2L and 1.4L gasoline engine. Refer to
⇒ “3.3.3 Brake Booster, Removing and Installing, RHD vehicles with 1.2L and 1.4L Gasoline Engines”,
page 119 .
❑ Brake master cylinder, removing and installing. Refer to
⇒ “3.4.2 Brake Master Cylinder, Removing and Installing, RHD Vehicles”, page 130 .
15 - Brake Line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ Identification: 6 mm diameter and tube fitting with a M12 x 1 thread
❑ 14 Nm
16 - Brake Line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ Identification: 6 mm diameter and tube fitting with a M12 x 1 thread
❑ 14 Nm

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3.2 ABS Control Module - J104- / ABS Hy‐ ir se
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draulic Unit - N55- , Removing and In‐ tho
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⇒ “3.2.4 ABS Control Module and ABS Hydraulic Unit, Removing
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Special tools and workshop
equipment required
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♦ Torque Wrench 1331
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♦ Torque Wrench 1410 -

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♦ Brake Pedal Actuator -
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Plugs 5Q0 698 311

1 - M10 Plug
2 - M12 Plug
Removing
Component Location:

The control module is bolted to the hydraulic unit and is located

at right in the engine compartment.
NOTICE
Risk of destroying the brake lines by bending.
– Never forcefully bend the brake lines in the hydraulic unit
area.
– Read and note the present control module code.

– On vehicles with a coded radio, note the code. Retrieve it if
necessary.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– For vehicles with a heat shield, remove the heat shield.
– Press the locking mechanism downward -arrow A-.AG. Volkswagen

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– Release the connector -arrow B-.
– Remove the connector -1-.
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– Attach the bleeder bottle bleed hose -1- to the left front brake
caliper bleed valve.
– Open the bleeder valve.
– Attach the bleeder bottle bleed hose -1- to the left rear brake
– Push the brake pedal at least 60 mm using the Brake Pedal
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Make sure no brake fluid gets on the contacts.
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– Remove the cover from the bulkhead and unclip the brake
lines.
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– First, mark both brake lines from the brake master cylinder and
remove from the hydraulic unit.
rrectne
– Immediately seal the threaded holes with the plugs from the
assembly repair kit 5Q0 698 311.
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– Mark the remaining brake lines (brake calipers), remove them
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and seal off the threaded holes.
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– Pull the hydraulic unit with the control module upward out of
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♦ Only remove the plugs on the new hydraulic unit if the corre‐
sponding brake line is installed.
♦ If the plugs are removed too early from the hydraulic unit,
brake fluid can escape and the unit may not be sufficiently filled
or adequately bled.
♦ When installing the hydraulic unit, make sure that the rubber
bushings are not pushed out of the bracket.

Brake Line Tightening Sequence:

– Remove the Brake Pedal Actuator - VAG1869/2- .
– Bleed the brake system. Refer to
– Code the radio.
– Code the ABS Control Module -J104- using the ⇒ Vehicle di‐
agnostic tester in "Guided Fault Finding".
While doing so, a basic setting for the Steering Angle Sensor -
G85- , Transverse Acceleration Sensor - G200- , Longitudinal
Acceleration Sensor - G251- and Brake Pressure Sensor 1 -
G201- must be performed.
Tightening Specifications
♦ ⇒ “3.1.1 Overview - Control Module and Hydraulic Unit ”, page
16
♦ Battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Bat‐
tery; Overview - Battery .
♦ Front bleeder valve. Refer to
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⇒ “2.1utOverview
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equipment required
5-50Nm - VAG1331-
VAG1410-
VAG1869/2- .
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Plugs 5Q0 698 311
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1 - M10 Plug
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2 - M12 Plug
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Removing
Component Location:
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The control module is bolted to the hydraulic unit -1- and is located
in the engine compartment on the right side.
NOTICE
area.

necessary.
– Remove the engine cover.
Diesel Engine with Particulate Filter:
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
– Remove the driveshaft heat shield -arrows-, if equipped. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Driveshaft;
Driveshaft Heat Shield, Removing and Installing .
For Vehicles with Parking/Auxiliary Heater:
– Remove the front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Ex‐
haust Pipes/Mufflers; Front Exhaust Pipe, Removing and In‐
stalling .
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– Disconnect the connector -1-.

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– Loosen the clamping sleeve -2- and slide it toward the rear.
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– Remove the bolts -1-.

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– Loosen the bolt -2- and remove the clamp.

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– Remove the front exhaust pipe.

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– Remove both nuts -arrows- from the brackets for the coolant
line -1- on the longitudinal member and the bulkhead.
– Remove the bracket from the pins. Then pull the coolant lines
as far downward as possible.
Continuation for all vehicles:
– Unclip the wiring guide.
– Press the locking mechanism downward -arrow A-.

AG. Volkswagen AG d
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– Insert the Brake Pedal Actuator - VAG1869/2- . an
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Rep. Gr.45 - Antilock Brake System
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Actuator - VAG1869/2- .
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– Place enough lint-free cloths under the control module and

hydraulic unit.
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– Pull the hydraulic unit with the control module upward out of
the shock absorbers -arrow-.
– Carefully place the hydraulic unit with the control module at
the bottom of the engine compartment.
Note
Position the ABS Hydraulic Unit - N55- with the ABS Control Mod‐
ule - J104- so that it cannot fall down.
– Raise the vehicle.

For Vehicles with Parking/Auxiliary Heater:

– Remove the bracket in the vehicle from the hydraulic unit

-arrows-.
– Guide out the hydraulic unit from the vehicle.
Installing
following:
Note
or adequately bled.

AG. Volkswagen AG d
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– Remove the Brake Pedal Actuator - VAG1869/2- . olksw not
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– Bleed the brake system. Refer to rise nte
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⇒ “6.2 Hydraulic System, Standard Bleeding”, page 146
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– Code the radio.
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agnostic tester.
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♦ Noise insulation bolts. Refer to ⇒ Body Exterior; Rep. Gr. 66 ;

m
Noise Insulation; Overview - Noise Insulation . a

com
tion in
♦ Front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/

r
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Mufflers; Front Exhaust Pipe, Removing and Installing .

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♦ Pendulum support. Refer to ⇒ Rep. Gr. 10 ; Subframe Mount;

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Overview - Subframe Mount .

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⇒ “1.1 Overview - Front Brake Caliper”, page 91 .
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♦ Rear bleeder valves. Refer to
agen
Prote AG.
⇒ “2.1 Overview - Rear Brake Caliper”, page 95 .
3.2.3 Control Module and Hydraulic Unit, Removing and Installing, LHD, AWD
Diesel Engine


equipment required
5-50Nm - VAG1331-
VAG1410-
VAG1869/2- .
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Removing
Component Location:

The control module is bolted to the hydraulic unit -1- and is located
in the engine compartment on the right side.
NOTICE AG. Volkswagen AG d

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Risk of destroying the brake lines by bending. ed b ara
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stalling .
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– Loosen the clamping sleeve -2- and slide it toward the rear.
or
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– Remove the bolts -1-.

– Loosen the bolt -2- and remove the clamp.
– Remove the front exhaust pipe.
– Remove the right driveshaft. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Driveshaft; Driveshaft, Removing and
Installing .
– Pivot the suspension strut to the rear and lock.
– Unclip the wiring guide.


– Insert the Brake Pedal Actuator - VAG1869/2- .
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– Place enough lint-free cloths under the control module and
hydraulic unit.
Note
Make sure that no brake fluid gets into the contacts.
lines.
remove from the hydraulic unit.
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Position the ABS Hydraulic Unit - N55- with the ABS Control Mod‐
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– Remove the bracket in the vehicle from the hydraulic unit rrectness of i
-arrows-.
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– Pivot the suspension strut -1- to the side and toward the rear.
Lock it in this position with a wooden block -2-.
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– Guide out the hydraulic unit -3- out of the vehicle through the
pt
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– Code the radio.

agnostic tester.
16
♦ Noise insulation bolts. Refer to ⇒ Body Exterior; Rep. Gr. 66 ;
Noise Insulation; Overview - Noise Insulation .
♦ Front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/
Mufflers; Front Exhaust Pipe, Removing and Installing .
♦ Pendulum support. Refer to ⇒ Rep. Gr. 10 ; Subframe Mount;
Overview - Subframe Mount .
♦ Driveshaft. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40 ; Driveshaft; Overview - Driveshaft .
♦ Lower control arm. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Lower Control Arm and Ball Joint; Overview -
Lower Control Arm and Ball Joint .

3.2.4 ABS Control Module and ABS Hydraulic

Unit, Removing and Installing
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1410 - VAG1410-
♦ Brake Pedal Actuator - VAG1869/2- .
Plug assembly part number 5Q0 698 311
1 - M10 plug
2 - M12 plug
Removing
Installed location:
The control module is bolted to the hydraulic unit and is located

at right in the engine compartment.
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Risk of destroying
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– Read and note the present control module coding.

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– If the vehicle has a coded radio, get the radio code from the
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customer before beginning.

hole
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es, in part or in w
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– Remove the heat shield -1- from the bracket -2-. Loosen the
rrectness of i
catch in the direction of the -arrow A- and remove the heat

shield in the direction of the -arrow B-.
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– Push down the lock washer in the direction of the -arrow A-.
– Release the connector -1- in the direction of the -arrow B- and
remove from the control module.
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– Open the bleed valve.
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– Open the bleed valve.
– Push the brake pedal with the Brake Pedal Actuator -
VAG1869/2- at least 60 mm.
– Close left front and left rear bleeder valves.
– Place sufficient lint-free cloths under the control module and
hydraulic unit.
Note
Pay attention that brake fluid does not get into the control module
contacts and the connector.
– First, mark both brake lines from master cylinder and remove
from the hydraulic unit.
– Seal the threaded holes immediatelyVwith plugs from the as‐
sembly part set part numbersw5Q0 AG. olkswagen AG d
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– Mark, remaining brake ed lines (brake calipers), unfasten and ran
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– Remove the ABS Hydraulic Unit - N55- with the bracket -1-
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upward in the direction of the -arrow- from the bracket.

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– Remove the ABS Hydraulic Unit - N55- with the bracket -1-
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following:
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Note
rrectness of i
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♦ Do not remove sealing plugs at new hydraulic unit until the

corresponding brake line is about to be installed.
nform
ercia
♦ If the sealing plugs are removed too early, brake fluid can es‐
cape and unit may not be sufficiently filled or adequately bled.
m
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ion
♦ When installing the hydraulic unit, make sure the damper rub‐
c
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or
ber is not pushed out of the console.

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Brake Line Tightening Sequence

– Install the brake lines in the sequence -1- to -6-.
– Tighten the brake lines in the sequence -1- to -6-.
– Bleed the brake system. Refer
AG. Volkto
swagen AG
agen Standard Bleeding”,
⇒ “6.2 HydraulicVoSystem, does
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146 .
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– Enter radio
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isecode. nte
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– Codessthe
a ABS Control Module - J104- using the -Vehicleac Di‐
agnostic Tester- in "Guided Fault Finding".
ce
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A Steering Angle Sensor - G85- , Transverse Acceleration Sensor
itte
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- G200- , Longitudinal Acceleration Sensor - G251- and Brake
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Pressure Sensor 1 - G201- basic setting must be done.
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♦ Refer to
es, in part or in w
⇒ “3.1.1 Overview - Control Module and Hydraulic Unit ”, page
t to the co
16
♦ Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
rrectness of i
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nf
ercia
♦ Rear bleeder valves. Refer to orm

⇒ “2.1 Overview - Rear Brake Caliper”, page 95
m
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AG. Volkswagen AG d
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Brake System - Edition 03.2015 s aut ra
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equipment required
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5-50Nm - VAG1331-
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Plugs 5Q0 698 311

1 - M10 Plug
2 - M12 Plug
Removing

Component location of the ABS Hydraulic Unit - N55- and the ABS
Control Module - J104- in RHD vehicles:
1 - Brake Booster with Master Brake Cylinder
2 - ABS Hydraulic Unit - N55- and ABS Control Module - J104-
NOTICE
area.

n AG. Volkswagen A
– On vehicles witholkaswcoded
age radio, note the code.
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– Disconnect
ut
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e o Rep.
ra
Gr. s27
s a ; Battery; Battery, Disconnecting and Connecting c .
ce
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– Remove the battery tray -1-. Refer to ⇒ Electrical Equipment;
pt
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Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing .
itte
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– Insert the Brake Pedal Actuator - VAG1869/2- .
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The illustration shows the installation position of the ABS Hy‐
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draulic Unit - N55- and the ABS Control Module - J104- in a LHD
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– Place enough lint-free cloths under the ABS Control Module -

J104- and the ABS Hydraulic Unit - N55- .
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Note
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Pay attention that brake fluid does not run on the ABS Control
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Module - J104- contacts.
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– First label both brake lines from the brake master cylinder gh ht
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– Remove both the brake master cylinder brake lines -A- and
-B- from the ABS Hydraulic Unit - N55- .
– Label the remaining brake lines (brake caliper) and remove.

Seal the threaded holes -2-.

– Remove the ABS Hydraulic Unit - N55- -1- together with the
bracket -2- in the direction of the -arrow-.
– This will remove the rubber buffers -arrows- from the bracket
stud bolts -3- at the same time.
– Guide out the hydraulic unit from the vehicle.
Installing
following:
Note
♦ Do not remove sealing plugs at new hydraulic unit until the

corresponding brake line is about to be installed.
♦ If the plugs are removed too early from
agen
Athe
G. Vhydraulic
olkswagen Aunit,
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brake fluid can escape and theVunit
olks may not be sufficiently filled
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♦ Do not bend the brake
au lines near the ABS Hydraulic Unit -
th or
ac
N55- ! ss
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♦ When installing the mount, make sure the rubber bushing does
du
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not push out of the bracket. Make sure the ABS Hydraulic Unit
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- N55- is secure after installing it otherwise malfunctions can
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– Pre-tighten the brake lines in the sequence -1- to -6-.
– Tighten the brake lines in the sequence -1- to -6-.
– Remove the Brake Pedal Actuator - VAG1869/2- . rrectness of i
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– Code the radio.

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G201- must be performed. t. Cop py
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Tightening Specifications p by
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♦ ⇒ “3.1.2 Overview - Control Module and Hydraulic Unit, RHD”, Prote AG.
page 18
♦ noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise
Insulation; Noise Insulation, Assembly Overview .
3.3 Control Module, Separating from Hy‐

draulic Unit

♦ ESD Work Surface - VAS6613-

♦ TORX® insert T25
♦ If the control module is faulty, then the control module is to be
separated from the hydraulic unit and only the control module
replaced.
♦ If the hydraulic unit is faulty, the hydraulic unit and the control
module are to be replaced together.
♦ The ESP unit must be removed in order to separate the control
module and the hydraulic unit.
NOTICE
There is a risk of destroying the hydraulic unit by removing the
return flow pump.
– Never separate the return flow pump from the hydraulic unit.
NOTICE
There is a risk of destroying the control module through the
electrostatic charge and reduced cleanliness.
– Discharge electrostatic charge: touch the electrostatic dis‐
charge work surface
– Protect the inner control module from moisture and dirt.
– Touch a grounded object before working on electrical equip‐

ment ESD Work Surface - VAS6613- . Do not touch connector
terminals or electronic components directly.
– Position the hydraulic unit with the control module on the ESD olkswage es n
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Work Surface - VAS6613- . db
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– Remove the three TORX® bolts from the control module tho and or
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set aside immediately (risk of confusing them newssTORX® ac
bolts).
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– Position the hydraulic unit with the control module from above
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– Pull control module off from hydraulic unit without angling.
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– Cover control module magnetic coils with a lint free cloth.
hole
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– Check the cleanliness of the hydraulic unit sealing surface if t to the co

necessary clean with mineral spirits and a lint-free cloth.
The hydraulic unit sealing surface must not be worked with a file,
rrectness of i
metal scraper, sand paper or similar.

l purpos
If the hydraulic unit sealing surface is damaged (for example

through grooves or scrapes) the hydraulic unit must be replaced
with the control module.
nform
ercia
The seal on the control module must not be pulled out or raised
m
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The seal on the control module cannot be replaced.

