Professional Documents
Culture Documents
AG. Volkswagen AG d
agen oes
ksw
Repair Manual
ol not
y V gu
d b ara
rise nte
o eo
Golf 2015 ➤
th
au ra
ss c
ce
Golf Variant 2015 ➤
le
un
pt
an
d
itte
y li
erm
ab
Brake System
ility
ot p
wit
is n
Edition 12.2015
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Repair Group
00 - General, Technical Data
45 - Antilock Brake System
46 - Mechanical Components
47 - Hydraulic Components
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.
Contents
pt
du
an
itte
ab
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ility
ot p
wit
, is n
46 - Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
h re
hole
spec
1 Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
es, in part or in w
t to the co
2 Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Overview - Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
m
at
om
io
in t
or
cum
or
en
ng
t.
2.6 Brake Shield, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
yi Co
Cop py
t.
3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
rig
gh ht
pyri by
3.1 Overview - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
o Vo
by c lksw
cted agen
Prote
3.2 Parking Brake, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
AG.
Contents i
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
47 - Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Overview - Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Brake Caliper Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Overview - Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 Brake Caliper Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3 Brake Booster/Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Overview - Brake Booster/Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Brake Lamp Switch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3 Brake Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.4 Brake Booster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.5 Brake Fluid Reservoir, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
AG. Volkswagen AG d
agen oes
4 Vacuum System Vol . . . . . . . . . . . . . . . . . . . . . o.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ksw n 121
y
4.1 Overviewris-e Vacuum Pump . . . . . . . . . . . . . . . . a.ra.n.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d b
121
e
4.2 ho
CheckautValve, Checking . . . . . . . . . . . . . . . . . . . . . .e o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
c
4.3 Vacuum
ss Sensor G608 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ce
e
nl
an
itte
y li
ab
wit
, is n
spec
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ii Contents
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
senger seat.
pt
du
an
itte
y li
ab
wit
, is n
h re
hole
spec
System:
l purpos
WARNING
nf
ercia
atio
om
n in
thi
sd
iva
o
r
cu
o
m
f
en
ng
1. Safety Precautions 1
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
2 Identification
⇒ “2.1 PR Number Allocation - Brakes”, page 2
ce
e
nl
pt
du
Vehicle Individual.
an
itte
y li
erm
ab
In this example, the vehicle has “1KU” rear brakes.
ility
ot p
wit
, is n
h re
hole
spec
portant for the combination brake caliper/brake rotor and
es, in part or in w
brake pad.
t to the co
rrectness of i
l purpos
ion
c
his
te
do
priv
en
ng
t.
1LJ PC60 (17”)
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
2.1.3 Rear Brakes
Prote AG.
ce
e
3.1 Brakes Technical Data
nl
pt
du
an
itte
y li
⇒ “3.1.1 Brake Master Cylinder and Brake Booster”, page 3
erm
ab
ility
ot p
⇒ “3.1.2 Front Brakes”, page 3
wit
, is n
h re
⇒ “3.1.3 Rear Brakes”, page 5
hole
spec
es, in part or in w
t to the co
ter
rrectness of i
Brake master cylinder, Diameter in mm 23.81 or 25.4
depending on the en‐
l purpos
gine installed
Brake booster, depend‐ Diameter in in‐ 10 or 11
nf
ercia
or
led
m
m
atio
om
n in
3.1.2 Front Brakes
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
3. Technical Data 3
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
e
nl
thickness
pt
du
an
itte
y li
Brake rotor, mm 22
erm
ab
wear limit
ility
ot p
wit
Brake caliper, diam‐ 57
, is n
h re
piston eter in
hole
mm
spec
es, in part or in w
t to the co
Front Brakes C60 (17”)
Item PR Number 1LJ/1LM
rrectness of i
1 Brake caliper C60 (17”)
l purpos
2 Brake pad, mm 13
thickness
nf
ercia
atio
limit without
om
back plate
n in
or c
thi
e
sd
iva
eter in
o
r
rp
cu
mm
o
m
f
en
ng
t.
yi
Brake rotor, mm 30
Co
op py
thickness
t. C rig
gh ht
yri by
Brake rotor, mm Refer to 27.
cop Vo
by lksw
cted
wear limit
agen
Prote AG.
back plate
un
pt
an
d
y li
rm
eter in
ab
pe
ility
mm
ot
wit
, is n
Brake rotor, mm 10
h re
hole
thickness
spec
es, in part or in w
Brake rotor, mm 8
t to the co
wear limit
4 Brake caliper, diam‐ 38
piston eter in
rrectness of i
mm
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Technical Data 5
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
pt
an
itte
y li
2 Brake pad, mm 11
erm
ab
thickness with‐
ility
ot p
out backing
wit
, is n
plate
h re
hole
spec
limit without
t to the co
backing plate
3 Brake Rotor diam‐ 272
eter in
rrectness of i
mm
l purpos
Brake rotor, mm 10
thickness
nform
ercia
Brake rotor, mm 8
wear limit
m
at
om
io
in t
or
piston eter in
his
ate
mm
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
thickness
un
pt
an
d
itte
Brake pad, wear mm 3
y li
erm
ab
limit without
ility
ot p
backing plate
wit
is n
h re
3 Brake Rotor diam‐ 253
ole,
eter in
spec
urposes, in part or in wh
mm
t to the co
Brake rotor, mm 10
thickness
rrectne
Brake rotor, mm 8
wear limit
s
4 Brake caliper, diam‐ 38
s o
piston eter in
cial p
f in
mm
form
mer
atio
m
n
c
i
or
n thi
e
sd
iva
o
pr
cum
1 Brake Caliper CI 38 HRA
r
fo
en
ng
t.
yi
2 Brake pad, mm 11
Co
op py
thickness
. C rig
ht ht
rig by
py
Brake pad, wear mm 3 co Vo
by lksw
limit without cted agen
Prote AG.
backing plate
3 Brake Rotor diam‐ 253
eter in
mm
Brake rotor, mm 10
thickness
Brake rotor, mm 8
wear limit
4 Brake caliper, diam‐ 38
piston eter in
mm
3. Technical Data 7
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4 Brakes Inspection
⇒ “4.1 General Information”, page 9
⇒ “4.2 Front Wheel Drive Vehicles, Checking”, page 9
ce
e
nl
pt
du
an
The brake control systems do not function when the ignition is off.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Volkswagen approved test stands meet these requirements.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Brakes Inspection 9
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ABS malfunctions do not affect the brake system and the booster.
Conventional brake system stays operative even without ABS. A
change in braking behavior should be checked. When the ABS
indicator lamp is lit up, the rear wheels may lock prematurely dur‐
ing braking! n AG. Volkswagen AG age does
ksw not
y Vol gu
Configuration ed
b ara
nte
oris eo
h
1 - ABS Hydraulic Unit -auN55-
t
and ABS Control Module - J104- ra
c
ss
2 - Brake Booster
ce
le
un
pt
an
d
itte
The ABS Hydraulic Unit - N55- and ABS Control Module - J104-
y li
rm
ab
are one unit. Separation can only be performed when removed
pe
ility
from vehicle. The hydraulic pump may also not be separated from
ot
wit
the ABS Hydraulic Unit - N55- .
, is n
h re
hole
spec
es, in part or in w
t to the co
cause of damage as well as the control module code using
“Guided Fault Finding”.
rrectness of i
“Guided Fault Finding” is performed. Refer to Vehicle Diagnostic
Tester .
l purpos
nform
ercia
a
com
ti
formation found here ⇒ General Information; Body Repairs,
on in
Body Collision Repair .
r
te o
thi
s
iva
en
ng
t.
yi
♦ After finishing any work that required opening the brake sys‐
Co
op py
tem, bleed the brake system using the Brake Charger/Bleeder
t. C rig
gh ht
yri
Unit - VAS5234- . p by
o Vo
by c lksw
cted agen
♦ During the final road test, make sure a controlled braking ma‐ Prote AG.
neuver is performed at least one time (pulsing must be felt in
brake pedal).
♦ It is necessary to maintain a high level of cleanliness when
working on the ABS system.
♦ Do not use fluid containing mineral oils, for example oils,
grease, etc.
♦ Thoroughly clean all connection points and their surrounding
areas before loosening. However, do not use aggressive
cleaning agents such as brake cleaner, gasoline, thinners or
similar compounds.
♦ Place the removed parts on a clean surface and cover them.
♦ Carefully cover or seal opened components if the repair is not
performed immediately. (Use plugs from repair set 1 H0 698
311 A)
♦ Only use lint-free cloths.
♦ Remove the replacement parts from their packaging just prior
to installing them.
♦ Only use parts in their original packaging.
♦ Do not work with compressed air when the system is open.
♦ Do not move the vehicle.
1. General Information 11
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
le
pt
an
d
itte
y li
♦ Make sure that brake fluid cannot get into the connectors.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ling. Refer to
un
pt
an
d
y li
ab
h re
and Installing”,
ole,
page 17 .
spec
urposes, in part or in wh
❑ Component location: in
the engine compartment on the front passenger side
rrectne
f inform
atio
m
❑ The ABS Hydraulic Pump - V64- and valve block must not be separated from one another.
o
n
c
i
or
⇒ “3.2.1 ABS Control Module J104 / ABS Hydraulic Unit N55 , Gasoline Engine, Removing and Instal‐
t
sd
iva
ling”, page 17 .
pr
cum
r
fo
en
ng
ce
e
pt
du
an
itte
9 - Diagnostic Connection
y li
erm
ab
❑ Component location: driver side footwell cover
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ Steering removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Steering Gear;
Steering Gear, Removing and Installing .
rrectness of i
11 - Right/Left Front ABS Wheel Speed Sensor -G45- / -G47-
l purpos
❑ Removing and installing. Refer to ⇒ “4.1 Overview - Front Axle Speed Sensor”, page 35 .
12 - Wheel Hub with Wheel Bearing nf
ercia
atio
m
n in
or c
❑ Removing and installing (FWD). Refer to ⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 36 .
thi
te
sd
iva
cu
o
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ling. Refer to
pt
an
d
itte
ab
Module J104 / ABS Hy‐
ility
ot p
h re
and Installing”,
ole,
spec
page 17 .
urposes, in part or in wh
t to the co
3 - TORX® Bolt
❑ 1. Step: Preliminary
tightening specification
rrectne
specification: 2.5 Nm
inform
mer
i
or
n thi
te
sd
4 - Brake Line
iva
o
pr
cum
❑ 14 Nm
r
fo
en
ng
t.
❑ Identification: 5.25 mm
yi Co
op
diameter and tube fitting
C py
t. rig
gh
with a M12 x 1 thread
ht
pyri by
Vo
co lksw
by
❑ To the right rear brake Prote
cted AG.
agen
caliper
5 - Brake Line
❑ 14 Nm
❑ Identification: 5.25 mm diameter and tube fitting with a M10 x 1 thread
❑ To the left front brake caliper
6 - Brake Line
❑ 14 Nm
❑ To the right front brake caliper
15 - Hex Nut
❑ 20 Nm
16 - Bracket
17 - Hex Nut
❑ 20 Nm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
16
c by lksw
cted agen
Rep. Gr.45 - Antilock Brake System Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ho
ir se Golf 2015 ➤te,eGolf Variant 2015 ➤
t or
au Brake System ac - Edition 12.2015
ss
ce
e
nl
pt
3.2 ABS Control Module - J104- / ABS Hy‐
du
an
itte
y li
draulic Unit - N55- , Removing and In‐
erm
ab
ility
ot p
stalling
wit
, is n
h re
⇒ “3.2.1 ABS Control Module J104 / ABS Hydraulic Unit N55 ,
hole
spec
Gasoline Engine, Removing and Installing”, page 17
es, in part or in w
t to the co
⇒ “3.2.2 ABS Control Module and ABS Hydraulic Unit, Removing
and Installing”, page 21
rrectness of i
3.2.1 ABS Control Module - J104- / ABS Hy‐
draulic Unit - N55- , Gasoline Engine,
l purpos
nf
ercia
o
Special tools and workshop equipment required
rm
m
atio
m
n in
or c
thi
♦ Open Ring Spanner Insert - AF 11mm - VAG1410/6-
te
sd
iva
o
r
cu
o
m
f
en
ng
WARNING
Do not bend the brake lines near the ABS Hydraulic Unit -
N55- !
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Push the lock washer downward in the direction of -arrow A-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Install the Brake Pedal Actuator - VAG1869/2- .
cted agen
Prote AG.
– Attach the bleeder bottle bleed hose -1- to the left front brake
caliper bleed valve.
– Open the bleed valve.
ce
e
nl
pt
du
an
– Push the brake pedal with the Brake Pedal Actuator -
itte
y li
VAG1869/2- at least 60 mm.
erm
ab
ility
ot p
– Close left front and left rear bleeder valves.
wit
, is n
h re
– Do not remove the Brake Pedal Actuator - VAG1869/2- .
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
– Remove the cover from the bulkhead and unclip the brake line.
nform
ercia
at
– Remove the brake lines -5 and 6- from the ABS Hydraulic Unit
om
io
- N55- .
n
c
in t
or
his
e
do
riv
from the Repair Kit - 1H0 698 311 A- or with suitable plugs
p
cum
or
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull the ABS Control Module - J104- with the ABS Hydraulic
Unit - N55- upward from the shock absorber -arrow-.
Installing
Install in reverse order of removal. Note the following:
Note
♦ Remove the plugs on the new ABS Hydraulic Unit - N55- only
when installing the brake line.
