BRAKES Contents Introduction 1. General Description. 14 Master Cylinder, Vacuum Booster, and Brake Lines Disc Brakes Rear Drum Brakes Proportioning Valves Parking Brakes Brake Applications and Identification 2. Maintenance 3. Troubleshooting, aa 32 a3 Basic Troubleshooting Principles. Diagnostic Tests Brake Noise. 4, Brake System Service 4a 42 43 44 Brake Fluid Bleeding Brakes Pressure Bleeding ‘Vacuum Bleeding Manual Bleeding Replacing Brake Fluid Flushing the Brake System Master Cylinder and Vacuum Booster Removing and Instaling Master Cylinder. Removing and Instaling Vacuum Booster. Proportioning Valves Pressure Testing Proportioning Valves, 10 " " Section 11 5. Front Dise Brakes 5a 82 Checking Brake Pad Wear Reconditioning Front Disc Brakes Removing and Installing Brake Pads Removing, Reconditioning, and Installing Front Brake Rotors Calipers. 6. Rear Drum Brakes. 1 62 ‘Checking Brake Lining Wear Reconditioning Rear Drum Brakes Removing and Instaling Brake Shoes. Reconditioning Brake Drums Inspecting and Replacing Wheel Cyinder Parking Brake (Drum Brakes) ‘Adjusting Parking Brake Replacing Parking Brake Cables. 7. Rear Disc Brakes. 7a 72 73 (Checking Brake Pad Wear. Reconditioning Rear Disc Brakes Removing and Instaling Rear Brake Pads, Removing, Reconditioning, and Installing Rear Brake Rotors. Parking Brake (Disc Brakes) ‘Adjusting Parking Brake Replacing Parking Brake Cable. Calipers 8. Technical Data |. Tolerances, Wear Limits, and Settings IL. Tightening Torques " " " " 14 4 4 16 16 16 18 18 18 18 19 19 19 19 21 21 BRE BBR11-2 BRAKES TABLES Brake Troubleshooting Brake Pressure Specifications. Front Rotor Reconditioning Specifications Brake Drum Reconditioning Specifications Rear Rotor Reconditioning Specifications eaege " 14 18 atBrakes 11-3 Brakes Introduction All cars covered by this manual are equipped either with front disc brakes and rear drum brakes, of with disc brakes at all four wheels. The brake system is a diagonal, dualcircut design, hydraulically actuated by the master cylinder, with a vacuum-powered booster to reduce braking effort. Proportioning valves help prevent the rear brakes from locking during heavy braking ‘A propery functioning brake system is essential to safe driving, if the red brake/parking ‘warning indicator lights up while driving, indicating low pressure in one of the brake circuits, then itis imperative that the system be given a thorough check, even if braking action stil seems satisfactory, The brakes should be regularly inspected, and all brake work must be done with extreme cleaniiness, careful attention to specifications, and proper working procedures. {Al information needed for performing routine inspection and maintenance is given here, ‘although some of the information may only be of value to the professional mechanic. H you lack the skis, the tools, or clean workplace for servicing the brake system, we suggest you leave these repairs to an authorized Volkswagen dealer or other qualified shop. We especially urge yyouto consult your authorized Volkswagen dealer before beginning repairs on a car which may be subject to Volkswagen warranty coverage.11-4 BRAKES 1. GENERAL DESCRIPTION Fig. 1-1 isaschematic diagram ofthe dual-diagonal hydrau- lic brake syste. The master cylinder, operated mechanically by the brake pedal, creates pressure in the hydrauiic system. At the wheels, the hydraulic pressure acts on the calipers or wheel cylinders to mechanically apply the brakes. The use of hydrau- lics makes it possible for the driver to generate high braking forces with comparatively litle efort. WARNING — “Friction materials such as brake linings or bake ‘pads may contain asbestos bers. Do not create ‘dust by grinding, sanding, or clearing the pads with compressed ai. Avoid broathing ary asbes- 10s fibers or dust. Breathing asbestos may resut In serous disoases such as asbestosis or cancer, or may resut in death WARNING — + Brake Mid is polsonous. Wear safety glasses when working with brake uid, and woar rubber gloves to prevent brake fud trom entering the loodsiream through cuts ar scratches. Bo not Siphon brake fd by mouth caurion— Brake Mid is very damaging to paint. immed ately wipe up any brake fu that spills on the venicte. Master Cylinder, Vacuum Booster, and Brake Lines ‘The master cylinder has two separate chambers for two separate hydraulc circuits. The front chamber operates the brakes on the right front and let rear wheels, while the rear chamber operates the brakes on the left front and right rear wheels. In the event of a loss of pressure in one circuit, the ‘ther wil stil supply approximately half of the normal braking force. ‘The vacuum booster uses engine vacuum to assist braki ‘effort, The rigid brake lines transmit hydraulic pressure to the wheels and resist expansion and pressure loss. Flexible hoses between the rigid lines and the brakes accommodate wheel ‘movement due to steering and suspension action. Disc Brakes ‘The disc brakes use a cast-iron caliper with a single hydrau- lic eyinder to clamp the rotor (disc) between two brake pads. Front rotors are mounted to the wheel hub. Rear rotors are Fig. 1-1. Schematic view of brake system. Front dsc and roar drum brakes shown. Fours! disc brake system is siaintegral with the whee! hub; they house the wheel bearings and, are held in place by the axle nut. Disc brakes automatically adjust for brake pad and rotor wear. Rear Drum Brakes ‘The seltadjusting rear drum brakes use a dual-opposed ‘hydraulic whee! cylinder to apply pressure to the brake shoes, forcing the friction linings against the inside of the brake drum. Proportioning Valves ‘To prevent rear-wheel lock-up during hard stops, all cars ‘covered by this manual are equipped with pressure regulating devices, called proportioning valves, that limit the amount of hydraulic pressure applied to the rear brakes, See Fig. 1-2. Fig. 1-2 Intaed poston of on brake proportoning valve A second valve fot shown is also mounted onthe master cyinder Parking Brakes ‘The cable-operated parking brake mechanically actuates either the rear brake shoes or the rear caliper pistons. The position of the parking brake lever is held by a thumb-release ratchet 1.1 Brake Applications and Identification All models except 16-valve are equipped with front disc brakes and rear drum brakes. 