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3.4 Control Module, Attaching to Hydraulic
agen
Prote AG.
Unit

♦ ESD Work Surface - VAS6613-

♦ Torque Screwdriver - VAG1624-
♦ TORX® insert T25
Note
Excessive shaking (for example, dropping, impact) may destroy

the control module. The control module must then no longer be
used.
• Surfaces must be cleaned before assembling.

– Place the control module on the hydraulic unit without tilting.
– Install the hydraulic unit and control module with the new inner
TORX® bolts switching back and forth in two steps according
to the tightening specification.
Note
The hydraulic unit threads cannot be re-cut to secure the control

module. In the threads are damaged (bolts are difficult to install
by hand or the bolts cannot be tightened to the tightening speci‐
fication). The hydraulic unit must be replaced.
Tightening Specification
♦ Refer to
16
Note
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♦ A new controlbymodule
Vol
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ara
to a usedohydraulic
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♦ Do not install a used control module.
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3.5 Brake Lines, Attaching to Hydraulic Unit

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⇒ “3.5.1 Brake Lines, Attaching to Hydraulic Unit ”, page 43

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3.5.1 Brake Lines, Attaching to Hydraulic Unit

spec
t to the co
On tandem master brake cylinder:

A - Primary piston circuit of master brake cylinder to hydraulic unit
rrectne
- Identification: Diameter 6 mm and tube fitting with thread M 12

x1
ss
B - Secondary piston circuit of master brake cylinder to hydraulic

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1 - Hydraulic unit to left front brake caliper

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3 - Hydraulic unit to left rear brake caliper

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4 - Hydraulic unit to rear right brake caliper

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On hydraulic unit:
1 - Hydraulic unit to rear right brake caliper
- Identification: Diameter 5.25 mm and tube fitting with shorter
thread M12 x 1
- Identification: 5.25 mm diameter and tube fitting with thread M
10 x 1
3 - Hydraulic unit to right front brake caliper
- Identification: Diameter 5.25 mm and tube fitting with shorter
thread M12 x 1
- Identification: 5.25 mm diameter and tube fitting with thread M
10 x 1
5 - Hydraulic unit to master cylinder secondary piston circuit
x1
6 - Hydraulic unit to primary piston circuit of master brake cylinder
x1
♦ Refer to
. Volkswagen AG
16 swagen AG does
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3.5.2 Brake Lines, Attaching to Hydraulic Unit,
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On tandem master brake cylinder:

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A - Master brake cylinder primary piston circuit to hydraulic unit

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- Identification: 6 mm diameter and tube fitting with a M12 x 1

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thread
hole
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B - Master brake cylinder secondary piston circuit to hydraulic unit

es, in part or in w
t to the co
- Identification: 6 mm diameter and tube fitting with a M12 x 1

thread
rrectness of i

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On the ABS Hydraulic Unit - N55- : db
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- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
ce
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2 - Hydraulic unit to right front brake caliper
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thread
4 - Hydraulic unit to right rear brake caliper
rrectness of i
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short thread
nform
ercia
♦ ⇒ “3.1.2 Overview - Control Module and Hydraulic Unit, RHD”,

m
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page 18
on in
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4 Sensors
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 46
⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 47
⇒ “4.3 ESP Sensor Unit G419 , Removing and Installing”,
page 48
⇒ “4.4 Right/Left Front ABS Wheel Speed Sensor G45 / G47 ,
Removing and Installing”, page 49
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⇒ “4.5 Right/Left Rear ABS Wheel Speed Vol Sensor G44 / G46 ,
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Removing and Installing”, page 49 ed by ara
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4.1 Overview - Front
ss
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1 - ABS Speed Sensor

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❑ Clean the inner surface
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of the opening before in‐
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h re
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❑ Coat the inner surface
spec
with Hot Bolt Paste - G
t to the co
052 112 A3- .
❑ Removing and Instal‐
ling. Refer to
rrectne
⇒ “4.4 Right/Left Front
ABS Wheel Speed Sen‐
s
sor G45 / G47 , Remov‐
s o
ing and Installing”, page
cial p
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49 .
form
mer
2 - Bolt
atio
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n
❑ 8 Nm
c
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or
n thi
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3 - Driveshaft
iva
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❑ Overview. Refer to ⇒
um
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Suspension, Wheels,
t.
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Steering; Rep. Gr. 40 ; Cop py
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Drive Axle; Overview - yri
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Drive Axle .
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❑ Removing and instal‐ Prote AG.
ling. Refer to ⇒ Suspen‐
sion, Wheels, Steering;
Rep. Gr. 40 ; Drive Axle;
Drive Axle, Removing
and Installing .
4 - Wheel Hub with Wheel
Bearing Unit
❑ The ABS sensor ring is
integrated in the wheel
bearing unit
❑ Check the ABS sensor
ring. Refer to
⇒ “4.6 ABS Sensor
Ring, Checking”, page 51 .
❑ Removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Wheel Bearing; Wheel
Bearing Unit, Removing and Installing .

4.2 Overview - Rear Axle Speed Sensor

⇒ “4.2.2 Overview - Rear Axle Speed Sensor ”, page 48
4.2.1 Overview - Rear Axle Speed Sensor, FWD
1 - ABS Speed Sensor

❑ Clean the inner surface
of the opening before in‐
serting the sensor
052 112 A3- .
ling. Refer to
⇒ “4.5.1 Right/Left Rear
sor G44 / G46 , Remov‐
ing and Installing,
FWD”, page 49 .
2 - Bolt
❑ 8 Nm AG. Volkswagen AG d
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3 - Wheel Hubbywith
Vo Wheel gu
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❑ sThe
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ABS sensor ring is ra
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ce
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bearing unit
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Ring, Checking”,
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page 51 .
ole,
spec

t to the co

Rep. Gr. 42 ; Wheel
Bearing, Trailing Arm;
rrectne
Wheel Bearing Unit, Re‐

moving and Installing .
ss o
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4. Sensors 47
4.2.2 Overview - Rear Axle Speed Sensor

1 - ABS Speed Sensor lkswage es n
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❑ Clean the inner surface ir se
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of the opening before in‐ utho tee
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052 112 A3- .
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ling. Refer to
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⇒ “4.5.2 Right/Left Rear
hole
spec
sor G44 / G46 , Remov‐ es, in part or in w
t to the co
ing and Installing,
AWD”, page 50 .
2 - Bolt
rrectness of i
❑ 8 Nm
l purpos
3 - Driveshaft
nform
ercia
❑ Overview. Refer to ⇒
Suspension, Wheels,
m
at
Steering; Rep. Gr. 42 ;
om
io
Drive Axle; Overview -
n
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Drive Axle .
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Rep. Gr. 42 ; Drive Axle; C py
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Drive Axle, Removing
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and Installing . cop Vo
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Prote AG.
4 - Wheel Hub with Wheel
Bearing Unit
❑ The ABS sensor ring is
integrated in the wheel
bearing unit
ring. Refer to
Ring, Checking”, page 51 .
❑ Removing and Installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing, Trailing
Arm; Wheel Bearing Unit, Removing and Installing .
4.3 ESP Sensor Unit - G419- , Removing

and Installing
The Transverse Acceleration Sensor - G200- , the Rotation Rate
Sensor - G202- and the Longitudinal Acceleration Sensor - G251-
are installed together with the Electromechanical Parking Brake
Control Module - J540- in the ABS Control Module - J104- .
The components cannot be replaced individually.
– ABS Control Module - J104- , Removing and Installing. Refer
to
⇒ “3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 ,
Removing and Installing”, page 20 .

4.4 Right/Left Front ABS Wheel Speed Sen‐

sor -G45- / -G47- , Removing and In‐
stalling
Note
The example describes the removal and installation of the left

front ABS wheel speed sensor. The removal and installation of
G. Volkswagen AG d
the right front ABS wheel speed sensor
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Removing tho
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– Raise the vehicle. ss
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– Disconnect the connector -3- from the Left Front ABS Wheel
du
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– Remove the bolt -2- and remove the Left Front ABS Wheel
ot p
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Speed Sensor - G47- -1- from the wheel bearing housing.
, is n
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Installing
spec
es, in part or in w
Install in reverse order of removal. Note the following:
t to the co
– Clean the inner surface of the hole before inserting the speed
sensor.
rrectness of i
– Coat the speed sensor all around with hot bolt paste G 052
l purpos
112 A3.
nf
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or
♦ Refer to
m
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atio
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 46
om
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4.5 Right/Left Rear ABS Wheel Speed Sen‐
Co
Cop py
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stalling
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⇒ “4.5.1 Right/Left Rear ABS Wheel Speed Sensor G44 / G46 ,

Removing and Installing, FWD”, page 49
⇒ “4.5.2 Right/Left Rear ABS Wheel Speed Sensor G44 / G46 ,
Removing and Installing, AWD”, page 50
4.5.1 Right/Left Rear ABS Wheel Speed Sen‐

stalling, FWD
Note
The example describes the removal and installation of the left rear
ABS wheel speed sensor. The removal and installation of the right
rear ABS wheel speed sensor is identical.
4. Sensors 49
Left Rear ABS Wheel Speed Sensor - G46- -1-

Removing
– Disconnect the connector -2- from the Left Rear ABS Wheel
Speed Sensor - G46- .
– Remove bolt -1-, and remove the speed sensor from the wheel
bearing housing. olks
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Installing db ara
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Install in reverse order
s au of removal. Note the following: ra
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112 A3.
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Tightening Specifications h re
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spec
♦ Refer to
es, in part or in w
t to the co
⇒ “4.2.1 Overview - Rear Axle Speed Sensor, FWD”,

page 47
rrectness of i
4.5.2 Right/Left Rear ABS Wheel Speed Sen‐

l purpos

stalling, AWD
nform
mercia
a
com
tio
Note
n in
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s
The example describes the removal and installation of the left rear
iva
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– Raise the vehicle. Prote
cted AG.
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– Disconnect the connector -3- from the Left Rear ABS Wheel
Speed Sensor - G46- -1-.
– Remove the bolt -2- and remove the Left Rear ABS Wheel
Speed Sensor - G46- -1- from the wheel bearing housing.
Installing
Install in reverse order of removal. Note the following:
sensor.
112 A3.
♦ Refer to
⇒ “4.2.2 Overview - Rear Axle Speed Sensor ”, page 48
4.6 ABS Sensor Ring, Checking

♦ Gauge - Sender Wheel - T10473-
Procedure
• The wheel bearing unit is removed.
– Check the entire circumference of the ABS sensor ring -2- with
the Gauge - Sender Wheel - T10473- as shown. n AG. Volkswagen A G do
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1 - Wheel Bearing Unit olks ot g
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2 - Seal with integrated ABS Sensor ris
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ABS sensor ring test diagram.

A - ABS Sensor Ring is OK
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B - ABS Sensor Ring is Faulty

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4. Sensors 51
5 Special Tools

equipment required
5-50Nm - VAG1331-
VAG1410-
VAG1869/2- .
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♦ Gauge - Sender Wheel - T10473-

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♦ ESD Work Surface - VAS6613- cop Vo
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♦ Torque Screwdriver - VAG1624-
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5. Special Tools 53
46 – Mechanical Components
1 Front Brakes
⇒ “1.1 Overview - Front Brakes”, page 54
⇒ “1.2 Brake Pads, Removing and Installing”, page 58
⇒ “1.3 Brake Caliper, Removing and Installing”, page 62
1.1 Overview - Front Brakes

⇒ “1.1.1 Overview - Front Brakes FS III”, page 54
⇒ “1.1.2 Overview - Front Brakes PC57 and C60”, page 56
1.1.1 Overview - Front Brakes FS III
Note
♦ After every brake pad replacement, firmly press down on the brake pedal several times with vehicle sta‐
tionary so that the brake pads are properly set in their respective operating position.
♦ Use the Brake Charger/Bleeder Unit - VAS5234- to extract brake fluid from the brake fluid reservoir.
♦ Install the Brake Pedal Actuator - VAG1869/2- before removing a brake caliper or disconnecting a brake
hose (doing so reduces the pressure).
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54 Rep. Gr.46 - Mechanical Components

1 - Brake Rotor
❑ Internally vented
❑ Wear limits. Refer to
⇒ “3.1.2 Front Brakes”,
page 4 .
❑ Always replace on both
axles.
❑ Remove the brake cali‐
per before removing
❑ Do not use excessive AG. Volkswagen AG d
force to separate the agen oes
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brake rotor from the ed by
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3 - Brake Pads
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❑ Thickness: 12 mm with‐
spec
es, in part or in w
out backing plate
t to the co
❑ Wear limit: 2 mm without
backing plate
rrectness of i
❑ Checking thickness.
Refer to ⇒ Mainte‐
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nance ; Booklet ; Front

and Rear Brake Pads:
Checking Thickness .
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Removing and Instal‐
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1. Front Brakes 55
III”, page 58 .
4 - Brake Caliper
❑ Do not remove the brake hose when changing the brake pads.
❑ Removing and Installing. Refer to
⇒ “1.3.1 Brake Caliper, Removing and Installing, Front Brakes FS III”, page 62 .
❑ Servicing. Refer to ⇒ “1.1.1 Overview - Brake Caliper FS III”, page 91 .
5 - Guide Pin
❑ 30 Nm
6 - Cap
❑ Remove
7 - Mounting Sleeve
8 - Brake Hose with Ring Connection and Banjo Bolt
❑ 35 Nm
9 - Wheel Hub with Wheel Bearing
❑ Pressing in and out. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Wheel Bearing; Overview
- Wheel Bearing .
10 - TORX® bolts
❑ 12 Nm
11 - Cover Plate
12 - Wheel Bearing Housing
❑ With integrated brake carrier
❑ Lightly grease the pad guide surfaces with Lithium Lubricating Grease - G 052 150 A2- .
13 - Speed Sensor
❑ Before inserting the sensor, clean the inner surface of the hole and coat with Hot Bolt Paste - G 052 112
A3- .
14 - Hex Socket Bolt ksw
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❑ 8 Nm se
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1.1.2 Overview - Front Brakes PC57 and C60

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♦ After replacing brake pads, depress brake pedal firmly several

hole
spec
times with vehicle stationary so that the brake pads are prop‐
es, in part or in w
erly seated in their normal operating position.

t to the co
♦ Use Brake Charger/Bleeder Unit - VAS5234- to extract brake

fluid from brake fluid reservoir.
rrectness of i
♦ Install the Brake Pedal Actuator - VAG1869/2- to relieve pres‐

l purpos
sure before removing a brake caliper or disconnecting a brake

hose.
nform
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Overview - front brakes PC57 and C60:

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1 - Cover Plate
2 - TORX® Screw
❑ 12 Nm
3 - Brake Rotor
❑ Vented on the inside
⇒ “3.1.2 Front Brakes”,
page 4 .
axles.
❑ Remove brake caliper
and brake carrier before
removing
4 - TORX® Screw
❑ 8 Nm
5 - Brake Carrier
❑ Lightly grease the pad AG. Volkswagen AG d
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❑ When wear limit is
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reached (limit: approxi‐
spec
mately 4 mm) the warn‐
es, in part or in w
t to the co
ing lamp in instrument
cluster will come on, the
contact sensor can be
replaced separately. rrectness of i
❑ Wear limit: 2 mm without
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backing plate
❑ Check the thickness. Refer to ⇒ Maintenance ; Booklet 36.1 .
nform
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❑ Always replace on both axles.

