BRAKES Contents Introduction 41, General Description at 42 43 44 Master Cylinder, Vacuum Booster, and Brake Lines Disc Brakes Rear Orum Brakes Proportioning Valves Parking Brakes rake Applications and Identiication Maintenance ‘Troubleshooting 3.1. Basic Troubleshooting Pancipies 32 Diagnostic Tests 33 Brake Noise. . Brake System Service Brake Fluid Bleeding Brakes Pressure Bleoding ‘Vacuum Bleeding Manuel 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 Praportoning Valves, 5 Section 11 5. Front Disc Brakes 54 62 Checking Brake Pad Wear Reconaltioning Front Disc Brakes Removing and Installing Brake Pade Removing, Recontitioning, and installing Front Brake Rotors Calipers 6. Rear Drum Brakes 61 62 ‘Checking Brake Lining Wear Reconditioning Rear Drum Brakes Removing and Installing Brake Shoes Reconditioning Brake Drums. Inspecting and Replacing Wheel Cylinder Parking Brake (Drum Brakes) ‘Adjusting Parking Brake Replacing Parking Brake Cables 7. Rear Dise Brakes 7 72 73 necking Brake Pad Wear Reconditioning Rear Disc Brakes Removing and Instaling Rear Brake Pads Removing, Reconditioning, and instaling Rear Brake Rotors Parking Brake (Disc Brakes) Adjusting Parking Brake Replacing Parking Brake Cable. Calipers 8. Technical Data |. Tolerances, Wear Limits, and Settings 1. Tightening Torques " " " "1 4 “4 ‘4 16 16 16 18 18 18 18 19 19 19 19 20 at a1 a 22 23 23 2B11-2 BRAKES TABLES Brake Troubleshooting Sake Pressure Specticatons Front Rotor Reconditioning Specifications Brake Drum Reconditioning Spectications Rear Rotor Reconditioning Specifications " 4 18 aBrakes 11-3 Brakes Introduction All cars covered by this manual are equipped either with front disc brakes and rear drum brakes, or with disc brakes al all four wheels. The brake system is a diagonal, dual-circut design, hydraulically actuated by the master cylinder, with a vacuum-powered booster to edivee braking effort, Proportioning valves help prevent the rear brakes from locking during heavy braking. A properly functioning brake system is essential to safe criving, if the red brakefparking warning indicator lights up wile 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 salistactory, The brakes should be regularly inspected, and all brake work must be done with extreme cleanliness, careful attention to specications, and proper working procedures. A information needed for performing routine inspection and maintenance is given here, though some of the information may only be of value to the profossional mechanic. yous lack the skis, the tools, ora clean workplace for servicing the brake system, we suggest you leave these repairs to an authorized Volkswagen dealer or cther quaitied shop. We especialy urge: you te consult your authorized Volkswagen deaier belore beginning repairs an a car which may be subject to Volkswagen warranty coverage11-4 BRAKES 1. GENERAL DESCRIPTION Fig. 1-1 isa schematic diagram ofthe dual-diagonal hydrau: lic brake system. The master cylinder, operated mechanically boy the brake pedal, creates pressure in the hydeaulic 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 dever to generate high raking {orces with comparatively litle effort. WARNING mm + Fiction materials such as brake bnings or brake pags may contain asbestes bers, Do not create ‘ust by grinding. sanding, or cleaning the pads ‘wth comprassed air. Avoid breathing ary asbos ‘0s fibers ov ust Breathing asbestos may asi Jn sorous diseases such 3s asbestosis or cance, or may result death WARNING — + Brake Mid is polsonous. Wear safety glasses hon working with Brake fui, and wear mboer gloves to prevent brake fv trom entering the Dloodsream through cuts or scratches. Do not ‘Siphon brake Mad by mouth Calis wih cyl Brake ft eerie Front dise brakes Fig. 1-1. Scremate view of piako sysern Front loc and rear um takes show. Fourtenl dsc brake acs bonster ‘caurion— Bake Mud s vory damaging to paint. immad! ately wipe up any brake fui that spits on the vontcie. Master Cylinder, Vacuum Booster, and Brake Lines ‘The master cylinder has two separate chambers for two separate hydraulic circuls. The front chamber operates the brakes on the right front and left rear wheels, while the rear chamber operates the brakes on the left front and right rear whee's. In the event of a loss of pressure in one circuit, the ‘other wil stil supply approximately hal of the normal braking force. The vacuum booster uses engine vacuum to assist braking cffor. The ngid brake lines transmit hydraulic pressure to the wheels and resist expansion and pressure loss. Flexible hoses between the rigid lines and the brekes accommodate whee! movement due to steering and suspension action. Disc Brakes ‘The disc brakes