♦ Brake fluid will leak out if the plugs are removed too early from
the ABS Hydraulic Unit - N55- . The system will then not have
sufficient brake fluid and will not adequately bled.
olkswagen AG
en AG. V
♦ Pay attention when installing the ABS Hydraulic Unit - N55-
olks
wag does
not
that the rubber bushings are not pushed out of the console.
ed
by
V gu
ara
ris nte
utho eo
– Before assembling the holder for the ABS - Hydraulic
ss
a Unit ra
c
N55- in the bracket, spray the rubber bushings with Silicone
ce
le
un
pt
Lubricant Spray - D 007 000 A2- .
an
d
itte
y li
erm
ab
– Install the brake lines carefully with the Torque Wrench - As‐
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
Tightening Sequence
o
n
c
i
or
n
– Remove the Brake Pedal Actuator - VAG1869/2- .
thi
te
sd
iva
o
r
cum
r
fo
t.
yi Co
op
– Enter radio code. C py
t. rig
gh ht
yri by
– Code ABS Control Module - J104- using the Vehicle Diagnos‐ cop Vo
by lksw
tic Tester in "Guided Fault Finding". cted agen
Prote AG.
Removing
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
Do not bend the brake lines near the ABS Hydraulic Unit -
hole
N55- !
spec
es, in part or in w
t to the co
– If the vehicle has a coded radio, get the radio code from the
customer before beginning.
l purpos
at
ion
in t
or
his
te
do
priv
cum
or
en
g
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
– Remove the front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Ex‐
pt
du
an
haust Pipes/Mufflers; Front Exhaust Pipe, Removing and In‐
itte
y li
erm
stalling .
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Disconnect the connector -1-.
l purpos
– Loosen the clamping sleeve -2- and slide it toward the rear.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Remove the bolts -1-. cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unclip the heat shield -1- from the bracket -2- -arrow-.
ility
ot p
wit
– On vehicles with heat shield, remove heat shield -item 14-
, is n
h re
⇒ Item 14 (page 16) .
hole
spec
– Unclip the wire routing.
es, in part or in w
t to the co
– Push the lock washer downward in the direction of -arrow A-.
– Release the locking mechanism in the direction of -arrow B-.
rrectness of i
– Remove the connector -1-.
l purpos
nform
mercia
at
om
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Attach the bleeder bottle bleed hose -1- to the left front brake
caliper bleed valve.
– Open the bleed valve.
– Attach the bleeder bottle bleed hose -1- to the left rear brake
caliper bleed valve.
– Open the bleed valve.
– Push the brake pedal with the Brake Pedal Actuator -
VAG1869/2- at least 60 mm.
– Close left front and left rear bleeder valves.
– Do not remove the Brake Pedal Actuator - VAG1869/2- .
– Place a lint-free cloth under the ABS Control Module - J104- agen
AG. Volkswagen AG d
oes
and the ABS Hydraulic Unit - N55- . Volksw not
gu
d by ara
ise nte
or eo
h
ut ra
Note ss a c
ce
e
nl
pt
du
Make sure no brake fluid gets onto contacts.
an
itte
y li
erm
ab
ility
– Remove the cover from the bulkhead and unclip the brake line.
ot p
wit
, is n
h re
– Label both brake lines -5 and 6-.
hole
spec
es, in part or in w
– Remove the brake lines -5 and 6- from the ABS Hydraulic Unit
t to the co
- N55- .
– Seal off the brake lines and the threaded holes right away with
the plugs from repair kit 1H0 698 311 A.
rrectness of i
– Mark, unfasten and plug the remaining brake lines (brake cal‐
l purpos
ipers).
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Pull the ABS Hydraulic Unit - N55- with the ABS Control Mod‐
iv
o
r
rp
cu
ule - J104- upward from the shock absorber -arrow-.
o
m
f
en
ng
t.
yi
– Place the ABS Hydraulic Unit - N55- with the ABS Control
Co
op py
Module - J104- at the bottom of the engine compartment. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted
Caution
agen
Prote AG.
Set aside the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- so that it cannot fall down.
ce
e
Install in reverse order of removal. Note the following:
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
♦ Remove the plugs on the new ABS Hydraulic Unit - N55- only
hole
spec
when installing the brake line.
es, in part or in w
t to the co
♦ Brake fluid will leak out if the plugs are removed too early from
the ABS Hydraulic Unit - N55- . The system will then not have
sufficient brake fluid and will not adequately bled.
rrectness of i
♦ Pay attention when installing the ABS Hydraulic Unit - N55-
that the rubber bushings are not pushed out of the console.
l purpos
nform
ercia
at
om
ion
c
in t
or
– Install the brake lines carefully with the Torque Wrench - As‐
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
3.2.3 ABS Control Module and ABS Hydraulic
le
un
pt
an
d
y li
rm
ab
pe
ility
Special tools and workshop equipment required
ot
wit
, is n
h re
♦ Torque Wrench 1331 5-50Nm - VAG1331-
hole
spec
♦ Open Ring Spanner Insert - AF 11mm - VAG1410/6-
es, in part or in w
t to the co
♦ Torque Wrench - Universal Joint - VAG1410/7-
♦ Mini Torque Wrench - VAS6854-
♦ Brake Pedal Actuator - VAG1869/2- . rrectness of i
l purpos
1 - M10 plug
a
com
tion in
2 - M12 plug
r
te o
thi
s
iva
Removing
do
r
rp
cum
fo
Component location:
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The control module is bolted to the hydraulic unit -1- and is located
at right in the engine compartment.
WARNING
Do not bend the brake lines near the ABS Hydraulic Unit -
N55- !
ce
le
pt
an
d
itte
y li
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
rm
ab
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
pe
ility
ot
wit
– Remove the front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Ex‐
, is n
h re
haust Pipes/Mufflers; Front Exhaust Pipe, Removing and In‐
hole
spec
stalling .
es, in part or in w
t to the co
– Disconnect the connector -1-.
– Loosen the clamping sleeve -2- and slide it toward the rear.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Remove the bolts -1-. C py
t. rig
gh ht
yri by
– Loosen the bolt -2- and the clamp. cop Vo
by lksw
cted agen
Prote
– Remove the front exhaust pipe.
AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
– Disconnect the connector -arrow B-.
itte
y li
erm
ab
– Remove the connector -1-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Attach the bleeder bottle bleed hose -1- to the left front brake
caliper bleed valve.
– Open the bleed valve.
– Attach the bleeder bottle bleed hose -1- to the left rear brake
caliper bleed valve. en AG. Volkswagen AG
ag does
ksw not
Vol valve.
– Open the bleed gu
by d ara
ise nte
– Pushutthe
ho brake pedal with the Brake
r
Pedal Actuator e o-
VAG1869/2-
ss
a at least 60 mm. ra
c
ce
le
pt
an
d
itte
y li
– Do not remove the Brake Pedal Actuator - VAG1869/2- .
rm
ab
pe
ility
– Place sufficient lint-free cloths under the control module and
ot
wit
, is n
hydraulic unit.
h re
hole
spec
es, in part or in w
Note
t to the co
Make sure that brake fluid does not come in contact with the ter‐
minals.
rrectness of i
l purpos
– Remove the cover from the bulkhead and unclip the brake line.
– First, mark both brake lines from master cylinder and remove
nform
ercia
a
com
t
– Seal the threaded holes immediately with plugs from the as‐
ion in
sembly part set part number 5Q0 698 311.
r
te o
thi
s
iva
en
ng
t.
yi Co
op
– Lift the hydraulic unit with control module up and out of the
C py
t. rig
dampers -arrow-.
gh ht
pyri by
Vo
o
by c lksw
– Place the hydraulic unit with the control module carefully below
Prote
cted AG.
agen
in the engine compartment.
Caution
Set aside the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- so that it cannot fall down.
Note
Position the ABS Hydraulic Unit - N55- with the ABS Control Mod‐
ule - J104- so that it cannot fall down.
– Guide out the hydraulic unit -3- out of the vehicle through the
wheel housing.
Installing
Note
ce
le
un
pt
– Before assembling the holder for the ABS Hydraulic Unit -
an
d
itte
y li
rm
ab
Lubricant Spray - D 007 000 A2- .
pe
ility
ot
wit
, is n
h re
hole
spec
– Install the brake lines carefully with the Torque Wrench - As‐
es, in part or in w
t to the co
– Install in reverse order of removal.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
cum
fo
en
ng
– Code the ABS Control Module - J104- using the Vehicle Di‐
agnostic Tester .
A Steering Angle Sensor - G85- , Transverse Acceleration Sensor
- G200- , Longitudinal Acceleration Sensor - G251- and Brake
Pressure Sensor 1 - G201- basic setting must be done.
Tightening Specifications
ce
e
jection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview
nl
pt
du
an
- Subframe Mount .
itte
y li
erm
ab
♦ Driveshaft. Refer to ⇒ Suspension, Wheels, Steering; Rep.
ility
ot p
wit
, is n
h re
♦ Lower control arm. Refer to ⇒ Suspension, Wheels, Steering;
hole
spec
Rep. Gr. 40 ; Lower Control Arm and Ball Joint; Overview -
es, in part or in w
t to the co
♦ Front bleeder valve. Refer to
⇒ “1.1 Overview - Front Brake Caliper”, page 97 .
rrectness of i
♦ Rear bleeder valves. Refer to
l purpos
nform
ercia
draulic Unit
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi Co
op py
♦ If the ABS Control Module - J104- is faulty, then the control t. C rig
gh ht
module is to be separated from the ABS Hydraulic Unit - N55- yri
p by
o Vo
and only the control module replaced.
c by lksw
cted agen
Prote AG.
♦ If the ABS Hydraulic Unit - N55- is faulty, then replace the ABS
Hydraulic Unit - N55- together with the ABS Control Module -
J104- .
♦ To separate the ABS Control Module - J104- and the ABS Hy‐
draulic Unit - N55- the unit must be removed.
WARNING
♦ The return flow pump may also not be separated from the
ABS Hydraulic Unit - N55- .
♦ The circuit board is exposed when the ABS Control Mod‐
ule - J104- is removed.
♦ Protect the ABS Control Module - J104- from moisture and
dirt particles from getting inside.
♦ Avoid build-up of static electricity!
– Place the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- on the ESD Work Surface - VAS6613- .
– Remove the three TORX® bolts from the ABS Control Module
- J104- and set aside immediately (risk of confusing them with
the new TORX® bolts).
– Place the ABS Hydraulic Unit - N55-swwith
agen the ABS Control
AG. Volkswagen AG d
oes
Module - J104- upward on the ESD
by
V Work Surface - VAS6613- . ot gu
olk n
ara
ed nte
ris
– Remove the ABS ControlthoModule - J104- from the ABS Hy‐ e or
draulic Unit - N55- without
s au tilting it. ac
s
ce
le
pt
free cloth.
an
d
itte
y li
rm
ab
– Clean the ABS Hydraulic Unit - N55- sealing surface using
pe
ility
mineral spirits and a lint-free cloth.
ot
wit
, is n
h re
The ABS Hydraulic Unit - N55- sealing surface must not be
hole
spec
worked with a file, metal scraper, sand paper or similar.
es, in part or in w
t to the co
If the ABS Hydraulic Unit - N55- sealing surface is damaged (for
example through grooves or scrapes) the ABS Hydraulic Unit -
N55- must be replaced with the ABS Control Module - J104- .
rrectness of i
The seal on the ABS Control Module - J104- must not be pulled
l purpos
nform
mercia
a
com
tion in
r
te o
thi
3.4 Control Module, Attaching to Hydraulic
s
iva
do
r
rp
Unit
um
fo
en
ng
t.
yi Co
Special tools and workshop equipment required t. Cop py
rig
gh ht
yri
♦ Torque Screwdriver - VAG1624- p by
o Vo
by c lksw
cted agen
♦ ESD Work Surface - VAS6613- Prote AG.
WARNING
Note
Tightening Specification
♦ Refer to
⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
page 15
Note
ce
le
un
pt
an
d
y li
rm
ab
pe
ility
ot
wit
, is n
thread
h re
hole
spec
1 - ABS Hydraulic Unit - N55- to the Left Front Brake Caliper
es, in part or in w
3 - ABS Hydraulic Unit - N55- to the Left Rear Brake Caliper t to the co
4 - ABS Hydraulic Unit - N55- to the Right Rear Brake Caliper
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Tightening Sequence:
1 - ABS Hydraulic Unit - N55- to the Right Rear Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
short thread
2 - ABS Hydraulic Unit - N55- to the Left Front Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M10 x 1
thread
3 - ABS Hydraulic Unit - N55- to the Right Front Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
short thread
4 - ABS Hydraulic Unit - N55- to the Left Rear Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M10 x 1
thread
5 - ABS Hydraulic Unit - N55- to the Master Brake Cylinder Sec‐
ondary Piston Circuit
- Identification: 6 mm diameter and tube fitting with a M12 x 1
thread
6 - ABS Hydraulic Unit - N55- to the Master Brake Cylinder Pri‐
mary Piston Circuit
- Identification: 6 mm diameter and tube fitting with a M12 x 1
thread
Tightening Specification AG. Volkswagen AG d
agen oes
♦ Refer to olksw not
yV gu
⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
rised b ara
nte
page 15 ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4 Sensors
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 35
⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 36
⇒ “4.3 Right/Left Front ABS Wheel Speed Sensor G45 / G47 ,
Removing and Installing”, page 37
⇒ “4.4 Right/Left Rear gABS
en AG.Wheel SpeeddoSensor
Volkswagen AG
G44 / G46 ,
swa es n
Removing andyInstalling”,
Volk page 38 ot g
u
b ara
ed n
⇒ “4.5 ESP ho Sensor Unit G419 , Removing and Installing”,
ris tee
page 39 aut or
ac
s s
ce
le
pt
page 39
an
d
itte
y li
erm
ab
⇒ “4.7 ABS Sensor Ring, Checking”, page 39
ility
ot p
wit
4.1 Overview - Front Axle Speed Sensor
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
G47- / -G45-
❑ Left Front ABS Wheel
rrectne
Speed Sensor - G47- /
Right Front ABS Wheel
Speed Sensor - G45- ss o
❑ Removing and instal‐
cial p
f in
ling. Refer to
form
mer
i
or
sd
a
37 .
iv
o
pr
cum
r
en
ng
2 - Bolt
❑ 8 Nm
3 - Drive Axle
❑ Overview. Refer to ⇒
Suspension, Wheels,
Steering; Rep. Gr. 40 ;
Drive Axle; Overview -
Drive Axle .
