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VW Polo 6 Brake System Eng
VW Polo 6 Brake System Eng
Workshop Manual
Polo 2018 ➤
Brake system
Edition 11.2017
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Polo 2018 ➤
Brake system - Edition 11.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.5 Removing and installing brake splash plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4 Removing and installing brake carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.5 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.6 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.7 Resetting drum brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.8 Removing and installing brake splash plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.3 Removing and installing handbrake warning switch F9 . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.5 Removing and installing rear brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
Polo 2018 ➤
Brake system - Edition 11.2017
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.4 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
ii Contents
Polo 2018 ➤
Brake system - Edition 11.2017
00 – Technical data
1 Safety information
(VRL010637; Edition 11.2017)
⇒ “1.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
1. Safety information 1
Polo 2018 ➤
Brake system - Edition 11.2017
2 Identification
⇒ “2.1 Allocation of PR number - brakes”, page 2
Note
Note
2. Identification 3
Polo 2018 ➤
Brake system - Edition 11.2017
3 Technical data
⇒ “3.1 Technical data for brakes”, page 4
3. Technical data 5
Polo 2018 ➤
Brake system - Edition 11.2017
3. Technical data 7
Polo 2018 ➤
Brake system - Edition 11.2017
4 Brake test
⇒ “4.1 General information”, page 8
⇒ “4.2 Checking vehicles with front-wheel drive”, page 8
Note
1. General information 9
Polo 2018 ➤
Brake system - Edition 11.2017
15 - Hexagon nut
❑ 20 Nm
16 - Bracket
17 - Hexagon nut
❑ 20 Nm
3.1.2 Assembly overview - control unit and hydraulic unit, right-hand drive
1 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ ∅ 6 mm and union
screw with thread M12 x
1
❑ 14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
2 - Brake line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit
❑ ∅ 6 mm and union
screw with thread M12 x
1
❑ 14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
3 - Brake line
❑ To rear right brake cali‐
per
❑ ∅ 5.25 mm and union
screw with thread M12 x
1
❑ 14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
4 - Brake line
❑ To front left brake cali‐
per
❑ ∅ 5.25 mm and union screw with thread M10 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
5 - Brake line
❑ To front right brake caliper
❑ ∅ 5.25 mm and union screw with thread M12 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
6 - Brake line
❑ To rear left brake caliper
❑ ∅ 5.25 mm and union screw with thread M10 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
7 - ABS hydraulic unit - N55-
❑ ⇒ “3.2.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 , RHD vehicles”, page
21
8 - Spacer sleeves
9 - Bolt
❑ Qty. 4
❑ 1st stage: preliminary tightening torque: 1.5 Nm to 2 Nm (to support seal)
❑ 2nd stage: final specified torque: 3 Nm.
10 - ABS control unit - J104-
❑ ⇒ “3.2.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 , RHD vehicles”, page
21
11 - Bracket
❑ Check for secure seating after installing.
12 - Bolt
❑ Qty. 2
❑ 8 Nm
13 - Rubber damper
❑ Qty. 3
14 - Bracket
15 - Nut
❑ Qty. 2
❑ 20 Nm
16 - Brake servo and brake master cylinder
❑ ⇒ “3.1.2 Assembly overview - brake servo/brake master cylinder, right-hand drive”, page 116
❑ ⇒ “3.3.2 Removing and installing brake servo, RHD”, page 124
❑ ⇒ “3.4.2 Removing and installing brake master cylinder, RHD”, page 129
17 - Brake line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ ∅ 6 mm and union screw with thread M12 x 1
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
18 - Brake line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ Properties: ∅ 6 mm and flare nut with M12 x 1 thread
❑ 14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
3.2.1 Removing and installing ABS control unit - J104- / ABS hydraulic unit - N55- ,
LHD vehicles
The ABS control unit - J104- -1- is bolted to the ABS hydraulic
unit - N55- and is located on the right in the engine compartment.
NOTICE
Risk of damage to brake lines if bent.
– Never excessively bend the brake lines in the area of the
hydraulic unit.
Removing:
– Read out and note the existing control unit code.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
Vehicles with diesel engine:
– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes and
silencers; Removing and installing front exhaust pipe .
– Remove exhaust gas temperature sender 3 - G495- ⇒ Rep.
gr. 26 ; Removing and installing exhaust gas temperature
sender 3 G495 .
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If the sealing plugs are removed, brake fluid can escape, and
it can then no longer be guaranteed that the unit is sufficiently
filled and bled.
♦ When installing the hydraulic unit, ensure that the rubber
dampers are not pressed out of bracket.
3.2.2 Removing and installing ABS control unit - J104- / ABS hydraulic unit - N55- ,
RHD vehicles
Fitting location of ABS hydraulic unit - N55- and ABS control unit
- J104- in RHD vehicles:
1- Brake servo and brake master cylinder
2- ABS hydraulic unit - N55- and ABS control unit - J104-
Removing:
NOTICE
Risk of damage to brake lines if bent.
– Never excessively bend the brake lines in the area of the
hydraulic unit.
– First, mark the two brake lines -A- and -B- coming from brake
master cylinder.
– Disconnect the two brake master cylinder brake lines -A- and
-B- from ABS hydraulic unit - N55- .
– Immediately seal brake lines and threaded holes with sealing
plugs.
– Mark, disconnect and seal remaining brake lines -1- to -4-.
– Pull off ABS hydraulic unit - N55- -1- together with bracket
-2- in -direction of arrow-.