16-valve models are equipped with four-wheel disc brakes. The front brake rotors ofall models are internally-ventiated for better cooling, 2. MAINTENANCE ‘The following routine maintenance operations should be performed at the time or mileage intervals listed in LUBRICA- TION AND MAINTENANCE. Instructions can be found in LU- BRICATION AND MAINTENANCE, or in this section under the listed numbered headings. Brakes 11-5 1. Checking brake fluid level Inspecting brake hoses and lines for leaks, ‘Checking brake pad andior fining wear. Replacing the brake fluid every two years. 4.2 3. TROUBLESHOOTING This heading describes symptoms of trouble with the brake system, and suggests possible causes and appropriate cor- rective actions. ‘The brake system has the sole function of generating the required friction to stop the car from any speed. Brake prob: lems are usually obvious because they affect the way the car Slows and stops. Problems which affect the car's handling or Create noise may also be caused by faults in the suspension or steering systems. Information on troubleshooting these sys- tems can be found in SUSPENSION AND STEERING. For ‘more help in selecting the appropriate section, soe the discus- sion of troubleshooting in FUNDAMENTALS atthe front of the manual 3.1 Basic Troubleshooting Principles Table a lists symptoms of problems commonly associated with the brakes, their probable causes, and suggested correc- tive actions. The numbers in bold type in the corrective action ‘column refer to numbered headings in this section where the suggested repairs are described, ‘As with any troubleshooting, analysis ofthe observed symp- toms i the key to isolating and identifying braking problems. Reliable brake system performance depends on creating and ‘applying hydraulic pressure inthe system. Brake performance is affected by three things: the brake fluid, the systems ablity to maintain pressure, and the frcton components. Air in the brake fluid, because itis compressible, wil make the brake pedal feel spongy during braking, or wllincrease the. force required at the brake pedal to stop the car. Moisture- or dit-contamninated fluid will dramatically increase internal corro- sion and wear. Seals are used throughout the system to maintain hydraulic pressure. Fauity seals or wear and corrosion on the sealing surfaces will reduce braking efficiency. A symptom of this Condition is the need to pump the pedal to get good braking. ‘Simple leaks at the brake line or hose unions may cause the ‘same problems.11-6 BRAKES Table a. Brake Troubleshooting brake shoes. Brake pad carters or backing plates ‘ity of covoded 4. Brake shoe retun springs woak «Pact antatle springs tauty or missing {. Brake pads or inings heat glazed or ‘ol-soaked 9. Whee! bearings misadjustog ‘Symptom Probable cause 1. Brake squeak or | a Normal condtion ‘Sea squeal . ncortect installed brake pads or Check instalation. 5.1, 64, 7.4 ‘. Clean calipers andior backing plats, 3.3, 6.1, 6.1, 7.1 4. Replace retun springs. 6.1 Instasiroplace antivatle springs. 8.1, 7.4 |. Replace brake padsfinings. Clean rotorsidrums, Replace leaking calpersiwheo cyindars as requires. 5.2, 6.1.7.1 Replace wheel ‘bearing grease seals as required. See SUSPENSION AND STEERING 2, Pedal goes to toor when Braking 8 nsufcient brake fic Master cylinder faulty 1g. See SUSPENSION AND STEERING 4. Check ud level See LUBRICATION AND MAINTENANCE Check for leaks. Fill and bleed system, 4.2 'b. Replace master cylinder. 4:3 3. Low pedal even after brake agustment and bleeding ‘2 Master cylinder fauty ‘8. Replace master oyinder. 4:3 ‘4. Pedal fees spongy lor rakes work only ater pedals pumped ‘2. Insuilent brake fac ‘bin brake fd «© Mastor cyinder spring weak 4. Leaking ine and hose unions «. Check fud evel. See LUBRICATION AND MAINTENANCE. Check for leaks. Fil and bleed system. 4.2 Bleed system. 42 Replace master cylinder. 43 4. Repair or replace lines and hoses. Bleed system, 4.2 5, Exoossive braking fort with ite eat «Brake pads oF inings wet 'b Brake pads or inings heat-gazed or soaked Vacuum Booster or vacuum line fauity Use ight pedal pressure to dry bakes while driving 'b. Replace brake padsfinings. Clean rotorsierums, Replace leaking caloersiwhee cylinders as requred. §.2,6.1,7-1. Replace wheal bearing grease seals See SUSPENSION AND STEERING «Inspect vacuum lines Test booster and replace as requied, 4.3 6. Brakes pulsate, chatter or grab a. Warped csc brake roiows '. Brake drums won or outotround «Brake pads o nings worn 4. Brake pads or linings heat- glazed or olrscakes ‘Recondition or replace rotor. 8.1, 7.1 'b. Recondition of replace brake drums 6.1 . Reconssiton brakes. 