❑ Removing and instal‐
ling. Refer to ⇒ Suspen‐
sion, Wheels, Steering;
Rep. Gr. 40 ; Drive Axle;
Drive Axle, Removing
and Installing .
4 - Wheel Hub with Wheel
Bearing Unit
❑ The ABS sensor ring is
integrated in the wheel bearing unit
❑ Removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Wheel Bearing; Wheel
Bearing Unit, Removing and Installing .
4. Sensors 35
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
le
ling. Refer to
un
pt
an
d
y li
ABS Wheel Speed Sen‐
erm
ab
sor G44 / G46 , Remov‐
ility
ot p
wit
is n
h re
38 .
ole,
spec
❑ Clean the inner surface
urposes, in part or in wh
t to the co
ing the sensor
❑ Coat the hole with Hot
Bolt Paste - G 052 112
rrectne
A3- .
s
2 - Bolt
s o
cial p
f
❑ 8 Nm
inform
mer
atio
m
Bearing Unit
o
n
c
i
or
n
❑ The ABS sensor ring is
thi
e
sd
iva
o
bearing unit
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
❑ Removing and Installing
an
d
itte
y li
erm
ab
2 - Bolt
ility
ot p
❑ 8 Nm
wit
is n
h re
ole,
3 - Driveshaft
spec
urposes, in part or in wh
❑ Overview. Refer to ⇒
t to the co
Suspension, Wheels,
Steering; Rep. Gr. 42 ;
Overview - Driveshaft .
rrectne
❑ Removing and instal‐
ling. Refer to ⇒ Suspen‐
s
sion, Wheels, Steering;
s o
Rep. Gr. 42 ; Driveshaft;
cial p
f in
Driveshaft, Removing
form
mer
and Installing .
atio
m
n
c
i
or
n
Bearing Unit
thi
te
sd
a
o
pr
bearing unit
en
ng
t.
yi Co
op
❑ Check the ABS sensor C py
t. rig
ring. Refer to
gh ht
pyri by
⇒ “4.7 ABS Sensor
co Vo
by lksw
cted
Ring, Checking”,
agen
Prote AG.
page 39 .
❑ Removing and Instal‐
ling. Refer to ⇒ Suspen‐
sion, Wheels, Steering;
Rep. Gr. 42 ; Wheel
Bearing, Trailing Arm;
Wheel Bearing Unit, Removing and Installing .
Note
Removing
– Raise the vehicle.
4. Sensors 37
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
le
un
pt
an
d
itte
– Coat the hole with Hot Bolt Paste - G 052 112 A3- .
y li
rm
ab
pe
Tightening Specification
ility
ot
wit
, is n
♦ Refer to
h re
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 35 hole
spec
es, in part or in w
t to the co
rrectness of i
4.4 Right/Left Rear ABS Wheel Speed Sen‐
l purpos
nform
ercia
stalling
m
a
com
t
Special tools and workshop equipment required
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
Note
n
t.
yi Co
Cop py
t. rig
The example describes the removal and installation of the left rear
gh ht
pyri by
ABS wheel speed sensor. The removal and installation of the right
co Vo
by lksw
cted
rear ABS wheel speed sensor is identical.
agen
Prote AG.
Removing
– Raise the vehicle.
– Disconnect the connector -2- from the wheel speed sensor.
– Remove bolt -1-, and remove the wheel speed sensor from the
wheel bearing housing.
Installing
Install in reverse order of removal. Note the following:
– Clean the inner surface of the opening before inserting the
sensor
– Coat the hole with Hot Bolt Paste - G 052 112 A3- .
Tightening Specification
♦ Refer to
⇒ “4.2.1 Overview - Rear Axle Speed Sensor, FWD”,
page 36
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Sensors 39
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5 Special Tools
ce
le
♦ Brake Pedal Actuator -
un
pt
VAG1869/2- .
an
d
itte
y li
erm
ab
♦ Torque Wrench - Assembly
ility
ot p
Tool - VAG1410/8-
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Special Tools 41
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
46 – Mechanical Components
1 Front Brakes
⇒ “1.1 Overview - Front Brakes”, page 43
⇒ “1.2 Brake Pads, Removing and Installing”, page 45
⇒ “1.3 Brake Caliper, Removing and Installing”, page 47
⇒ “1.4 Brake Carrier, Removing and Installing”, page 49
⇒ “1.5 Brake Rotor, Removing and Installing”, page 51
⇒ “1.6 Brake Shield, Removing and Installing”, page 52
n AG. Volkswagen AG do
Note lkswage es n
o ot g
byV ua
ed ran
♦ After replacing brake pads, depress brake tpedal
horis firmly several tee
times with vehicle stationary so that thes abrake
u pads are prop‐ or
ac
erly seated in their normal operating position.
s
ce
e
nl
pt
du
an
itte
y li
fluid from brake fluid reservoir.
erm
ab
ility
ot p
wit
, is n
h re
hose.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Front Brakes 43
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
1 - Cover Plate
2 - Bolt
❑ 12 Nm
3 - Brake Rotor AG. Volkswagen AG d
agen oes
❑ Vented on the inside olksw not
byV gu
ara
d
❑ Wear limits orise nte
eo
h
ut
❑ Replace in pairs (Rotors ss a ra
c
replaced in pairs per
ce
le
un
axle)
pt
an
d
itte
y li
❑ Remove brake caliper
rm
ab
and brake carrier before
pe
ility
removing
ot
wit
, is n
h re
4 - Bolt hole
spec
❑ 8 Nm
es, in part or in w
t to the co
5 - Brake Carrier
❑ Lightly grease the pad
guide surface with Lithi‐
rrectness of i
um Grease - G 052150
l purpos
A2- .
6 - Brake Pads
nform
ercia
❑ Thickness 14 mm with‐
m
a
com
tio
❑ Vehicles with front right
n in
r
te o
thi
s
iva
tor
do
r
rp
cum
❑ When wear limit is
fo
en
g
t.
yi Co
op
mately 4 mm) the warn‐ C py
ht. rig
ing lamp in instrument rig ht
py by
cluster will come on, the co Vo
by lksw
cted
contact sensor can be
agen
Prote AG.
replaced separately.
❑ Wear limit: 2 mm without
backing plate
❑ Check the thickness. Refer to ⇒ Maintenance ; Booklet 36.1 ; Procedure Descriptions; Front and Rear
Brake Rotors, Checking Brake Pad Thickness and Condition .
❑ Replace in pairs
❑ Removing and installing. Refer to ⇒ “1.2 Brake Pads, Removing and Installing”, page 45 .
7 - Trim
❑ Vehicles with emblem
❑ For allocation. Refer to the Parts Catalog
8 - Brake Caliper
❑ Do not disconnect the brake hose when replacing a brake pad
❑ Removing and installing. Refer to ⇒ “1.3 Brake Caliper, Removing and Installing”, page 47 .
❑ Servicing. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
❑ For allocation. Refer to the Parts Catalog
9 - Hex Bolt, Self-Locking
❑ 35 Nm
❑ Replace after removing
10 - Ribbed Bolt
❑ 200 Nm
❑ Clean if using again.
ce
e
nl
pt
du
an
itte
y li
❑ Make sure it is installed in the correct position
erm
ab
ility
ot p
13 - Clip
wit
, is n
h re
14 - Bracket
hole
spec
15 - Bolt
es, in part or in w
t to the co
❑ 8 Nm
rrectness of i
1.2 Brake Pads, Removing and Installing
l purpos
nform
ercia
at
♦ Piston Resetting Tool - T10145-
om
ion
c
in t
or
his
e
Caution
at
do
priv
cum
or
en
ng
t.
yi
to component overview prior to starting procedure.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Mandatory Replacement Parts cted agen
Prote AG.
Note
When removing, mark brake pads that will be used again. Install
in the same position, otherwise braking effect will be uneven.
1. Front Brakes 45
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
– Counterhold the guide pins and remove both screws from the
brake caliper.
– Remove the brake caliper -1- and secure with wire so that the
weight of the brake caliper does enot stress
n AG. Volkswor damage
agen AG d the
brake hose. olks
wag oes
no
V t gu
by a
– Remove the brake pads
ris
ed -2 and 3- from the brake carrier -4-.ran
te
tho eo
Cleaning s au ra
c
s
ce
e
nl
pt
du
an
WARNING
itte
y li
erm
ab
ility
Do not blow brake system using compressed air, the dust pro‐
ot p
wit
h re
hole
spec
es, in part or in w
Note
nf
ercia
atio
om
n in
c
Installing
or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op py
Before pressing pistons into cylinder using piston resetting tool, t. C rig
gh ht
brake fluid must be extracted from brake fluid reservoir. Other‐ yri
p by
o Vo
wise, especially if reservoir has been topped off, fluid will overflow
c by lksw
cted agen
and cause damage.
Prote AG.
ce
le
– Place the brake pads -1- and the springs -2- into the opening
un
pt
an
d
in the brake carrier -3-.
itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
After installing the brake pads -arrow-, check the seating of all the
es, in part or in w
springs -2-.
t to the co
– Place the brake caliper carefully on the brake carrier.
rrectness of i
l purpos
– Counterhold the guide pins and attach the brake caliper to the
nform
ercia
a
com
ti
– Connect the brake pad wear indicator connector.
on in
r
te o
thi
– Install the wheels.
s
iva
do
r
Tightening Specification
rp
cum
fo
en
ng
♦ Refer to
t.
yi Co
op
⇒ “1.1.1 Overview - Front Brakes (PC57 and C60)”, page 43 C py
t. rig
gh ht
yri by
♦ Wheel bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep.
op Vo
by c lksw
Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Specifica‐ cted agen
Prote AG.
tions .
Note
Caution
Note
1. Front Brakes 47
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
Removing
– Remove the wheels.
– Disconnect the brake pad wear indicator connector.
– Attach the bleeder bottle bleed hose -1- to the brake caliper
bleed valve.
– Open the bleeder valve.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Install the Brake Pedal Actuator - VAG1869/2- .utho eo
ra
s a c
– Close the bleed valve and remove the bleeder bottle. s
ce
le
un
pt
– Remove the brake hose.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Counterhold the guide pins and remove both bolts from the
brake caliper.
– Remove the brake caliper from the brake carrier.
Installing
• Piston is pressed back.
• Both brake pads and their springs fit into the opening in the
brake carrier.
– Place the brake caliper carefully on the brake carrier.
– Counterhold the guide pins and attach the brake caliper to the
brake carrier with new self-locking screws.
– Attach the brake hose to the brake caliper.
– Remove the Brake Pedal Actuator - VAG1869/2- .
– Connect the brake pad wear indicator connector.
– Bleed the brake system. Refer to
⇒ “6 Hydraulic System”, page 132 .
– Install the wheels.
– Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads correctly in their operating
position.
– Check brake fluid level.
Tightening Specification
♦ Refer to
⇒ “1.1.1 Overview w-aFront
gen AGBrakes (PC57
. Volkswagen AG and C60)”, page 43
does
ks not
Vol g
♦ Refer to ⇒e“1.1
d b Overview - Front Brake Caliper”,
y uapage 97
ran
is tee
or
♦ Referauto
th ⇒ Suspension, Wheels, Steering; Rep. Gr. 44
or ;
a
Wheels and Tires; Wheel Bolt Tightening Specificationsc .
ss
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
♦ With the vehicle stationary, firmly press the brake pedal sev‐
is n
h re
spec
t to the co
i
or
n thi
e
Removing
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
♦ When removing, mark brake pads that will be used again. In‐
p by
co Vo
by lksw
stall in the same position, otherwise braking effect will be
Prote
cted AG.
agen
uneven.
♦ Do not open the brake hydraulic system when removing!
1. Front Brakes 49
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
d by ara
Clean brake caliper
horis with mineral spirits exclusively.
e nte
eo
aut ra
ss c
Installing
ce
le
un
pt
an
d
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
Before installing, clean carefully and check for wear and damage.
urposes, in part or in wh
t to the co
If using the brake pads again, install the marked pads in the same
location.
ss o
cial p
f in
Note
form
mer
atio
m
Before pushing back the piston, extract some of the brake fluid
o
n
c
n thi
e
especially if reservoir has been topped off, fluid will overflow and
t
sd
va
cause damage.
i
o
pr
cum
r
fo
en
ng
t.
yi
– Before moving the vehicle, press the brake pedal firmly sev‐
Co
Cop py
eral times to seat the brake pads correctly in their operating
t. rig
gh ht
yri
position. p by
o Vo
by c lksw
cted agen
– Check brake fluid level. Prote AG.
Tightening Specification
♦ Refer to
⇒ “1.1.1 Overview - Front Brakes (PC57 and C60)”, page 43
♦ Refer to ⇒ “1.1 Overview - Front Brake Caliper”, page 97
♦ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ;
Wheels and Tires; Wheel Bolt Tightening Specifications .
Note
ce
le
pt
an
d
itte
y li
– Raise the vehicle.
erm
ab
ility
ot p
wit
is n
h re
– Remove the brake carrier. Refer to
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Front Brakes 51
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Installing
urposes, in part or in wh
t to the co
Install in reverse order of removal. Note the following:
rrectne
Note
s
♦ Carefully clean before installing.
s o
cial p
f i
♦ Check for wear, damage, dimension and damaged threading.
nform
mer
atio
m
per axle).
o
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
If using the brake pads again, install the marked pads in the same
yi Co
op
location.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Note
AG.
Before pushing back the piston, extract some of the brake fluid
out of the brake fluid reservoir using a bleeder bottle. Otherwise,
especially if reservoir has been topped off, fluid will overflow and
cause damage.
– Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads correctly in their operating
position.
– Check brake fluid level.
Tightening Specification
♦ Refer to
⇒ “1.1.1 Overview - Front Brakes (PC57 and C60)”, page 43
♦ Refer to ⇒ “1.1 Overview - Front Brake Caliper”, page 97
♦ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ;
Wheels and Tires; Wheel Bolt Tightening Specifications .
Note
♦ When removing, mark brake pads that will be used again. In‐
stall in the same position, otherwise braking effect will be
uneven.
♦ Do not open the brake hydraulic system when removing!
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Front Brakes 53
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
d
rise nte
o eo
Clean brake caliper awith mineral spirits exclusively.
uth
ra
c
ss
ce
le
un
Installing
pt
an
d
itte
y li
Install in reverse order of removal. Note the following:
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Before installing, clean carefully and check for wear and damage.
t to the co
– Thoroughly clean the contact surfaces on the brake carrier for
the brake pads and remove any corrosion.
rrectness of i
If using the brake pads again, install the marked pads in the same
l purpos
location.
nform
ercia
Note
m
a
com
tion in
Before pushing back the piston, extract some of the brake fluid
r
te o
thi
do
especially if reservoir has been topped off, fluid will overflow and
r
rp
cum
cause damage.
fo
en
ng
t.
yi Co
Cop py
– Before moving the vehicle, press the brake pedal firmly sev‐
t. rig
gh ht
yri
eral times to seat the brake pads correctly in their operating p by
co Vo
lksw
position.
by
cted agen
Prote AG.
– Check brake fluid level.
Tightening Specification
♦ Refer to
⇒ “1.1.1 Overview - Front Brakes (PC57 and C60)”, page 43
♦ Refer to ⇒ “1.1 Overview - Front Brake Caliper”, page 97
♦ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ;
Wheels and Tires; Wheel Bolt Tightening Specifications .
ce
e
nl
pt
du
an
itte
y li
2 Rear Brakes
erm
ab
ility
ot p
wit
, is n
h re
⇒ “2.2 Brake Pads, Removing and Installing”, page 60
hole
spec
es, in part or in w
t to the co
⇒ “2.4 Brake Carrier, Removing and Installing”, page 72
⇒ “2.5 Brake Rotor, Removing and Installing”, page 74
rrectness of i
⇒ “2.6 Brake Shield, Removing and Installing”, page 76
l purpos
nf
ercia
or
⇒ “2.1.1 Overview - Rear Brakes, Multi-Link Rear Axle”,
m
m
atio
page 55
om
n in
or c
thi
e
page 58
t
sd
iva
o
r
rp
cu
2.1.1 Overview - Rear Brakes, Multi-Link Rear Axle
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
o Vo
by c lksw
cted agen
Prote AG.
♦ Use Brake Charger/Bleeder Unit - VAS5234- to extract brake fluid from brake fluid reservoir.
♦ Install the Brake Pedal Actuator - VAG1869/2- to relieve pressure before removing a brake caliper or dis‐
connecting a brake hose.
♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake
pads are properly seated in their normal operating position.
2. Rear Brakes 55
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
1 - Bolt
❑ 8 Nm
2 - Bolt
❑ 90 Nm +90°
❑ Quantity: 2
❑ Replace after removing
3 - Wheel Speed Sensor
❑ Overview. Refer to
⇒ “4.2 Overview - Rear
Axle Speed Sensor”,
page 36 .
❑ Removing and instal‐
ling. Refer to
⇒ “4.4 Right/Left Rear
ABS Wheel Speed Sen‐
sor G44 / G46 , Remov‐
ing and Installing”, page
38 .
❑ Before inserting sensor,
clean inner surface of
mounting hole and coat
with Hot Bolt Paste - G
052 112 A3- . AG. Volkswagen AG d
agen oes
lksw not
4 - Wheel Bearing Housing by
Vo gu
ara
ed
❑ Refer to ⇒ Suspension,
horis nte
eo
Wheels, sSteering;
au
t
Rep. ra
c
Gr. 42 ;sWheel Bearing
ce
e
pt
du
an
y li
erm
ab
h re
5 - Cover Plate
hole
spec
ling. Refer to
t to the co
6 - Bolt
l purpos
❑ 12 Nm
❑ Quantity: 3
nf
ercia
❑ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing and Trailing Arm; Overview -
atio
m
Wheel Bearing .
o
n in
or c
thi
sd
iva
o
r
8 - Bolt
rp
cu
o
m
f
en
ng
9 - Dust Cap
❑ Replace after removing
❑ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing and Trailing Arm; Overview -
Wheel Bearing .
10 - Brake Rotor
❑ Diameter 272 mm
❑ Brake rotor thickness 10 mm
ce
le
un
pt
❑ Remove brake caliper before removing
an
d
itte
y li
erm
ab
ility
ot p
11 - Bolt
wit
is n
h re
❑ 8 Nm
ole,
spec
urposes, in part or in wh
12 - Brake Pads
t to the co
❑ Thickness without protective plate 11 mm
❑ Wear limit without protective plate 3 mm
rrectne
❑ Check the thickness. Refer to ⇒ Maintenance ; Booklet 36.1 ; Procedure Descriptions; Front and Rear
Brake Rotors, Checking Brake Pad Thickness and Condition .
s
❑ Always replace on both sides of the axle.
s o
cial p
f
❑ Removing and installing. Refer to ⇒ “2.2 Brake Pads, Removing and Installing”, page 60 .
inform
mer
13 - Brake Carrier
atio
m
n
c
i
or
n thi
❑ Vehicles with guide pins and protective caps
te
sd
iva
o
r
14 - Cap
p
cum
r
fo
en
ng
2. Rear Brakes 57
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
e
nl
♦ Install the Brake Pedal Actuator - VAG1869/2- to relieve pressure before removing a brake caliper or dis‐
pt
du
an
connecting a brake hose.
itte
y li
erm
ab
♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
1 - Bolt
t to the co
❑ 8 Nm
2 - Wheel Speed Sensor
rrectness of i
❑ Overview. Refer to
l purpos
nf
ercia
or
❑ Removing and instal‐
m
m
atio
ling. Refer to
om
n in
⇒ “4.4 Right/Left Rear
or c
thi
te
sd
a
o
r
rp
cu
ing and Installing”, page
o
m
f
38 .
en
ng
t.
yi Co
op
❑ Before inserting sensor, C py
t. rig
clean inner surface of
gh ht
pyri by
mounting hole and coat
co Vo
by lksw
cted
with Hot Bolt Paste - G
agen
Prote AG.
052 112 A3- .
3 - Bolt
❑ 90 Nm +90°
❑ Replace after removing
❑ Quantity: 2
4 - Brake Line
❑ 35 Nm
5 - Subframe
❑ Refer to ⇒ Suspension,
Wheels, Steering; Rep.
Gr. 42 ; Rear Axle;
Overview - Rear Axle
6 - Parking Brake Cable
❑ Overview. Refer to
⇒ “3.1 Overview - Park‐
ing Brake”, page 81 .
❑ Adjusting. Refer to ⇒ “3.2 Parking Brake, Adjusting”, page 81 .
❑ Removing and installing. Refer to ⇒ “3.3 Rear Brake Cable, Removing and Installing”, page 82 .
7 - Cover Plate
❑ For allocation. Refer to the Parts Catalog
8 - Axle Stub
❑ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing and Trailing Arm; Overview -
Wheel Bearing .
9 - Bolt
❑ 30 Nm +90°
❑ 8 Nm
un
pt
an
d
itte
y li
14 - Dust Cap
rm
ab
pe
ility
wit
, is n
❑ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing and Trailing Arm; Overview -
h re
Wheel Bearing .
hole
spec
es, in part or in w
15 - Brake Carrier
t to the co
16 - Brake Pads
l purpos
tion in
⇒ “2.2.2 Brake Pads, Torsion Beam Axle, Removing and Installing”, page 63 .
r
te o
thi
17 - Brake Caliper
s
iva
do
r
rp
en
ng
❑ Do not detach the brake line when replacing the brake pads.
t.
yi Co
Cop py
❑ Removing and installing. Refer to ⇒ “2.3 Brake Caliper, Removing and Installing”, page 66 .
ht. rig
rig ht
py by
❑ Parking brake must be adjusted after repair work or replacing.
co Vo
by lksw
cted agen
❑ Adjusting the parking brake. Refer to ⇒ “3.2 Parking Brake, Adjusting”, page 81 .
Prote AG.
18 - Bolt
❑ 35 Nm
❑ Replace after removing
❑ Quantity: 2
❑ Self-locking
2. Rear Brakes 59
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Golf a2015
uth ➤ , Golf Variant 2015 ➤ or
ac
Brake System - Edition 12.2015
ss
ce
e
nl
pt
du
an
2.2 Brake Pads, Removing and Installing
itte
y li
erm
ab
ility
ot p
wit
ling”, page 60
, is n
h re
hole
spec
ling”, page 63
es, in part or in w
t to the co
2.2.1 Brake Pads, Multi-Link Rear Axle, Re‐
moving and Installing
rrectness of i
Special tools and workshop equipment required
l purpos
nform
ercia
at
om
ion
Caution
c
in t
or
his
ate
do
riv
cum
to component overview prior to starting procedure.
for
en
ng
t.
yi Co
Cop py
t. rig
gh
Mandatory Replacement Parts
ht
pyri by
Vo
co lksw
by
cted
♦ Bolt - Wheel bearing housing to brake carrier
agen
Prote AG.
Note
When removing, mark brake pads that will be used again. Install
in the same position, otherwise braking effect will be uneven.
WARNING
Adjust the brake piston is permitted only with the Brake Caliper
Tool - T10165- .
ce
le
un
pt
of the brake caliper does not burden or damage the brake
an
d
itte
hose.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the brake pads -arrows- from the brake carrier.
Cleaning
rrectness of i
l purpos
WARNING
Do not blow brake system using compressed air, the dust pro‐
nform
ercia
a
com
tion in
r
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Thoroughly clean the contact surfaces -arrows -for the brake
Co
op py
pads on the brake carrier -1- and remove any corrosion.
t. C rig
gh ht
pyri by
Vo
o
Installing by c lksw
cted agen
Prote AG.
Install in reverse order of removal. Note the following:
Note
♦ The repair kit has 4 self-locking screws for installing the brake
caliper. Always use these.
♦ After replacing brake pads, depress brake pedal firmly several
times with vehicle stationary so that the brake pads are prop‐
erly seated in their normal operating position.
♦ Check brake fluid level after replacing brake pad.
If using the brake pads again, install the marked pads in the same
location.
2. Rear Brakes 61
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Before pushing back the piston, extract some of the brake fluid
out of the brake fluid reservoir using a bleeder bottle. Other‐
wise, especially if reservoir has been topped off, fluid will
overflow and cause damage.
Note
– install the brake pads -2- with the spring -1- in the opening in
the brake carrier -3-.
olkswagen AG
en AG. V
– Carefully install the
olkbrake
swa
g caliper on the brake
does carrier.
no
yV t gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
wrench.
– After replacing brake pads, depress brake pedal firmly several
nform
ercia
times with vehicle stationary so that the brake pads are prop‐
m
ion
c
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Brake fluid level must be between the markings -1- and -2-.
Tightening Specification
♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 55
♦ Refer to ⇒ “2.1 Overview - Rear Brake
gen ACaliper”,
G. Volkswapage
gen AG100
d wa oes
olks no
♦ Wheel bolts. Refer to ⇒ Suspension,
db
yV Wheels, Steering; Rep.t guar
Gr. 44 ; Wheels and Tires;
rise
Wheel Bolt Tightening Specifica‐ an
tee
tions . utho or
a a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
moving and Installing
hole
spec
es, in part or in w
t to the co
♦ Torque Wrench 1331 5-50Nm - VAG1331-
rrectness of i
♦ Brake Caliper Tool - T10165-
l purpos
Caution
nform
ercia
a
com
tion in
r
te o
thi
s
iva
cum
fo
t.
yi Co
op
♦ Bolt - Axle stub to subframe C py
t. rig
gh ht
yri
♦ Bolt - Wheel hub with wheel bearing
p by
co Vo
by lksw
cted agen
♦ Dust cap
Prote AG.
Note
When removing, mark brake pads that will be used again. Install
in the same position, otherwise braking effect will be uneven.
WARNING
Adjust the brake piston is permitted only with the Brake Caliper
Tool - T10165- .
2. Rear Brakes 63
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Remove brake caliper -1- and secure with wire -A- so that the s
ce
e
nl
pt
du
an
brake hose.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Cleaning
m
at
om
ion
WARNING
c
in t
or
his
ate
do
riv
Do not blow brake system using compressed air, the dust pro‐
p
cum
en
ng
t.
yi Co
Cop py
t. rig
gh
Use only Appropriate Solvents for Cleaning Brake Caliper
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ The repair kit has four self-locking screws for installing the
brake caliper. Always use these.
♦ After replacing brake pads, depress brake pedal firmly several
times with vehicle stationary so that the brake pads are prop‐
erly seated in their normal operating position.
♦ Check brake fluid level after replacing brake pad.
If using the brake pads again, install the marked pads in the same
location.
ce
le
un
pt
an
d
itte
y li
erm
WARNING
ab
ility
ot p
wit
is n
Before pushing back the piston, extract some of the brake fluid
h re
out of the brake fluid reservoir using a bleeder bottle. Other‐
ole,
spec
wise, especially if reservoir has been topped off, fluid will
urposes, in part or in wh
t to the co
– Install the Brake Caliper Tool - T10165- so that the collar on
rrectne
the Resetting & Extracting Tool - Plate - T10165/1- is touching.
s
– Use the Resetting & Extracting Tool - Plate - T10165/1- to help
s o
you bolt it on.
cial p
f inform
– Turn the thumbwheel on the Brake Caliper Tool - T10165- to
mer
atio
m
piston collar.
o
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi Co
For pistons that are difficult to move, an open-end wrench (size
Cop py
13 mm) can be applied at the appropriate wrench surface
t. rig
gh ht
yri by
-arrow A-. cop Vo
by lksw
cted agen
Prote AG.