– The rubber dampers -arrows- will be pulled off the studs of the
bracket -3-.
– Guide hydraulic unit out of vehicle.
Installing:
Install in the reverse order of removal, observing the following:
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If the sealing plugs are removed, brake fluid can escape, and
it can then no longer be guaranteed that the unit is sufficiently
filled and bled.
♦ When installing the hydraulic unit, ensure that rubber dampers
are not pressed out of bracket.
NOTICE
Risk of damage to hydraulic unit caused by removal of the return
flow pump.
– Never detach the return flow pump from the hydraulic unit.
NOTICE
Risk of damage to control unit caused by static charge and dirt.
– Discharge any static charge: touch an ESD workplace (earth
yourself).
– Protect interior of control unit from moisture and dirt.
Note
– Secure ABS hydraulic unit - N55- and ABS control unit - J104-
using the new external Torx head bolts provided. Tighten them
to specified torque in three stages and in diagonal sequence.
The hydraulic unit's threads for securing the control unit must not
be recut.
If the threads are damaged, the hydraulic unit needs to be re‐
newed.
If it is difficult to screw in the bolts by hand or tighten them to
specified torque, renew hydraulic unit.
Specified torque in three stages:
Use new bolts!
Stage 1: position and centre control unit; screw in -
Torx bolts until Torx bolts contact housing
Stage 2: Seat sealing lugs evenly on all sides and 1.5 to
tighten initially. 2 Nm
Stage 3: final torque 3 Nm
Note
On hydraulic unit:
1 - Hydraulic unit to rear right brake caliper
- Properties: ∅ 5.25 mm and flare nut with short thread M12 x 1
2 - From hydraulic unit to front left brake caliper
- Properties: ∅ 5.25 mm and flare nut with M10 x 1 thread
3 - From hydraulic unit to front right brake caliper.
- Properties: ∅ 5.25 mm and flare nut with short thread M12 x 1
4 - From hydraulic unit to rear left brake caliper
- Properties: ∅ 5.25 mm and flare nut with M10 x 1 thread
5 - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
6 - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Properties: ∅ 6 mm and flare nut with M12 x 1 thread
Specified torques:
♦ ⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 13
4 Sensors
⇒ “4.1 Assembly overview - speed sensor on front axle”,
page 31
⇒ “4.2 Assembly overview - speed sensor on rear axle”,
page 32
⇒ “4.3 Removing and installing speed sensors on front axle G45 /
G47 ”, page 33
⇒ “4.4 Removing and installing speed sensors on rear axle G44 /
G46 ”, page 34
⇒ “4.5 Checking ABS sensor ring”, page 34
4. Sensors 31
Polo 2018 ➤
Brake system - Edition 11.2017
Removing:
– Raise vehicle.
– Separate connector -2- from speed sensor .
– Unscrew bolt -1- from wheel bearing housing.
– Pull speed sensor out of wheel bearing housing.
Installing:
Install in the reverse order of removal, observing the following:
– Clean inside surface of hole before inserting speed sensor .
Coat speed sensor all-round with high-temperature paste - G
052 112 A3- .
– Move steering to full left and right lock. When doing so, check
speed sensor wire for freedom of movement.
Specified torques
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page
31
4. Sensors 33
Polo 2018 ➤
Brake system - Edition 11.2017
Removing:
– Raise vehicle.
– Separate connector -2- from speed sensor .
Diagram shows a disc brake. Allocation for drum brake is identi‐
cal.
– Unscrew bolt -1- from stub axle.
– Pull speed sensor out of stub axle.
Installing:
Install in the reverse order of removal, observing the following:
– Clean inside surface of hole before inserting speed sensor .
Coat speed sensor all-round with high-temperature paste - G
052 112 A3- .
Specified torques
♦ ⇒ “4.2.1 Assembly overview - speed sensor on rear axle”,
page 32
Procedure
• Wheel bearing unit is removed.
– Using sensor gauge - T10473- , check ABS sensor ring -2- all
around, as shown in illustration.
1 - Wheel bearing unit
2 - Seal with integrated ABS sensor ring
4. Sensors 35
Polo 2018 ➤
Brake system - Edition 11.2017
46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brakes”, page 36
⇒ “1.2 Removing and installing brake pads/linings”, page 40
⇒ “1.3 Removing and installing brake caliper”, page 46
⇒ “1.4 Removing and installing brake disc”, page 51
⇒ “1.5 Removing and installing brake splash plate”, page 54
Note
♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose
(release pressure in system).
1 - Brake disc
❑ Internally ventilated
❑ Wear limit ⇒ page 5
❑ Always renew on both
sides of an axle.
❑ Removing and installing
⇒ page 51
❑ Never remove brake
discs from wheel hub by
force. If necessary use
penetrating fluid, be‐
cause otherwise brake
discs can be damaged.
2 - Torx bolt
❑ 4.5 Nm
3 - Brake pads
❑ Thickness 14 mm not in‐
cluding backplate
❑ Wear limit: 2 mm ex‐
cluding backing plate.
❑ Check thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake pads/linings:
Checking thickness
❑ Always renew on both
sides of an axle.
❑ Removing and installing
⇒ page 40
4 - Brake caliper
❑ Do not disconnect brake
hose when changing
1. Front brakes 37
Polo 2018 ➤
Brake system - Edition 11.2017
pads.