6.1 6.1, 7.4 4. Replace brake pads(inings. Clean rotorscrums, Replace leaking calperaiwee! cyinders as required. 5.2, 6.1, 7.1. Replace wheet bearing grease seals as requirod, See SUSPENSION AND STEERING 7. Uneven braking, car pulls o one sige, Fear brakes lock €.Incomect tre pressures 'b. Brake pads or lnings heat gazed or ‘oltsoaked «.Proportioning valves faulty 4. Calperiwhesl cylinders or brake Padsishoes binding «©. Drum brake settadjusters faulty {Brake tid contaminated {9 Worn thes or suspension components ‘8. Check and correct tre pressures. See LUBRICATION AND MAINTENANCE »b. Replace brake padsfinings. Clean rotorsidrums, Replace leaking calpersiwneo! cyinders as required. 5.2,6.1,7.1 Replace wheal ‘bearing grease seals as required. See SUSPENSION AND’ ‘STEERING «Replace proportioning vahes 4.4 4. Clean and reconclton brakes. 5.1, 6.1, 7.1 ©. Clean, repair, oF replace seltadjusting mechanism. 6:4 4 Drain, fush, rofl, and bleed brake system. 4.2 9. See SUSPENSION AND STEERING ‘8. Brakes crag, bind, or overheat 'a. Brake shoe retum springs weak 'b. Brake caliperwhoe! cylinder or brake padishoe binding Master cylinder faulty ‘a. Replace springs. 6.4 'b. Clean and reconction brakes. 5:1, 6.1, 7.1 Replace master cylinder. 43Wom or contaminated brake linings are an obvious cause of ‘poor braking performance. The fiction material is slowly con- ‘sumed by use ofthe brakes and must be periodically replaced ‘Also, pads and linings which are oilcontaminated or glazed, due to overheating cannot produce as much friction, and stopping distances will increase. When troubleshooting the brake system, consider how ‘Quickly the problem occurred. Sudden brake system failure is, ‘most likely caused by the failure of one component, such as a Durst hose or a disconnected vacuum booster vacuum line. A ‘gradual deciine in braking efficiency probably indicates the ‘general state of wear in the system, and more than one com> ponent may need to be repaired or replaced. 3.2 Diagnostic Tests ‘Some general checks of brake system function and com- ponent inspection can help isolate problems. Test the vacuum booster frst by pumping the brake pedal a {ow times with the engine of and then holding the pedal down. ‘When the engine is started, the pedal should fal sightly. The booster diaphragm rarely falls, but leaks in the vacuum line or a faulty check valve will decrease the vacuum assist. Check the valve by removing it from the booster vacuum line and blowing, through it. Air should pass through in the direction of the arrow fon the check valve, but not through the opposite way. ‘Test the rear brakes by applying the parking brake. It should 'be able to hold the car, perhaps even stalling the engine, when, you ty to drive away. if not, the brakes probably need adjust: ‘ment or reconditioning, Test the master cylinder by holding the pedal down hard with the car stopped and the engine running. The pedal should, {eel solid and stay solid. tthe pedal slowiy falls othe floor, then the master cylinder is fauty and should be replaced, 3.3 Brake Noise ‘Occasional groaning of squealing sounds coming from the brakes, especially disc brakes, ae usually caused by vibrations transmitted through the brake pads. The problems not unique to Volkswagens. New brake friction materials, using litte or no asbestos for health reasons, may contribute to an increase in, bake noise problems in all makes. These noises, though ‘dscomtorting, are normal and rarely indicate a problem in brake system function or effectiveness, ‘Although there is no permanent solution, proper mainte- ‘nance and repair can help minimize brake noise. Disc brake caliper assemblies include anti-rattle springs, designed to min- mize vibration and noise. As much as possible, brake pads, and caiipers should be kept tree of foreign matter and corrosion, which may inhibit smooth operation, Always resurface or ro- place brake rotors when changing brake pads. BRAKES 11-7 ‘A reduction in brake noise may be possible by instaling a sshim kit wth the pads. The kit, Volkswagen part no. 171 698 £998, contains self-adhesive shims which attach to the backs of the brake pads to damp vibration. The backs of the pads must bbe cleaned down to the metal for good adhesion, and the shims can only be installed on thinner, partially won pads. The ‘combined thickness of the pad and shim must not exceed the thickness of anew pad. See 5.1 Checking Brake Pad Wear for specifications. Rear drum brake squeak may be more easily corrected. A lubricant is available to coat the points on the backing plate where the brake shoes make contact withthe plate (raised or ‘embossed points). The lubricant is Wotfacote grease, part ‘number G 000 650, and is available from authorized Volkswa- {gen dealers ‘cauTion— Part rumbers are subjectto change. Always ely (0n an authorized Volkswagen dealer parts de- partment forthe latest and most accurate infor ‘mation. To eliminate squeaking drum brakes, remove the brake shoes as described n 6.1 Reconditioning Rear Drum Brakes, ‘and apply a small amount of Wottracote grease to the contact points of the brake backing plate, then reinstall the brake shoes, 4. BRAKE SYSTEM SERVICE This section provides the requirements for the brake fluid, the methods for bleeding the brake system, and the servicing Of the master cylinder, vacuum booster, and proportioning valves. 