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❑ Removing and installing. Refer to

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tion in
⇒ “1.2.2 Brake Pads, Removing and Installing, Front Brakes PC57 and C60”, page 60 .
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⇒ “1.3.2 Brake Caliper, Removing and Installing, Front Brakes PC57 and C60”, page 64 .
❑ Servicing. Refer to ⇒ “1.1 Overview - Front Brake Caliper”, page 91 .
9 - Hex Bolt, Self-Locking

❑ 35 Nm
❑ Replace after removing
10 - Ribbed Bolt
❑ 200 Nm
❑ Clean if using again.
1. Front Brakes 57
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12 - Brake Hose with Ring Connection and Banjo Fitting
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❑ Make sure it is installed in the correct position.
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13 - Clip
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spec
14 - Bracket
es, in part or in w
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15 - Bolt
❑ 8 Nm
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1.2 Brake Pads, Removing and Installing
nform
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⇒ “1.2.1 Brake Pads, Removing and Installing, Front Brakes FS

III”, page 58
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⇒ “1.2.2 Brake Pads, Removing and Installing, Front Brakes
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1.2.1 Brake Pads, Removing and Installing,
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♦ Torque Wrench 1331 5-50Nm - VAG1331- Prote
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♦ Piston Resetting Tool - T10145-

♦ Lithium Lubricating Grease - G 052150 A2-
Removing
Label the brake pads that will be used again when removing. In‐
stall in the same position, otherwise the braking effect will be
uneven.
– Remove the wheels.
– Remove the caps.

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– Remove both tho -arrows- from the brake caliper.
guideaupins or
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– Remove the brake caliper and secure with wire so that the
ce
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un
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weight of the brake caliper does not burden or damage the
an
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brake hose.
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– Remove brake pads from brake caliper.
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Cleaning:
h re
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spec
WARNING
es, in part or in w
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Health risk due to toxic dust from the brake system.
Irreversible deposit of dust particles in the lungs. Breathing im‐
rrectness of i
pairments may occur.
– Never blow out the brake system with compressed air.
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– Thoroughly clean the contact surfaces for the brake pads on
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– Clean the brake caliper.
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Before pushing back the pistons, extract some of the brake fluid
out of the brake fluid reservoir using a bleeder bottle. Otherwise
brake fluid will overflow and cause damage, especially if the brake
fluid was added intermittently.
– Lightly grease the pad guide surfaces on the brake carrier with
Lithium Lubricating Grease - G 052150 A2- .
– Press the piston back.

– Insert the brake pads in the brake caliper and piston.
– Insert the brake pad with the lettering “piston side” on the
backing plate in the brake piston.
1. Front Brakes 59
– Install the brake caliper with the brake pads on the wheel
bearing housing.
– Place brake caliper on the brake carrier first at the bottom
-arrow-.
• Pin of brake caliper must stand behind guide of brake carrier!
– Tighten brake caliper to brake carrier using both guide pins.
– Install both caps.
– Install the wheels.
Note
♦ After every brake pad replacement, firmly press down on the

brake pedal several times with vehicle stationary so that the
brake pads are properly set in their respective woperating
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♦ Refer to ⇒ “1.1.1 Overview - Front Brakes FS III”, page 54

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♦ Wheel Bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep.
ility
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Gr. 44 ; Wheels, Tires; Wheel Bolt Tightening Specifications .
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1.2.2 Brake Pads, Removing and Installing,
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Front Brakes PC57 and C60
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– Remove the wheels from the front axle. C py
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– Disconnect the brake pad wear display connector. copy Vo
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The brake pad wear indicator is installed at the front right.
AG.

– Counterhold the guide pins and remove both screws from the
brake caliper.
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– Remove the brake caliper -1- and secure with wire so that the
weight of the brake caliper does not stress or damage the
brake hose.
nform
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– Remove the brake pads -2 and 3- from the brake carrier -4-.
at
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Cleaning:
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WARNING
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Health risk due to toxic dust from the brake system.

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– Never blow out the brake system with compressed air. Prote
cted AG.
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– Thoroughly clean contact surfaces for brake pads at brake

carrier, remove corrosion.
Note
Use only appropriate solvents for cleaning brake caliper.
Installing
following:
Note
Before pressing piston into cylinder using piston resetting tool,

brake fluid must be extracted from brake fluid reservoir. Other‐
wise, especially if reservoir has been topped off, fluid will overflow
and cause damage.
1. Front Brakes 61
– Press the piston back.

– Lightly grease the pad guide surface on the brake carrier with
lithium grease G 052150 A2.
– Place the brake pads -1- and the springs -2- into the opening
in the brake carrier -3-.
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After installing the abrake
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pads -arrow-, check the seating of all or
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– Counterhold the guide pins and attach the brake caliper to the spec
brake carrier with new self-locking screws.

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– Connect the brake pad wear display connector.

rrectne
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♦ Refer to
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mer
♦ Wheel bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep.

atio
m
Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Specifica‐

o
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♦ Check brake fluid level after replacing brake pad.
1.3 Brake Caliper, Removing and Installing

⇒ “1.3.1 Brake Caliper, Removing and Installing, Front Brakes FS
III”, page 62
⇒ “1.3.2 Brake Caliper, Removing and Installing, Front Brakes
PC57 and C60”, page 64
1.3.1 Brake Caliper, Removing and Installing,

Front Brakes FS III


Removing
Note
The procedure only applies to the replacement of or subsequent

repair work done on the brake caliper.
– Remove the wheels.

– Attach the bleeder bottle bleed hose -1- to the brake caliper
bleed valve.
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– Install the Brake Pedal Actuator
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– Close the bleeder valve ed b and remove the bleeder bottle. ran
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– Remove the brake aut hose. or
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– Remove both caps from the brake caliper bearing bushings.
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– Loosen both guide pins and remove from brake caliper.
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– Remove the brake caliper from the brake carrier.
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spec
Installing
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• Piston is pressed back.
– Insert the brake pads in the brake caliper and piston.
– Insert the brake pad with the lettering “piston side” on the rrectne
backing plate in the brake piston.
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– Install the brake caliper with the brake pads on the wheel
cted agen
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bearing housing.
1. Front Brakes 63
– Place brake caliper with brake pads on brake carrier first at

bottom -arrow-.
– Tighten brake caliper to brake carrier using both guide pins.
• Pin of brake caliper must stand behind guide of brake carrier!
– Install both caps.
– Screw brake hose on brake caliper.
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♦ With the vehicle stationary, firmly press the brake pedalsssev‐
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respective operating position.
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♦ Check the brake fluid level.
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♦ Refer to ⇒ “1.1.1 Overview - Front Brakes FS III”, page 54
es, in part or in w
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♦ Wheel Bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 44 ; Wheels, Tires; Wheel Bolt Tightening Specifications .
rrectness of i
1.3.2 Brake Caliper, Removing and Installing,
l purpos
Front Brakes PC57 and C60

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Work procedure applies only for replacing or when performing C py
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Removing
AG.
– Remove the wheel from the affected front side.

– Disconnect the brake pad wear display connector.
bleed valve.


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– Close the bleed valve and remove the bleeder obottle.
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– Remove the brake hose. rise nte
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– Counterhold the guide pins and remove both screws from the
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Installing
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following:
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• Piston is pressed back.

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• Both brake pads and their springs fit into the opening in the
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brake carrier.
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– Counterhold the guide pins and attach the brake caliper to the
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brake carrier with new self-locking screws.
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– Attach the brake hose to the brake caliper. co Vo
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– Connect the brake pad wear display connector.
– Install the wheel.
♦ Refer to
♦ Bleeder valve. Refer to
tions .
Note
♦ Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads correctly in their operating
position.
♦ Check brake fluid level.
1. Front Brakes 65
2 Rear Brakes
⇒ “2.1 Overview - Rear Brakes”, page 66
⇒ “2.2 Brake Pads, Removing and Installing”, page 68
⇒ “2.3 Brake Caliper, Removing and Installing”, page 72
2.1 Overview - Rear Brakes

Overview - Rear Brakes:
Note
♦ Use Brake Charger/Bleeder Unit - VAS5234- to extract brake

fluid from brake fluid reservoir.
olkswagen AG
en AG. V
♦ Install the Brake Pedal Actuator - VAG1869/2-
olks to relieve pres‐
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sure before removing a brake caliper or d bdisconnecting a brake
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1 - Brake Shield
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❑ Allocation ⇒Electronic
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2 - TORX® Screw
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❑ 12 Nm
spec
es, in part or in w
3 - Brake Rotor
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⇒ “3.1.3 Rear Brakes”,
rrectness of i
page 6 .
❑ Do not use excessive
l purpos
force to separate the

brake rotor from the
nf
ercia
wheel hub. If necessary,

or
use rust penetrant, oth‐

m
m
atio
m
erwise the brake rotors

o
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c
could be damaged.
or
thi
e
❑ Replace both sides if

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worn.
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❑ To remove, first remove

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brake caliper and carrier
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4 - TORX® Screw
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❑ 8 Nm Prote
cted AG.
agen
5 - Brake Caliper
❑ Do not remove the
brake hose when
changing the brake
pads.
ling. Refer to
⇒ “2.3 Brake Caliper,
ling”, page 72 .
❑ Servicing. Refer to
⇒ “2 Rear Brake Cali‐
per”, page 95 .
❑ After servicing or replacing perform the “Basic Setting” with the -Vehicle Diagnostic Tester- .

6 - Internal Multi-Point Bolt

❑ 90 Nm +90°
❑ Remove and install using Multipoint Socket - T10035- . Refer to
⇒ Fig. ““ Multipoint Socket -T10035- ”“ , page 68
7 - Brake Carrier
8 - Spring
9 - Outer Brake Pad
❑ Thickness 11 mm without backing plate
❑ Wear limit: 2 mm without backing plate
❑ Removing and installing. Refer to ⇒ “2.2 Brake Pads, Removing and Installing”, page 68 .
10 - Inner Brake Pad
❑ With spring
❑ Thickness 11 mm without backing plate
❑ Wear limit: 2 mm without backing plate
❑ Removing and installing. Refer to ⇒ “2.2 Brake Pads, Removing and Installing”, page 68 .
11 - Spring
❑ Installed on the inner brake pad only. olkswagen AG
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❑ Pay attention to the installed position.olkswag does
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12 - Brake Line rise nte
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❑ 14 Nm s au ra
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13 - Bracket
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14 - Brake Hose Spring on the Bracket

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ility
15 - Brake Hose with Ring Connection and Banjo Fitting

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❑ To the brake caliper: 35 Nm

h re
ole,
❑ To the brake line: 14 Nm

spec
16 - Guide Pins
t to the co
❑ 35 Nm
17 - Caps
rrectne
❑ For guide pins

ss
18 - Seal
o
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❑ For the parking brake motor

nform
mer
❑ Replace
atio
om
19 - Hex Socket Head Bolt

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❑ 8 Nm
t
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pr
20 - Parking Brake Motor

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⇒ “3.3 Left/Right Parking Brake Motor V282 / V283 , Removing and Installing”, page 77 . C py
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2. Rear Brakes 67
Multipoint Socket - T10035-
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2.2 Brake Pads, Removing and Installing
hole
spec
es, in part or in w
t to the co
♦ Vehicle Diagnostic Tester
rrectness of i
♦ Brake Bleeding Tool Set - VAS6564-
♦ Torque Wrench 1331 Insert - Ratchet Head - VAS6784-
l purpos
♦ Hex Bit - 7mm - T10503-
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Removing
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The installed location of the brake caliper depends on the rear
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axle. Because of this the removal and insulation varies slightly but
cop Vo
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cted
there are additional tools required.
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Installed location of the brake caliper on a Torsion beam axle:

1 - Brake caliper
A - Torsion beam axle

Installed location on a multi-link suspension.

1 - Brake caliper
B - Multi-link suspension.
When removing, mark brake pads that will be used again. Install
in the same position, otherwise braking effect will be uneven.
Note
Do not disconnect the connectors from the parking brake motors.
• Electromechanical parking brake not actuated.

– Remove the rear axle wheels.
The pistons on the electromechanical parking brake must be driv‐
en back using the -Vehicle Diagnostic Tester- .
Note
Before pressing piston back, draw off brake fluid from reservoir
using a bleeder bottle. Otherwise, especially if reservoir has been
topped off, fluid will overflow and cause damage.
– Drive back the piston with the -Vehicle Diagnostic Tester- .
CAUTION
There is a risk of injury because the spring is tensioned.
The spring can jump out and cause eye or skin injury.
– Hold the spring with a hand.
AG. Volkswagen AG d
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– Using screwdriver Vo-A-,
lksw pry off the brake pad eretaining
s no
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-1- from brake d by
caliper -arrow-, while doing so secure ara the re‐
se n
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taining spring
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– Remove caps -arrows-.

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2. Rear Brakes 69
– Remove both guide pins from the brake caliper using the Hex
Bit - 7mm - T10503- and Torque Wrench 1331 Insert - Ratchet
Head - VAS6784- .
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– Remove brake caliper -1- and secure with wire -A- so that the
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weight of the brake caliper does not stress or damage the
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brake hose.
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Note
hole
spec
es, in part or in w
Driving back the pistons with using the -Vehicle Diagnostic Test‐
t to the co
er- is not necessary. The pressure nut in the piston is a floating
mount so the piston can only be pressed and cannot be pulled
back. Only the spindle with the pressure nut is moved back.
rrectness of i
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The piston must first be reset using the -Vehicle Diagnostic Test‐
er- .
nf
ercia
or
– Use the Piston Resetting Tool - T10145- to press back the
m
m
atio
piston.
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– Remove the brake pads -2 and 3-.

Cleaning: agen
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Health risk due to toxic dust from the brakeaut system. ra
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– Never blow out the brake system with compressed air.
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– Thoroughly clean contact surfaces for brake pads at brake , is n
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carrier, remove corrosion.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
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Use only appropriate solvents for cleaning brake caliper.
Installing
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ercia

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following:
on in
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te o
thi
s
– Install the inner brake pad -2- and outer -3- in the brake carrier.
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– Attach the brake caliper.
2. Rear Brakes 71
– Install the caps -arrows-.
– Install the brake pads spring in the brake caliper opening

-arrow-.
Note
Make sure that the spring is seated correctly in the holes on the
brake caliper. agen
AG. Volkswagen AG d
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– Drive out the pistons ris using the
ed
-Vehicle Diagnostic Tester- r.ante
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ss
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♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 66

erm
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Note
Check brake fluid level after replacing brake pad.

rrectness
2.3 Brake Caliper, Removing and Installing

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♦ Torque Wrench 1331 Insert - Ratchet Head - VAS6784-

p
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fo
en
ng
♦ Hex Bit - 7mm - T10503-

t.
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♦ Torque Wrench 1331 5-50Nm - VAG1331- opyri
gh by
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c lksw
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Removing
Note
Work procedure applies only for replacing or when performing

subsequent service work on brake caliper.