❑ Removing and installing
⇒ page 46
❑ Repairing ⇒ page 104
5 - Guide pin
❑ 30 Nm
6 - Cap
7 - Clamping sleeve
❑ Not present: brake caliper has limit stop instead
8 - Brake hose with banjo union and banjo bolt
❑ 35 Nm
9 - Wheel hub with wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 40 ; Wheel bearing; Assembly over‐
view – wheel bearing
10 - Torx bolts
❑ 12 Nm
11 - Cover plate
12 - Wheel bearing housing
❑ With integrated brake carrier.
❑ Lightly grease guide surfaces with lithium grease - G 052 150 A2- .
13 - Speed sensor
❑ Before inserting sensor, clean inner surface of hole and coat with high-temperature paste - G 052 112
A3- .
14 - Hexagon socket head bolt
❑ 8 Nm
Note
♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose
(release pressure in system).
1 - Cover plate
2 - Torx bolt
❑ 12 Nm
3 - Brake disc
❑ Internally ventilated
❑ Wear limits ⇒ page 4
❑ Always renew on both
sides of an axle.
❑ Removing and installing
⇒ page 52
4 - Torx bolt
❑ 8 Nm
5 - Brake carrier
❑ Apply thin coat of lithium
grease G 052150 A2 to
brake pad guide surfa‐
ces.
6 - Brake pads
❑ Thickness 14 mm not in‐
cluding backplate
❑ With front right brake
pad wear indicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm), the warn‐
ing lamp in the dash
panel insert comes on.
Sensors can be re‐
newed individually.
❑ Wear limit: 2 mm ex‐
cluding backing plate.
❑ Check thickness
⇒ Maintenance ; Book‐
let ; Checking condition of discs and thickness of pads at front and rear
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 43
7 - Trim with badge
Allocation ⇒ Electronic parts catalogue (ETKA)
8 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 49
❑ Repairing ⇒ page 104
1. Front brakes 39
Polo 2018 ➤
Brake system - Edition 11.2017
1. Front brakes 41
Polo 2018 ➤
Brake system - Edition 11.2017
– Unscrew and remove both guide pins -arrows- from brake cal‐
iper -1-.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Mark brake pads or linings when removing if they are to be
reused. Fit in same position when installing, or braking will be
uneven.
– Take brake pads out of brake caliper.
Cleaning:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
– Push back piston into brake caliper -2- using piston resetting
tool - T10145- -1-.
– Insert inner brake pad with retaining spring -1- in piston and
outer brake pad with retaining spring -2- in brake caliper.
1- Inner brake pad with large 3-finger clip -1- (silver in colour)
and lettering “Kolbenseite” (German for “piston side”) on
backplate.
2- Outer brake pad with small 3-finger clip -2- (coloured black).
– Bolt brake caliper -1- with both guide pins -arrows- to back‐
plate.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “1.1.1 Assembly overview – front brake, FS III front brake”,
page 36
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
1. Front brakes 43
Polo 2018 ➤
Brake system - Edition 11.2017
Removing
Note
– Remove brake caliper -1- and secure with wire so that weight
of brake caliper does not strain or damage brake hose.
– Remove brake pads -2 and 3- from brake carrier -4-.
Cleaning:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
Note
– Place brake pads -1- together with retaining springs -2- in re‐
cess of brake carrier -3-.
– After fitting brake pads, make sure that all retaining springs
-2- are properly seated -arrow-.
– Carefully place brake caliper on brake carrier.
1. Front brakes 45
Polo 2018 ➤
Brake system - Edition 11.2017
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - front brake, PC57 front brake”,
page 39
♦ Wheels, tyres; Specified torque for wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres; Specified
torque for wheel bolts
Removing
Note
– Remove wheels.
– Connect bleed bottle bleeder hose -1- to bleeder valve of
brake caliper.
– Open bleeder valve.
1. Front brakes 47
Polo 2018 ➤
Brake system - Edition 11.2017
– Unscrew and remove both guide pins -arrows- from brake cal‐
iper -1-.
– Pull brake caliper off brake carrier.
– Take brake pads out of brake caliper.
Installing
– Installing brake pads ⇒ page 40 .
– Bolt brake caliper -1- with both guide pins -arrows- to back‐
plate.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “1.1.1 Assembly overview – front brake, FS III front brake”,
page 36
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Note
1. Front brakes 49
Polo 2018 ➤
Brake system - Edition 11.2017
Removing
– Remove front wheel on relevant side.
– Disconnect connector for brake pad wear indicator.
– Connect bleed bottle bleeder hose -1- to bleeder valve of
brake caliper.
– Open bleeder valve.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - front brake, PC57 front brake”,
page 39
♦ Bleed valve
⇒ “1.1.2 Assembly overview - front brake caliper, PC 57 front
brake”, page 105
♦ Wheels, tyres; Specified torque for wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres; Specified
torque for wheel bolts
1. Front brakes 51
Polo 2018 ➤
Brake system - Edition 11.2017
Removing:
– Remove wheels.
– Remove brake pads ⇒ page 40 .
– Unscrew bolt -arrow- for brake disc -1-.
– Remove brake disc -1- from wheel hub.
Installing:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques:
♦ ⇒ “1.1 Assembly overview - front brakes”, page 36
♦ ⇒ Rep. gr. 44 ; Wheels and tyres; Tightening torques of wheel
bolts
Removing:
– Remove wheels.
– Remove brake pads ⇒ page 40 .
– Unscrew bolt -arrow- for brake disc.
– Remove brake disc from wheel hub.
