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
BBR11-2 BRAKES
TABLES
Brake Troubleshooting
Brake Pressure Specifications.
Front Rotor Reconditioning Specifications
Brake Drum Reconditioning Specifications
Rear Rotor Reconditioning Specifications
eaege
"
14
18
atBrakes 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.