use a castron caliper witha single hycrau- lic cyinder to clamp the rotor (disc) between two brake pads. Front rotors are mounted fo the wheel hub. Rear rotors are Pasting brake cabiem—>y Rear drum brakes BuLoppaset hea yin E setcee — (beaks ine)Integral with the wheel 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 self-adjusting rear drum brakes use a dualopposed hyCraulic whee! cylinder Io 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 evices, calied proportioning valves, that limit the amount of hydraulic pressure applied to the rear brakes, See Fig. 1-2. Fig. 1-2 Instat postion of one brake proportioning -Asoecend va (ne shows alsa mounted on te nasi cyiner Parking Brakes ‘The cabie-operated parking brake mechanically actuates either the rear brake shoes or the rear caliper pistons. The postion of the parking brake lever is held by a thumb-elease ratchet 1.1 Brake Applications and Identification Al models except 16-valve are equipped with front dise brakes and rear drum brakes. 16-valve models are equipped with four-wheel disc brakes. The front brake rotors ofall models are internally ventilated for better cooing, 2. MAINTENANCE The following routine maintenance operations should be performed at the time or mileage intervals sted 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 2 Inspecting brake hoses and lines for leaks ‘Checking brake pad andlor lining wear. 4. Replacing the brake fluid every two years. 4.2 3. TROUBLESHOOTING This heading describes symptoms of rouble with the brake system, and suggests possible causes and appropriate cor- rectve actions. The brake system has the sole function of generating the requifed friction to stop the car from any speed. Brake prab- lems are usualy 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 ot steering systems. Information on troubleshooting these sys- tems can be found in SUSPENSION AND STEERING. For ‘more help in selecting the appropriate section, see the discus: sion of troubleshooting in FUNDAMENTALS at the front of the manual 3.1 Basic Troubleshooting Principles Table a lists symptoms of problems commonly associated wi the brakes, their probable causes, and suggested corre: 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 is the key to isolating and identifying braking problems, Relable brake system periormance depends on creating and applying hydraulic pressure in the system. Brake performance: 's affected by throe things: the brake fluid, the system's abity to maintain pressure, and the friction components, Arn the brake fluid, because It is compressibie, wil make the brake pedal feel spongy during braking, or wllincrease the: force required at the brake pedal to stop the car. Moisture: of tated by hand. Check that when the parking brake is fully released, both rear wheels rotate freely. Reaglust i necessary. 6, Tighten the locknutsReplacing Parking Brake Cables The cables can be replaced separatoly Remove the locknut {and the adjusting nut that hold the cable to the compensating bar Remove the rear brake drum as described in Removing, and Installing Brake Shoes, and then unhook the parking brake cable from the lover on the rear brake shoo, t may be necessary to pantialy disassemble the brakes. Pull the cable ‘and conduit out of tha backing plate and remove the cable from the guides and hangers which secure it to the taling arr, ul the oid cable out of the body trom the rear. Lubricate the new cable wth multipurpose grease before inserting #, Feed the cab into the backing plate without kinking it, and hook the fend of the cable to the fever on the rear brake shoe. Reinstall the rear brake drum as described in Removing and Installing, Brake Shoes. At the parking brake lever inside the car, insta ‘the compensating bar, the adjusting nut, and thelocknu on the cable and adjust the parking brake as described above in Adjusting Parking Brake. 7. REAR DISC BRAKES ‘The components of the rear dise brakes are shown in Fig 7-1. The rear disc brakes operate in much the same way as the front disc brakes described in 8. Front Dise Brakes, except thal the rear dist rotor doubles as the whee! hub and whee! bearing housing, and the rear calipers can be mechanically activated by the parking brake cables. The whwel lug Dots ‘thread directly into the rotor, and te inner diameter of the rotor hub houses the wheel bearings. Because the rear brakes do iess of the work of stopping the car, they are not ikely ta wear as quickly or require service as. ‘requently as the front brakes. Uniess problem symptoms are actualy observed at the rear brakes, troubleshooting of brake probiems should always include the front brakes. f the rear brakes are worn and require