Installing:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques:
♦ ⇒ “1.1 Assembly overview - front brakes”, page 36
♦ ⇒ Rep. gr. 44 ; Wheels and tyres; Tightening torques of wheel
bolts
1. Front brakes 53
Polo 2018 ➤
Brake system - Edition 11.2017
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
Removing
– Remove affected brake disc ⇒ page 51 .
– Remove bolts -arrows-
– Remove splash plate -1-.
Installing
Install in the reverse order of removal, observing the following:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - front brake, PC57 front brake”,
page 39
1. Front brakes 55
Polo 2018 ➤
Brake system - Edition 11.2017
2 Rear brakes
⇒ “2.1 Assembly overview - rear brakes”, page 56
⇒ “2.2 Removing and installing brake pads/linings”, page 61
⇒ “2.3 Removing and installing brake caliper”, page 67
⇒ “2.4 Removing and installing brake carrier”, page 72
⇒ “2.5 Removing and installing brake disc”, page 74
⇒ “2.6 Removing and installing brake shoes”, page 75
⇒ “2.7 Resetting drum brakes”, page 82
⇒ “2.8 Removing and installing brake splash plate”, page 83
Note
♦ After renewing the wheel brake cylinder, brake carrier and brake shoes, depress the brake pedal 25 times
forcefully with the vehicle stationary. This process ensures that brake shoes are properly seated in their
normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Before removing a wheel brake cylinder, brake carrier or disconnecting a brake line from the wheel brake
cylinder, fit brake pedal depressor - V.A.G 1869/2- (release pressure in system).
1 - Axle beam
2 - Hexagon socket head bolt
❑ 8 Nm
3 - Speed sensor
❑ Before inserting sensor,
clean inner surface of
hole and coat with high-
temperature paste -
G 052 112 A3 - .
4 - Brake line
❑ 14 Nm
5 - Stub axle
6 - Parking brake cable
❑ Adjusting parking brake
⇒ page 88
7 - Hexagon bolt
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Rear axle
8 - Torx bolt
❑ 4 Nm
9 - Brake drum
❑ Wear limit ⇒ page 6
❑ Reset brake before re‐
moving brake drum
⇒ page 82
❑ Clean carefully and
check for wear, dam‐
age, dimensional accu‐
racy and flawless brake
surface.
10 - Cap
❑ Pressing off and driving in ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
11 - Bolt
❑ Renew after removing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
12 - Wheel hub with wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
13 - Brake backplate with brake shoes
❑ Minimal thickness of brake lining: 2.5 mm.
❑ Check thickness ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings: Checking thickness
❑ Reset brake before removing brake drum ⇒ page 82
2. Rear brakes 57
Polo 2018 ➤
Brake system - Edition 11.2017
1 - Plug
❑ Remove to check thick‐
ness of brake shoes
2 - Roll pin
3 - Bolt
❑ 10 Nm
4 - Bleeder valve
❑ 10 Nm
5 - Protective cap
❑ Fit onto bleeder valve.
6 - Brake carrier
7 - Wheel brake cylinder
❑ Check for leaks
⇒ page 59
8 - Automatic adjuster
❑ With adjusting screw
❑ Fitting position
⇒ page 59
❑ Grease contact surfa‐
ces with lubricating
paste - G 000 650-
9 - Brake shoe with lever for
parking brake
❑ Removing and installing
⇒ page 75
❑ Adjusting parking brake
⇒ page 88
❑ Always replace both
sides of axle
10 - Retaining clip
❑ For locking brake shoe
❑ Fitting position ⇒ page 59
11 - Lower return spring
12 - Upper return spring
13 - Brake shoe
❑ Removing and installing ⇒ page 75
❑ Check brake pad thickness ⇒ Maintenance ; Booklet KJ1
❑ Always replace both sides of axle
NOTICE
Thermal clip - bi-metallic strip must point towards brake drum.
Note
♦ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that
brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose
(release pressure in system).
♦ Note the different versions of rear brake, disc brake CI 38 and PC 38 HRA.
2. Rear brakes 59
Polo 2018 ➤
Brake system - Edition 11.2017
1 - Axle beam
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Rear axle
2 - Bolt
❑ 8 Nm
3 - Speed sensor
❑ Assembly overview
⇒ page 32
4 - Brake cable
❑ Adjusting parking brake
⇒ page 89
❑ Removing and installing
⇒ page 90
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
5 - Bolt
❑
❑ 30 Nm +30°
6 - Brake hose
❑ With banjo bolt and
seals
❑ Do not disconnect brake
hose when changing
pads.
❑ Specified torque of ban‐
jo bolt to brake caliper:
38 Nm
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Stub axle
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Rear axle Volkswagen Technical Site: http://vwts.ru http://vwts.info
8 - Hexagon bolt
❑ Self-locking
❑ Renew after removal.
❑ 35 Nm
9 - Brake caliper
❑ Repairing ⇒ page 108
❑ Removing and installing ⇒ page 61
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
10 - Brake pads
❑ Thickness ⇒ page 6
❑ Wear limit ⇒ page 6
❑ Check thickness ⇒ Maintenance ; Booklet ; Front and rear brake pads/linings: Checking thickness
❑ Always replace both sides of axle
❑ Removing and installing ⇒ page 61
11 - Brake carrier
❑ With guide pins and protective cap.
❑ Replacement part is supplied assembled with sufficient grease on guide pins
❑ If protective cap or guide pins are damaged, install set of repair components. Use grease sachet from
repair kit.
2. Rear brakes 61
Polo 2018 ➤
Brake system - Edition 11.2017
Removing
– Remove wheels.