Note
Do not disconnect the connectors from the parking brake motors.
– Remove the wheel from the affected rear side.

The pistons on the electromechanical parking brake must be driv‐
. Volkswage AG
en back using the -Vehicle Diagnostic
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Before pressing piston back, draw off brake fluid from reservoir
nl
pt
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using a bleeder bottle. Otherwise, especially if reservoir has been
an
itte
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topped off, fluid will overflow and cause damage.
erm
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ility
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– Drive back the piston with the -Vehicle Diagnostic Tester- .
, is n
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hole
– Remove the bolts -arrows- for the parking brake motor.
spec
es, in part or in w
– Remove the parking brake motor and set aside, without dis‐
t to the co
connecting the connectors.
rrectness of i
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nf
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bleed valve.
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– Open the bleeder valve. C py
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– Close the bleed valve and remove the bleeder bottle.
Prote AG.
– Remove the brake hose.
CAUTION
There is a risk of injury because the spring is tensioned.
The spring can jump out and cause eye or skin injury.
– Hold the spring with a hand.
– Using screwdriver -A-, pry off the brake pad retaining spring
-1- from brake caliper -arrow-, while doing so secure the re‐
taining spring with the other hand.
2. Rear Brakes 73
– Remove caps -arrows-.
AG. Volkswagen AG d
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ate
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for
en
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t.
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Cop py
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co lksw
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– Remove both guide pins from the brake caliper using the Hex
Bit - 7mm - T10503- and Torque Wrench 1331 Insert - Ratchet
Head - VAS6784- .
Installing
following: AG. Volkswagen AG d
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• Brake pads sit in retaining springs on the brake carrier.by Vol not
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– Secure brake caliper on brake carrier using new self-locking
hor eo
ut
bolts. ss a ra
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un
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Note
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ility
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Ring groove and contact surface of parking brake motor must be
wit
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clean.
h re
ole,
spec
– Install new seal.
t to the co
– Turn the spindle back slightly using a E11 TORX® socket, until
the parking brake motor can be correctly positioned.
rrectne
– Carefully install the parking brake motor, while doing so pay
attention to the seating of the seals.
ss
– Rotate the parking brake motor until the bolt hole and threads
o
cial p
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are aligned.
nform
mer
atio
om
Note
n
c
i
or
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sd
a
Make sure that the parking brake motor is seated flush against
iv
o
pr
c
the brake caliper. Do not, under any circumstances, pull the park‐
um
r
fo
en
ing brake motor against the brake caliper using the bolts.
ng
t.
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– Install new hex socket bolts by hand and then tighten.
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pyri by
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– Screw brake hose on the brake caliper.
cted agen
Prote AG.

After driving the pistons out using the -Vehicle Diagnostic Tester- ,
a basic setting of the brake system must be performed.
– Perform the basic setting of the brake system with the -Vehicle
Diagnostic Tester- .
– Install the wheel.
♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 66
♦ Bleeder valve. Refer to
tions .
Note
Check brake fluid level.
2. Rear Brakes 75
3 Parking Brake
⇒ “3.1 Overview - Parking Brake Component Location”,
page 76
⇒ “3.2 Electromechanical Parking Brake Control Module J540 ,
Removing and Installing”, page 77
⇒ “3.3 Left/Right Parking Brake Motor V282 / V283 , Removing
and Installing”, page 77
AG. Volkswagen AG d
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3.1 Overview - Parking Brake Component Location d by Vol not
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1 - Hex Socket Head Bolt ss c
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❑ 8 Nm
pt
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❑ Left Parking Brake Mo‐
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tor - V282- , component
, is n
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location: on the left rear
hole
spec
brake caliper
es, in part or in w
❑ Right Parking Brake
t to the co
Motor - V283- , compo‐
nent location: on the
right rear brake caliper
rrectness of i
l purpos
ling. Refer to
⇒ “3.3 Left/Right Park‐
ing Brake Motor V282 /
nform
ercia
V283 , Removing and

m
Installing”, page 77 .
at
om
ion
c
3 - Electromechanical Parking
in t
or
his
e
Brake Control Module - J540-

at
do
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❑ Integrated in the ABS

p
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or
Control Module - J104-

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ng
t.
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and cannot be replaced
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❑ ABS Control Module - cop Vo
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J104- , removing and in‐ cted agen
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stalling. Refer to
Gasoline Engine”,
page 20 .
4 - -AUTO HOLD- Button -
E540-
❑ With -AUTO HOLD- In‐
dicator Lamp - K237-
❑ Component location: inside the center console
❑ Removing and Installing. Refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Controls; Component Location
Overview - Center Console Controls .
5 - Electromechanical Parking Brake Button - E538-
❑ With Electromechanical Parking Brake Indicator Lamp - K213-
❑ Component location: inside the center console
❑ Removing and Installing. Refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Controls; Component Location
Overview - Center Console Controls .
6 - Instrument Cluster
❑ With Brake System Indicator Lamp - K118-

❑ With the Electric Parking/Hand Brake Malfunction Indicator Lamp - K214-
7 - Nut
❑ Not equipped
8 - Rear Brake Caliper
9 - Seal
❑ Replace AG. Volkswagen AG d
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3.2 Electromechanical Parking Brake Con‐
h
aut ra
ss c
trol Module - J540- , Removing and In‐
ce
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nl
pt
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stalling
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The Electromechanical Parking Brake Control Module - J540- is
ility
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integrated in the ABS Control Module - J104- and cannot be re‐
wit
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placed separately.
h re
hole
spec
– ABS Control Module - J104- , removing and installing. Refer
es, in part or in w
to
t to the co
⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Re‐
moving and Installing, LHD, Gasoline Engine”, page 20 .
rrectness of i
3.3 Left/Right Parking Brake Motor -V282- /
l purpos
-V283- , Removing and Installing

nf
ercia
orm
m
atio
om
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te
Removing
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Note
Co
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Ignition must be switched off for at least 30 seconds before dis‐ op Vo
by c lksw
connecting the connector. cted agen
Prote AG.
– Remove the connector -2- from the parking brake motor -1-.
3. Parking Brake 77
– Remove both hex socket bolt -arrows- from the parking brake
motor.
– Remove the parking brake motor from the brake caliper, while
doing so turn the parking brake motor back and forth.
– Remove the seal.
Note
Make sure that the ring groove of the seal and the contact surface
of the parking brake motor do not become damaged.
– Clean the parking brake motor ring groove and contact sur‐
face.
Installing
– Lightly grease the seal and install, while doing so do not twist
or damage the seal.
– Completely grease the TORX® socket on the parking brake
motor driveshaft.
Note AG. Volkswagen AG d

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Do not remove the gasket when assembling theoparking
ris
e
brake nte
eo
motor. aut
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nl
– Carefully push the parking brake motor on the brake caliper
pt
du
an
while doing so pay attention that the seals are seated correctly.
itte
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ility
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Note
h re
hole
spec
If necessary slightly turn back the drive shaft using a E11 TORX®
es, in part or in w
socket -A- so that the parking brake motor can be correctly posi‐
t to the co
tioned.
rrectness of i
– Rotate the parking brake motor until the bolt hole and threads
l purpos
are aligned.
nf
ercia
Note
rm
m
atio
m
Make sure that the parking brake motor is seated flush against
o
n in
or c
the brake caliper. Do not, under any circumstances, pull the park‐
thi
te
ing brake motor against the brake caliper using the bolts.
sd
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rig ht
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– Set the hex socket bolts -arrows- in place by hand and then
tighten.
– Install connector -1-.
– Perform the basic setting of the brake system with the -Vehicle
Diagnostic Tester- .
♦ Refer to
⇒ “3.1 Overview - Parking Brake Component Location”, page
76
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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3. Parking Brake 79
4 Brake Pedal
⇒ “4.1 Overview - Brake Pedal”, page
wage
80
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⇒ “4.2 Bracket, Removing eand
d b Installing”, page 83
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⇒ “4.3 Brake Pedal, Removing
au
th from Brake Booster”, page 87 eo
ra
ss c
⇒ “4.4 Brake Pedal, Attaching to Brake Booster”, page 88
ce
le
un
pt
an
d
⇒ “4.5 Brake Pedal, Removing and Installing”, page 88

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4.1 Overview - Brake Pedal
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⇒ “4.1.1 Brake Pedal, Assembly Overview ”, page 80
ole,
spec
4.1.1 Brake Pedal, Assembly Overview
t to the co
Note
rrectne
♦ Do not shorten the bath for the brake pedal with additional
s
carpets.
s o
cial p
f in
♦ Do not lubricate or grease the mounting pin. The mounting pin
form
mer
must remain dry.
atio
om
n
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i
or
n thi
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1 - Self-Locking Hex Nut

t
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pr
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❑ 25 Nm
um
r
fo
en
ng

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❑ Bolt tightening se‐ t. C rig
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quence. Refer to yri
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⇒ Fig. ““Tightening Se‐
lksw
cted agen
quence”“ , page 81
Prote AG.
2 - Mounting Pin
❑ Remove the bracket to
remove.
❑ Removing Turn the
mounting pin clockwise,
while doing so the tabs
on the mounting pin
break.
❑ Replacing the mounting
pin
❑ Do not lubricate or
grease the mounting
pin. The mounting pin
must remain dry.
❑ Installing Turn the
mounting pin counter-
clockwise, until the tabs
at stop engage audibly
3 - Foot Pedal Assembly/
Bracket
ling. Refer to
⇒ “4.2 Bracket, Remov‐
83 .
4 - Bearing Bushing
❑ Not exchangeable,

make sure that it is in‐

stalled in the correct position.
5 - Brake Pedal
❑ Separate the brake pedal from brake booster. Refer to
⇒ “4.3 Brake Pedal, Removing from Brake Booster”, page 87 .
❑ Brake pedal to brake booster, connecting. Refer to
⇒ “4.4 Brake Pedal, Attaching to Brake Booster”, page 88 .
❑ Removing and installing. Refer to ⇒ “4.5 Brake Pedal, Removing and Installing”, page 88 .
6 - Cover
n AG . Volkswage
7 - Bearing Bushing wage
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❑ Not exchangeable, make sure ethat
d by it is installed in the correct position.
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8 - Bearing Shell utho eo
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ss
9 - Mount
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le
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pt
❑ For the ball head on the brake booster push rod
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d
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10 - Clip
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ot
❑ Replacing
wit
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❑ Install in both holes on the bracket.
hole
spec
es, in part or in w
t to the co
Tightening Sequence
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
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4. Brake Pedal 81
Golf 2013 ➤ , Golf Variant. V2014 ➤
G olkswagen AG d
gen A03.2015
Brake System -olkEdition
swa oes
no
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db ara
ise
4.1.2 Overview - Brake Pedal, RHD
r nte
tho eo
s au ra
c
s
ce
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nl
pt
du
Note
an
itte
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erm
ab
♦ Do not shorten the bath for the brake pedal with additional carpets.
ility
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♦ Do not lubricate or grease the mounting pin. The mounting pin must remain dry.
h re
hole
spec
es, in part or in w
t to the co
1 - Screw
❑ 20 Nm
rrectness of i
2 - Bracket
l purpos

ling. Refer to
⇒ “4.2 Bracket, Remov‐
nform
ercia

83 .
m
at
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ion
3 - Nut
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❑ 25 Nm
at
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4 - Clip um
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❑ Insert in both holes on
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5 - Nut Prote AG.
❑ To secure the brake

booster
❑ Quantity: 2
❑ 25 Nm
6 - Mounting Pin
❑ Remove the bracket to
remove.
❑ Removing: Turn the
mounting pin clockwise
and while doing so, the
tabs on the mounting pin
break.
❑ Replace the mounting
pin
❑ Do not lubricate or
grease the mounting
pin. The mounting pin
must remain dry.
❑ Installing: Turn the mounting pin counter-clockwise until the tabs engage audibly in the stop
7 - Bearing Bushing
❑ Not replaceable; check for proper installation position
8 - Brake Pedal
❑ Brake Pedal, Removing from Brake Booster. Refer to
❑ Brake Pedal, Attaching to Brake Booster. Refer to
❑ Removing and Installing. Refer to ⇒ “4.5 Brake Pedal, Removing and Installing”, page 88 .
9 - Bearing Shell
10 - Mount
❑ For the brake booster push rod ball head

11 - Bearing Bushing
❑ Not replaceable; check for proper installation position
12 - Cap
4.2 Bracket, Removing and Installing

⇒ “4.2.1 Mounting Bracket, Removing and Installing”, page 83
4.2.1 Mounting Bracket, Removing and Instal‐

ling
– Remove the driver side instrument panel side cover. Refer to
⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument
Panel Side Cover, Removing and Installing .
– Remove the footwell cover on the driver side. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Storage Compartment/Covers .
– Remove the driver side center console cover. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Center Console; Center Console Cover,
Removing and Installing .
– Remove the driver side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartment/Covers .
– Remove the driver side instrument panel cover. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments/Covers;
Driver Side Instrument Panel Cover, Removing and Installing .
– Remove the knee airbag -1-. Refer to ⇒ Body Interior; Rep.
Gr. 69 ; Overview - Knee Airbag .
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– Remove the driver side footwell vent. Refer to ⇒ Heating,

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erm
ab
Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing;

ility
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Overview - Passenger Compartment Air Ducts and Air Distri‐

wit
bution .
is n
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ole,
– Remove the brake pedal crash bolster and set aside. Refer to
spec
⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel Central Tube;

t to the co
Overview - Instrument Panel Central Tube .

rrectness o
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f inform
mer
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4. Brake Pedal
– Remove the bolt -2-, and disengage the crash bolster -1- and
push aside.
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– Remove the Data Bus On Board Diagnostic Interface - J533-
es, in part or in w
t to the co
-3- control module and set aside. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 97 ; Control Module; Overview - Data Bus On
Board Diagnostic Interface .
rrectness of i
– Disconnect the brake pedal from the brake booster. Refer to
⇒ “4.3 Brake Pedal, Removing from Brake Booster”,
l purpos
page 87 .
nf
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– Remove the connector from the accelerator pedal position
or
sensor.
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– Remove the bolts -1- and fold the footwell trim panel -2- in the
f
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t.
direction of the -arrow- into the vehicle interior.
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– Remove the nuts -1 through 4-.

– Carefully remove the pedal assembly.
Installing
following:
– Connect the brake pedal with the brake booster. Refer to

Nut Tightening Sequence:

♦ Refer to
⇒ “4.1.1 Brake Pedal, Assembly Overview ”, page 80
♦ Crash Bolster. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instru‐
ment Panel Central Tube; Overview - Instrument Panel Cen‐
tral Tube .
♦ Footwell Vent. Refer to ⇒ Heating, Ventilation and Air Condi‐
tioning; Rep. Gr. 87 ; Air Routing; Overview - Passenger n AG. Volkswagen AG do
Compartment Air Ducts and Air Distribution . olks
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♦ Knee Airbag. Refer to ⇒ Body Interior; Rep. Gr.rise69
d ; Knee
nte
Airbags; Overview - Knee Airbag ut
ho eo
ra
a c
ss
♦ Driver Side Covers. Refer to ⇒ Body Interior; Rep. Gr. 68 ;
ce
le
Storage Compartment/Covers; Component Location Over‐ un
pt
an
d
view - Storage Compartment/Covers .
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pe
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4.2.2 Mounting Bracket, Removing and Instal‐
ot
wit
, is n
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ling, RHD
hole
spec
es, in part or in w
Removing
t to the co
– Remove the windshield wiper arms. Refer to ⇒ Electrical
Equipment; Rep. Gr. 92 ; Windshield Wiper System; Wiper
rrectness of i
Arms, Removing and Installing .
l purpos
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;

Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing
and Installing .
nform
ercia
– Remove the Windshield Wiper Motor - V- . Refer to ⇒ Elec‐

m
a
trical Equipment; Rep. Gr. 92 ; Windshield Wiper System;
com
tion in
Windshield Wiper Motor V, Removing and Installing .
r
te o
thi
– Remove the bolt -1-.
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Panel Side Cover, Removing and Installing . C py
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– Remove the footwell cover on the driver side. Refer to ⇒ Body cop Vo
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Interior; Rep. Gr. 68 ; Storage Compartment/Covers . cted agen
Prote AG.

– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
69 ; Knee Airbags; Overview - Knee Airbag .
– Remove the driver side footwell vent -1-. Refer to ⇒ Heating,

Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Duct; Over‐
view - Air Ducts and Air Distribution in Passenger Compart‐
ment .
– Remove the bolt -2- and remove the driver side footwell vent
-1-.
page 87 .
4. Brake Pedal 85
– Disconnect and remove the connector -arrow-.

– Remove the Accelerator Pedal Module -1- from the bracket
-2-. Refer to ⇒ Rep. Gr. 20 ; Accelerator Pedal Mechanism;
Accelerator Pedal Module with Accelerator Pedal Position
Sensor G79/G185, Removing and Installing .
– Unclip the wiring harness -2- from the bracket -1- -arrows-.
– Remove the nuts -arrows- from the bracket -1-.
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– Secure the brake booster -1- from falling out.

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following:
hole
spec
es, in part or in w
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ate
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– Route the wiring harness -2- correctly so that it is not pinched.

– Clip in the wiring harness -2- on the bracket -1- -arrows-.
– Connect the brake pedal with the brake booster. Refer to
♦ ⇒ “4.1.2 Overview - Brake Pedal, RHD”, page 82
tral Tube .
tioning; Rep. Gr. 87 ; Air Routing; Overview - Passenger
Compartment Air Ducts and Air Distribution .
♦ Knee Airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee
Airbags; Overview - Knee Airbag
Storage Compartment/Covers; Component Location Over‐
♦ Windshield wiper system. Refer to ⇒ Electrical Equipment;
Rep. Gr. 92 ; Windshield Wiper System; Overview - Wind‐
shield Wiper System n. AG. Volkswagen A
ge G do
swa es
♦ Plenum chamberyV
olk cover. Refer to ⇒ Body Exterior;
not
gu Rep. Gr.
db
50 ; Bulkhead; Overview - Plenum Chamber
ara
Cover
ris
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s au ra
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4.3 s
Brake Pedal, Removing from Brake
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♦ Release Tool - T10159B-

, is n
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spec

es, in part or in w
t to the co
– Press and hold the brake pedal in the direction of the brake
booster.
rrectness of i
2 - Push Rod
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3 - Retaining Tabs
– Insert the Release Tool - T10159B- and pull in the direction of
nform
ercia
the driver seat. While doing so, counterhold on the brake pedal
(at this moment the pedal must not move to the driver seat).
m
at
om
The mount retaining tabs -3- will thereby be pressed off the
on
c
ball head of the push rod -2-.

in t
or
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ate
The process of separating the brake pedal from the brake booster
do
priv
is shown with the pedal assembly removed.

um
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– Pull the Release Tool - T10159B- and brake pedal together in
Co
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the direction of the driver seat. (This will pull the brake pedal
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off of the push rod ball head). p by
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Tightening Specification Prote AG.
♦ Driver Side Footwell Cover. Refer to ⇒ Body Interior; Rep. Gr.

68 ; Storage Compartment/Covers; Component Location
Overview - Storage Compartment/Covers .
4. Brake Pedal 87
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4.4 Brake Pedal, Attaching to Brake Booster
e
ris tee
tho or
s au ac
– Hold the push rod
s ball head in front of the mount and push the
ce
le
brake pedal toward the brake booster so that the ball head
un
pt
an
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engages audibly.
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– Check the engagement by pulling briefly on the brake pedal.
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Install in reverse order of removal.
h re
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spec
t to the co
rrectness
4.5 Brake Pedal, Removing and Installing
o
cial p
f inform
⇒ “4.5.1 Brake Pedal, Removing and Installing”, page 88
mer
atio
m
4.5.1 Brake Pedal, Removing and Installing

o
n
c
i
or
n thi
te
Removing the brake pedal separately in the vehicle is not possi‐
sd
iva
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r
ble.
p
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fo
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– Remove the pedal assembly/bracket first. Refer to

t.
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⇒ “4.2 Bracket, Removing and Installing”, page 83 . C py
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Note Prote AG.
Remove the brake pedal from the removed bracket.

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– Turn the mounting pin clockwise in the d bdirection of the ara
ise nte
-arrow-. thor eo
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-1- = 14 mm Hex Socket Wrench ss
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erm
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While doing so, the tabs -B- break. Replace the mounting pin.
, is n
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hole
spec
– Remove the clip from the mounting pin.
es, in part or in w
t to the co
– Remove the mounting pin toward the right.
– Remove the brake pedal from the bracket.
rrectness of i
Installing
l purpos

following:
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orm
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atio
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Note
o
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Replace the mounting pin and clip.

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t.
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op
Note C py
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Do not lubricate or grease the mounting pin. The mounting pin
c by lksw
cted agen
must remain dry. Prote AG.
– Push the mounting pin from the right to the left through the
bracket and brake pedal.
– Place the clip on the mounting pin, while doing so place the
mounting pin in both openings on the bracket.
– Turn the mounting pin counter-clockwise in the direction of the

-arrow- until the tabs -A- on the stop engage audibly in the
bracket.
– Install the pedal assembly/bracket. Refer to
⇒ “4.2 Bracket, Removing and Installing”, page 83 .
4. Brake Pedal 89
5 Special Tools

equipment required
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♦ Brake BleedinghoTool
ris Set - tee
VAS6564- s aut or
ac
s
♦ Torque Wrench 1331 Insert
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- Ratchet Head - VAS6784-
an
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♦ Hex Bit - 7mm - T10503-
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5-50Nm - VAG1331-
hole
spec
♦ Piston Resetting Tool -
es, in part or in w
t to the co
T10145-
rrectness of i
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Prote AG.
♦ Brake Servo Release Tool - T10159A-


47 – Hydraulic Components
1 Front Brake Caliper
⇒ “1.1 Overview - Front Brake Caliper”, page 91
⇒ “1.2 Brake Caliper Piston, Removing and Installing”,
page 93
1.1 Overview - Front Brake Caliper

⇒ “1.1.1 Overview - Brake Caliper FS III”, page 91
⇒ “1.1.2 Overview - Brake Caliper PC57”, page 92
1.1.1 Overview - Brake Caliper FS III
1 - Dust Cap
❑ Attach to bleeder valve
2 - Bleeder Valve
❑ 10 Nm
❑ Lightly grease the
threads with Lithium Lu‐
bricating Grease - G 052
150 A2- before screwing AG. Volkswagen AG d
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3 - Bearing Bushing ris
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tee
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❑ Insert in brakesscaliper
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4 - Guide Pin
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❑ 30 Nm
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5 - Caps
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❑ Insert in bushing
h re
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6 - Brake Caliper
spec
t to the co
7 - Seal
ling. Refer to
rrectne
⇒ “1.2.1 Brake Caliper

Piston PC57, Removing
and Installing”,
ss o
page 93 .
cial p
f inform
8 - Piston
mer
atio
❑ Apply thin coat of as‐

om
sembly paste G 052 150

n
c
i
or
A2 on the piston before

thi
te
sd
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inserting.
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pr
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ling. Refer to
t.
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⇒ “1.2.1 Brake Caliper C py
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Piston PC57, Removing
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and Installing”, cop Vo
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page 93 .
agen
Prote AG.
7 - Protective Cap
⇒ “1.2.1 Brake Caliper Piston PC57, Removing and Installing”, page 93 .
❑ When inserting the piston do not damage the protective cap.
1. Front Brake Caliper 91

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1.1.2 Overview - Brake Caliper PC57 r nte
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un
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1 - Dust Cap
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❑ Install onto bleeder
erm
ab
valve.
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2 - Bleeder Valve
h re
ole,
❑ 10 Nm
spec
❑ Lightly grease the
t to the co
threads with Lithium Lu‐
bricating Grease - G 052
150 A2- before screwing
rrectne
in.
3 - Bolt
ss o
❑ 35 Nm
cial p
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❑ Replace after removing.
mer
atio
4 - Guide Pins
om
n
c
i
or
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5 - Protective Cap
thi
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❑ Lubricate the groove

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pr
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with the grease that
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comes with the repair kit

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and then install the cap Cop py
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into the groove on the yri
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brake carrier and the cop Vo
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guide pin.
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6 - Brake Carrier
❑ Is assembled with the
guide pins and caps as
well as with sufficient
grease on the guide
pins.
❑ Install the repair kit if the
caps or guide pins are
damaged. Use grease
packet supplied to lubri‐
cate guide pins.
7 - Protective Cap
❑ When inserting the piston, do not damage the protective cap.
8 - Piston
❑ Apply thin coat of assembly paste G 052 150 A2 on the piston before inserting.
9 - Seal
10 - Brake Caliper
92 Rep. Gr.47 - Hydraulic Components

1.2 Brake Caliper Piston, Removing and In‐

stalling
⇒ “1.2.1 Brake Caliper Piston PC57, Removing and Installing”,
page 93
1.2.1 Brake Caliper Piston PC57, Removing

and Installing
♦ Trim Removal Wedge - 3409-
Removing
– Force piston from brake caliper using compressed air.
Place a wooden board into the recess of the caliper housing so it
is not damaged.
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– Remove seal with wedge 3409.
h re
hole
spec
When removing, make sure that surface of cylinder is not dam‐
es, in part or in w
aged.
t to the co
Installing
rrectness of i
following:
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– Clean the surfaces on the pistons and seal with mineral spirits.
– Apply a thin coat of installation paste G 052 150 A2 on the
nform
ercia
piston and the seal before installing.

m
at
om
– Insert oil seal into brake caliper.

ion
c
in t
or
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te
– Place the cap with the outer sealing lip on the piston.
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Cop py
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1. Front Brake Caliper 93

– Insert inner sealing lip in cylinder groove with trim removal

wedge 3409.
Hold piston in front of brake caliper for this procedure.
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– Press piston into the brake caliper using piston resetting tool.
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Outer sealing lip of protective cap will then engage in piston
erm
ab
groove.
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es, in part or in w
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2 Rear Brake Caliper

⇒ “2.1 Overview - Rear Brake Caliper”, page 95
⇒ “2.2 Dust Cap, Removing and Installing”, page 95
2.1 Overview - Rear Brake Caliper

♦ Install complete repair kit when servicing.
♦ Only use mineral spirits to clean brake parts.
♦ New brake calipers are filled with brake fluid and are pre-bled.
1 - Brake Caliper
2 - Damping Sleeves
3 - Guide Pins
4 - Caps
5 - Hex Socket Head Bolt
❑ 8 Nm
7 - Seal
❑ Replace
8 - Pressure Nut
❑ Removing and installing
is not possible.
9 - Seal
❑ Removing and installing AG. Volkswagen AG d
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10 - Piston ris
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❑ Removing andssinstalling
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is not possible.
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11 - Protective Cap
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wit
⇒ “2.2 Dust Cap, Re‐

is n
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moving and Installing”,

ole,
spec
page 95 .
t to the co
Note
To change the protective cap the

rrectne
brake caliper does not need to be

removed, do not remove the brake
s
hose.
s o
cial p
f inform
12 - Bleeder Valve
mer
atio
❑ 10 Nm
om
n
c
❑ Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.
i
or
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13 - Dust Cap
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2.2 Dust Cap, Removing and Installing
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Prote AG.
2. Rear Brake Caliper 95

♦ Trim Removal Wedge - 3409-

♦ Press Piece - T10502- for the rear brakes FNc-M38 (15”)
♦ Piston Resetting Tool - Caps /1,/2,/3,/4,/5 - T10146/5- for the
rear brakes FNc-M42 (17”)
Removing
It is possible to only replace the protective cap.
Note
To change the protective cap the brake caliper does

agen not need to AG does
AG. Volkswagen
be removed, do not remove the brake hose.yV
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• The piston is driven back. au
th or
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ss
• The parking brake motor is removed.
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NOTICE
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There is a risk of destroying the ball thread by removing from
ot p
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the piston and thrust nut.
, is n
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– Never completely remove the piston and thrust nut.
hole
spec
es, in part or in w
t to the co
– Remove the piston maximum 20 mm -dimension a- with a E11
TORX® socket in the direction of the -arrow-.
rrectness of i
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ion
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ate
do
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en
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t.
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– Pry up the protective cap with the Trim Removal Wedge -
Co
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3409- from the brake caliper -arrows-. t. C rig
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Installing
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Prote AG.
following:
– The surface on the piston and the brake caliper must only be
cleaned with mineral spirits and then dried.

AG. Volkswagen AG d Brake System - Edition 03.2015
agen oes
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– Place the protective cap in the by
d groove -arrow- on the piston. ara
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ility
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es, in part or in w
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rrectness of i
– Reinstall the piston in the direction of the -arrow-.
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staller - Camshaft O-Ring - T10502- -2- and the Piston Reset‐
AG.
ting Tool - T10145- -1- so that it is all around the brake caliper.
2. Rear Brake Caliper 97

3 Brake Booster/Master Brake Cylin‐

der
⇒ “3.1 Overview - Brake Booster/Master Brake Cylinder”,
page 98
⇒ “3.2 Brake Lamp Switch, Removing and Installing”, page 102
⇒ “3.3 Brake Booster, Removing and Installing”, page 105
3.1 Overview - Brake Booster/Master Brake

Cylinder
⇒ “3.1.1 Overview - Brake Booster/Brake Master Cylinder ”, page
98
3.1.1 Overview - Brake Booster/Brake Master

Cylinder
Note
Only use new brake fluid conforming to VW standard (VW 501

14).
1 - Self-Locking Hex Nut

❑ 25 Nm
❑ Tightening sequence.
Refer to
⇒ Fig. ““Tightening Se‐
quence”“ , page 99
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3 - Bulkhead rised ara
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4 - Self-Locking Hex Nut ra
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❑ 23 Nm
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5 - Brake Master Cylinder

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❑ Cannot be serviced. Re‐

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place as complete unit if

hole
malfunctioning.
spec
es, in part or in w

t to the co
ling. Refer to
⇒ “3.4.1 Brake Master
Cylinder, Removing and
rrectness of i
Installing”, page 127 .

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nform
ercia
ling. Refer to
⇒ “3.2.1 Brake Lamp
m
at
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Switch, Removing and

ion
c
Installing ”, page 102 .