– check the protective caps for damage and correct seating
-item 9- ⇒ Item 9 (page 102) .
– Check the guide pins for ease of movement -item 8-
⇒ Item 8 (page 102) .
2. Rear Brakes 65
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
– Brake fluid level must be between the markings -1- and -2-.
Tightening Specification
♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 55
♦ Refer to ⇒ “2.1 Overview - Rear Brake Caliper”, page 100
♦ Wheel bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Specifica‐
tions .
ce
e
nl
pt
du
an
♦ Brake Pedal Actuator - VAG1869/2- .
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
spec
to component overview prior to starting procedure.
es, in part or in w
t to the co
Mandatory Replacement Parts
rrectness of i
♦ Bolt - Wheel bearing housing to brake carrier
l purpos
nform
♦ Dust cap
mercia
at
om
ion
c
Removing in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op
Work procedure applies only for replacing or when performing
C py
t. rig
gh
subsequent service work on brake caliper.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Loosen the wheel bolts.
– Raise the vehicle.
– Remove the wheel.
ce
le
un
pt
an
d
– Push the lever on the brake caliper -2- in the direction of the
itte
y li
-arrow-.
erm
ab
ility
ot p
– Disengage the parking brake cable -1- from the lever on the
wit
is n
brake caliper -2-.
h re
ole,
spec
– Squeeze the retainers -3-.
urposes, in part or in wh
t to the co
– Remove the parking brake cable -1- from the bracket on the
brake caliper -4-.
rrectness o
cial p
f inform
– Connect the bleed hose -1- from the bleeder bottle to the brake
caliper bleed valve and open the bleed valve. mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Rear Brakes 67
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
– Remove the brake hose -1- from the brake caliper -2-.
– To do this, remove banjo bolt -arrow-.
Volkswa
– Close the brake line sand
wagethreaded hole immediately
n AG. gen AG
does using
Sealing Plugs from
by
Volkthe Repair Kit - 1H0 698 311 not
A-
gu .
a d ran
se
– Counterhold tho the guide bolt and remove the bolts -arrows-e ofrom
ri te
the brake
ss
au
caliper -1-. ra
c
ce
e
pt
du
an
itte
y li
Cleaning
erm
ab
ility
ot p
wit
WARNING
, is n
h re
hole
spec
Do not blow brake system using compressed air, the dust pro‐
es, in part or in w
t to the co
rrectness of i
Note
l purpos
nf
ercia
orm
m
atio
m
Installing
o
n in
or c
sd
iva
cu
o
m
f
en
ng
– Guide the parking brake cable -1- through the bracket -4- on
the brake caliper until the tabs -3- engage.
AG. Volkswagen AG d
– Push the lever on the brake caliper -2- in direction ofag-arrow-.
lksw
en oes
not
o
yV gu
– Attach the parking brake cable -1- to the lever
rised -2- on the brake
b ara
nte
caliper. ut
ho eo
ra
s a c
– Pre-bleed the brake caliper before installing. Refer to
s
ce
le
⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105 .
un
pt
an
d
itte
y li
– Bleed the brake system. Refer to
rm
ab
⇒ “6 Hydraulic System”, page 132 .
pe
ility
ot
wit
, is n
– Adjust parking brake. Refer to
h re
⇒ “3.2 Parking Brake, Adjusting”, page 81 .
hole
spec
es, in part or in w
t to the co
– Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads correctly in their operating
rrectness of i
position.
l purpos
nform
ercia
a
com
t
♦ Refer to ⇒ “2.1 Overview - Rear Brake Caliper”, page 100
ion in
r
te o
thi
s
iva
do
r
rp
c
tions .
um
fo
en
ng
t.
yi Co
op
2.3.2 Brake Caliper, Torsion Beam Axle, Re‐
C py
ht. rig
rig ht
moving and Installing
py by
co Vo
by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Brake Pedal Actuator - VAG1869/2- .
Caution
2. Rear Brakes 69
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
Removing
Note
– Connect the bleed hose -1- from the bleeder bottle to the brake
caliper bleed valve and open the bleed valve.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
ab
ility
ot p
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
70
copy Vo
by lksw
Rep. Gr.46 - Mechanical Components cted agen
Prote AG.
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
– Remove the brake hose -1- and banjo bolt -2- to the brake
caliper.
– Close the brake hose immediately with Sealing Plugs from the
Repair Kit - 1H0 698 311 A- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Remove the brake caliper -1- from the brake carrier.
s s
ce
le
un
pt
– To do this, remove bolts -arrows-.
an
d
itte
y li
rm
ab
– Remove the brake caliper from the brake carrier.
pe
ility
ot
Cleaning
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
rrectness of i
l purpos
Note nform
ercia
a
com
tion in
r
te o
thi
Installing
s
iva
do
r
rp
cum
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ Replace the self-locking screws for installing the brake caliper.
Prote AG.
2. Rear Brakes 71
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Golf 2015 ➤ , Golf Variant tho2015
r ➤ eo
u ra
Brake System - Editionss a12.2015 c
ce
le
un
pt
– Attach the brake caliper -1- with the new self-locking screws
an
d
itte
y li
-arrows- to the brake carrier.
rm
ab
pe
ility
– While tightening counterhold the guide pin with a suitable
ot
wit
wrench.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Attach the brake hose connection -1- and the banjo bolt -2- to
the brake caliper.
m
a
com
tio
– Remove the Brake Pedal Actuator - VAG1869/2- .
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Push the parking brake cable -1- through the bracket -4- on
the brake caliper until the tabs -3- engage.
– Push the lever on the brake caliper -2- in the direction of the
-arrow-.
– Engage the parking brake cable -1- in the lever on the brake
caliper -2-.
– Bleed the brake system. Refer to
⇒ “6 Hydraulic System”, page 132 .
– Adjust parking brake. Refer to
⇒ “3.2 Parking Brake, Adjusting”, page 81 .
– Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads correctly in their operating
position.
– Check brake fluid level.
Tightening Specification
♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 55
♦ Refer to ⇒ “2.1 Overview - Rear Brake Caliper”, page 100
♦ For installing the wheel bolts. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheels and Tires; Wheel Bolt Tight‐
ening Specifications .
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Dust cap
ility
ot p
wit
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ When removing, mark brake pads that will be used again. In‐
stall in the same position, otherwise braking effect will be
l purpos
uneven.
♦ Do not open the brake hydraulic system when removing!
nform
mercia
at
– Loosen the wheel bolts.
om
ion
c
in t
– Raise the vehicle.
or
his
ate
do
– Remove the wheel.
priv
cum
for
t.
yi
⇒ “2.2.1 Brake Pads, Multi-Link Rear Axle, Removing and In‐
Co
Cop py
stalling”, page 60 .
t. rig
gh ht
pyri by
Vo
o
– Remove brake caliper and secure with wire so that the weight by c lksw
cted agen
of the brake caliper does not burden or damage the brake Prote AG.
hose.
2. Rear Brakes 73
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
Note ss a ra
c
ce
e
nl
pt
Use only appropriate solvents for cleaning brake system.
du
an
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
h re
hole
spec
– Thoroughly clean the contact surfaces on the brake carrier for
es, in part or in w
t to the co
If using the brake pads again, install the marked pads in the same
location.
rrectness of i
– Secure the brake caliper with new self-locking bolts. Refer to
l purpos
nform
ercia
– Before moving the vehicle, press the brake pedal firmly sev‐
m
at
om
io
position.
n
c
in t
or
his
e
do
priv
c
Tightening Specification
um
for
en
ng
t.
yi
♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 55
Co
Cop py
ht. rig
♦ Refer to ⇒ “2.1 Overview - Rear Brake Caliper”, page 100 rig ht
py by
co Vo
by lksw
♦ Wheel bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep. cted agen
Prote AG.
Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Specifica‐
tions .
Note
♦ When removing, mark brake pads that will be used again. In‐
stall in the same position, otherwise braking effect will be
uneven.
♦ Do not open the brake hydraulic system when removing!
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Rear Brakes 75
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
Note
Installing
Install in reverse order of removal. Note the following:
Note
pt
du
y li
erm
ab
– Before moving the vehicle, press the brake pedal firmly sev‐
wit
, is n
h re
position.
spec
es, in part or in w
t to the co
tions .
m
atio
om
n in
or c
sd
iva
o
r
cu
o
ling”, page 76
f
en
ng
t.
yi Co
op
⇒ “2.6.2 Brake Shield, Multi-Link Rear Axle, Removing and In‐
C py
t. rig
gh
stalling”, page 78
ht
pyri by
Vo
o
by c lksw
2.6.1 Brake Shield, Torsion Beam Axle, Re‐
cted agen
Prote AG.
Note
♦ When removing, mark brake pads that will be used again. In‐
stall in the same position, otherwise braking effect will be
uneven.
AG. Volkswagen AG d
agen
♦ Do not open the brake hydraulic systemVowhen
lksw removing!
oes
not
gu
y
db ara
rise nte
– Loosen the wheel bolts. tho eo
au ra
c
ss
– Raise the vehicle.
ce
e
nl
pt
du
an
– Remove the wheel.
itte
y li
erm
ab
– Remove the brake carrier. Refer to
ility
ot p
wit
, is n
h re
– Remove brake rotor. Refer to
hole
spec
⇒ “2.5 Brake Rotor, Removing and Installing”, page 74 .
es, in part or in w
t to the co
– Remove the wheel bearing unit. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing and Trailing
Arm; Overview - Wheel Bearing .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Rear Brakes 77
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
Note
Installing
Install in reverse order of removal. Note the following:
If using the brake pads again, install the marked pads in the same
location.
– Secure the brake caliper with new self-locking screws. Refer
to the Parts Catalog.
– Install wheel and tighten.
– Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads ecorrectly in their operating
n AG. Volkswagen AG do
position. olkswag es n
o V t gu
by ara
– Check brake fluid level.
ris
ed nte
tho eo
au
Tightening Specification ra
c
ss
ce
e
pt
du
an
itte
y li
ab
ility
ot p
tions .
hole
spec
es, in part or in w
orm
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Note
♦ When removing, mark brake pads that will be used again. In‐
stall in the same position, otherwise braking effect will be
uneven.
♦ Do not open the brake hydraulic system when removing!
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Rear Brakes 79
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
WARNING
Do not blow brake system using compressed air, the dust pro‐
duced is harmful to health!
Note
Installing
Install in reverse order of removal. Note the following:
If using the brake pads again, install the marked pads in the same
location.
– Secure the brake caliper with new self-locking screws. Refer
to the Parts Catalog.
– Install wheel and tighten.
AG. Volkswagen AG d
agen o
– Before moving the vehicle, pressVol
ksw the brake pedal firmlyessev‐
not
eral times to seat the braked by pads correctly in their operatingguar
e an
position. ris tee
tho o
au ra
c
– Check brake fluidsslevel.
ce
le
un
pt
Tightening Specification
an
d
itte
y li
rm
ab
ility
ot
h re
hole
tions .
t to the co
Wheel Bearing .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
⇒ “3.2 Parking Brake, Adjusting”, page 81
nl
pt
du
an
itte
y li
erm
ab
ility
3.1 Overview - Parking Brake
ot p
wit
, is n
h re
hole
spec
1 - Handle
es, in part or in w
t to the co
❑ For allocation. Refer to
the Parts Catalog
2 - Trim for Parking Brake Lev‐
rrectness of i
er
l purpos
nform
ercia
at
4 - Bolt
om
ion
c
in t
❑ 20 Nm +90°
or
his
ate
do
priv
cum
❑ Quantity: 2
for
en
ng
t.
yi Co
5 - Relay Pull Rod t. Cop py
rig
gh ht
6 - Compensator Bracket yri
p by
co Vo
by lksw
cted
7 - Adjusting Nut
agen
Prote AG.
Note
Adjusting
– Raise the vehicle.
3. Parking Brake 81
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
– Remove the center console. Refer to ⇒ Body Interior; Rep. le
un
pt
an
d
y li
erm
ab
– Adjust the parking brake using the adjusting nut -1-.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Tighten the adjusting nut until the levers -1- on the brake cal‐
o
n
c
i
or
n thi
te
sd
a
– The distance -a- to the stop -2- on the left and right brake cal‐
iv
o
pr
c
iper must not exceed 1.5 mm together.
um
r
fo
en
ng
t.
yi
– Check whether wheels turn freely.
Co
Cop py
t. rig
Due to the automatic rear brake adjuster, there is no need to ad‐
gh ht
pyri by
just the parking brake after making initial adjustment.
co Vo
by lksw
cted agen
Prote AG.
– Press the lever -2- located on the brake caliper in the direction
of the -arrow- and disengage the brake cable -1-.
– Squeeze the tabs -3- and remove the brake cable from the
bracket -4- on the brake caliper.
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Center Console; Overview - Center Console .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
– Pull the brake cable -1- out of the retainer -arrow A- on the
nl
pt
du
bracket -2-.
an
itte
y li
erm
ab
– Pull the brake cable -1- in the direction of the -arrow- out of the
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Disengage the brake cable -1- from the bracket -3- and pull it
nf
ercia
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Parking Brake 83
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
Installing
Install in reverse order of removal. Note the following:
– Pay attention that the guide tube and the seal are seated cor‐
rectly.
– Push the brake cable -1- in the guide tube -2- until stop.
– Engage the brake cable -1- in the bracket -3- and push in wire.
– Engage the brake cable at the marking -arrow-.
– Insert the brake cable -1- into the guide -arrow B- on the
bracket -2- opposite the direction of -arrow-.
