Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System: 47 Brakes - Hydraulic Components (Page GR-47)

Volkswagen Jetta, Golf, GTI 1999, 2000
Brake System
47 Brakes - Hydraulic Components (Page GR-47)
FS III front brake calipers, servicing

Front brake caliper piston, removing and installing
FN 3 front brake calipers, servicing
Front caliper piston, removing and installing
Rear brake caliper, servicing
Pressure leak test
Rear brake caliper piston, removing and installing
Brake pressure regulator, mounting
Brake pressure regulator, checking and adjusting
Specifications for load dependent brake pressure regulator
Brake system, bleeding
Brake system, bleeding using US1116 pressure bleeder
Brake system, bleeding without pressure bleeder
Brake master cylinder/brake booster, servicing
Vacuum pump for brake booster, removing and installing (vehicles with Diesel engines)
Brake master cylinder, removing and installing
Brake booster, removing and installing
Brake System
FS III front brake calipers, servicing (Page 47-1)
Notes:
Install all parts supplied in the repair kit.
New brake calipers are filled with brake fluid and are pre-bled.
Apply a thin coat of lubricant, Part No. G 052 150 A2 to brake cylinders, pistons and
seals.
1 - Dust cap
2 - Bleeder valve
Apply thin coat of assembly lubricant G 052 150 A2 to threads before installing
3 - Cap
Install in mounting bushing
4 - Guide pin, 28 Nm (21 ft lb)
Removing and installing Page 47-3
Brake System
5 - Mounting bushing
Install in brake caliper housing
6 - Brake caliper housing
7 - Protective seal
8 - Piston
Before installing apply a thin coat of assembly lubricant, Part No. G 052 150 A2, to
piston
9 - Piston seal
Brake System
Front brake caliper piston, removing and installing

Special tools and equipment required
3409 Wedge
Piston resetting tool
Removing
- Force piston out of brake caliper housing using compressed air.

Notes:
Place a piece of wood in the recess to prevent damaging the piston.
Brake System
- Remove piston seal using wedge 3409.

Notes:
When removing piston seal make sure that the cylinder bore is not damaged.
Installing
- Lubricate piston, piston seal and cylinder bore lightly with assembly lubricant G 052
150 A2
- Install new piston seal in caliper.
- Place protective seal with outer sealing lip on piston.

Brake System
- Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using
wedge 3409.
- Press piston into brake caliper housing using piston resetting tool.
The protective seal outer sealing lip must slip into the piston groove.
Brake System
FN 3 front brake calipers, servicing (Page 47-6)
Notes:
Install all parts supplied in the repair kit.
New brake calipers are filled with brake fluid and are pre-bled.
Apply a thin coat of lubricant, Part No. G 052 150 A2 to brake cylinders, pistons and
seals.
1 - Dust cap
2 - Bleeder valve
Apply thin coat of assembly lubricant G 052 150 A2 to threads before installing
3 - Cap
Insert in mounting bushing
Brake System
4 - Guide pin, 28 Nm (21 ft lb)

5 - Mounting bushing
Insert into brake caliper housing
6 - Brake caliper housing
7 - Brake carrier
8 - Retaining spring
Insert with both ends in holes in brake caliper housing
9 - Piston seal
Brake System
11 - Piston
Apply thin coat of assembly lubricant G 052 150 A2 to piston before installing
Piston diameter: 54 mm (2.125 in.)
12 - Protective seal
Do not damage when inserting piston
Brake System
Front caliper piston, removing and installing

3409 Wedge
VAG 1331 Torque wrench or equivalent

Piston resetting tool
Brake System
Removing
- Force piston out of brake caliper housing using compressed air.

Notes:
Place a piece of wood in the recess to prevent damaging the piston.
- Remove seal using wedge 3409.