4.1 Brake Fluid Brake fluid is the heart of the hydraulic system. It ransmits| the mechanical braking force at the pedal to the brake mech anisms at the wheels. Any contamination ofthe fluid will have a directinfiuence on braking efficiency, Dirt in the system will cog, small passages and wear rubber parts. Brake fluid absorbs moisture. Moisture inthe fluid lowers its boiling point, alowing it to be boiled more easily by the heat {generated during braking. Boling the fluid will create air in the system and, since air is compressible, will reduce braking efficiency. Moisture in the system also causes corrosion. When adding brake fluid, use only new fluid from unopened containers. Do not reuse brake fluid that has been bled from the system, even if it is brand new. The bleeding operation ‘aerates the fluid. See LUBRICATION AND MAINTENANCE for brake fluid specifications. For best performance and system roliabilty, use only Volkswagen-approved brake fluid.11-8 BRAKES Because it readily absorbs moisture, brake fluid should be ‘changed every two years, regardless of the number of miles ‘driven annually. The brake system should also be bled of air after any repairs in which brake lines are disconnected. See Replacing Brake Fluid for more information WARNING — Brake fui Is poisonous. Wear safety glasses when working with brake uid, and wear rubber loves to prevent brake Mud trom entering the loodstream through cuts or scratches. De not siphon brake tid by mouth caurion— Brake fuid is very damaging to pain. immed ately wipe up any brake uid that spits on Painted surfaces. 42 Bleeding Brakes Bleeding brakes is the process of purging aerated or con- taminated brake fluid from the system and replacing itwith new, ‘lean fluid. Bleeding brakes periodically is good preventive maintenance, but itis also essential if brake lines or compo- nents have been disconnected, or any time air is introduced. into the system. Vague or spongy brakes may indicate the ‘need to bleed air from the system, ‘There are three widely used methods of bleeding brakes, Each employs some means of forcing the fluid through the system to the calipers or wheel cylinders, and releasing con- taminatod fluid through the bleeder valves, The system can be bled using a pressure bieeder, using a hand-held vacuum bleeder, or manually using the brake pedal and a helper. Each method accomplishes the same result. Pressure bleeding, available, is fastest. Manual bleeding requires no special tools. For the best possible results, bleeding should start at the wheel farthest from the master cylinder and end at the whee! Closest to the master cylinder. This bleeding sequence is as follows: 1. right rear caliper or whee! cylinder 2, lett rear caliper or wheel cylinder 2. tight front caliper 4, left front caliper For best access to the bleeder valves when bleeding the brakes, the car should be raised and firmly supported on jack. stands designed for the purpose. The engine should be off, {and the vacuum hose and check valve should be disconnected, from the vacuum booster. The bieeder valves on both disc brake calipers and drum brake wheel cylinders are opened and, Closed using an 8 mm (5/16 in.) box wrench. Use a clear ‘container to catch the expelled fluid and a piece of 4 mm (5/32 In) inside diameter clear, flexible tubing connected to the bieeder valve, as shown in Fig. 4-1, so that outgoing air bub- bles are visible. Fig. 4-1. Container (pata fed win brake thi) connected to caiporbleeder valve vith clear tubing for bls: ing beakes. Bleeding rear um brake whee! cyl doris seria Pressure Bleeding Pressure bleeding, using special equipment and com: pressed air, is the method used by most commercial repair shops. Its the quickest method and the best way to prevent ‘contaminants and air from entering the brake system. The pressure bleeder is connected to the brake fluid reservoir and fils the system with fluid under pressure. Follow the instruc- tions supplied by the equipment manufacturer Vacuum Bleeding Vacuum bleeding uses an inexpensive hand pump con- nected at the bleeder valve to draw the fluid through the system. It is a practical, do-it-yourself alteative to pressure bleeding, is faster than manual bleeding, and can be accom- plished by only one person, Pumps of this general type are avaliable from auto parts and supply outlets. Follow the pump manufacturer's instructions very carefully. ‘Make sure that the hose connection tothe brake bleeder valve is secure and air-tight. Check the brake fluid levetin the master cylinder often to guard against emptying the reservar. Manual Bleeding Bleeding the brake system by pumping the brake pedal is the most economical method. The only disadvantage is that it requires @ helper. When manually bleeding the brakes, first fil the brake fluid reservoir on top of the master cylinder unti the level is well ‘above the MAX mark, and replace the cap to prevent contam- ination of the fui, ‘Starting with the right rear caliper or cylinder, clean the area ‘around the bleeder valve and remove the dust cap. Fit the box. wrench to the bleeder valve, then sip one end of the hase onto the valve and submerge the other end in clean brake fluid in the Clear container. Have a helper slowly pump the brake pedal ‘about three times and, on the last time, hold it down. Slowly ‘open the bleeder valve approximately one-half turn. When the brake pedal goes to the floor and fluid stops flowing from the bleeder valve, close the bleeder valve, then release the brake pedalcaurion— Until some pressure has built up inthe system, ‘only depress the pedal approximately away. This will prevent overrunning the