– Clip the brake cable -1- back into the retainer -arrow A- on the
bracket -2-.
AG. Volkswagen AG d
agen oes
lksw not
– Push the brake cable by
V -1- through the bracket -4- on
o gthe
ua brake
caliper until both
ris tabs -3- engage.
ed ran
tee
tho or
u
– Press thess lever -2- located on the brake caliper in direction of
a ac
-arrow- and engage the brake cable -1-.
ce
e
nl
pt
du
an
y li
bracket on the brake caliper and the bracket on the rear axle.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
-3-.
l purpos
-1-.
atio
om
n in
c
thi
e
sd
iva
o
r
rp
cu
Tightening Specification
o
m
f
en
ng
t.
yi
♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Over‐
Co
op py
view - Center Console . t. C rig
gh ht
pyri by
♦ For installing the wheel bolts. Refer to ⇒ Suspension, Wheels,
o Vo
by c lksw
cted
Steering; Rep. Gr. 44 ; Wheels and Tires; Wheel Bolt Tight‐
agen
Prote AG.
ening Specifications .
ce
le
– Remove the wheel.
un
pt
an
d
itte
y li
– Loosen the parking brake lever.
rm
ab
pe
ility
• Parking brake lever in released position.
ot
wit
, is n
h re
– Press the lever -2- located on the brake caliper in the direction hole
of the -arrow- and disengage the brake cable -1-.
spec
es, in part or in w
– Squeeze the tabs -3- and remove the brake cable from the
t to the co
bracket -4- on the brake caliper.
– Remove the center console. Refer to ⇒ Body Interior; Rep.
rrectness of i
Gr. 68 ; Center Console; Overview - Center Console .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Loosen the adjusting nut -1- until it is possible to disengage
s
iva
do
the parking brake cable -2- from the compensator bracket
r
rp
cum
fo
-3-.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disengage the brake cable -1- from the bracket -3- and pull it
from the guide tube -2-.
– Release the bracket from the rear axle and remove upward.
– Remove the brake cable rearward from the guide bushing on
the rear axle.
3. Parking Brake 85
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
Installing
Install in reverse order of removal. Note the following:
– Guide the brake cable from the rear in the guide bushing.
– Clip in the bracket on the rear axle.
– Check for secure fit by pulling on it.
– Pay attention that the guide tube and the seal are seated cor‐
rectly.
– Push the brake cable -1- in the guide tube -2- until stop.
– Engage the brake cable -1- in the bracket -3- and push in wire.
– Engage the brake cable at the marking -arrow-.
– Push the brake cable -1- through the bracket -4- on the brake
caliper until both tabs -3- engage.
– Press the lever -2- located on the brake caliper in the direction
of the -arrow- and engage the brake cable -1-.
The brake cable must be installed without tension between the
bracket on the brake caliper and the bracket on the rear axle.
Tightening Specification
pt
du
an
itte
y li
ab
wit
, is n
spec
ening Specifications .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4 Brake Pedal
⇒ “4.1 Overview - Brake Pedal”, page 87
⇒ “4.2 Brake Pedal, Removing from Brake Booster”, page 88
⇒ “4.3 Brake Pedal, Attaching to Brake Booster”, page 89
. Volkswagen AG
⇒ “4.4 Brake Pedal, Removing and Installing”, page 89kswagen AG does
not
ol
yV gu
⇒ “4.5 Mounting Bracket, Removing and Installing”,
ed b page 90 ara
nte
ris
ho eo
ut
4.1 Overview - Brake Pedal ss
a ra
c
ce
le
un
pt
an
WARNING d
itte
y li
rm
ab
pe
ility
The path of the brake pedal must not be shortened via extra
ot
wit
, is n
floor mats.
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Do not lubricate or grease the mounting pin. The mounting pin must remain dry.
l purpos
nform
ercia
❑ 25 Nm
m
a
com
ti
❑ Replace after removing
on in
r
thi
s
quence. Refer to
iva
do
r
cum
fo
quence”“ , page 88
en
ng
t.
yi Co
op
2 - Mounting Pin
C py
t. rig
gh ht
yri
❑ Remove the bracket to p by
o Vo
by c lksw
remove. Prote
cted AG.
agen
4. Brake Pedal 87
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
ce
le
un
pt
an
Tightening Sequence
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
Booster
com
tion in
r
te o
do
r
cum
fo
en
ng
t.
– Remove the footwell cover on the driver side. Refer to ⇒ Body
yi Co
op
Interior; Rep. Gr. 68 ; Storage Compartments and Covers .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
3 - Retaining tabs
y li
rm
ab
pe
ility
– Insert Release Tool - Brake Servo - T10159- and pull in direc‐
ot
wit
tion of driver seat. When doing this, counter-hold on brake
, is n
h re
pedal. (At this moment the pedal must not be allowed to move
hole
to the driver seat). The mount retaining tabs -3- will thereby be
spec
es, in part or in w
t to the co
The process of separating the brake pedal from the brake booster
is shown with the pedal assembly removed.
rrectness of i
– Pull Release Tool - Brake Servo - T10159- and brake pedal
together toward the driver seat. (This will pull the brake pedal
l purpos
nform
mercia
a
com
ti
Rep. Gr. 68 ; Storage Compartments and Covers; Component
on in
Location Overview - Storage Compartment/Covers .
r
te o
thi
s
iva
do
r
rp
c
4.3 Brake Pedal, Attaching to Brake Booster
um
fo
en
ng
t.
yi Co
– Hold the push rod ball head in front of the mount and push the . Cop py
brake pedal toward the brake booster until the ball head en‐
ht rig
rig ht
by
gages audibly. copy Vo
by lksw
cted agen
Prote
– Check the lock by pulling on the brake pedal.
AG.
Note
4. Brake Pedal 89
olkswagen AG
ag en AG. V
Golf 2015 ➤ , Golf Variant 2015 o➤
lksw
does
not
yV gu
Brake System - Edition 12.2015
se
d b ara
nte
ri
ho eo
ut ra
– Turn the mounting pins clockwise
ss
a in the direction of the c
-arrow-.
ce
le
un
pt
an
d
-1- = Hex Socket Wrench SW 14.
itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
At the same time the tabs -B- break. Replacing the mounting pin.
es, in part or in w
t to the co
– Remove the clip from the mounting pin.
– Remove the mounting pin from the right.
rrectness of i
– Remove the brake pedal from the bracket.
l purpos
Installing
nform
ercia
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
Replace the mounting pin and clip.
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Note co Vo
by lksw
cted agen
Prote AG.
Do not lubricate or grease the mounting pin. The mounting pin
must remain dry.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
ab
ility
ot p
h re
Installing
hole
spec
t to the co
– Connect the brake pedal together with the brake booster. Re‐
fer to
⇒ “4.3 Brake Pedal, Attaching to Brake Booster”, page 89 .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Brake Pedal 91
. Volkswagen AG
Golf 2015 ➤ , Golf Variant 2015 ➤ kswagen AG does
not
ol
Brake System - Edition 12.2015 d by V gu
ara
e nte
ris
ho eo
Tightening Sequence au
t ra
c
ss
Tightening Specification
ce
le
un
pt
an
d
itte
♦ Refer to ⇒ “4.1 Overview - Brake Pedal”, page 87
y li
rm
ab
pe
ility
♦ Crash bolster. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instru‐
ot
wit
ment Panel Central Tube; Overview - Instrument Panel Cen‐ , is n
h re
tral Tube .
hole
spec
♦ Footwell vent. Refer to ⇒ Heating, Ventilation and Air Condi‐
es, in part or in w
t to the co
tioning; Rep. Gr. 87 ; Air Routing; Overview - Air Routing and
Air Distribution in Passenger Compartment .
♦ Knee airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee
rrectness of i
Airbags; Overview - Knee Airbag
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5 Special Tools
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Special Tools 93
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
♦ Torque Wrench 1331 rise
d
nte
5-50Nm - VAG1331- utho eo
ra
s a c
s
♦ Torque Wrench 1332
ce
le
un
40-200Nm - VAG1332-
pt
an
d
itte
y li
♦ Brake Caliper Tool -
erm
ab
T10165-
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Special Tools 95
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
47 – Hydraulic Components
1 Front Brake Caliper
⇒ “1.1 Overview - Front Brake Caliper”, page 97
⇒ “1.2 Brake Caliper Piston, Removing and Installing”,
page 98
1 - Dust Cap
❑ Install onto bleeder
valve
2 - Bleeder Valve
AG. Volkswagen AG d
❑ 10 Nm agen oes
olksw not
V gu
by
❑ Apply a thin risedcoat of As‐ ara
nte
semblyutPaste - G 052
ho eo
ra
150 A2-
ss a to the threads c
before screwing in.
ce
le
un
pt
an
d
3 - Hex Bolt
itte
y li
rm
ab
❑ 35 Nm
pe
ility
ot
h re
4 - Guide Pin
hole
spec
es, in part or in w
5 - Cap
t to the co
6 - Brake Carrier
m
a
com
ti
thi
do
cum
pins.
fo
en
ng
t.
yi
❑ If protective caps or
Co
op py
guide pins are damaged
t. C rig
gh ht
yri
use repair kit. Use sup‐ p by
o Vo
by c
plied grease packet to
lksw
cted agen
Prote
lubricate guide pins.
AG.
7 - Cap
❑ Removing and instal‐
ling. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
❑ Do not damage when installing piston
8 - Piston
❑ Removing and installing. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
❑ Apply thin coat of Assembly Paste - G 052 150 A2- to piston before inserting
9 - Seal
❑ Removing and installing. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
10 - Brake Caliper
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Remove seal with Trim Removal Wedge - 3409- .
ility
ot p
wit
is n
h re
ole,
aged.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
Installing
o
n
c
i
or
n
– Clean the surfaces on the pistons and seal with mineral spirits. thi
te
sd
iva
cum
r
fo
t.
yi Co
op
– Insert oil seal into brake caliper. C py
t. rig
gh ht
yri by
– Place the cap with the outer sealing lip on the piston. op Vo
by c lksw
cted agen
Prote AG.
ce
le
un
Hold piston in front of brake caliper for this procedure.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Press piston into the brake caliper using piston resetting tool.
ss
The outer seal lip of the cap thereby slips into the groove on the
o
cial p
f i
piston.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
page 102
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
♦ Only use mineral spirits to clean brake parts.
♦ Apply thin coat of Lithium Grease - G 052 150 A2- to brake cylinders, pistons and seals.
rrectness of i
♦ When servicing or replacing the brake caliper the brake caliper must be pre-bleed before installing in the
l purpos
vehicle (without brake pads). Refer to ⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 - Brake Caliper
❑ Vehicles with parking
brake cable lever
❑ If a leak exists at lever
for parking brake cable,
replace brake caliper.
❑ Pre-bleed brake caliper
after replacing. Refer to
⇒ “2.1 Overview - Rear
Brake Caliper”,
page 100 .
2 - Bleeder Valve
❑ 10 Nm
❑ Before installing lightly
coat the threads with
Lithium Grease - G 052
150 A2- .
3 - Dust Cap
4 - Bolt
❑ 35 Nm
❑ Replace after removing
❑ Quantity: 2
❑ Self-locking
❑ When loosening and
tightening, counterhold
at guide pin
5 - Guide Pin
❑ Vehicles with recess
❑ Lubricate before instal‐
ling the cap
❑ For allocation. Refer to
the Parts Catalog n AG. Volkswagen AG do
lkswage es n
o ot g
yV
6 - Guide Grommet d b ua
ran
ir se tee
ho
7 - Cap aut or
ac
ss
❑ Install on brake carrier and guide pin.
ce
le
un
pt
an
d
8 - Guide Pin
itte
y li
rm
ab
ility
ot
wit
9 - Brake Carrier
, is n
h re
spec
❑ If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate guide
es, in part or in w
t to the co
pins.
❑ For allocation. Refer to the Parts Catalog
rrectness of i
10 - Cap
❑ Pull onto piston with outer sealing lip
l purpos
❑ Removing and installing. Refer to ⇒ “2.2 Brake Caliper Piston, Removing and Installing”, page 103 .
nform
ercia
❑ Removing and installing. Refer to ⇒ “2.2 Brake Caliper Piston, Removing and Installing”, page 103 .
a
com
tio
❑ Apply thin coat of Assembly Paste - G 052 150 A2- to piston before inserting
n in
r
te o
thi
12 - Seal
s
iva
do
r
rp
❑ Removing and installing. Refer to ⇒ “2.2 Brake Caliper Piston, Removing and Installing”, page 103 .
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
101
cted agen
Prote AG.
2. Rear Brake Caliper
Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
1 - Cap
❑ Pull onto piston with out‐
er sealing lip
❑ Removing and instal‐
ling. Refer to
⇒ “2.2.1 Brake Caliper
Piston, Removing and
Installing”, page 103 .
2 - Piston with Automatic Ad‐
justment
❑ Removing and instal‐
ling. Refer to
⇒ “2.2.1 Brake Caliper AG. Volkswagen AG d
agen oes
ksw
Piston, Removing and byV
ol not
gu
ara
Installing”, page 103 . rised
nte
ho eo
❑ Apply thin coat of As‐ aut ra
c
sembly Paste - G 052 ss
ce
e
pt
du
an
inserting
itte
y li
erm
ab
3 - Seal
ility
ot p
wit
, is n
h re
ling. Refer to
hole
spec
Piston, Removing and
es, in part or in w
t to the co
Installing”, page 103 .
4 - Brake Caliper
rrectness of i
❑ Removing and instal‐
ling. Refer to
l purpos
nform
ercia
at
brake cable lever
om
ion
c
in t
❑ Replace brake caliper if
or
his
e
do
riv
cable lever
p
cum
for
t.
yi
⇒ “2.3.1 Brake Carrier, Multi-Link Rear Axle, Removing and Installing”, page 66 .