Notes:
When removing the piston seal make sure that the cylinder bore is not damaged.
Brake System
Installing
- Thinly coat piston and piston seal with assembly lubricant G 052 150 A2 before
inserting.
- Place protective seal with outer sealing lip on piston.
- Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using
sedge 3409.
Brake System
- Press piston into brake caliper housing using piston resetting tool.
The protective seal outer sealing lip must slip into the piston groove.
Brake System
Rear brake caliper, servicing (Page 47-13)
Notes:
When repairing install all parts supplied in repair kit.
New brake calipers are filled with brake fluid and pre-bled.
Apply a thin coat of assembly lubricant, Part No. G 052 150 A2, to brake cylinders,
pistons and seals.
When repairing, it is essential to appropriately pre-bleed the brake calipers (without
brake pads) before installation in the vehicle Page 47-19
1 - Self-locking hex bolt, 35 Nm (26 ft lb)
Always replace
When loosening and tightening counter-hold on guide pin
2 - Bleeder valve
Apply a thin coat of assembly lubricant G 052 150 A2 to threads before installing
Brake System
3 - Dust cap
4 - Guide pins
Grease before pulling on protective cap
5 - Protective cap
Pull onto brake carrier and guide pin
6 - Brake carrier with guide pin and protective cap
Replacement part is assembled with sufficient grease on guide pins
If protective caps or guide pins are damaged, install repair kit. Use grease packet
supplied to lubricate the guide pins.
Brake System
7 - Protective seal
Pull outer sealing lip onto piston
8 - Piston with automatic adjustment
Apply thin coat of assembly lubricant G 052 150 A2 to piston before inserting
9 - Sealing ring
11 - Brake caliper housing with parking brake cable lever
If a leak exists at the parking brake cable lever replace brake caliper housing
After repairing, pre-bleed caliper housing Page 47-19
Brake System
Rear brake caliper piston, removing and installing

3272 Piston resetting and removal tool
3409 Wedge
Bleeder bottle
Brake System
Removing
- Remove piston from brake caliper housing by turning knurled wheel counter-
clockwise.
Notes:
Install special tool 3272 with the collar (arrow) positioned before the piston.
If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow -
A-) provided for this purpose.
- Remove seal using wedge 3409.

Brake System
Installing
- Apply a thin coat of assembly lubricant G 052 150 A2 to piston and seal before
inserting.
- Place protective seal with outer sealing lip on the piston.
- Hold piston in front of caliper housing and install inner sealing lip into groove in
cylinder using wedge 3409.
Brake System
- Screw piston into housing by turning knurled wheel clockwise.

Notes:
Install special tool 3272 with the collar (arrow) seated on the brake caliper.
If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow -
A-) provided for this purpose.
If the piston is pushed back with a piston resetting tool or by operating the foot
brake, the automatic adjustment in the brake caliper is destroyed.
- Install brake pads.
Pre-bleeding brake caliper
- Position brake caliper as shown in illustration.

- Open bleeder valve (arrow -A-) and fill a standard bleeder bottle with brake fluid until
bubble-free brake fluid flows from brake hose connection (arrow -B-).
- Close bleeder valve.
Brake System
Pressure leak test

VAG 1310 A Brake pressure gauge

Requirements
Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) must
function properly and not leak.
- Remove bleeder valve at one front brake caliper. Connect pressure gauge from VAG
1310 and bleed.
- 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 during the test period of 45
seconds. Renew master cylinder if pressure drops greatly.
Pressure must not drop by more than 4 bar (58 psi) during the test period (45
seconds)
- If pressure drops more than specified, replace master cylinder.
Brake System
Brake pressure regulator, mounting (Page 47-21)
1 - Brake pressure regulator

Checking and adjusting Page 47-22
2 - Socket head bolt, 21 Nm (15 ft lb)
3 - Bolt
4 - Nut, 21 Nm (15 ft lb)
5 - Spring
6 - Mounting bracket
Brake System
Brake pressure regulator, checking and adjusting (Page 47-22)
VAG 1310 Brake pressure gauge
The brake pressure regulator is mounted on a bracket and mounted to the rear axle. The
regulator is controlled from the rear axle by a spring.
Checking function
- Depress brake pedal firmly once and release quickly (vehicle standing on its
wheels).
Brake pressure regulator must move.
Brake System
Checking and adjusting

Requirements
Vehicle emptied of all cargo and passengers
Driver (approx. 75 kg [165 lb]) in driver's seat
Full fuel tank
Full windshield washer / headlight washer reservoir
Spare tire, tool kit and jack in place
Checking
- Lift vehicle and connect pressure gauges to left front and right rear brake calipers.
- Bleed both gauges.
- Lower and bounce rear of vehicle several times.
- Depress brake pedal to obtain specified pressure at front axle, then read pressure at
rear axle.
- Compare reading with specifications Page 47-24 and if necessary adjust.
Brake System
Specifications for load dependent brake pressure regulator

Brake System
Adjusting brake pressure regulator

Rear axle test pressure too high:
- Release tension on regulator spring.
Rear axle test pressures too low:
- Increase tension regulator spring.
Notes:
Do not adjust with brake pedal depressed. Use the following work sequence:
- Read pressure.
- Release brake pedal.
- Adjust spring.
- Depress brake pedal again.
- Read pressure and if necessary, readjust.
- Remove pressure gauges and bleed brake system Page 47-26.
Brake System
Brake system, bleeding (Page 47-26)
Vehicles with ABS and ABS/EDL