master cylin- ders normal stroke, which may damage tho ‘master cylinder piston seals. CAUTION Be sure that the Bleeder valve is fully closed Detore releasing the brake pedal to avoid draw: Ing air back into the Bleeder vane. Repeat the procedure untl clea fluid with no air bubbles is ‘coming from the bleeder valve, then fully tighten the valve and replace the dust cap. Using the sequence described above, follow the same procedure atthe other three wheels. Check the fluid level in the master cylinder frequently, and add more to keep the level at the MAX mark. Replacing Brake Fluid Remove the fiter/strainer from the brake fluid reservoir and lean it in new, unused brake fluid. Reinstall it, and refil the reservoir wth new, unused brake fluid, Expel the old fluid from the system using the brake bleeding procedure described above, Keep the reservoir refilled, and remove at least 1 pint {about 500 mi) of brake fluid at each caliper or wheel cylinder to expelthe old fluid andreplace it withnew. See the brake fluid ‘specifications in LUBRICATION AND MAINTENANCE. Use only brake fluid of the type approved by Volkswagen. Flushing the Brake System Do not rely on flushing alone to clean a brake system contaminated with dirt or corrasion. The flushing procedure ‘may actualy force dit in the lines into the wheel cyinders. The brake system must be disassembled and the parts individually, ‘cleaned. Use only brake fluid to flush the lines. Alcohol must ‘not be used since it wil encourage the accumulation of water inthe system, 4.3 Master Cylinder and Vacuum Booster ‘The master oyliner, its vacuum booster, and the brake pedal assembly are shown in Fig. 4-2. The vacuum booster land master cylinder are mounted to the firewall in the engine ‘compartment. The pedal operates the master cylinder via a pushrod which passes through the firewall. The master cylinder, piston acts on the brake fluid to create pressure in the system, “The brake fluid reservoir is mounted atop the master cylinder. ‘The vacuum booster, mounted between the pedal mecha- nism and the master cylinder, uses the difference between tengine vacuum and atmospheric pressure to help actuate the master cylinder and reduce pedal effort. BRAKES 11-9 When the engine is running, vacuum is applied equally to both sides of the booster diaphragm. When the brake pedal is pressed, almospheric pressure reaches the pedal side of the diaphragm and creates the brake-boosting pressure differen- tial. A check valve in the vacuum hose holds vacuum in the booster when the engine is stopped. The pedal pushrod is directly connected to the master cylinder so that a failure of the vacuum booster, although it willincrease braking effort, will not result in total brake failure. Removing and Installing Master Cylinder Master cylinder parts or rebuild kits are not available. A ‘faulty master cylinder must be replaced. Itcan be removed and installed with ordinary hand tools. On installation, use a new {gasket between the cyiinder and the vacuum booster, and new self-locking mounting nuts. Make sure to have an adequate supply of new, unopened brake fluid on hand, as bleeding the brakes will be necessary after installation, See 4.2 Bleeding Brakes. To remove and install: 1. Disconnect the battery negative (—) terminal. Discon- rect the electrical connector from the brake fluid reser- voir cap. 2. Remove the reservoir cap and, using a clean syringe, ‘empty the brake fluid reservot. WARNING — Brake fide poisonous, Da not siphon the brake ‘ud with your mouth. 3. Disconnect the brake lines from the master cylinder. Remove the two nuts holding the master cylinder to the vacuum booster, then remiove the master cylinder. 4. If necessary, remove the brake fluid reservoir trom the top of the master cylinder by prying it out ofthe rubber ‘mounting grommets, and install the reservoir on the new master cylinder. 5. Using a new gasket and seltocking nuts, install the new master cylinder. Torque the nuts to 21 Nm (15 ft. fb) Connect the brake lines and torque the brake line unions to 15 to 20 Nm (11 to 15 ft Ib). ‘CAUTION Do not exceed recommended mounting torque of master cylinder mounting nuts. Overighten- ing may cause damage tothe vacuum booster.11-10 BRAKES NoTE— The master cylinder pushrod does not require adjustment prior to installation of the master cylinder, even if a new vacuum booster has been installed 6. Fill the reservoir with new brake fluid and bleed the system as described in 4.2 Bleeding Brakes. Recon: nect the battery negative (—) terminal and the fluid reservoir cap connector. Road test the car and repeat the brake bleeding operation f necessary. Master cyinler (a) WARNING — Do net reise fastonors that are wom or deformed ‘i nomal use, Mary fastanors are designed to bo used only ence and become unreliable and may {a whon used a second tie, This includes, buts notlimitedo, nuts, bots, washers, salHiocking nats orbots, crip, cotter pins. Away’ replace tase fasteners with new pats Fig. 4-2. Exploded vew othe brake pedal vacuum boost andl master cyinder assemy When instaling new acum booster, pustvod faath must be acusted diene mim Removing and Installing Vacuum Booster A faulty vacuum booster is not repairable, and must be replaced. It can be removed and installed with ordinary hand tools. Replacing the vacuum booster requires removing and instaling the master cylinder. See Removing and Installing Master Cylinder above. To remove the vacuum booster, disconnect the vacuum hose from the booster, and