Co
Cop py
ht. rig
5 - Bleeder Valve
rig ht
py by
co Vo
by lksw
❑ 10 Nm Prote
cted AG.
agen
❑ Apply a thin coat of Assembly Paste - G 052 150 A2- to the threads before screwing in
6 - Dust Cap
7 - Bolt
❑ 35 Nm
❑ Replace after removing
❑ Self-locking
❑ When loosening and tightening, counterhold at guide pin
8 - Guide Pin
❑ Lubricate before installing the cap
❑ Check for ease of movement
9 - Cap
❑ Install on brake carrier and guide pin
ce
e
nl
pt
du
an
itte
Removing
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
Adjust the brake piston is permitted only with the Brake Caliper
es, in part or in w
Tool - T10165- .
t to the co
– Install the Brake Caliper Tool - T10165- so that the collar
rrectness of i
touches the piston.
l purpos
nform
ercia
at
om
io
-arrow A-.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Remove the sealing ring using the Trim Removal Wedge -
op Vo
by c lksw
3409- . cted agen
Prote AG.
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
♦ Install complete repair kit when servicing.
ility
ot p
wit
♦ Only use mineral spirits to clean brake parts.
, is n
h re
hole
♦ New brake calipers are filled with brake fluid and are pre-bled.
spec
es, in part or in w
t to the co
cylinders, pistons and seals.
♦ In case of repair, brake calipers must always be pre-bled be‐
rrectness of i
fore being installed into vehicle (without brake pads). Refer to
⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105 .
l purpos
– Clean the surfaces on the pistons and seal only with mineral
nform
ercia
at
om
ion
c
in t
or
his
te
do
priv
cum
or
– Place the cap with the outer sealing lip on the piston.
f
en
ng
t.
yi Co
Cop py
– Insert inner sealing lip in cylinder groove with Trim Removal
t. rig
gh ht
yri
Wedge - 3409- . p by
co Vo
by lksw
cted agen
– Hold piston in front of brake caliper for this procedure. Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
page 106
erm
ab
ility
ot p
wit
, is n
h re
⇒ “3.3 Brake Master Cylinder, Removing and Installing”,
hole
page 110
spec
es, in part or in w
t to the co
⇒ “3.5 Brake Fluid Reservoir, Removing and Installing”,
page 118
rrectness of i
3.1 Overview - Brake Booster/Brake Master Cylinder
l purpos
nform
ercia
WARNING
m
at
om
ion
14).
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
1 - Hex Nut
yi Co
Cop py
❑ 25 Nm ht. rig
rig ht
py by
❑ Self-locking
co Vo
by lksw
cted agen
Prote
❑ Replace after removing
AG.
❑ Tightening sequence.
Refer to
⇒ Fig. ““Tightening Se‐
quence”“ , page 108
2 - Bracket/Pedal Assembly
❑ Assembly sequence.
Refer to
⇒ “4.1 Overview - Brake
Pedal”, page 87 .
❑ Mounting bracket, re‐
moving and installing.
Refer to
⇒ “4.5 Mounting Brack‐
et, Removing and Instal‐
ling”, page 90 .
❑ Separate the brake ped‐
al from brake booster.
Refer to
⇒ “4.2 Brake Pedal, Re‐
moving from Brake
Booster”, page 88 .
❑ Brake pedal to brake
booster, connecting.
Refer to
⇒ “4.3 Brake Pedal, At‐
taching to Brake Boos‐
ter”, page 89 .
❑ Brake Pedal, removing
and installing. Refer to
⇒ “4.4 Brake Pedal, Re‐
moving and Installing”,
page 89 .
3 - Bulkhead
4 - Hex Nut
❑ 23 Nm
❑ Self-locking
❑ Replace after removing
5 - Brake Master Cylinder
❑ Cannot be serviced. Replace as complete unit if malfunctioning.
❑ Removing and installing. Refer to ⇒ “3.3 Brake Master Cylinder, Removing and Installing”, page 110 .
6 - Brake Lamp Switch - F-
❑ Removing and installing. Refer to ⇒ “3.2 Brake Lamp Switch, Removing and Installing”, page 108 .
7 - Bolt
❑ 8 Nm
8 - Brake Line
❑ 14 Nm
❑ Brake master cylinder/secondary piston circuit to the ABS Hydraulic Unit - N55-
9 - Brake Line
❑ 14 Nm
❑ Brake master cylinder/primary piston circuit to the ABS Hydraulic Unit - N55-
10 - Sealing Plug
❑ Moisten with brake fluid and press into brake fluid reservoir
11 - Brake Fluid Level Warning Switch - F34-
12 - Brake Fluid Reservoir
❑ Bolt 8 Nm
13 - Vacuum Hose AG. Volkswagen AG d
agen oes
❑ Vehicles with check valve Volksw not
gu
by ara
❑ Insert into brake booster rise
d
nte
ho eo
❑ On some vehicles with a gasoline engine
s a the Brake Booster Vacuum Sensor - G608- is installed.
ut ra
c Refer
to ⇒ “4.3 Vacuum Sensor G608 , Removing
s and Installing”, page 122 .
ce
e
nl
pt
du
14 - Cap an
itte
y li
erm
ab
15 - Seal ility
ot p
h re
16 - Seal
hole
spec
t to the co
17 - Brake Booster
❑ Functional check:
rrectness of i
– Vehicles with engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in
l purpos
the unit).
– Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working
nf
ercia
properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).
orm
m
atio
❑ Replace completely if there are malfunctions (check the vacuum system for the brake booster first; refer
om
n in
thi
e
❑ Removing and installing. Refer to ⇒ “3.4 Brake Booster, Removing and Installing”, page 113 .
t
sd
iva
o
r
rp
cu
18 - Seal
o
m
f
en
ng
❑ Replacing
t.
yi Co
Cop py
❑ Attached, only at the factory
t. rig
gh ht
yri by
❑ Do not replace the gluing on the brake booster and plenum chamber cop Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
Removing
om
n in
c
Diesel Vehicles
or
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Remove the air guide hose.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
698 311 A-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
Component Location
en
ng
t.
yi Co
op
1 - ABS Hydraulic Unit -
C py
t. rig
gh
N55- and ABS Control
ht
pyri by
Vo
o
Module - J104-
c by lksw
cted agen
Prote AG.
2 - Brake Booster
Removing
– If the vehicle has a
coded radio, get the
radio code from the
customer before be‐
ginning.
Diesel Vehicles
– Unclip the vacuum line from the air guide hose.
– Open the clamps -1 and 2-.
– Remove the air guide hose.
n AG. Volkswagen AG do
– Remove the air filter housing. Refer to ⇒ Engine Mechanical, olks
wage es n
ot g
Fuel Injection and Glow Plug; Rep. Gr. 23 ; Air Filter; Aird bFilter
y V ua
ran
Housing, Removing and Installing . or
ise tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Vehicles with 2.0 L Gasoline Engine
ot p
wit
, is n
h re
hole
spec
– Remove the air guide hose -1-.
es, in part or in w
t to the co
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
Vehicles with a Manual Transmission olksw not
y V gu
d b ara
– Remove the supply hose -2- for the clutch rise master cylinder nte
tho eo
-3- from the brake fluid reservoir -4-.s au ra
c
s
– Seal the supply hose -2- for the clutch master cylinder -3- using
ce
le
un
pt
Sealing Tool - T10249- -1- or Engine Bung Set - VAS6122- .
an
d
itte
y li
erm
ab
– Tie up the return hose -2-.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Continuation for All Vehicles
– If equipped release the connector -2- from the Vacuum Sensor rrectne
- G608- .
ss o
cial p
– Release and remove the connector -3- from the Brake Fluid
inform
atio
and remove.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Remove the bolt -1- and pull the brake fluid reservoir -2- from
p by
co Vo
by lksw
the sealing plugs. Prote
cted AG.
agen
ce
le
– Carefully take brake master cylinder out of brake booster.
un
pt
an
d
itte
– Remove the Brake Light Switch - F- from brake master cylin‐
y li
erm
ab
der.
ility
ot p
wit
Installing
is n
h re
ole,
Install in reverse order of removal. Note the following:
spec
urposes, in part or in wh
t to the co
booster, make sure that the push rod is correctly located in the
brake master cylinder.
rrectne
– Make sure the seal fits correctly when attaching the master
brake cylinder to the brake booster -item 15-
s
⇒ Item 15 (page 107) .
s o
cial p
f
– Make sure the sealing plugs are seated correctly in the brake
inform
master cylinder -item 10- ⇒ Item 10 (page 107) .
mer
atio
m
– Coat the plugs with brake fluid before pushing the brake fluid
o
n
c
i
or
n thi
e
sd
iva
o
pr
c
– Bleed the brake system. Refer to
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Vehicles with Manual Transmission
gh ht
pyri by
Vo
o
by c lksw
– The seals -2- must be located in the return hose -1- to the cted agen
Prote AG.
clutch master cylinder.
– Bleed the clutch mechanism. Refer to ⇒ Manual Transmis‐
sion; Rep. Gr. 30 ; Clutch Mechanism; Clutch Mechanism,
Bleeding .
Tightening Specification
♦ Refer to
⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”, page
106
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing and
Installing .
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 23 ; Air Filter; Overview - Air Filter Housing .
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 24 ; Air Filter; Overview - Air Filter Housing .
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Over‐
view - Battery .
ce
e
nl
pt
du
an
itte
♦ Torque Wrench 1410 - VAG1410-
y li
erm
ab
♦ Hot air gun for example Wiring Harness Repair Set - Hot Air
ility
ot p
Blower - VAS1978/14A- .
wit
, is n
h re
hole
♦ Brake Charger/Bleeder Unit - VAS5234-
spec
es, in part or in w
♦ Engine Bung Set - VAS6122-
t to the co
♦ Adhesive Strip Remover - VAS6349-
♦ Sealing Plugs from the Repair Kit - 1H0 698 311 A-
rrectness of i
♦ Drill for example cordless drill or straight sander.
l purpos
nf
ercia
Note
orm
m
atio
m
n in
c
thi
e
sd
iva
o
r
rp
cu
o
m
f
Component Location
en
ng
t.
yi Co
op
1 - ABS Hydraulic Unit - N55- and ABS Control Module - J104-
C py
t. rig
gh ht
yri by
2 - Brake Booster
cop Vo
by lksw
cted agen
Prote AG.
Removing
– If the vehicle has a coded radio, get the radio code from the
customer before beginning.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the engine cover. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 10 ; Engine Cover; Engine
Cover, Removing and Installing .
Diesel Vehicles
– Unclip the vacuum line from the air guide hose.
– Open the clamps -1 and 2-.
– Remove the air guide hose.
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Glow Plug; Rep. Gr. 23 ; Air Filter; Air Filter
Housing, Removing and Installing .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
h re
– Remove the supply hose -2- for the clutch master cylinder
hole
spec
t to the co
– Seal the supply hose -2- for the clutch master cylinder -3- using
Sealing Tool - T10249- -1- or Engine Bung Set - VAS6122- .
rrectness of i
nform
mercia
at
om
ion
c
in t
his
ate
- G608- .
um
for
en
ng
t.
yi
– Release and remove the connector -3- from the Brake Fluid
Co
op py
Level Warning Switch - F34- .
t. C rig
gh ht
pyri by
Vo
– Release the connector -1- from the Brake Lamp Switch - F-
co lksw
by
cted agen
and remove. Prote AG.
ce
le
pt
an
d
y li
erm
ab
– Remove the footwell cover on the driver side. Refer to ⇒ Body
ility
ot p
wit
is n
h re
– Remove the driver side center console cover. Refer to ⇒ Body
ole,
spec
Interior; Rep. Gr. 68 ; Center Console; Center Console, Re‐
urposes, in part or in wh
t to the co
– Remove the driver side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
rrectne
ers .
– Remove the driver side instrument panel cover. Refer to ⇒
ss
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
o
cial p
f
ers; Driver Side Instrument Panel Cover, Removing and In‐
inform
stalling .
mer
atio
– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
om
n
69 ; Knee Airbags; Overview - Knee Airbag .
c
i
or
n thi
te
sd
– Remove the footwell vent on the driver side. Refer to ⇒ Heat‐
iva
o
r
cum
r
fo
t.
yi
partment .
Co
Cop py
t. rig
gh
– Remove the crash bolster. Refer to ⇒ Body Interior; Rep. Gr.
ht
pyri by
Vo
70 ; Instrument Panel Central Tube; Overview - Instrument
co lksw
by
cted agen
Panel Central Tube . Prote AG.
– Remove the bolt -1- and fold the footwell trim panel -2- in the
direction of the -arrow- into the vehicle interior.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
the factory.
spec
es, in part or in w
t to the co
chamber, but replace the seal.
rrectness of i
– Remove all adhesive residue from the plenum chamber and if
necessary the brake booster. To do this use Adhesive Strip
l purpos
– Warm the adhesive residue gentle heat using a hot air gun and orm
remove.
m
atio
om
n in
sd
iva
o
r
cu
o
m
f
en
ng
ce
le
view - Knee Airbag
un
pt
an
d
itte
y li
♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments
rm
ab
and Covers; Component Location Overview - Storage Com‐
pe
ility
partment/Covers .
ot
wit
, is n
h re
♦ Refer to ⇒ Manual Transmission; Rep. Gr. 34 ; Selector
hole
spec
Mechanism; Overview - Selector Mechanism .
es, in part or in w
t to the co
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control Mod‐
ules; Data Bus On Board Diagnostic Interface - J533- , Re‐
moving and Installing .
rrectness of i
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
l purpos
nform
ercia
a
com
tio
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
n in
r
te o
thi
s
iva
do
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Over‐
r
rp
cum
view - Battery .
fo
en
ng
t.
yi Co
Cop py
3.5 Brake Fluid Reservoir, Removing and
t. rig
gh ht
pyri by
Installing
co Vo
by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
♦ Sealing Tool - T10249-
♦ Brake Charger/Bleeder Unit - VAS5234-
♦ Engine Bung Set - VAS6122-
Removing
– Place sufficient lint-free cloths in the area of the engine and
transmission.