When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking
system) the hydraulic unit must be bled using the VAG 1551 scan tool in function 04, "basic
setting".
WARNING!
Do not exceed a filling pressure of 1 bar (14.5 psi) when filling with brake fluid using
pressure bleeder US1116. The brake system will not be completely bled if excessive
pressure is used.
Basic setting
Repair Manual, ABS/EDL On Board Diagnostic (OBD), Repair Group 01
Notes:
Bleeding the brake system on vehicles with ABS is the same as for vehicles with
conventional braking systems.
Brake fluid absorbs moisture from the air and must therefore be replaced every two
years. Use only new, unused and approved brake fluid that complies with MVSS 116
DOT 4.
Brake fluid is poisonous. Also due to its corrosive effect brake fluid must not come
into contact with paintwork.
Brake fluid must always be stored in air tight containers.
Do not use silicone-based brake fluid (DOT 5). Even the smallest trace can cause
severe corrosion in the brake system.
Rinse off brake fluid spillages using plenty of water.
Brake System
Brake system, bleeding using US1116 pressure bleeder

US 1116 brake bleeder

Notes:
Bleeding the brake system on vehicles with ABS is the same as for vehicles with a
conventional brake system
On vehicles with a brake pressure regulator, move the regulator lever when bleeding
rear brakes.
- Connect brake filling and bleeding unit.
- Open bleeder valves in specified sequence and bleed brake calipers.
Bleeding sequence
1-Right rear caliper

2-Left rear caliper
3-Right front caliper
4-Left front caliper
Vehicles with ABS or ABS/EDL
- Test drive vehicle and perform at least one brake application sufficient to engage
ABS regulation.
Brake System
Brake system, bleeding without pressure bleeder

- Build-up brake pressure in brake system by pumping brake pedal.
- Connect hose from bleeder bottle to brake bleeder valve at each wheel in turn
(Bleeding sequence Page 47-27).
- Open bleeder valve.
- Hold brake pedal down, close bleed screw.
Notes:
The brake fluid level in the reservoir must not fall below the MIN mark during bleeding.
- Release brake pedal.
- Repeat operation until brake fluid flows without air bubbles.
Brake fluid, changing
Repair Manual, Maintenance
Brake System
Brake master cylinder/brake booster, servicing (Page 47-29)
Notes:
Master cylinders and brake boosters can be replaced separately.
1 - Brake booster
With gasoline engines vacuum is taken from the intake manifold
With Diesel engines a vacuum pump provides the required vacuum.
Functional check:
- With engine switched off, depress brake pedal firmly several times (to exhaust
vacuum in booster).
- Depress brake pedal with average foot pressure, hold and start engine. If the
booster is working properly, the pedal will give slightly under foot (booster becomes
effective).
If faulty replace complete.
Check valve (in vacuum hose), Functional check Page 47-33
Separating booster from brake pedal Page 46-39
Brake System
2 - Cap
3 - Brake fluid reservoir
4 - Sealing plug
Moisten with brake fluid and press into reservoir
5 - Retainer pin
Insert through brake master cylinder
6 - Brake master cylinder
Cannot be repaired. If faulty, replace complete.
7 - Self-locking hex nut, 20 Nm (15 ft lb)
8 - Seal
Always replace
9 - Sealing plug
Brake System
10 - Vacuum hose
Insert into brake booster
11 - Gasket
12 - Self-locking nut, 20 Nm (15 ft lb)
13 - Boot
Must be seated correctly or may cause air noise
Brake System
Vacuum pump for brake booster, removing and installing (vehicles with Diesel
engines)
Removing
- Remove retainer for wiring harness from vacuum pump.
- Loosen vacuum hose clamp (arrow -A-) and remove hose from pump.
- Remove bolts (arrow -B-) on flange.
- Remove vacuum pump.
Notes:
The vacuum pump cannot be repaired.
Brake System
Installing
Notes:
When installing the vacuum pump be sure that the follower engages correctly with the camshaft.
- Install bolts (arrows -B-) on cylinder head flange.

- Secure vacuum hose with clamp (arrow -A-).
- Check function of check valve -A-.