service, then at the very least the front brakes should also be thoroughly inspected. The brake pads andi rotors are subjected to the greatest woar. and are the ‘components that mast often need attention, ‘The brake pads are designed to be routinely replaced as they wear out. Whila itis possible to restore the brakes by replacing only the brake pads, tu braking pertormance and minimum pad wear can only be achieved i! the rolars are, resurfaced of replaced atthe same time. Removal of the brake rotors requires cleaning, repacking, and adjusting the whee! bearings during reassembly, as descrited in SUSPENSION. AND STEERING, waning — rake pad fiction materiais ray contain asbestos fibers. Oo not create cust by grinding, sanding, oF Cleaning the pacs with compressed air. Avoid breathing ay asbostas fers oF ust. Breathing asbestos may raul in senous diseases euch as asbestosis or cancer, or may result in cea Brakes 11-19 Dust boot Brake pace Guide pin Sinn (26 8) 165 N (48 core ‘\ ss Pathe brake cable Nat ook Grease ca Fig. 7-1, Exploded view of tea dis brake asseenby ‘Checking Brake Pad Wear ‘The inspection procedure and specications for checking the brake pads are found in LUBRICATION AND MAINTE: NANCE. For mote complete inspection of pad condition, the pads must be removed, as described in 7.1 Reconditioning Rear Dise Brakes, 7.4 Reconditioning Rear Disc Brak Recondittoning of the rear disc brakes typically includes repiscing the brake pads and resurlacing or replacing the brake rotors. Uniass the calipers and hoses are damaged, extremely worn, or leaking fluid, more extensive rear brake repairs are not normally required. It the brake pads are soaked with oil, grease, oF brake uid, the cause of the contamination must be found and corrected before new pads are installed. Brake rotors must be replaced11-20 BRAKES when resurfacing exceeds spectied limits. Seo Removing, Reconditioning, and installing Rear Brake Rotors for rotor, thickness specifications Removing and installing Rear 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 hydraulc system sealed oliminatas the need to bleed the brakes afterward, Brake pads and the surtaces of the rotors wear slightly ditterently trom one another. Always replace brake pads in ‘complete sets. I old pads are to be reinstalled, such as after inspecting them, always make sure they are refitted in their ‘original locations. \Wmhen replacing the brake pads, the two upper setHiocking caliper mounting bolts should be replaced, To remove: 1. Raise the rear cf the car and support it securely on jack stands. Remove the rear wheels. Roloase the parking brake. 2. Remove the wire clip that secures the parking brake ‘cable to the brake caliper, as shown in Fig. 7-2, and unhook the cable from the actuating lever. Slide the cable out of the cable guide 3, Remove the upper settlocking caliper mounting bolt {ror the brake caliper. See Fig. 7-2. Hold the guide pin with an open-end wrench 10 remove the bolt. Pot the caliper downward off the brake pads, as shown in Fig. 73, Fig. 7-2, Wre cp 1 10 be rernewrd wren diseennecing parking crake cabie fom cable guide 2 Upper alge moxnteng ch i at 3 Fig. 7-3. Upper caiper mouning bot renenes anc calper Bivoled downwarcon ower guide pin for romovalol rae pads 4 Lit out the brake pads. caurion— Do notinterchange used pads. Ite pads aro t0 'be reused, mark tom for roinsalaton in Vete ‘same pastons. To instal: 11. Place the brake pads in postion on the brake pad carrer 2, When instaling new brake pads, adjust the caliper to provide clearance forthe thicker new brake pads. Use a ‘hex wrench in the piston socket to turn the caliper piston Clockwise al the way into the caliner housing, as shown in Fig. 7-4, NOTE — Turning in the caliper pstons to gain clearance forte thickor new brake pads val cause brake Fluid to overtiow the master cylinder fd reser voir. To prevent this, use a clean syringe to frst Temove some fluid fom the reservoir 3. Pivot the caliper back into position and install a new upper settiocking mounting bok. Hold the guide pin wth an open-end wrench, and torque the sett-locking bolt to 35 Nm (26 fb). 4. i new brake pads were insaled, achust the parking brakeas desorbed in 7.2 Parking Brake (Disc Brakes) 5. Mount the wheel and loosely install the lug bolts, then lower the car and torque the bolts to 110 Nin (Bt fb),Fig. 7-4, Rear calper piston being tuned ito caine wth hex wrench 66. Before running the engine or moving the car, pump the brake pedal at least 40 times to reset the automatic adjustment of the rear calipers caunion— Running the engine and providing vacuum ‘boost (0 the brakes wisle reseting the auto matic adjusimert may jam the caliper. 