– Extract as much brake fluid as possible from the brake fluid
reservoir with the Brake Charger/Bleeder Unit - VAS5234- .
pt
and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Re‐
y li
erm
ab
wit
is n
h re
ole,
spec
urposes, in part or in wh
– Release the connection -2- for the Brake Fluid Level Warning
Switch - F34- and remove.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
119
copy Vo
by lksw
cted 3. Brake Booster/Brake Master Cylinder
agen
Prote AG.
n AG. Volkswagen AG do
wage es n
Golf 2015 ➤ , yGolf Vo Variant 2015 ➤
lks ot g
b ua
Brake Systemir se - Edition 12.2015
d ran
tee
tho
u or
a ac
– Release the
ss left and right catches -2- in direction of -arrow-
and remove the brake fluid reservoir from the sealing plug
ce
le
un
pt
upward.
an
d
itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Installing
Install in reverse order of removal. Note the following:
rrectness of i
– Make sure the sealing plugs are seated correctly in the brake
l purpos
nform
ercia
a
com
tio
– Bleed the brake system. Refer to
n in
r
te o
thi
s
iva
do
r
rp
cum
Vehicles with Manual Transmission
fo
en
ng
t.
yi Co
– The seals -2- must be located in the return hose -1- to the Cop py
clutch master cylinder.
t. rig
gh ht
pyri by
Vo
co
– Bleed the clutch mechanism. Refer to ⇒ Manual Transmis‐
by lksw
cted agen
sion; Rep. Gr. 30 ; Clutch Mechanism; Clutch Mechanism,
Prote AG.
Bleeding .
Tightening Specification
♦ Refer to
⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”, page
106
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 23 ; Air Filter; Air Filter Housing, Removing and In‐
stalling
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing and
Installing or ⇒ Engine Mechanical, Fuel Injection and Glow
Plug; Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing
and Installing .
4 Vacuum System
⇒ “4.1 Overview - Vacuum Pump”, page 121
⇒ “4.2 Check Valve, Checking”, page 122
⇒ “4.3 Vacuum Sensor G608 , Removing and Installing”,
page 122
⇒ “4.4 Vacuum System, Checking”, page 123
1 - Vacuum Hose
❑ Replace if damaged.
2 - Vacuum Line
❑ Replace if damaged.
3 - Seal
❑ Replace
4 - Vacuum Pump
❑ Refer to ⇒ Engine Me‐
chanical, Fuel Injection
and Ignition; Rep. Gr.
15 ; Cylinder Head;
Overview - Cylinder wage
n AG. Volkswagen AG do
es n
Head or ⇒ Engine Me‐ y Volks ot g
ua
chanical, Fuel Injectionised b ran
and Glow Plug; Rep.ut
hor tee
or
Gr. 15 ; Cylinder
ss Head;
a ac
Overview - Cylinder
ce
e
nl
Head .
pt
du
an
itte
y li
5 - Bolt
erm
ab
ility
ot p
❑ 9 Nm
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
t.
yi Co
op
Vehicles
C py
t. rig
gh ht
pyri by
Vo
o
The vacuum pump is installed behind the oil pump.
c by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
4.3 Vacuum Sensor - G608- , Removing
es, in part or in w
and Installing
t to the co
The Vacuum Sensor - G608- -2- is only installed on some gaso‐
rrectness of i
line engines.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Removing
p
cum
for
en
ng
t.
– Disconnect the connector -1- from the Vacuum Sensor - G608-
yi Co
op
-2-.
C py
t. rig
gh ht
yri by
– Pull vacuum line out of brake booster. cop Vo
by lksw
cted agen
Prote AG.
– Unclip the Vacuum Sensor - G608- from the vacuum line.
Installing
Install in reverse order of removal. Note the following:
ce
le
un
pt
4.4.1 General Information
an
d
itte
y li
rm
ab
Special tools and workshop equipment required
pe
ility
ot
wit
, is n
h re
hole
spec
The following checks will be helpful when performing “Fault Find‐
es, in part or in w
ing” if there are complaints regarding the brake booster or the so-
t to the co
called hard brake pedal.
The following components are included in the check:
rrectness of i
♦ Brake Booster
l purpos
♦ Seal between the master brake cylinder and the brake booster
♦ Check valve
nform
ercia
a
com
tion in
♦ Vacuum pump (if equipped)
r
te o
thi
The geographic location will influence the measurement results.
s
iva
do
r
The higher above sea level, the lower the air pressure.
rp
cum
fo
en
g
t.
yi Co
Cop py
.
♦ Check all the vacuum hoses for damage (for example, tears
t rig
gh ht
yri by
or damaged caused by animals) and make sure they are se‐ cop Vo
by lksw
cure cted agen
Prote AG.
ce
-see following illustrations-. le
un
pt
an
d
itte
y li
Des‐ Com‐ Explanation
rm
ab
igna‐ po‐
pe
ility
tion nent
ot
wit
, is n
h re
A Shut- In direction toward the vacuum hose, the check
hole
spec
off valve and vacuum pump (if equipped)
es, in part or in w
valve
t to the co
B Shut- ♦ Opening the Brake Servo Tester - VAS6721-
off makes it easier to remove.
valve
rrectness of i
♦ Open to simulate an incorrect source
l purpos
nform
ercia
a
valve
com
tion in
r
te o
thi
s
iva
do
r
rp
c
vacuum hose.
um
fo
en
ng
t.
yi
– Push the adapter -C- into the brake booster.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damaged caused by animals) and make sure
they are secure
– Connect the Brake Servo Tester - VAS6721- . Refer to
⇒ “4.4.2 Brake Servo Tester VAS6721 , Connecting”,
page 123 .
– Open the shut-off valve -A-.
ce
e
nl
pt
du
an
itte
Check the vacuum system for leaks if the measured value is not
y li
erm
ab
reached, even though all requirements (see notes).
ility
ot p
wit
– Create the vacuum using a Hand Vacuum Pump - VAS6213-
, is n
h re
for comparison purposes. Refer to
hole
spec
es, in part or in w
t to the co
Opening the shut-off valve -B- makes it easier to remove the hose
connections and the adapter.
rrectness of i
4.4.4 Leak Test
l purpos
nform
ercia
Note
m
at
om
io
♦ The average earth atmospheric air pressure at sea level (N.
n
c
in t
r
his
ate
do
riv
cum
or
en
ng
t.
yi Co
♦ Local and time fluctuations will influence the vacuum. ht. Cop py
rig
rig ht
♦ A cold engine, the Air Conditioning (A/C) switched being on py by
co Vo
and even only the engine idling can negatively influence the
by lksw
cted agen
Prote
vacuum.
AG.
– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damaged caused by animals) and make sure
they are secure
– Connect the Brake Servo Tester - VAS6721- . Refer to
⇒ “4.4.2 Brake Servo Tester VAS6721 , Connecting”,
page 123 .
– Open the shut-off valve -A-.
– Close the shut-off valves -B+C-.
– Start the warm (greater than 60 °C (140 °F)) engine and press
the accelerator pedal one time quickly (engine RPM higher
than 2,000).
Normally (see note) the vacuum should be between 600 and 950
mbar (8.7 and 13.7 psi) (depending on the engine installed).
– Open the shut-off valve -C- and evacuate the brake booster.
– Turn off the engine.
– Read the measured value displayed and write it down.
The vacuum may drop 400 mbar (5.8 psi) within 12 hours.
If the vacuum drops more, check at the following points:
1- Brake Booster
2- Check valve, vacuum hoses and connections and vacuum
pump/intake manifold
The vacuum will drop considerably within a few seconds if there
are large leaks.
Note
Vacuum test near the check valve, vacuum hoses and connec‐
tions and vacuum pump/intake manifold.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Close the shut-off valve -C- after creating the vacuum to checkorise nte
the Brake Servo Tester - VAS6721- vacuum up to the intake auth eo
ra
manifold or up to the vacuum pump. ss c
ce
e
nl
pt
Opening the shut-off valve -B- makes it easier to remove the hose
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.4.5 Vacuum, Creating with Hand Vacuum
l purpos
Pump - VAS6213- nf
ercia
atio
uum pump.
om
n in
or c
sd
iva
VAS6721- .
r
rp
cu
o
m
f
en
ng
5 Brake Lines
⇒ “5.1 Brake Lines, Repairing”, page 127
ce
e
nl
pt
du
an
itte
y li
erm
ab
Working with Brake Line Kit - VAG1356- is not permitted because
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Do not bend the brake lines more than maximum 90°.
♦ Otherwise the lines will kink or otherwise deform.
rrectness of i
♦ From this the diameter of the line will be narrowed.
l purpos
nf
ercia
orm
cannot rub against moving parts.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
Clamp Jaws - VAS6056/7-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
❑ Must be removed to
nl
pt
du
an
itte
y li
retaining bolt
erm
ab
ility
ot p
3 - Bolt
wit
, is n
h re
hole
section
spec
es, in part or in w
t to the co
❑ Center and hold the
clamp jaws
rrectness of i
❑ 2 mm inner hex socket
l purpos
5 - Clamp Jaws
❑ Various
nf
ercia
o
❑ Assembly instructions.
rm
m
Refer to
atio
m
n in
c
stallation Instructions”“ ,
or
thi
e
page 129
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ The arrow on the rounded side of the clamp jaws must point
toward the edge of the housing.
♦ The straight side of the clamp jaws must be installed toward
the spindle, otherwise the flanged head will not be formed cor‐
rectly.
5.1.3 Instructions
– Remove the corresponding brake line on the brake caliper or
wheel brake cylinder.
– Be sure to catch any leaking brake fluid and dispose of it cor‐
rectly.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Remove the locking pliers and push the tube fitting -D- onto
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Push the brake line -B- against the stop -A- inside the flaring
i
or
n thi
tool.
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
ht. rig
Brake line must contact stop when hex socket heat screws are rig ht
py by
tightened, otherwise the flanged head will not be formed correctly.
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 Hydraulic System
⇒ “6.1 Brake Fluid General Information”, page 132
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132
⇒ “6.3 Hydraulic System, Post-Bleeding”, page 133
⇒ “6.4 Checking for Leaks”, page 133
WARNING
Note
pt
an
d
itte
y li
erm
Note ab
ility
ot p
wit
is n
f inform
n
c
n thi
te
sd
a
o
pr
cum
r
fo
t.
yi Co
op
4 - Right rear brake caliper C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
Note agen oes
o lksw not
byV gu
ara
ed
is nte
This bleeding procedure must be performed fivehor times per brake eo
ut
caliper. ss a ra
c
ce
e
nl
pt
du
Bleeding sequence:
an
itte
y li
erm
ab
1- Front left brake caliper
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
at
om
ion
in t
or
his
te
do
priv
cum
or
en
ng
t.
yi Co
Test Prerequisites ht. Cop py
rig
rig ht
• Brake system ( ABS Hydraulic Unit - N55- , brake hoses, brake py by
co Vo
lines and brake calipers) operating properly and free of leaks.
by lksw
cted agen
Prote AG.
Checking
– Remove the bleeder valve at one front brake caliper.
– Attach and bleed the Brake Pressure Gauge - VAG1310A- .
– Apply pressure to brake pedal until the gauge indicates a
pressure of 50 bar (725 psi). The pressure must not drop by
more than 4 bar (58 psi) during the test period of 45 seconds.
Replace master cylinder if pressure drops greatly.
ce
le
un
Special tools and workshop equipment required
pt
an
d
itte
y li
♦ Brake Caliper Tool - T10165-
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
♦ Sealing Tool - T10249-
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
♦ Brake Charger/Bleeder Unit - VAS5234-
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
♦ Brake Bleeding Tool Set - VAS6564-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8 Revision History
DRUCK NUMBER: K0059241321
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
tion ck
Up‐ pt
an
d
itte
date y li
rm
ab
12/1 Fac‐ N/ Tom
pe
ility
ot
14 Up‐
h re
hole
date
spec
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected onwan AG. Volkswa
automatic gen AG
transmission
does vehicle, it will be necessary to
agen
ks
Vol
reestablish Transmission Control Moduleby(TCM) basic settings using the nVAG
ot g 1551 Scan Tool (ST).
u ara
ed nte
oris e
h
•= ut
Never work under a lifted vehicle aunless it is solidly supported on stands designed ofor
r a the
purpose. Do not support
s c
a vehicle on cinder blocks, hollow
s tiles or other props that may crumble under continuous load. Never work under a
ce
e
nl
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
pt
du
an
itte
y li
erm
ab
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
ility
ot p
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
wit
, is n
h re
hole
spec
•=
es, in part or in w
If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
t to the co
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
rrectness of i
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
l purpos
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
nform
ercia
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
m
at
om
ion
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
c
in t
or
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
his
ate
do
priv
cum
or
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
f
en
ng
t.
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe op
yi Co
py
injury could result. t. C rig
gh ht
pyri by
Vo
co lksw
by
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used Prote
cted AG.
agen
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Cautions & Warnings
th or
au ac
ss
ce
e
nl
pt
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
du
an
itte
y li
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
erm
ab
fuel or oil.
ility
ot p
wit
, is n
h re
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
hole
spec
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
es, in part or in w
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
t to the co
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
rrectness of i
l purpos
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
nf
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
ercia
or
repairs.
m
m
atio
om
n in
c
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
or
thi
e
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
t
sd
iva
once, but do not store the oily rags, which can ignite and burn spontaneously.
o
r
rp
cu
o
m
f
en
ng
t.
yi
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
Co
Cop py
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
t. rig
gh ht
yri by
listed. cop
by
Vo
lksw
cted agen
Prote AG.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Page 3 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0