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Brake and clutch system: Changing brake fluid Page 1 of 5

Brake and clutch system: Changing brake fluid


Instructions for use and safety Chapter.
Brake fluid specification Chapter.

Procedure, changing brake fluid Chapter.

Instructions for use and safety

Note
 From model year 2006 a new brake fluid will be introduced.
 The new brake fluid can also be used for older vehicles.
 For this purpose it can be mixed with the previous brake fluid.

WARNING
 Brake fluid must under no circumstances come into
contact with fluids containing mineral oils (oil, petrol,
cleaning solutions). Mineral oils will damage seals and
sleeves of brake system.
 Brake fluid is poisonous. In addition, due to its
corrosive nature, it must not come into contact with
paint.
 Brake fluid is hygroscopic, i.e. it attracts moisture from
the surrounding air and therefore must always be
stored in air-tight containers.
 Wash away spilt brake fluid using plenty of water.
 Do not reuse extracted (used) brake fluid.
 Observe disposal regulations!

Carry out the following procedure:

Brake fluid specification


Permissible specifications:
 Brake fluid conforming to US standard FMVSS 116 DOT 4
(previous brake fluid)
 Brake fluid conforming to VW standard, VW 501 14 (new
brake fluid).

Procedure, changing brake fluid


Special tools and workshop equipment required

 Brake pedal actuator -V.A.G 1869/2-

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 Brake filling and bleeding equipment -VAS


5234-

Observe instruction manual for -VAS 5234-!


Unscrew cap from brake fluid reservoir.

Extract as much brake fluid as possible


using suction hose from -VAS 5234--1- or

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using a suction bottle with built-in strainer.

Note
Ensure that no brake fluid runs through the
strainer after completing extraction (the brake
fluid level in the reservoir must be even with
the lower edge of the strainer).

WARNING
Do not reuse extracted (used) brake
fluid.

Fit brake pedal actuator -V.A.G 1869/2-


between driver seat and brake pedal and
pretension.

Connect adapter -1- to brake fluid


reservoir.

Note
If the adapter -1- cannot be fitted due to space
limitations, use adapter -VAS 5234/1-.

Note
Use an appropriate bleed hose. It must seat
tightly on bleeder screw so that no air can
enter the brake system.

Connect filling hose of -VAS 5234- to


adapter.

Continued for all vehicles (left-hand drive):


Remove cover caps from bleeder screws.

Connect collector bottle bleed hose -1- to


rear bleed screw, open bleed screw and
allow the appropriate amount of brake fluid
to flow out (see table). Close bleeder
screw, specified torque: Running
gear; Rep. Gr.47Servicing rear brake
calipers
Repeat procedure on left-hand side of vehicle
at rear.

Push bleeder hose -1- of collector bottle


onto front bleeder screw, open bleeder

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screw and let appropriate quantity of brake


fluid run out (see table). Close bleeder
screw, specified torque: Running
gear; Rep. Gr.47Servicing front brake
calipers

Repeat procedure on left-hand side of vehicle


at front.

Vehicles with manual gearbox:


Remove cover cap from bleeder screw of
clutch slave cylinder.

Connect bleed hose -arrow- to clutch slave


cylinder -1-.

Open valve and allow approx. 100 ml


brake fluid to flow out.
Close valve and depress clutch pedal 10 to
15 times quickly in succession.
Open valve again and allow approx. 50 ml
brake fluid to flow out.
Close valve, remove bleed hose and
depress clutch pedal several times.
Table - Sequence and quantity of brake
fluid

Brake fluid quantity


Sequence
which must flow out of bleeder
bleeder valves:
valves:
Wheel brake
cylinder/brake caliper
Rear right 0.25 litres (250 ml)
Rear left 0.25 litres (250 ml)
Brake caliper
Front right 0.25 litres (250 ml)
Front left 0.25 litres (250 ml)
Clutch slave cylinder 0.15 litres (150 ml)

Total quantity: Approx. 1.15 litres


Fit cover caps on wheel brake cylinder and brake caliper
bleeder screws.

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Set fill lever of -VAS 5234- to position -B- (see operating


instructions).
Remove filler hose from adapter.

Unscrew adapter from brake fluid reservoir.


Check brake fluid level and correct if necessary.
Screw in cap of brake fluid reservoir.

Remove brake pedal actuator.


Check pressure and free travel of brake pedal. Free travel:
1
Max. of pedal travel.
3

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