7. Check the level of brake fuid in the reservoir # neces: sary, add new broke fluid to fil the reservoir to the MAX: mat. WARNING — New brake pads require some broakin. low for sight lorger stopping cistances fr the frst 100 {0 180 miles of cy driving, and avoid hard stops. Removing, Reconditioning, and Installing Rear Brake Rotors ‘To romove the rear brake rotors, frst remove the brake pads {as described above. Remove the two bolts holding the beake pad carrier to the stub axle, and suspend the caliper and pad ‘cari frorn the suspension or body. Avoid stretching or kinking the hose. if the brake hose remains connected, twill nat be necessary fo bleed the brakes, NoTe— Be caraful when suspending the caliper assem: Dy. The quide pins are ubocates an wi atow the catipar to separate tom the pad cari: Remove the whee! bearing grease cap from the center of {he brake rotor, and then remove the cotter pin, the nut lock, and the axle nut fro the stub axle. Tugging on the brake rotor slightly f necessary, remove tho thrust washer and the outer BRAKES 11-21 wheel bearing, Remove the brake rotor, Use a scrowdkiver to pry out the dust cap and grease seal from the back of the rotor hub, and remove the inner bearing parts, Installation is the reverse of removal. See SUSPENSION [AND STEERING {or information on cleaning the whee! bear. lings, packing them with new grease, and adjusting them after installation. Install anew inner grease seal. Torque the brake ‘pad carier mounting bolts to 65 Nm (48 ft. Ib). Reinstall the Dreke pads as described in Removing and Installing Rear Brake Pads, NOTE — New ceplacament brake rotors should be Cleaned wih a grease free solvent, such as commercially available brake cleaner, before inetasing the caliper and brake pads. Brake rotors should always be resurfaced in pair, with an ‘equal amount of material remaved ftom bath sides of each Fotor. Table e lists the minimum requirements for resurfacing brake rotors —the minimum thickness of a rotor which can sti be resurfaced, and the minimum allowable thickness after resurfacing, Rotors which fail to meet either minimum are too thin to be relably used and should be replaced. Brake rotors can be resurfaced by mostany local automotive machine shop. Table e. Rear Rotor Reconditioning Specifications Thiekneas now 70.0 mm (368m) Minimum mickness. 80 mm (315 in) Maier runout 10.06 men (002 in} 7.2 Parking Brake (Disc Brakes) The parking brake operates only on the rear wheels, It is mechanically actuated, and is independent of the hydraulic brake system. Fig. 67 above is a cut-away view of the parking brake jever assembly. The lever operates two separate, ro- placeable cables connected to the rear brake calipers. When the lever is pulled, the actuating lever on the caliper applies pressure to the brake caliper piston. Adjusting Parking Brake The parking brake should only have to be adjusted if the ‘cable, the brake rotor, the brake caliper, or the brake pads are replaced. Fallure of the brake to hold the car most likely indi. ‘cates wor rake pads or a faulty caliper. Chack to see that the parking brake functions properly whenever the cables have been dotached for rear brake service cauTion— Before adjusting the parking brake cables, ac- just the rear disc brakes by rlrectng the caliper pistons and pumping the brake pode! to reset {ho auamaie adjustment, a8 described in Re- ‘moving and Installing Rear Brake Pads.11-22 Brakes To adjust: 1. Raise the rear ofthe car and suppor it securely on jack stands. Remave the rear wheels. Release the parking brake if itis applied. 2. Loosen the parking brake cable lacknuts and ackusting fuls under the parking brake lever just until tension on the cables is ralieved. NOTE — The actuator fevers on the calipers should be against their stops as shown in Fig. 7-5. 1 not then the calipers automatic adjustment mech ‘anism may Be faut Fig. 7-8, Acie: aver age! op (an) on ake cal ‘Set and release the parking brake three times to steich and seat the cables, 4, Tighten the adjusting nuts so that when the parking brake is applied, the folowing conditions are met: at the first dotent (one cfck) the rear rotors should turn by hand wih moderate drag; at the second detent the rotors should turn only with considerable effort; at the thie detent it should not be possible to turn the rotors by ‘rand, NOTE ‘When the parking brake release, the rotors shoukt again tun freely. 