– Push lever -2- in direction of -arrow-. Unhook parking brake
cable -1- from lever.
– Press together two retaining tabs -arrows- and remove parking
brake cable from brake caliper carrier.
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
Note
Before pressing piston back, draw off some brake fluid from res‐
ervoir with a bleeder bottle, for example. Otherwise, particularly if
reservoir has been topped up, fluid will overflow and cause dam‐
age.
2. Rear brakes 63
Polo 2018 ➤
Brake system - Edition 11.2017
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 59
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
It is only permissible to change the position of the brake piston
with the piston compressing tool - T10165- .
– Remove wheels.
– Unbolt brake caliper -1- from brake carrier.
– To do so, remove bolts -arrows-.
– While doing so, counter hold on guide pin in brake carrier using
a suitable wrench.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
2. Rear brakes 65
Polo 2018 ➤
Brake system - Edition 11.2017
Note
Note
– Ensure that protective caps are not damaged and are seated
correctly ⇒ Item 6 (page 110) .
– Check guide pins for ease of movement
⇒ Item 5 (page 110) .
– Insert brake pads -2- together with retaining springs -1- in re‐
cesses in brake carrier -3-.
– Carefully fit brake caliper onto brake carrier.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 59
♦ ⇒ “2.1.2 Assembly overview - rear brake caliper, PC 38 HRA
disc brake”, page 109
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Specified torques for wheel bolts
2. Rear brakes 67
Polo 2018 ➤
Brake system - Edition 11.2017
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 59
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Removing
This procedure is only relevant when replacing or repairing the
brake caliper.
– Remove wheels.
2. Rear brakes 69
Polo 2018 ➤
Brake system - Edition 11.2017
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
2. Rear brakes 71
Polo 2018 ➤
Brake system - Edition 11.2017
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 59
♦ ⇒ “2.1.2 Assembly overview - rear brake caliper, PC 38 HRA
disc brake”, page 109
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Specified torques for wheel bolts
2. Rear brakes 73
Polo 2018 ➤
Brake system - Edition 11.2017
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 59
♦ ⇒ “2.1.2 Assembly overview - rear brake caliper, PC 38 HRA
disc brake”, page 109
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Specified torques for wheel bolts
Removing:
– Remove brake pads ⇒ page 61 .
– Remove backplate ⇒ page 72 .
– Unscrew bolt -arrow- for brake disc -1-.
– Remove brake disc -1-.
– Never remove brake discs from wheel hub by force. If neces‐
sary use penetrating fluid, because otherwise brake discs can
be damaged.
– Thoroughly clean contact surface on wheel hub to remove any
corrosion.
Installing:
Install in the reverse order of removal, observing the following:
– Place brake disc on wheel hub.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques:
♦ ⇒ “2.1.3 Assembly overview – rear brake, disc brake”,
page 59
♦ ⇒ Rep. gr. 44 ; Wheels and tyres; Tightening torques of wheel
bolts
2. Rear brakes 75
Polo 2018 ➤
Brake system - Edition 11.2017
♦ Pliers - T30115A-
Removing:
– Reset drum brake ⇒ page 82 .
– Remove brake drum ⇒ page 56 .
– Remove wheel hub with wheel bearing assembly ⇒ Running
gear, axles, steering; Rep. gr. 42 ; Rear axle .
– Move parking brake lever -A- back into working position with
hook - 3438- .
– Lever off brake shoe with parking brake lever -1- in direction
of -arrow A- from lower support -2- with aid of water pump
pliers -4-.
– Place brake shoe -1- in front of lower support -2- in direction
of -arrow B-.
– Unhook lower return spring -3-.
2. Rear brakes 77
Polo 2018 ➤
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– Unhook parking brake cable -1- from parking brake lever -2-.
– Lever out upper return spring -1- from brake shoe without
parking brake lever -3- using a screwdriver -2-.
Note
Cleaning:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
Note
– Insert upper return spring -1- in both brake shoes -2 and 3-.
– Place brake shoe without parking brake lever -3- on wheel
brake cylinder -4- as shown in diagram. Then lever around in
direction of -arrow- and place in front of lower support -5-.
– Attach bottom spring -1-. Lever brake shoe -3- into lower sup‐
port -4- using pipe wrench -2-.
2. Rear brakes 79
Polo 2018 ➤
Brake system - Edition 11.2017
– Insert roll pin and retaining clip -1- with assembly tool -
T30114- -2-.
Note
Note
Adjustment dimensions:
A - 8” brake (∅ 203 mm) dimension -a-: 7.0 mm + 0.5 mm
B - 9” brake (∅ 228 mm) dimension -a-: 3.0 mm + 0.5 mm
Note
Do not allow the corrosion protection - AKR 322 000- to enter the
wheel bolt threads.
Note
♦ The drum brake tool - T20215- has holes with and without
thread.
♦ The threaded holes are for storing the bolts.
♦ The through holes are for securing the tool on the wheel hub.
2. Rear brakes 81
Polo 2018 ➤
Brake system - Edition 11.2017
– Secure drum brake tool - T20215- -1- on wheel hub using bolts
-3- supplied.
Note
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques:
♦ ⇒ “2.1.1 Assembly overview – rear brake, drum brake”,
page 56
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Removing:
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove backplate ⇒ page 72 .
– Remove brake disc ⇒ page 74 .
2. Rear brakes 83
Polo 2018 ➤
Brake system - Edition 11.2017
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
NOTICE
Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
After changing brake pads/linings, check brake fluid level.