disconnect the pushrod from the brake pedal. Working in the engine compartment, remove the four nuts that mount the vacuurn booster to its suppor bracket ‘and remove the booster. Installation is the reverse of removal.Use new seltlocking nuts when installing the booster. Before attaching the pushrod tothe brake pedal, adjust the pushrod to the length indicated above in Fig. 4-2 by turing the pushrod, levis, 4.4 Proportioning Valves Sciroccs and Cabriolets use proportioning valves, ‘mounted in the brake lines at the master cylinder, to control the pressure to the rear wheels. The proportioning valves are not adjustable. Pressure Testing Proportioning Valves Testing the pressure-regulating function of the system re- ‘quires measuring brake system pressure at each wheel, using {wo pressure gauges with a range of atleast 0t0 160 bar (010 2320 psi) connected in place of the brake bleeder valves. Because of the need for this specialized equipment, we rec- ‘ommend having this test performed by an authorized Volkswa- {gen dealer or other qualified repair shop. ‘The gauges are connected to one front and the diagonally ‘opposite rear brake to test one hydraulic crcutt, and then tothe ther front brake and its diagonally opposite rear brake to tast the other hydraulic circuit. The system must be bled at the ‘gauges each time they are connected. Have a helper depress. the brake pedal while observing the pressure readings on the gauges. ‘Table b lists the brake pressure specifications forall models. Replace proportioning valves that are not within specications. Table b. Brake Pressure Specifications Front ealipar Rear wheel cylinder pressure ‘oF caliper pressure 55 bar(798 ps) 136-45 barS65-624 pa) 100 bar(¥480 pel) ‘51-67 bar(740-825 ps) 5. FRONT DISC BRAKES ‘An exploded view ofa front disc brake is shown in Fig. 5-1. ‘The single-piston caliper is a floating design. When the brakes are applied, the caliper pushes the inside brake pad againstthe rotor. This moves the caliper body at the same time, puling the outside pad against the roto. Because the front brakes do more of the work of stopping the car, they are likely to wear faster and require service more frequently than the rear brakes. The brake pads and rotors are ‘subjected to the greatest wear and are the components which ‘most often need attention. Brakes 11-11 ‘The brake pads are designed to be routinely replaced as they wear out. While itis possible to restore the brakes by replacing only the brake pads, full braking performance and. ‘minimum pad wear can only be achieved ifthe rotors aro resurfaced or replaced at the same time. WARNING — ‘Brake pad friction materials may contain asbestos ‘bers. Do not create dust by grining, sanding, or ‘loaning the pads with compressed air. AVIS breathing any asbestos fibers or dust. Breathing asbestos may resuttin soous diseases such as ‘asbestosis or cancer, or may result in death. ‘Checking Brake Pad Wear ‘The inspection procedure and specifications for checking the brake pads are found in LUBRICATION AND MAINTE- NANCE. For more complete inspection of pad condition, the pads must be removed as described in 5.1 Reconditioning Front Disc Brakes. 5.1. Reconditioning Front Disc Brakes Reconditioning of the front disc brakes typically includes replacing the brake pads and resurfacing or replacing the brake rotors. Unless the calipers and hoses are damaged, extremely worn, oF leaking fluid, more extensive front brake: repairs are not normally required. Ifthe brake pads are soaked with ol, grease, or brake fluid, the cause of the contamination must be found and corrected before new pads are installed. Brake rotors must be replaced when resurfacing exceeds specified limits. See Removing, Reconditioning, and Installing Brake Rotors for rotor thick- ness and runout specifications Removing and Installing Brake Pads ‘Although the calipers must be removed to change the brake ‘pads, this can be done without disconnecting the flexible brake hose. Keeping the hydraulic systom sealed eliminates the need. to bleed the brakes afterward. Brake pads and the surfaces of the rotors wear slightly diflerently from one another. Always replace brake pads in ‘complete sets. if old pads are to be reinstalled, such as after inspecting them, always make sure they are refitted in their ‘original locations. To remove: 1, Raise the front ofthe car and support it securely on jack stands. Remove the front wheels.11-12 BRAKES Seltockng bot ; 35 Nm 26 ve e— Bld va wth dst cap _—Calper _— Brake pad carer tor meunting screw (conn) SQ rote re _-- Brake pad WARNING — y Do not xs fasteners that aro wom or deformed Brake pad carn in nome use. Many fastaners are designed to bo Used only ance and bacome unreliable and may {al whon used a second tie, This includes, buts notiimtod'e, nuts bots, washers, selocking nuts lorbots ilps, cottr pin. Aways replace those {fasteners with new parts Fig. 5-1. Exploded view of font dise brake assembly. Ca ets for both 16-vave models (op) and all except 16.vabe (bottor are shown —Anivate sping2. On all except 16-valve models, remove the antivattie ‘springs, then use a hex wrench to remove the two brake caliper mounting bots shown in Fig. 5-2. Also remove the spacers and the sleeves. Pull the caliper away trom the brake pad carrier and suspend it from the car body with a stif wie to avoid stretching the brake hose. Fig. 6-2. Calor mounting bls (arows) to be removed. 