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7 - Bolt
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❑ 8 Nm
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8 - Brake Line
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10 - Sealing Plug
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❑ Moisten with brake fluid and press into brake fluid reservoir
11 - Brake Fluid Level Warning Switch - F34-
rrectness of i
12 - Brake Fluid Reservoir
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❑ Bolt 8 Nm
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13 - Vacuum Hose
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❑ With check valve
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❑ Insert into brake booster
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❑ On some vehicles with a gasoline engine the Brake Booster Vacuum Sensor - G608- is installed. Refer
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to ⇒ “4.3 Vacuum Sensor G608 , Removing and Installing”, page 136 .
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16 - Seal
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❑ Master brake cylinder/brake booster

17 - Brake Booster
❑ Functional check:
– With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
– Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working
properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).
❑ Replace completely if there are malfunctions (check the vacuum system for the brake booster first; refer
to ⇒ “4.4 Vacuum System, Checking”, page 137 )
❑ Removing and installing. Refer to ⇒ “3.3.1 Brake Booster, Removing and Installing ”, page 105 .
18 - Seal
❑ Replacing
❑ attached, only at the factory
❑ Do not replace the gluing on the brake booster and plenum chamber.
Tightening Sequence
3. Brake Booster/Master Brake Cylinder 99

3.1.2 Overview - Brake Booster/Brake Master Cylinder, RHD
Note
Only use new brake fluid conforming to VW standard (VW 501 14).
1 - Cap
2 - Brake Fluid Reservoir
❑ With Brake Fluid Level
Warning Switch - F34-
3 - Brake Booster
ling. Refer to
⇒ “3.3.2 Brake Booster,
ling, RHD with Diesel
Engine”, page 110 .
❑ Functional check: AG. Volkswagen AG d
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– With engine switchedd by V o gu
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firmly several times
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working properly, pedal

spec
will be felt to give notice‐

ably under foot (booster
t to the co
assistance becomes ef‐

fective).
rrectne
❑ Replace completely if
there are malfunctions
s
(check the vacuum sys‐

s o
tem for the brake boos‐

cial p
f in
ter first; refer to

form
mer
⇒ “4.4 Vacuum System,

atio
Checking”, page 137 )

om
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4 - Seal
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❑ Vacuum hose/brake
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5 - Vacuum Line
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6 - Seal
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❑ Replace after removing Prote
cted AG.
agen
❑ attached, only at the factory

❑ Removing the adhesive residue
❑ Do not replace the gluing on the brake booster and plenum chamber.
7 - Nut
❑ Quantity: 2
❑ 20 Nm
8 - Bracket with Brake Pedal
❑ Remove the bracket. Refer to ⇒ “4.2 Bracket, Removing and Installing”, page 83 .
❑ Remove the brake pedal. Refer to ⇒ “4.5 Brake Pedal, Removing and Installing”, page 88 .

❑ Separate the brake pedal from brake booster. Refer to
❑ Brake pedal to brake booster, connecting. Refer to
9 - Seal
❑ Replace if damaged.
❑ Make sure the seal is seated correctly.
❑ Master brake cylinder/brake booster
10 - Brake Master Cylinder
⇒ “3.4.2 Brake Master Cylinder, Removing and Installing, RHD Vehicles”, page 130 .
❑ Connecting the brake lines. Refer to ⇒ “3.5 Brake Lines, Attaching to Hydraulic Unit”, page 43 .
❑ When installing together the brake master cylinder and brake booster, make sure that the push rod is
correctly located in the brake master cylinder.
⇒ “3.2.2 Brake Lamp Switch, Removing and Installing, RHD Vehicle”, page 103 .
12 - Bolt
❑ 8 Nm
13 - Bolt
❑ 8 Nm
14 - Heat shield
❑ On the brake fluid reservoir
15 - Heat shield
❑ For the brake booster
16 - Nut
❑ Replace after gremoving AG. Volkswagen AG d
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❑ Self-locking
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17 - Brake line
un
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❑ Master brake cylinder/secondary piston circuit to hydraulic unit

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❑ 14 Nm
, is n
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18 - Sealing Plug
spec
es, in part or in w
❑ Replace if damaged.
t to the co
❑ Make sure the plugs are seated correctly.

❑ Coat the plugs with brake fluid before pushing the brake fluid reservoir into the master brake cylinder.
rrectness of i
❑ Brake Master Cylinder/Brake Fluid Reservoir

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19 - Brake line
nform
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m
❑ 14 Nm
com
tion in
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20 - Expanding Rivet
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❑ To secure the brake fluid reservoir

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3.2 Brake Lamp Switch, Removing and In‐

stalling
⇒ “3.2.1 Brake Lamp Switch, Removing and Installing ”,
page 102
3.2.1 Brake Lamp Switch, Removing and In‐

stalling
Removing
On vehicles with diesel engine:
– Remove the air guide hose from the air filter housing.
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On »R« vehicles:
tho tee
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– Open the lock washer -2- and the screw-type clamp -3-.
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– Remove the air guide hose -1-.

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– Disconnect the connector -2- from the Brake Lamp Switch - F-

-1-.
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– Remove the lower Brake Lamp Switch - F- -1- from the brake
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master cylinder.
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Install in reverse order of removal. Watch out for the following:

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– Pay attention that the Brake Lamp Switch - F- -1- is positioned

correctly on the edge -arrow- of the brake master cylinder.
♦ Refer to
⇒ “3.1.1 Overview - Brake Booster/Brake Master Cylinder ”,
page 98
swage es n
3.2.2 Brake Lamp Switch, Removing and In‐
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– Remove the engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine

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CAUTION
spec
es, in part or in w
Fuel system is under pressure.

t to the co
Risk of injury from fuel spraying out.

– Wear protective eyewear.
rrectness of i
– Wear safety gloves.

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– Reduce the pressure: Lay clean cloths around the connec‐

tion point and carefully open the connection point.
nform
ercia
– Release and disconnect the fuel supply lines -1- and -2-.
m
at
om
ion
– Disconnect the couplings. Refer to ⇒ Rep. Gr. 20 ; Couplings;

c
in t
or
Couplings, Disconnecting .
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ate
do
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– Unclip the fuel lines -1- and -2- from the bracket -arrow- on the
p
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or
coolant expansion tank -3-.

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– Remove bolts -2-.
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– Remove the nut -1-.
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– Open the bracket -arrow- and unclip the fuel lines -1-.
– Then move the fuel filter to the side.

– Release the catches with a screwdriver -arrow-.
– Lay the coolant reservoir on the engine.
– Remove the upper toothed belt guard. Refer to ⇒ Rep. Gr.
15 ; Toothed Belt Drive; Toothed Belt Guard, Removing and
Installing .
– Release and disconnect the connector -2- on the Brake Lamp

Switch - F- -1-.
– Remove the bolt -arrow-.
AG. Volkswagen AG d
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– Remove the Brake VLight
olks Switch - F- from brake smaster
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pt
following:
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hole
– Pay attention that the Brake Lamp Switch - F- -1- is positioned

spec
correctly on the edge -arrow- of the brake master cylinder.

es, in part or in w
t to the co
♦ ⇒ “3.1.2 Overview - Brake Booster/Brake Master Cylinder,
rrectness of i
RHD”, page 100

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♦ Toothed belt guard. Refer to ⇒ Rep. Gr. 15 ; Toothed Belt

Drive; Overview - Toothed Belt Guard .
nform
ercia
♦ Fuel filter. Refer to ⇒ Rep. Gr. 20 ; Overview - Fuel Filter .

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tion in
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3.3 Brake Booster, Removing and Installing

⇒ “3.3.1 Brake Booster, Removing and Installing ”, page 105
3.3.1 Brake Booster, Removing

gen AG
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♦ Brake Charger/Bleeder
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♦ Torque Wrenchs 1331 5-50Nm - VAG1331-
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e
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♦ Sealing Tool - T10249-
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♦ Adhesive Strip Remover - VAS6349-
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hole
spec
es, in part or in w
Note
t to the co
Check the brake boost vacuum first if there are complaints re‐
garding the brake booster. Refer to
rrectness of i
⇒ “4.4 Vacuum System, Checking”, page 137 .
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Removing
nform
ercia
– If the vehicle has a coded radio, get the radio code from the
customer before beginning.
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at
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ion
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ate
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– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.

p
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or
Gr. 27 ; Battery; Battery, Removing and Installing .

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t.
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On vehicles with diesel engine: C py
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– Remove the engine cover. copy Vo
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– Loosen hose clamp -1- and remove the air guide hose and air
AG.
filter housing. Refer to ⇒ Rep. Gr. 23 ; Air Filter; Air Filter

Housing, Removing and Installing .
On »R« vehicles:
– Loosen the hose clamps -2- and -3-.
– Remove the air guide hose -1- and air filter housing. Refer to
⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and
Installing .
– Remove the battery holder. Refer to ⇒ Electrical equipment;
Rep. Gr. 27 ; Battery; Battery, Removing and Installing .
– Place sufficient lint-free cloths in the area of the engine and
transmission.

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– Extract as much brake fluid as possible from the brake fluid y Volks ot g
ua
reservoir with the Brake Charger/Bleeder Unit - VAS5234-ris
ed.
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For vehicles with manual transmission:
n in
r
te o
thi
– Remove the clutch slave cylinder return hose -1-, close using
s
iva
do
the Sealing Tool - T10249- tie up or the using a commercially
r
rp
cum
available tool for example Hazet 4590 disconnect and remove
fo
en
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the clutch slave cylinder return hose -1-.

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– Remove the connectors from the -3- Brake Fluid Level Warn‐
ing Switch - F34- , if equipped from the -2- Vacuum Sensor -
G608- and from the -1- Brake Lamp Switch - F- .
– Remove the vacuum in the brake booster by pressing the
brake pedal repeatedly.
– Remove the vacuum hose from the brake booster.
– Disconnect the brake lines at the brake master cylinder and
seal the lines with sealing plugs from repair kit part number.
1H0 698 311 A.
For vehicles with 7-Gear DSG transmission:
– Remove the selector lever cable and cable bracket from the
transmission. Refer to ⇒ Rep. Gr. 34 ; Selector Mechanism;
Overview - Selector Mechanism .
Volkswagen AG
Continuation for all vehicles: swagen AG. does
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– Remove the side scovered b from the driver side instrument panel. ara
nte
Refer to ⇒ Body hori
Interior; Rep. Gr. 70 ; Instrument Panel; eo
ut
Instrument Panel
ss a Side Cover, Removing and Installing . ra
c
ce
e

nl
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du
an
Interior; Rep. Gr. 68 ; Storage Compartments and Covers .
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– Remove the driver side center console cover. Refer to ⇒ Body
ility
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Interior; Rep. Gr. 68 ; Center Console; Center Console Cover,
wit
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Removing and Installing .
h re
hole
spec
es, in part or in w
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐ t to the co

ers .
rrectness of i
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐

ers; Driver Side Instrument Panel Cover, Removing and In‐
l purpos
stalling .
nform
ercia
– Remove the knee airbag -1-. Refer to ⇒ Body Interior; Rep.

Gr. 69 ; Knee Airbags; Overview - Knee Airbag .
m
at
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ion
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or
his
ate
do
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for
en
ng
t.
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Cop py
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rig ht
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– Remove the footwell vent on the driver side. Refer to ⇒ Heat‐

ing, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing;
Overview - Air Routing and Air Distribution in Passenger Com‐
partment .

– Remove the Data Bus on Board Diagnostic Interface - J533-

-3- control module and set aside. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 97 ; Control Modules; Data Bus On Board
Diagnostic Interface - J533- , Removing and Installing .
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– Remove the brake pedal crash bolster olks -1- disengage -2- and s not g
wa oe
set aside. Refer to ⇒ Body Interior;by V Rep. Gr. 70 ; Instrument ua
ed ran
Panel Central Tube; Overview
thoris - Instrument Panel Central tee
or
Tube . s au ac
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– Disconnect brake pedal from brake booster. Refer to

un
pt
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page 87 .
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– Remove the bolts -1- and fold the footwell trim panel -2- in the
rrectne
direction of the -arrow- into the vehicle interior.
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– Remove the nuts -3, and 4- from the brake booster.

– Pull the brake booster from the plenum chamber against the
seal adhesiveness.
– Carefully remove the brake booster from the vehicle.
– Remove the master brake cylinder nuts.
– Remove any heat shield.
– Carefully remove the master brake cylinder from the brake
booster.
Installing
following:
Note
♦ The brake booster is only additionally glued with the seal at

the factory.
♦ Do not replace the gluing on the brake booster and plenum
chamber, but replace the seal.
– Remove all adhesive residue from the bulkhead and the brake
booster, if necessary. To do so, use the Adhesive Strip Re‐
mover - VAS6349- with a drill, cordless drill or straight sander.
– Allow the Adhesive Strip Remover - VAS6349- run slowly and
rub against the running direction.
– Replace the seal.
– Attach the brake pedal to the brake booster. Refer to agen
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– After installing, bleed brake system (refer to tho
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♦ Refer to
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ility
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page 98
h re
hole
♦ Crash bolster. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instru‐

spec
es, in part or in w
ment Panel Central Tube; Overview - Instrument Panel Cen‐ t to the co

tral Tube .
♦ Footwell vent. Refer to ⇒ Heating, Ventilation and Air Condi‐
tioning; Rep. Gr. 87 ; Air Routing; Overview - Air Routing and
rrectness of i
Air Distribution in Passenger Compartment .

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♦ Knee airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee

nform
ercia
♦ Covers on the driver side. Refer to ⇒ Body Interior; Rep. Gr.

m
68 ; Storage Compartments and Covers; Component Location

com
tio
Overview - Storage Compartment/Covers .

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3.3.2 Brake Booster, Removing and Installing,

RHD with Diesel Engine
Note
First check the vacuum system for the brake booster in case of
complaints regarding the brake booster. Refer to

equipment required
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un
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Unit - VAS5234-
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♦ Hose Clamps - Up To 25 mm - 3094-
♦ Hose Clip Pliers - VAG1921- n AG. Volkswagen AG do

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♦ Socket T30 - T10405-
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Brake booster component location in RHD vehicles:

Removing
necessary.
CAUTION n AG. Volkswagen AG do

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– Remove the battery tray -1-. Refer to ⇒ Electrical Equipment;

Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing .
– Remove the subframe with the steering gear. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe
and Steering Gear, Removing and Installing .
stalling .
– Drain the coolant. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant; Coolant, Draining and Filling .
– Remove the left coolant pipes. Refer to ⇒ Rep. Gr. 19 ; Cool‐
ant Pipes; Overview - Coolant Pipes .
– Remove the rear coolant pipe. Refer to ⇒ Rep. Gr. 19 ; Cool‐
ant Pipes; Overview - Coolant Pipes .
– Remove the EGR cooler. Refer to ⇒ Rep. Gr. 26 ; Exhaust
Gas Recirculation (EGR); EGR Cooler, Removing and Instal‐
ling .
AG. Volkswagen AG d
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– Remove the heated oxygen sensor -arrow-. Refer to ⇒ Rep.

Gr. 23 ; Heated Oxygen Sensor, Removing and Installing .
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tion and Air Conditioning; Rep. Gr. 00 ; Working with the A/C
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Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr.
hole
87 ; Refrigerant Circuit; Refrigerant Lines with Inner Heat Ex‐
spec
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changer, Removing and Installing .
t to the co
Vehicles with Manual Transmission:
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– If equipped remove the heat shield.
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the Sealing Tool - T10249- -1- or with the Hose Clamps - Up

To 25mm - 3094- .
– Tie up the supply hose -2-.

Note

vehicle:
– Place enough lint-free cloths in the engine area.

– Extract as much brake fluid as possible from the brake fluid
reservoir with the Brake Charger/Bleeder Unit - VAS5234- .
– If equipped, remove the heat shield -1-.