Ensure that brakes work properly before the vehicle is driven.
Specified torques:
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 56
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing,
trailing arm
♦ ⇒ Wheels and Tyres Guide; Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
3 Parking brake
⇒ “3.1 Assembly overview - parking brake”, page 85
⇒ “3.2 Removing and installing handbrake lever”, page 86
⇒ “3.3 Removing and installing handbrake warning switch F9 ”,
page 87
⇒ “3.4 Adjusting parking brake”, page 88
⇒ “3.5 Removing and installing rear brake cable”, page 90
1 - Push-button
❑ Pulling off ⇒ page 86
❑ Will be destroyed when
pulling off; must be re‐
newed
❑ Push onto handbrake
lever push rod and en‐
sure both locking lugs
are engaged by pulling
slightly.
2 - Handbrake lever trim
❑ ⇒ General body repairs,
interior; Rep. gr. 68 ;
Compartments/covers
3 - Adjustment nut
❑ Adjusting parking brake:
❑ Vehicles with drum
brakes ⇒ page 88 .
❑ Vehicles with disc
brakes ⇒ page 89 .
4 - Compensator
5 - Hexagon nut
❑ 23 Nm
6 - Parking brake lever
❑ ⇒ “3.2 Removing and in‐
stalling handbrake lev‐
er”, page 86
7 - Handbrake warning switch
- F9-
❑ ⇒ “3.3 Removing and in‐
stalling handbrake
warning switch F9 ”,
page 87
8 - Rubber grommet
9 - Right guide tube
10 - Left guide tube
11 - Parking brake cables
❑ Removing and installing (drum brakes) ⇒ page 90
❑ Removing and installing (disc brakes) ⇒ page 93
3. Parking brake 85
Polo 2018 ➤
Brake system - Edition 11.2017
Note
– Loosen adjustment nut -1- until parking brake cable -2- can be
pulled out of compensator.
3. Parking brake 87
Polo 2018 ➤
Brake system - Edition 11.2017
Note
Note
Note
Adjusting:
Vehicles with front centre armrest
– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .
Continued for all vehicles
– Raise vehicle.
– Depress brake pedal forcefully at least 3 times.
Below the first notch, the handbrake lever must return to its re‐
leased position.
• Handbrake lever in rest position.
– Set parking brake once tightly.
– Release parking brake.
3. Parking brake 89
Polo 2018 ➤
Brake system - Edition 11.2017
– Pull out brake cable -2- from its attachment points on rear axle
-1-.
3. Parking brake 91
Polo 2018 ➤
Brake system - Edition 11.2017
Removing:
Vehicles with front centre armrest
– Remove front centre armrest ⇒ General body repairs, interior;
Rep. gr. 68 ; Front centre armrest .
Vehicles without front centre armrest
– Pull rear storage compartment trim out of centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console .
Continued for all vehicles
– Release parking brake.
3. Parking brake 93
Polo 2018 ➤
Brake system - Edition 11.2017
– Loosen adjustment nut -1- until parking brake cable -2- can be
detached from compensator.
– Raise vehicle.
– Pull out brake cable -2- from its attachment points on rear axle
-1-.
3. Parking brake 95
Polo 2018 ➤
Brake system - Edition 11.2017
4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 96
⇒ “4.2 Separating brake pedal from brake servo”, page 99
⇒ “4.3 Connecting brake pedal to brake servo”, page 100
⇒ “4.4 Removing and installing mounting bracket”, page 100
⇒ “4.5 Removing and installing brake pedal”, page 102
Note
♦ The handbrake pedal travel must not be restricted by additional floor coverings.
♦ Do not lubricate or grease the pivot pin. The pivot pin must remain dry.
1 - Hexagon nut
❑ Self-locking
❑ Renew after removal
❑ 20 Nm
❑ Bolting sequence
⇒ page 97
2 - Pivot pin
❑ Cannot be removed
3 - Mounting bracket
❑ Removing and installing
⇒ page 100
4 - Bearing bush
5 - Brake pedal
❑ Separating brake pedal
from brake servo
⇒ page 99
❑ Connect brake pedal to
brake servo
⇒ page 100
❑ Removing and installing
⇒ page 102
6 - Cap
7 - Bearing bush
8 - Support
❑ For ball head of brake
servo push rod
9 - Clamping washer
Bolting sequence:
4. Brake pedal 97
Polo 2018 ➤
Brake system - Edition 11.2017
Note
♦ The handbrake pedal travel must not be restricted by additional floor coverings.
♦ Do not lubricate or grease the pivot pin. The pivot pin must remain dry.
1 - Brake servo
❑ Assembly overview
⇒ page 116
❑ Removing and installing
⇒ page 124
2 - Mounting bracket
❑ Removing and installing
⇒ page 102
3 - Nut
❑ 20 Nm
❑ Tightening sequence
⇒ page 99
4 - Nut
❑ To secure brake servo
❑ Qty. 2
❑ 25 Nm
5 - Nut
❑ Cannot be removed
6 - Bearing bush
❑ Cannot be removed
7 - Brake pedal
❑ Cannot be removed
8 - Cover
9 - Bearing bush
❑ For ball head of brake
servo plunger rod.
10 - Support
❑ For ball head of brake
servo plunger rod.
11 - Pivot pin
❑ Cannot be removed
12 - Bearing bush
❑ Cannot be removed
13 - Bearing bush
Tightening sequence:
– Tighten nuts in specified sequence -1- to -5-.