3. On 16valve models, hold the caliper guide pin with an ‘open end wrench, then remove the lower brake caliper ‘mounting bolt. See Fig. 5:3. Swing the caliper up and away from the brake pads. Fig. 6-3. Low caliper mounting bolt being removed. H guide pin wih open end wrench when remaving mounting bot NOTE — Wf the piston creeps out ofthe caliper due to residual pressure in the brake lines, place @ rubber band around the piston and caliper to hold the piston Brakes 11-13 4, Lift out the pads from the pad carrier. caurio¢n— 11 te pads are to be reused, mark the pads so that they can be reinstalled in their original po- tions. To install: 1. Install the brake pads on the pad carrier. 2. When instaling new brake pads, slowly push the piston back into the caliper to provide clearance for the thicker new brake pads. NoTE— Pushing in the caliper pistons to gain cloarance forthe thicker new brake pads wil cause brake fluid to overiow the master cylinder uid reser. vor. To prevent ths, use a clean syringe to frst remove some fui from the reserva 3. On all except 16-valve models, engage the caliper with the pad carrier and install the spacers, sleeves, and ‘mounting boits, torquing the bolts to 25 Nm (18 ft ib), Then instal the antiratle springs. 4, On 16yalve models, swing the caliper down and install, the lower mounting bott. Hold the guide pin stationary as ‘shown above in Fig. 5-3 while torquing the mounting bott 10.35 Nm (26 ft), caurion— Make sure that all caliper mounting hardware is loan andl fee of corrosion ‘5. Mount the whee! and loosely install the lug botts. Lower the car and then torque the lug bolts to 110 Nm (81 ft. by. 6. Depress the brake pedal several times to adjust the caliper and brake pads to the rotor. 7. Check the level of brake fluid in the reservoir. it neces- sary, add new brake fluid to fil the reservoir to the MAX ma. WARNING — "Now brake pads require some breakin. AoW for ‘Sig longer stopping distances for he fst 100 10 150 miles of city driving, and avoid hard stops.11-14 BRAKES Removing, Reconditioning, and Installing Front Brake Rotors ‘To remove the brake rotors, frst remove the caliper and brake pads as described above, then remove the brake pad, carrier mounting botts and the brake pad carrier. On 16:vaNve ‘models, it will be necessary to suspend the caliper and pad carrier assembly from the body with a st wire to avoid stretch: ing the brake hose. Remove the countersunk flathead sorew ‘between two of the whee! bolt holes, and pull the rotor off the wheel hub. Use a softfaced mallet to free a stuck rotor. caurion— Do not ty to remove the rotor without first re- ‘moving the caliper. Excessive force may dam. {age the rotor oF the whee! Bearing housing. NOTE — Be careful when suspending the caliper assem- by. The guide pins are lubricated and wil allow the caliper to separate from the pad carrer Installation is the reverse of removal. Use new seltlocking bolts for the brake pad carrier, and torque them to 70 Nm (52. ft. tb), Make sure that the rotor and wheel hub mounting surfaces mate property and are free of dit and corrosion. NoTE— New replacement brake rotors should be cleaned with a grease-roe solvent, such as a commercially avaliable brake cleaner, before Instaling the caliper and brake pads. Brake rotors should always be resurfaced in pairs, with an ‘equal amount of material removed from both sides of each rotor. Table ¢ lists brake rotor specications, including the ‘minimum thickness to which a rotor can be resurfaced. Rotors which fail to meet the minimum thickness are too thin to be reliably used and should be replaced. Brake rotors can be resurfaced by most local automotive machine shops. Table c. Front Rotor Reconditioning Specifications Thickness new 260 mn (787 in) Minimum thickness 18.0 rmm (709 in) Maximum runout 0.08 mm (002 in} 5.2 Calipers Fig. 5-4is an exploded view ofthe front disc brake caliper. ‘The piston seal holds the hydraulic pressure in the system as the piston moves, and also provides the calipers seltadjusting action, Bleeder vate ‘and dust cap Fig. 5-4. Exploded view o front cise brake calipa. (Calipers Used on models covered by this manual cer sight trom one shown) ‘The caliper is settadjusting. When the piston moves and presses on the brake pads, the seal is distorted slightly. When the pressure is removed, the seal pulls the piston back slight, Creating a small gap to minimize brake pad wear. As the pads wear, the seal is repositioned on the piston, so that the gap remains approximately the same. Brake fluid leaks around the brake caliper piston are the result of a failed or damaged piston seal, perhaps caused by ‘corrosion, scoring, or pitting ofthe piston or caliper bore. The: seal can be replaced, but a damaged piston, which is not available as a replacement part, will promptly destroy the new ‘eal. To remedy a leaking caliper piston seal and avoid future problems, complete replacement of the caliper is. recom- mended. A damaged caliper dust seal can be replaced sopa- rately. ‘To remove front brake calipers, remove the front brake pads ‘as described in Removing and Installing Brake Pads. On ‘16-valve mode's, also remove the second bolt that hokds the caliper to the brake pad carrier. Disconnect the brake hose {rom the caliper and drain the brake fluid into a container. Cap. the end of the brake line to prevent dirt and moisture from entering the brake system. Installation isthe reverse of removal. Torque the brake hose Union to 15Nm (11 ft. 1b). Bleed the brake system as described in 4.2 Bleeding Brakes. Do not let brake fluid contaminate the brake pads or brake rotor surface. 