Air must pass through in direction of arrow
Valve must remain closed in opposite direction
- Ensure that check valve is installed correctly.
Brake System
Brake master cylinder, removing and installing (Page 47-34)
3094 Hose clamps or equivalent

Additional information
Repair Manual, Manual Transmission 02J
Removing
- Obtain radio code on vehicles with coded radio.
- Disconnect battery.
- Disconnector connector -1- of Mass Air Flow MAF sensor from air filter tube.
- Remove bolts -2- at air filter -3- and move filter to left side.
- On vehicles with Diesel engines, remove relay panel above brake booster.
Brake System
- Spread sufficient lint-free cloths in area of plenum, and on engine and transmission
to catch any escaping brake fluid.
- Using a bleeder bottle, draw off as much brake fluid as possible from brake fluid
reservoir.
- Clamp clutch master cylinder supply hose with clamp 3094.
- Remove clutch master cylinder supply hose from reservoir.
- Disconnect brake fluid level sensor wiring connector.
Vehicles with automatic transmission
- Disconnect wiring connectors from pressure sensors -a- and -b-.

All vehicles
- Disconnect brake lines at brake master cylinder and seal with plugs from repair kit,
Part No. 1H0 698 311 A.
- Remove nuts securing brake master cylinder to brake booster.
- Remove heat shield if installed.
- Carefully remove brake master cylinder from brake booster.
Installing
- Install master cylinder in reverse order of removal.
Brake System
Observe the following points when installing:

- When connecting brake master cylinder and brake booster, be sure that push rod is
correctly located in brake master cylinder.
- After installing, bleed brakes Page 47-26 and clutch.
Repair Manual, Manual Transmission 02J, Repair Group 30
- Restore basic setting.
Repair Manual, ABS, ABS/EDL On Board Diagnostic (OBD), Repair Group 01
Brake System
Brake booster, removing and installing (Page 47-37)
3094 Hose clamps or equivalent

Additional information
Removing
- Note or request radio code on vehicles with coded radio if necessary.
- Disconnect battery.
Vehicles with manual transmission
- Clamp clutch master cylinder supply hose with special tool 3094 or equivalent.
- Remove clutch master cylinder supply hose from reservoir.
All vehicles
- Remove ABS control module and hydraulic unit Page 45-10.
- Disconnect vacuum hose from brake booster.
Brake System
Vehicles with automatic transmission
- Remove connector -1- from retainer -2-.

- Separate connector -1-.
All vehicles
- Remove trim below instrument panel.
- Remove bolts -1-.

- Remove cover -A-.
Brake System
- Remove connecting plate between clutch and brake pedals on vehicles with a
manual transmission.
- Remove brake light switch -1-.
- Separate brake pedal from brake booster Page 46-39.
- Guide brake booster with brake master cylinder out forward and remove.
Installing
Install brake booster in reverse order of removal.
- Adjust brake light switch.
Repair Manual, ABS, ABS/EDL On Board Diagnostic (OBD), Repair Group 01
- After installing, bleed brakes Page 47-26 and clutch.
Repair Manual, Manual Transmission 02J, Repair Group 30

Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System: 47 Brakes - Hydraulic Components (Page GR-47)

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Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System: 47 Brakes - Hydraulic Components (Page GR-47)

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Copyright:

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Volkswagen Jetta, Golf, GTI 1999, 2000

FS III front brake calipers, servicing

Front brake caliper piston, removing and installing

- Force piston out of brake caliper housing using compressed air.

- Remove piston seal using wedge 3409.

- Place protective seal with outer sealing lip on piston.

4 - Guide pin, 28 Nm (21 ft lb)

Front caliper piston, removing and installing

VAG 1331 Torque wrench or equivalent

- Force piston out of brake caliper housing using compressed air.

- Remove seal using wedge 3409.

- Place protective seal with outer sealing lip on piston.

Rear brake caliper piston, removing and installing

3272 Piston resetting and removal tool

- Remove seal using wedge 3409.

- Place protective seal with outer sealing lip on the piston.

- Screw piston into housing by turning knurled wheel clockwise.

- Position brake caliper as shown in illustration.

Pressure leak test

VAG 1310 A Brake pressure gauge

1 - Brake pressure regulator

Special tools and equipment required

VAG 1310 Brake pressure gauge

Checking and adjusting

Specifications for load dependent brake pressure regulator

Adjusting brake pressure regulator

Vehicles with ABS and ABS/EDL

Brake system, bleeding using US1116 pressure bleeder

US 1116 brake bleeder

1-Right rear caliper

Brake system, bleeding without pressure bleeder

- Install bolts (arrows -B-) on cylinder head flange.

- Check function of check valve -A-.

Special tools and equipment required

3094 Hose clamps or equivalent

- Disconnect wiring connectors from pressure sensors -a- and -b-.

Observe the following points when installing:

Special tools and equipment required

3094 Hose clamps or equivalent

Vehicles with automatic transmission

- Remove connector -1- from retainer -2-.

- Remove bolts -1-.

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