4. Brake pedal 99
Polo 2018 ➤
Brake system - Edition 11.2017
– First press brake pedal -1- in direction of brake servo and hold.
1 - Brake pedal
2 - Push bar
3 - Retaining lugs
4 - Mounting bracket
A - Release tool - T10159B- for left-hand drive vehicles and re‐
lease tool - T10242- for right-hand drive vehicles
– Insert release tool -A- and pull it in direction of driver seat.
When doing this, counter hold on brake pedal -1- (at this stage,
the pedal must not be allowed to move towards driver seat).
This action will press retaining lugs -3- of mounting off ball
head of plunger rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool - T10159B- and brake pedal together towards
driver seat. While doing so, the brake pedal will be pulled off
the ball head of the plunger rod.
Specified torque
♦ Footwell cover on driver side ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers
Note
Note
47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - front brake caliper”, page 104
⇒ “1.2 Removing and installing brake caliper piston”, page 105
1 - Dust cap
❑ Fit onto bleed valve
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of lithium
grease - G 052 150 A2-
to thread
❑ 10 Nm
3 - Bearing bush
❑ Insert into brake caliper.
4 - Guide pin
❑ 30 Nm
5 - Caps
❑ Insert into bearing bush
6 - Brake caliper
7 - Seal
❑ Removing and installing
⇒ page 105
8 - Piston
❑ Removing and installing
⇒ page 105
9 - Seal
❑ Removing and installing
⇒ page 105
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve
❑ Before screwing in,
grease thread with thin
coat of lithium grease -
G 052 150 A2-
❑ 10 Nm
3 - Hexagon bolt
❑ Renew after removal.
❑ 35 Nm
4 - Guide pin
5 - Protective cap
❑ Insert into brake carrier
and guide pin groove;
grease groove, use re‐
pair kit grease pack.
6 - Brake carrier
❑ Supplied as preassem‐
bled replacement part
with greased guide pins
and protective caps.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Protective cap
❑ Removing and installing
⇒ page 105
❑ When inserting piston,
take care not to damage
protective cap
8 - Piston
❑ Removing and installing ⇒ page 105
❑ Apply thin coat of assembly paste G 052 150 A2 to piston.
9 - Seal
❑ Removing and installing ⇒ page 105
10 - Brake caliper
Removing
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.
1 - Hexagon bolt
❑ Self-locking
❑ When loosening and
tightening, counter hold
on guide pin.
❑ Renew after removal
❑ 35 Nm
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of lithium
grease - G 052 150 A2-
to thread
❑ 10 Nm
3 - Dust cap
4 - Guide pin
❑ Grease before fitting
protective cap.
5 - Cap
❑ Fit onto brake carrier
and guide pin.
6 - Brake carrier
❑ With guide pins and pro‐
tective cap.
❑ Replacement part is
supplied assembled
with sufficient grease on
guide pins
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Cap
❑ Pull on so that outer sealing lip goes over piston.
8 - Piston
❑ With automatic adjusting mechanism
❑ Removing and installing ⇒ page 111
9 - Seal
❑ Removing and installing ⇒ page 111
10 - Brake caliper
❑ With handbrake cable lever
❑ If there is a leak at handbrake cable lever, renew brake caliper.
❑ Following repair work, pre-bleed brake caliper ⇒ page 113 .
12 - Seal
❑ Removing and installing ⇒ page 111
♦ Bleeder bottle
Removing
– Turn piston anti-clockwise out of brake caliper using piston
compressing tool - T10165- .
♦ If piston moves sluggishly, an open-jaw spanner (AF 13) can
be used on the flats designed for the wrench -arrow A-.
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper.
– Mount piston resetting appliance - T10165- on piston of brake
caliper.
Note
3.1.1 Assembly overview - brake servo/brake master cylinder, left-hand drive ve‐
hicles
Complete brake master cylinders and brake servos can be re‐
newed independently of each other.
1 - Hexagon nut
❑ Self-locking
❑ Renew after removal
❑ 23 Nm
2 - Heat shield
❑ Equipment version
3 - Brake master cylinder
❑ Cannot be repaired If
faulty, renew complete.
❑ Removing and installing
⇒ page 126
4 - Brake line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit
❑ 14 Nm
5 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ 14 Nm
6 - Torx bolt
❑ 8 Nm
7 - Brake light switch - F-
❑ Including brake pedal
switch - F47- .
❑ Removing and installing
⇒ page 118
8 - Warning contact for brake
fluid level - F34-
9 - Pin
10 - Brake fluid reservoir
11 - Cap
12 - Vacuum hose
❑ With non-return valve
❑ Checking non-return valve ⇒ page 140 .
❑ With vacuum sender - G608- on some petrol engines
❑ Removing and installing vacuum sender - G608- ⇒ page 141
13 - Plug
14 - Plug
❑ Moisten with brake fluid and press into brake master cylinder.
15 - Brake servo
❑ Operation check:
– With engine switched off, depress brake pedal firmly several times (to exhaust any negative pressure in
the unit).
– Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the brake pedal will now give perceptibly under foot (servo assistance becomes activated).
❑ If faulty renew complete
❑ Checking ⇒ page 141
1 - Cap
2 - Brake fluid reservoir
❑ With brake fluid level
warning contact - F34-
3 - Brake servo
❑ Removing and installing
⇒ page 124
❑ Operation check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust any negative
pressure in the unit).