5. Check the gap between the actuator lever and the stop ‘on the caliper. When the parking brake is correctly ad- justed, t should be no greater than #.0 mm (089 in}. I itis, loosen the cable agjusting nuts in small increments nti the gap is correct 6. Tighten the parking brake cable locknuts, Mount the wheels and loosely install the lug bolts. Lower the car land torque the tug botts fo 110 Nm (81 ft Ib). Replacing Parking Brake Cable The cables can be replaced separately. Remove the locknut and the adjusting nut that hold the cable to the compensating bar. Remove the wie clip that holds the parking brake cable 10 the caliper. Unhook the cabye from the actuator lever on the caliper and remove the cable from the guides and hangers which secure it fo the trang arm. Pullthe old cable out ofthe body from the rear. Lubricate the new cable with multipurpose grease before inserting it. Feed the cable into place without kinking i, through the cable guide ‘on the caliper. Hook the cable to the caliper actuating lever and secure itwith the wire clip. At the parking brake lever inside the ‘ar, instal the compensating bar. the adjusting aut, and the locknut on the cable, and adjust the parking brake as de- scribed above in Adjusting Parking Brake 7.3 Calipers Fig. 7-6 1s an exploded view of the rear disc brake caliper. ‘The rear calipers differ from thase used at the front, mainly in the addition of the automaticaly adjusting parking brake actu- ‘ating mechanism, Brake fluid leaks around the brake caliper piston are the ‘esult ofa faled or damaged piston seal, perhaps caused by ‘corrosion, scoring, or piting ofthe piston or caliper bore. The ‘seal can be replaced, but a damaged piston, which is net avaliable as a replacement part, wil prompily destroy the new seal 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 sepa- rately. To repiace a caliper, fist remove the parking brake cable from the caliper, as described in 7.2 Parking Brake (Disc Brakes), may be necessary to loosen tho cablo adjusting ruts under the parking brake fever Remove the two self locking caliper mounting bolts and pull the caliper away from the brake pads and carrier. Hold the guide pins with an open- fend wrench to remove the boits. Disconnect the brake hose from the caliper and drain the brake fluid into a container. Cap the end of the brake line to prevent dirt and moisture from tentering the brake system, Installation is the reverse of removal. Pre-bieed the caliper by laying it on ts side, as shown in Fig, 7-7. Fil the piston ‘chamoer with brake fluid through the bleader valve unt clear fluid runs out of the brake hase connection, then close the biceder valve. Torque the brake hase union to 1 Nm (11 ft.) Use new sat-locking botts to maunt the caliper to the brake pac carrier, and torque them to 35 Nm (26 ft 1b). Bleed the brake system 2s describad in 4.2 Bleeding Brakes. Reconnect the parking brake cable and adjust it as described in Adjusting Parking Brake. Do not let brake fluid contaminate the brake pads or brake rotor surface.actualng leer Auiaticaly adusing parkng, Fig. 7-7. Row hhaso connection (are fa a caning theo of a ‘nu fad es Brakes 11-23 8. TECHNICAL DATA |. Tolerances, Wear Limits, and Settings ‘rake dss, Wont vertaioa £20.00 mm (787 in) 18.00 mmm (709 in) 1.08 ms (002 in) Brake dumm, oa inside ameter, new drum 180,00 mm 7.087 in) inside diameter, maximum ate resurtscing 180.50 rh i0ain) 161.00 men 17126.) (02 mm (008 >} (0.05 me (002 in) neice darter, maxim, runout aera! et wheel mounting sire rrout radial at tition surtace Brake disc, eae thewness, now part leks, rim, runout, maximum permissible 10.00 ren (394 in) 860 mmm (315.0) ‘8.08 mm (002 in) fi, Tightening Torques ‘Brake caper (Wont fo wheel bearing ouwsing fool) exospt 6-vave 25 Nm (1841) teveve '35 Nim (26 1B) Brake dsc Splash stiel io whet bearing housing Got) 10 New (a7 in. 1) ‘rake pad camer or) Ta wheel bearing housing (bo) 70.Nm (82.9) Fear brake backing pale and stub axle "a axle beam (bat) 160 Nm (44 fb) Roa wtieel cylinder 3 backing pte (508). 10 New (87. 1b) Brake caliper (ea to brake pad carrier (eattecang 20) Brake ac camer to stub ave flange (Cot) £35 Nm (26 tb) 165 Nin (8 1.) Brake hose to brake caliper Brake hose fo whee eyinder Brake hoses except lo caper cr ‘wea eyincor AS Nm (itt ) 45 Nm (14 1b) 15-20 Nm (91-15 fb) ake ine unions (anion nas) 15-20 Ni (34-181 1b) Brake ines to master cylinder 15-206 (11 15% Ib) Proportionng valves to master Cynder 13-20 Nm (11-18 &(b) Master oytnder to vacuum booster ‘Yecuur boodlr to support bracket ir} 21 Nm (15 tb) 21 Nm (15) ‘Wheel to brake disc or brake ‘Gram (a bet. 110 New (81 ta) WARNING — {Do not 0-use factonors that ave wor or dformed ‘in nomal use. Mary tastanors are dosined to be tused only ance and become wielable and may {i whon used a second tie, Thisinchudos, tts nottimied', nuts, bots, washers, sHocking nuts ‘or bors cips, cotter pins. Abnays replace these fastonors vith new parts,