6. REAR DRUM BRAKES Fig, 6-1 is an exploded view of the rear drum brake assem- bi. Retaining springs hold the brake shoes in place. The shoes rest against a fixed bracket at the bottom of the backing plat, ‘When the brakes are applied, the wheel cylinder pushes against the tops of the shoes to force them against the brake drum. Return springs retract the brake shoes when the brakes are released, ‘The rear brakes are equipped with a settadjusting mecha- nism which compensates for wear. At the top of the backing plate, the brake shoes rest against the slotted adjusting bar. AsWARNING — Do net reuse fastoners that are wom or deformed ‘nome use. Many tastaners are desgned to be Used only once and become unraiable and may fai when used a a9cond time, Tis includes, bu is rnotlmitod', nuts, bots, washers, seiHockingnuts orbols, cilps, cate pins. Alvays replace these fastoners with now parts Cotter pn — \ Theust washer Aejusting bar Upper tun song wet cyinaer Tensioning spring / Retaing sprng Spring retainer the brake lining wears and brake shoe travel increases, the spring-loaded adjusting wedge fll the gap between the brake shoe and the adjusting bar, essentially lengthening the adjust. ing bar and keeping the brake shoes from retracting too far from the drum. Lower retun spring Because the rear brakes do less ofthe work of stopping the car, they are not likely to wear as quickly or requice service as, ‘frequently as the front brakes. Unless problem symptoms are actualy observed at the rear brakes, troubleshooting of brake problems should always include the front brakes. f the rear Brake chum. gp 9 Wheel bearing, cute BRAKES 11-15 Bleeds vate wth dust cap - Shoe retaining pin 10NM 7 Spring washer Backing plate Parking brake cable camp Fig. 6-1. Exploded view ol rear drum brake assembly brakes are worn and require service, then at the very least the front brakes should also be thoroughly inspected. The brake shoes, the drums, and the attaching and adjusting parts are subjected to the greatest wear and are the components that ‘mast often need attention. ‘The brake shoes are designed to be routinely replaced as, they wear out. While itis possible to restore the brakes by replacing only the brake shoes, full braking performance and ‘minimum lining wear can only be achieved if the drums are resurfaced or replaced atthe same time. Removal ofthe brake11-16 BRAKES {drums requires cleaning, repacking, and adjusting the wheel bearings during reassembly, as described in SUSPENSION ‘AND STEERING, WARNING — ‘Brake pad friction materials may contain asbestos ‘bers. Do not create dust by grincing, sanding, or cleaning the pads with compressed al. Avoid breathing any asbestos bers oF dus. Breathing ‘asbestos may result in serious diseases such as ‘asbestosis or cancer, or may rutin oath Checking Brake Lining Wear ‘The inspection procedure and specifications for checking the brake lining wear are found in LUBRICATION AND MAIN- ‘TENANCE. For more complete inspection of lining condition, the drums must be removed, as described in 6.1 Recondi- tioning Rear Drum Brakes, 6.1 Reconditioning Rear Drum Brakes Reconditioning of the rear drum brakes typically includes replacing the brake shoes, resurfacing or replacing the brake. ‘drums, replacing the attaching and adjusting hardware, and Cleaning and repacking the whee! bearings. Unless the wheel, cylinders or hoses are damaged or leaking flu, more exten- sive rear drum brake repairs are not normally required. lithe brake linings are soaked with grease or brake fluid, the cause of the contamination must be found and corrected before new brake shoes are installed. Brake drums must be replaced when resurfacing exceeds specified limits. See Re- conditioning Brake Drums for specticatons. Removing and Installing Brake Shoes ‘The brake shoes only need to be removed when they are bbeing replaced. i the backing plate must be removed for other, ‘repairs, the brake shoes can remain attached to it. Bleeding the brake system will not be necessary as long as the brake lines, ‘or hoses are not disconnected. The brake drums can be removed with or without the wheel in piace. To remove: 1. Raise the rear ofthe car and support it securely on jack stands. Remove the wheels, or simply remove one of the Whee! lug bolts from each side, 2. With the parking brake released, rotate the brake drum nti the adjusting wedge can be seen through a wheel botthole. Using a screwdriver as shown in Fig. 6-2, push the adjusting wedge up as far as possible. Fig. 62. Phaniom view of ear rum brake showing aus: ing wedge being pushed up wh soreadver to back off adiusment, 3. Pry off the wheel bearing grease cap and remove the ‘cotter pin, the nut lock, and the axle nut. Tugging on the brake drum slightly if necessary, remove the thrust ‘washer and the outer whee! bearing, Remove the wheel ‘and the brake drum, ‘4. While supporting the head of one shoe retaining pin from behind the backing plate, push the spring retainer in and rotate it 90° to remove it See Fig. 6-3. Repeat the step for the other retainer. Fig. 6-8. Rear brake assembly shoving brake shoe retiring Bins and sping retaners (ight arrows), and lower brake shoe support (ark arto). 5. Disengage the brake shoes from the lower brake shoe ‘support atthe bottom of the backing plate, and remove the lower return spring, 6, Unhook the parking brake cable from the lever that is attached to the rear brake shoe. See Fig. 6-4