– To do so remove the bolt -3- using the Socket T30 T10405 -
T10405- .
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-arrows- on the brake fluid reservoir -2-.
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-arrow-.
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master cylinder -2-.
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pedal repeatedly.
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swage es n
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page 87 .
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Note
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booster.
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are seated correctly in the brake master cylinder.
– Coat the plugs -item 18- ⇒ Item 18 (page 101) with brake fluid
before pushing the brake fluid reservoir into the brake master
cylinder.
– Attach the brake pedal to the brake booster. Refer to
– Fill the coolant. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
– Bleed the clutch mechanism. Refer to ⇒ Rep. Gr. 30 ; Clutch
Mechanism; Clutch Mechanism, Bleeding .
Vehicles with A/C system:
– Fill the refrigerant circuit. Refer to ⇒ Heating, Ventilation and
Air Conditioning; Rep. Gr. 00 ; Working with the A/C Service
Station; Filling the Refrigerant Circuit with the A/C Service
Station .
RHD”, page 100
♦ ⇒ “3.4.2 Brake Master Cylinder, Removing and Installing, RHD
Vehicles”, page 130
tral Tube .


♦ Subframe. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40 ; Overview - Subframe .
♦ Cooling system. Refer to ⇒ Rep. Gr. 19 ; Overview - Coolant
Pipes .
♦ Emissions control. Refer to ⇒ Rep. Gr. 26 ; Overview - Emis‐
sions Control .
♦ EGR. Refer to ⇒ Rep. Gr. 26 ; Overview - EGR .
♦ Exhaust system. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/
Mufflers; Overview - Muffler .
♦ Exhaust gas temperature sensor. Refer to ⇒ Rep. Gr. 26 ;
Overview - Exhaust Gas Temperature Sensor .
♦ A/C system. Refer to ⇒ Heating, Ventilation and Air Condi‐
tioning; Rep. Gr. 87 ; System Overview - Refrigerant Circuit .
Insulation; Noise Insulation, Assembly Overview . . Volkswagen AG
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equipment required
♦ Release Tool - Brake Servo
- T10159A-
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– Drain the coolant. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
rrectness of i
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– Remove the catalytic converter -10-. Refer to ⇒ Rep. Gr. 26 ;

Emissions Control; Catalytic Converter, Removing and Instal‐
nform
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– Loosen the hose clamp -2- and remove the coolant hose.
– Remove the bolts -arrows- and move the coolant lines -1- to
the right.

– Remove the bolts -arrows-.

– Remove the heat shield -1-.

– Free up the hoses on the bracket -3-.
– Loosen the clamps -arrows- and remove the upper toothed
belt cover -1-.
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Vehicles with Manual Transmission: byV
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– If equipped remove the heat shield. ut
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changer, Removing and Installing .


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draulic Unit - N55- and the ABS Control Module agen
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-1-.


-arrow-.
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ment .
– Remove the bolt -2- and remove the driver side footwell vent
-1-.
page 87 .
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– Remove the nuts -arrows- from the bracket.

Installing
following:
Note
♦ The brake booster is also bonded with the seal at the factory
only.
♦ The bonding on the brake booster and bulkhead must not be
replaced
– Carefully insert the brake booster and tighten the nuts.
booster, make sure that the push rod is correctly seated in the
when assembling the brake master cylinder with the braken AG. Volkswagen A
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t to the co

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rrectness of i
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Overview - Turbocharger .
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3.4 Brake Master Cylinder, Removing and

Installing
⇒ “3.4.1 Brake Master Cylinder, Removing and Installing”,
page 127
3.4.1 Brake Master Cylinder, Removing and

Installing
♦ Brake Charger/Bleeder Unit - VAS5234-
Removing
necessary.
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .

On Vehicles with Diesel Engine:

– Loosen hose clamp -1- and remove the air guide hose and air
filter housing. Refer to ⇒ Rep. Gr. 23 ; Air Filter; Air Filter
Housing Removing and Installing .
On »R« Vehicles:
– Loosen the hose clamps -2- and -3-.
– Remove the air guide hose -1- and air filter housing. Refer to
⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing Removing and
Installing .
Continuation for All Vehicles:

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For Vehicles with Manual Transmission:

– Remove the clutch slave cylinder return hose -1-, close using
the Sealing Tool - T10249- tie up or the using a commercially
available tool for example Hazet 4590 disconnect and remove
the clutch slave cylinder return hose -1-.
Continuation for All Vehicles:

– Remove the connectors from the -3- Brake Fluid Level Warn‐
ing Switch - F34- , if equipped from the -2- Vacuum Sensor -
G608- and from the -1- Brake Lamp Switch - F- .
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– Disconnect the brake lines -1- at the brake master cylinder and
seal the lines with sealing plugs from repair kit part number
1H0 698 311 A.
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– Remove the heat shield, if equipped.
– Carefully take the brake master cylinder out of the brake boos‐
ter. wage
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First check the vacuum system for the brake booster in case of cop Vo
by lksw
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Prote AG.


AG. Volkswagen AG d
♦ Sealing Tool - T10249- agen oes
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d b ara
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un
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an
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ility
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t to the co
Brake master cylinder component location in RHD vehicles:
rrectne
ss
o
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f in
Removing
form
mer
atio
om
necessary.
n
c
i
or
n thi
e
Diesel vehicles:
t
sd
iva
o
pr

um
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fo
en
ng

t.
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Cop py
t. rig
CAUTION
gh ht
pyri by
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co lksw
by
Fuel system is under pressure. cted agen
Prote AG.
Risk of injury from fuel spraying out.

– Release and disconnect the fuel supply lines -1- and -2-.
lkswage es n
o ot g
byV ua
– Remove bolts -2-. ir se
d ran
tee
tho
or
– Remove the nut -1-.s au ac
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
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by
– Disconnect the connector -1-. cted agen
Prote AG.

– Remove the upper toothed belt guard. Refer to ⇒ Rep. Gr.
15 ; Toothed Belt Drive; Toothed Belt Guard, Removing and
Installing .


– If equipped remove the heat shield.
– To do so remove the lock washer -4- from the bulkhead.
-3- from the brake fluid reservoir -4-.
To 25mm - 3094- .

AG. Volkswagen AG d
– Discharge the refrigerant circuit. Refer to ⇒ Heating, wage Ventila‐
n oes
olks not
tion and Air Conditioning; Rep. Gr. 00 ; Workingby
V with the A/C gu
ara
Service Station; Discharging the Refrigerant ed Circuit with the A/ nte
oris eo
C Service Station . au
th ra
ss c
– Remove the nuts -2- from the refrigerant line -1-.
ce
le
un
pt
an
d
– Remove the refrigerant line -1-.

itte
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erm
Continuation for all vehicles: ab

ility
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Note
spec
t to the co

vehicle:
rrectne

ss o

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form
mer
atio
m

o
n
c
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or
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– Remove the bolt -3- to do so.

te
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o
r

p
cum
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fo

en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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cted agen
Prote AG.


Switch - F- -1-.
AG. Volkswagen AG d
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nl
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-1-. , is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
-arrow-.
n in
or c
thi
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t
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f
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t.
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Cop py
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gh ht
pyri by
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by c lksw
cted agen
Prote AG.
– While doing so lightly push the refrigerant line -1- upward.

– Remove brake lines -2- on the master brake cylinder -1-.

– Seal off the brake lines with the plugs from the repair kit 1H0
698 311 A.
– Remove the nuts -arrows-. n AG. Volkswagen AG do
lkswage es n
– Remove the heat shield -3-. byV
o ot g
ua
d ran
ir se
– Carefully remove the brake master cylinder fromuth the brake
o tee
or
booster. ss
a ac
ce
le
Installing
un
pt
an
d
itte
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erm
ab
following:
ility
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– When assembling the brake master cylinder with the brake is n
h re
ole,
spec
t to the co
when assembling the brake master cylinder with the brake
booster.
rrectne
– Make sure the sealing plugs -item 18- ⇒ Item 18 (page 101)
ss o
cial p
f in
form
mer
cylinder.
atio
om
n
c
i
or
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thi
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Mechanism; Clutch Mechanism, Bleeding . Cop py
t. rig
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Vehicles with A/C system: p by
co Vo
by lksw
cted agen
– Fill the refrigerant circuit. Refer to ⇒ Heating, Ventilation and Prote AG.
Station .
RHD”, page 100
♦ ⇒ “3.5.2 Brake Lines, Attaching to Hydraulic Unit, RHD”, page
44

4 Vacuum System
⇒ “4.2 Check Valve, Checking”, page 136
⇒ “4.3 Vacuum Sensor G608 , Removing and Installing”,
page 136
⇒ “4.4 Vacuum System, Checking”, page 137
4.1 Overview - Vacuum Pump

⇒ “4.1.1 Brake Booster Vacuum Pump, Diesel Vehicles”,
page 136
4.1.1 Brake Booster Vacuum Pump, Diesel

Vehicles
Vacuum Pump for 4-Cylinder Diesel Engines (1.6L Common
Rail):
The vacuum pump is installed behind the oil pump.
– Vacuum Pump/oil pump removing and installing. Refer to ⇒
Rep. Gr. 17 ; Oil Pan/Oil Pump; Overview - Oil Pan/Oil Pump .
4.2 Check Valve, Checking

Inspection process
– Carefully remove the checkwvalve
agen with the vacuum
AG. Volkswagen AG d line -1- from
oes
the brake booster. y V olks not
gu b ara
ed
– Blow some air first
ho in one then in the other direction through e o
ris nte
the check valve
s aut -1-. ra
c s
• The check valve -1- must allow air through in the direction of
ce
e
nl
pt
du
the -arrow-.
an
itte
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erm
ab
• The check valve -1- must remain locked in the opposite direc‐
ility
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tion of the -arrow-. If this is not the case, replace the check
wit
, is n
valve of the complete vacuum line.

h re
hole
spec
es, in part or in w
Note
t to the co
Pay attention when installing that the vacuum line with the check
valve installation position is correct on the brake booster.
rrectness of i
l purpos
nform
mercia
4.3 Vacuum Sensor - G608- , Removing

at
om
ion
c
and Installing
in t
or
his
ate
do
priv
cum
or
Note
f
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Cop py
The Vacuum Sensor - G608- is only installed on some gasoline ht. rig
rig ht
engines.
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
On »R« vehicles:
– Open the lock washer -2- and the screw-type clamp -3-.
– Remove the air guide hose -1-.

– Disconnect the connector -3- from the Vacuum Sensor - G608-
-1-.
– Unclip the Vacuum Sensor - G608- -1- from the vacuum line
-2-.
Installing
Install in reverse order of removal. Watch out for the following:
Note AG. Volkswagen AG d

agen oes
olksw not
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♦ Pay attention that before installing the Vacuum
ise
d b Sensor - G608- ara
nte
is checked for leaks and damage. utho r eo
a ra
c
Replace the vacuum sensor if thes seal is damaged.
s
♦
ce
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nl
pt
du
an
itte
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ab
ility
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4.4 Vacuum System, Checking

h re
hole
spec
⇒ “4.4.1 Test Instructions”, page 137
es, in part or in w
t to the co
⇒ “4.4.2 Brake Servo Tester VAS6721 , Connecting”,

page 138
rrectness of i
⇒ “4.4.3 Vacuum, Checking”, page 139

l purpos
⇒ “4.4.4 Leak Test”, page 139

⇒ “4.4.5 Vacuum, Creating with Hand Vacuum Pump VAS6213 ”,
nf
ercia
page 141
orm
m
atio
m
4.4.1 Test Instructions

o
n in
or c
thi
e
The following checks will be helpful when performing Fault Find‐

t
sd
iva
ing if there are complaints regarding the brake booster or the so-
o
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cu
called »hard brake pedal«.

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ng
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The following components are included in the check: t. Cop py
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♦ Brake Booster yri
p by
co Vo
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cted
♦ Seal between the brake master cylinder and the brake booster
agen
Prote AG.
♦ Check Valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if equipped)
4. Vacuum System 137

Keep the geographical surrounding in mind when evaluating the

measured results. The higher above sea level, the lower the air
pressure.
Always observe all test requirements before checking the vacuum
system:
♦ Visually inspect all of the vacuum hoses for damage (for ex‐
ample, tears or damage caused by animals) and secure fit
♦ Maintain clean working conditions when working on the vac‐
uum system
♦ Clean the engine compartment before starting, if necessary
4.4.2 Brake Servo Tester - VAS6721- , Con‐

necting
♦ Brake Servo Tester - VAS6721-
– Remove the vacuum hose from the brake booster.
Pressing the brake pedal a few times beforehand makes it easier
to remove the vacuum hose.
– Connect the Brake Servo Tester - VAS6721- . Refer to the
following illustrations.
Item Com‐ Explanation
num‐ po‐
ber nent
A Shut- In direction toward the vacuum hose, the check
off valve and vacuum pump (if equipped)
valve
B Shut- ♦ Opening the Brake Servo Tester - VAS6721-
off makes it easier to remove.
valve n AG. Volkswagen AG do
♦ Open to simulate an incorrect source wage es n
olks ot V gu
by ara
♦ Connect the Hand Vacuum
or
isPump
ed - VAS6213- . nte
th eo
au ra
C Shut- Toward the brake booster
ss c
ce
le
off
un
pt
valve
an
d
itte
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rm
ab
pe
ility
ot
– Connect the Brake Servo Tester - VAS6721- hose -A- too the
wit
, is n
vacuum hose and push the adapter -C- into the brake booster.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.4.3 Vacuum, Checking
Note
♦ The average earth atmospheric air pressure at sea level (N.

N.) is 1013 mbar (15 psi) and it decreases dramatically at
higher altitudes (approximately 100 mbar (1.5 psi) every 1000
meters higher) Local and time fluctuations will influence the
vacuum.
♦ A cold engine, the A/C switched being on and even only the
engine idling can negatively influence the vacuum.
– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damaged caused by animals) and make sure
they are secure
– Connect the Brake Servo Tester - VAS6721- . Refer to
page 138 .
– Open the shut-off valve -A-.
– Close the shut-off valves -B+C-.
– Start the warm (above 60 °C) engine and press the acceleratoragen
AG. Volkswagen AG d
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pedal one time quickly (engine RPM higher than 2,000). olksw not
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ed
– Read the measured value displayed. thoris nte
e or
au ac
Normally (see note) the vacuum should be between
ss 600 and 950
ce
mbar (8.7 and 13.8 psi) (depending on the engine installed).
e
nl
pt
du
an
itte
Check the vacuum system for leaks if the measured value is not
y li
erm
ab
reached, even though all requirements (see notes).
ility
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wit
– Create the vacuum using a Hand Vacuum Pump - VAS6213-
, is n
h re
for comparison purposes. Refer to
hole
⇒ “4.4.5 Vacuum, Creating with Hand Vacuum Pump
spec
es, in part or in w
VAS6213 ”, page 141 .
t to the co
Opening the shut-off valve -B- makes it easier to remove the hose
connections and the adapter.
rrectness of i
4.4.4 Leak Test
l purpos
nf
ercia
Note
orm
m
atio
m
♦ The average earth atmospheric air pressure at sea level (N.

o
n in
or c
N.) is 1013 mbar (15 psi) and it decreases dramatically at

thi
te
higher altitudes (approximately 100 mbar (1.5 psi) every 1000

sd
iva
meters higher) Local and time fluctuations will influence the

r
rp
cu
o
vacuum.
f
en
ng
t.
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op
♦ A cold engine, the A/C switched being on and even only the C py
t. rig
engine idling can negatively influence the vacuum.
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Vo
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by c lksw
cted agen
Prote
– Check all the vacuum hoses beforehand for damage (for ex‐
AG.
ample, tears or damaged caused by animals) and make sure

they are secure
– Connect the Brake Servo Tester - VAS6721- . Refer to
page 138 .
– Open the shut-off valve -A-.