7 - Nut
❑ Qty. 2
❑ 20 Nm
8 - Seal
❑ Renew if damaged
❑ Ensure that seals are correctly seated
❑ Between brake master cylinder and brake servo
9 - Brake master cylinder
❑ ⇒ “3.4.2 Removing and installing brake master cylinder, RHD”, page 129
❑ When attaching brake master cylinder to brake servo, make sure plunger rod is properly positioned in
brake master cylinder.
❑ Complete brake master cylinders and brake servo can be renewed individually
10 - Brake light switch - F-
❑ ⇒ “3.2.2 Removing and installing brake light switch, right-hand drive”, page 119
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ 8 Nm
13 - Heat shield
❑ On brake fluid reservoir.
14 - Heat shield
❑ For brake servo
15 - Nut
❑ Renew after removing
❑ Qty. 2
❑ Self-locking
❑ 23 Nm
16 - Brake line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ 14 Nm
17 - Plug
❑ Renew if damaged
❑ Ensure that seals are correctly seated
❑ Moisten sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder
❑ Between brake master cylinder and brake fluid reservoir
18 - Brake line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ 14 Nm
19 - Spreader rivet
❑ For securing brake fluid reservoir
Installing
Install in the reverse order of removal, observing the following:
– Make sure that brake light switch - F- -1- seats properly against
edge -arrow- of brake master cylinder.
Specified torques
♦ ⇒ “3.1.1 Assembly overview - brake servo/brake master cyl‐
inder, left-hand drive vehicles”, page 114
Note
If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 141 .
Removing
Vehicles with battery in engine compartment:
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
Vehicles with battery in luggage compartment:
– Remove jump-start terminal ⇒ Electrical system; Rep. gr. 27 ;
Jump-start terminal; Removing and installing jump-start ter‐
minal .
Continued for all vehicles:
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Lay out sufficient lint free clothes in area of engine and gear‐
box.
Note
♦ The brake servo is given the additional bonded joint only dur‐
ing factory assembly.
♦ The adhesive bond between the brake servo and the bulkhead
does not need to be renewed, but the seal does.
Note
If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 141 .
Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
Continued for all vehicles:
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Lay out sufficient lint free clothes in area of engine and gear‐
box.
Manual gearbox:
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal supply hose -2- with sealing tool - T10249- -1-, raise and
tie.
Continued for all vehicles
– Unscrew stud -1- and pull brake fluid reservoir -2- out of seal‐
ing plugs.
– Lever cable retainer off pin.
– Unscrew brake lines from brake master cylinder -1- and seal
holes using sealing plugs - 1H0 698 311 A- .
– Fit dust caps of bleeder valves onto brake lines.
♦ Socket Torx T 30 -
T10405-
♦ Torque wrench -
V.A.G 1410-
Removing:
– Release connector -2- and pull off brake light switch - F- -1-.
– Remove brake fluid reservoir ⇒ page 134 .
Removing:
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234-
and adapter - VAS 5234/1- .
– As protection against escaping brake fluid, place a number of
lint-free cloths in area beneath brake master cylinder.
Vehicles with manual gearbox
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch sender cylinder -3- with sealing
tool - T10249- -1-.
– Raise supply hose -2- and tie.
Continued for all vehicles
– Unscrew stud -1- and pull brake fluid reservoir -2- out of seal‐
ing plugs.
NOTICE
Push brake line slightly to one side.
Installing:
Install in the reverse order of removal, observing the following:
– Lightly lubricate seals with brake fluid before installing brake
fluid reservoir.
– Fit brake fluid reservoir.
CAUTION
Make sure that the brake fluid reservoir engages in the retainers
and is seated securely.
CAUTION
Before initial road test, ensure that brakes work correctly.
Specified torques:
• ⇒ “3 Brake servo and brake master cylinder”, page 114
• ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery .
4 Vacuum system
⇒ “4.1 Assembly overview - vacuum pump”, page 139
⇒ “4.2 Checking non-return valve”, page 140
⇒ “4.3 Removing and installing vacuum sender G608 ”,
page 141
⇒ “4.4 Checking vacuum system”, page 141
1 - Bracket
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Secure to engine
mounting
❑ 20 Nm
2 - Vacuum pump for brakes -
V192-
❑ ⇒ “4.5.1 Removing and
installing electric vac‐
uum pump, vehicles
with 1.0 l petrol engine”,
page 146
3 - Bracket
4 - Rubber damper
❑ Ensure it is properly
seated
❑ Observe installation po‐
sition: washer points
downwards
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
Note
Removing
– Disconnect connector -3- from vacuum sender - G608- -1-.
– Unclip vacuum sender - G608- -1- from vacuum line -2-.
Installing
Install in reverse order. The following should be observed:
Note
♦ Make sure to check the seal for damage before installing the
vacuum sender - G608- .
♦ If the seal is damaged, the vacuum sender must be renewed.
– Connect hose -A- from brake servo tester - VAS 6721- to vac‐
uum hose.
– Press adapter -C- into brake servo.
Note
Note
Note
5 Brake lines
⇒ “5.1 Repairing brake lines”, page 148
Note
Note
– Remove set of grips and slide union bolt -D- onto brake line.
Note
6 Hydraulic system
⇒ “6.1 General notes on brake fluid”, page 153
⇒ “6.2 Bleeding hydraulic system following standard procedure”,
page 153
⇒ “6.3 Subsequent bleeding of hydraulic system”, page 154
⇒ “6.4 Testing for leaks”, page 156
Note
Note
Note
Specified torques
♦ ⇒ “1.1.1 Assembly overview - front brake caliper, FS III front
brake”, page 104