– Close the shut-off valves -B+C-.

– Start the warm (greater than 60 °C) engine and press the ac‐
celerator pedal one time quickly (engine RPM higher than
2,000).
Normally (see note) the vacuum should be between 600 and 950
mbar (8.7 and 13.8 psi) (depending on the engine installed).
– Open the shut-off valve -C- and evacuate the brake booster.
– Turn off the engine.
– Read the measured value displayed and write it down.
The vacuum may drop 400 mbar (5.38 psi) within 12 hours.
If the drop in vacuum is greater, check for leaks in the area of
the....
1- Brake Booster
or the
2- Check Valve, the Vacuum Hoses with Connectors and the
Vacuum Pump/Intake Manifold
for leaks.
The vacuum will drop considerably within a few seconds if there
are large leaks. gen AG
. Volkswagen AG
d wa oes
olks not
Checking the vacuum near the brake booster: byV gu
ara
ed nte
ris
tho eo
– Close the shut-off valve -A- after creatings authe vacuum to test ra
c
the brake booster vacuum. s
ce
e
nl
pt
du
Vacuum test near the check valve, vacuum hoses and connec‐
an
itte
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tions and vacuum pump/intake manifold

erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Close the shut-off valve -C- after creating the vacuum to check
the Brake Servo Tester - VAS6721- vacuum up to the intake
manifold or up to the vacuum pump.
nf
ercia
orm
Opening the shut-off valve -B- makes it easier to remove the hose
m
atio
m
connections and the adapter.

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

4.4.5 Vacuum, Creating with Hand Vacuum

Pump - VAS6213-
In certain situations, the vacuum can be created using a Hand
Vacuum Pump - VAS6213- instead of using the engine or a vac‐
uum pump.
– Connect the Hand Vacuum Pump - VAS6213- to the vacuum
hose on the connection -B- on the Brake Servo Tester -
VAS6721- .
– Open the shut-off valve -B-.
– Create the vacuum using the Hand Vacuum Pump - VAS6213-
until a vacuum between 600 and 950 mbar (8.7 and 13.8 psi)
on the Brake Servo Tester - VAS6721- is displayed.
– Perform the tests.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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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 Brake Lines
⇒ “5.1 Brake Lines, Repairing”, page 142
5.1 Brake Lines, Repairing

wage
e ks s no
Vol t gu
⇒ “5.1.1 Overview - Flanging Tool”,
ed
by page 142 ara
is nte
or
⇒ “5.1.2 Flanging Tool, Instructions”,
au
th page 143 eo
ra
ss c
5.1.1 Overview - Flanging Tool
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
♦ Brake Line Tool Kit - VAS6056-
ot
wit
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h re
hole
spec
Flare the brake lines with 5 mm outer diameter using the Brake
es, in part or in w
Line Tool Kit - VAS6056- without damaging coating. In this way,
t to the co
brake lines can be inexpensively partially replaced in certain ca‐
ses.
rrectness of i
l purpos
Note
♦ Brake lines must not be bent more than 90°, otherwise they
nform
ercia
kink or deform causes unacceptable constriction in the line.

m
a
com
ti
♦ Disconnect the brake lines preferably at the underbody.
on in
r
te o
thi
♦ Position of intermediate pieces should be selected so that they s
iva
cannot rub against moving parts.

do
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rp
cum
fo
♦ Do not lubricate the spindle, clean only with mineral spirits.

en
ng
t.
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Cop py
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List of individual tools: opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

1 - Brake Line Tool Kit - Flang‐

ing Tool - VAS6056/1-
❑ The Clamp Jaws -
VAS6056/6- are inclu‐
ded in the Brake Line
Tool Kit - Flanging Tool
- VAS6056/1- .
2 - Brake Line Tool Kit - Pipe
Cutter - VAS6056/2-
3 - Brake Line Tool Kit - Brake
Line Scraper - VAS6056/3-
❑ The threaded pins (in
AG. Volkswagen AG d
shaft and at sides) are ksw
agen oes
not
l
set and must not be ad‐ byV
o gu
ara
justed! rised
nte
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ut
4 - Brake Line Tool Kit - Liness a ra
c
Grips - VAS6056/4-
ce
le
un
pt
an
d
5 - Brake Line Tool Kit - Pipe

itte
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Bending Tool - VAS6056/5-
erm
ab
ility
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6 - 6 mm Offset Screwdriver
wit
is n
h re
7 - Brake Line Tool Kit - Flaring
ole,
spec
Jaws - VAS6056/6- or Brake
Line Tool Kit - Flaring Jaws -
t to the co
VAS6056/7-
❑ Brake Line Tool Kit -
Flaring Jaws -
rrectne
VAS6056/6- for black
brake lines
ss o
❑ Brake Line Tool Kit -
cial p
f i
Flaring Jaws -
nform
VAS6056/7- for green
mer
brake lines atio

om
n
c
i
or
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Note
te
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iva
o
pr
The arrow on the rounded side of

um
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en
ng
the flaring jaws must face toward

t.
yi Co
edge of housing and the straight Cop py
. rig
side of the flaring jaws must be in‐
ht ht
rig by
py
stalled toward spindle, otherwise co Vo
by lksw
flared head will not be formed cor‐
cted agen
Prote AG.
rectly.
5.1.2 Flanging Tool, Instructions

– Remove the affected brake line from the brake caliper or brake
cylinder. Be sure to catch any leaking brake fluid and dispose
of it correctly.
5. Brake Lines 143

– Cut the brake line at a suitable place (straight, easily accessi‐

ble piece) with the pipe cutter -2-.
– Remove the piece to be exchanged.
– Lubricate the brake line surface.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
– Clamp the brake line in the locking pliers -4- so that approxi‐
ility
ot p
mately 50 mm is sticking out of the plastic clamping jaws.
wit
is n
h re
ole,
– Mount the shearing tool -3- in a drill and place it on the brake
spec
line.
t to the co
– Shear the coating from the brake line at a slow drill RPM and
with light pressure against the brake line.
rrectne
The length of the sheared-off portion is determined by the stop in
the shearing tool.
ss
– Remove the shearing tool from the brake line and remove the
o
cial p
f
shavings.
inform
mer
atio
m
– Remove the locking pliers and push the pipe fitting -D- onto
o
n
c
i
the brake line.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Push the brake line -B- against the stop -A- inside the flanging
tool.
Note
The brake line must contact the stop when tightening the hex
socket bolts, otherwise the flanged head will not be formed cor‐
rectly.
– Clamp the brake line in the flaring tool until it cannot be moved
any more. Fold the stop -A- up and tighten the hex socket head
screws diagonally with the angle screw driver -C-.

– Turn the spindle all the way in the flanging tool.

– Turn the spindle back.
– Loosen the hex socket bolts diagonally.
– Remove the brake line from the flanging tool, clean and check
the brake line and flared head.
Briefly rinse the part of the brake line remaining in the vehicle:
– Connect the Brake Charger/Bleeder Unit - VAS5234- , place
the bleeder bottle hose on the flared head of the brake line and
run the Brake Charger/Bleeder Unit - VAS5234- briefly until
some brake fluid runs through.
– Clean the new brake line to be inserted with compressed air.
– Join the brake lines with the connecting piece -E-.

– Assemble the brake line.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
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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
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cum
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fo
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t.
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Cop py
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co lksw
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cted agen
Prote AG.
5. Brake Lines 145

6 Hydraulic System
⇒ “6.1 Brake Fluid General Information”, page 146
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 146
⇒ “6.3 Hydraulic System, Post-Bleeding”, page 147
⇒ “6.4 Checking for Leaks”, page 147
6.1 Brake Fluid General Information

⇒ “6.1.1 Brake Fluid General Information”, page 146
⇒ “6.1.2 Brake Fluid, Changing”, page 146
6.1.1 Brake Fluid General Information
Note
♦ Only use new brake fluid conforming to VW standard (VW 501

14).
♦ Brake fluid is poisonous. Due to its caustic nature, it must also
never come in contact with paint.
♦ Brake fluid is hygroscopic, meaning that it absorbs moisture
from the surrounding air, and must therefore be
nAG. stored
Volkswagin
enair-
AG do
tight containers. olks
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♦ Rinse any spilled brake fluid with
ris plenty of water.
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s au ra
c
6.1.2 Brake Fluid, Changing
s
ce
le
un
pt
an
d
Refer to ⇒ Maintenance ; Booklet ; Brake and Clutch System,

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rm
Changing Brake Fluid .

ab
pe
ility
ot
6.2 Hydraulic System, Standard Bleeding

wit
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spec
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Note
♦ The bleeding of hydraulic system using the Brake Charger/

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Bleeder Unit - VAS5234- is described.

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♦ A positive pressure of 2 bar (29 psi) required to bleed the ABS

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Hydraulic Unit - N55- .

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Perform the following:

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– Remove the rear wheels on vehicles with 15" rims.

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Adhere strictly to work sequence when bleeding brake system.
– Connect the Brake Charger/Bleeder Unit - VAS5234-

– Open bleeder valves in the prescribed sequence and bleed
brake caliper.
1- Front left brake caliper

2 - Right front brake caliper

3 - Left rear brake caliper
4 - Right rear brake caliper
Note
Use suitable bleeder hose. It must fit tightly on bleeder valve so

that no air gets into brake system.
– With bleeder bottle hose attached, leave bleeder valve open

long enough that brake fluid exits without bubbles.
6.3 Hydraulic System, Post-Bleeding
Note
Perform a post-bleeding when:
♦ the brake pedal travel is too long, or the so-called »soft brake
pedal«
A second technician is required during the post-bleeding.
– Connect the Brake Charger/Bleeder Unit - VAS5234-
– Depress brake pedal forcefully and hold.
– Open bleeder valve at brake caliper.
– Press brake pedal down onto stop.
– Close bleeder valve with pedal depressed.
– Release brake pedal slowly.
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Bleeding sequence:
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1- Front left brake caliper

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2 - Right front brake caliper

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3 - Left rear brake caliper

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4 - Right rear brake caliper

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A road test must be performed after bleeding. During this, at least

one ABS regulation must be performed!
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6.4 Checking for Leaks

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♦ Brake Pressure Gauge - VAG1310A-

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♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-

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147
AG.
6. Hydraulic System
Test Prerequisites
• Brake system (hydraulic unit, brake hoses, brake lines and
brake calipers) operating properly and free of leaks.
Perform the following:
Checking
– Remove the bleeder valve at one front brake caliper.
– Attach and bleed the Brake Pressure Gauge
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– Apply pressure to brake pedal until
ed the gauge indicates a
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pressure of 50 bar (725 psi).hoThe
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more than 4 bar (58 psi) during
sa
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Replace master cylinder if pressure drops greatly.
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7 Special
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Tools
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♦ Piston
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♦ Piston Resetting Tool - Caps /1,/2,/3,/4,/5 - T10146/5-
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♦ Press Piece - T10502-
7. Special Tools 149

♦ Brake Pressure Gauge - VAG1310A-
♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-

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♦ Torque Wrench 1331 Insert - Ring Wrench - 11mm & 17mm -
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VAG1331/2-
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♦ Brake Line Tool Kit - VAS6056-

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♦ Adhesive Strip Remover - VAS6349-

♦ Brake Servo Tester - VAS6721-
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♦ Trim Removal
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Edition: K0059210621 - FU - 04/01/2015 – TMP

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7. Special Tools 151

Brake System - Edition 03.2015 lkswage es n
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8 Revision History
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Re Dat Job Type Feedback # Notes Editor
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AG. Volkswagen AG d
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Cautions & Warnings c
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
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and repair work. You must answer that you have read and you understand these
h re
hole
WARNINGS and CAUTIONS before you will be allowed to view this information.
spec
es, in part or in w
t to the co
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
rrectness of i
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
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•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
nf
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system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
orm
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•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
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n in
or c
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
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check with your authorized Volkswagen retailer parts department for the latest information.
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST). t. Co py
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•=
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Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
Prote AG.
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
olkswagen AG
G. Vaccidentally
Make sure the bulb is enclosed by a wire cage. The hot filament ageof
n Aan broken
does bulb can ignite spilled
lksw not
fuel or oil. by Vo gua
ed ran
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tho
•= Friction materials such as brake pads and clutchaudiscs may contain asbestos fibers. Do not create or dust by
ac
s
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
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un
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
pt
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•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
pe
ility
crushed by heavy parts.
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wit
, is n
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hole
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
spec
es, in part or in w
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
t to the co
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
rrectness of i
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
l purpos
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
nform
ercia
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
m
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
com
tion in
listed.
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iva
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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Co py
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of rig
ht. rig
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that py by
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govern the disposal of wastes. Prote
cted AG.
agen
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
AG. Volkswagen AG d
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I have read and I understand
rise
d by
these Cautions and ara Warnings.
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au ra
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Service

Repair Manual Volksw

Golf Variant 2014 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D4B804B24F7

1.1 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 1

3.1 Brakes Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.4 Parking Brake, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

45 - Antilock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5 Brake Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

00 – General, Technical Data

1.1 Safety Precautions during Road Test with Testing Equipment

2.1 Brake PR Numbers

2.1.1 Front Brakes

1.6L -66; 77 kW TDI 1; AG. Volkswagen AG d

1.4L - 103 kW TSI 1)

1.6L -66; 77 kW TDI 1;

2.0L - 110 kW TDI 1ZA/1ZD PC57 (16”)

2.0L - 135 kW TDI 1ZA/1ZD/1ZB 2)

2.0L - 162 kW TSI 1ZB

2.0L - 169 kW TSI 1LJ C60 (17”)

2.0L - 206; 213; 221 kW 1LM

1) Vehicles with adaptive chassis DCC receive the 16" brakes.

2 Rep. Gr.00 - General, Technical Data

– For information regarding each brake installed. Refer to ELSA/

2.0L - 162 kW TSI 1KV

2.0L - 169 kW TSI 1KJ FNc-M42 (17”)

2.0L - 206; 213; 221 1KY

depending on the en‐

Brake booster, depend‐ Diameter in in‐ 10 or 11

3.1.2 Front Brakes

4 Rep. Gr.00 - General, Technical Data

Brake pad, wear mm 2

4 Brake caliper, diam‐ 57

Front brakes PC57 (16”):

Brake pad, wear mm 2

Front brakes C60 (17”):

1 Brake caliper FNc-M38 (15”)

Brake pad, wear mm 2

4 Brake caliper, diam‐ 38

piston eter in ion

6 Rep. Gr.00 - General, Technical Data

Rear brakes FNc-M42 (17”):

4 Brake caliper, diam‐ 42

4.1 General Information

Brake regulation system does not function with ignition off.

4.2 Front Wheel Drive Vehicles, Checking

⇒ “4.3.1 Controlled Opposite-Running Test Stand ”, page 8

4.3.1 Controlled Opposite-Running Test

“Moving in opposite directions” means: The rollers on the one-

on the other side.

directions, to prevent delivering power to the other axle.

“Controlled” means: The speed of the test stand rollers must be

8 Rep. Gr.00 - General, Technical Data

4.3.2 Without Test Stand

With AWD, Testing with Standard One-Axle Dynamometer

– Drive the vehicle forward onto the rollers.

4.4 Parking Brake, Checking

⇒ “4.4.2 Electromechanical Parking Brake, Checking, AWD Ve‐

4.4.1 Electromechanical Parking Brake,