SM 4

Service
Workshop Manual
Fox 2004 ➤
Fox 2010 ➤
Fox 2014 ➤
SpaceFox 2011 ➤
Brake systems
Edition 02.2019
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data
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45 - Anti-lock brake system
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46 - Brakes - mechanism
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47 - Brakes - hydraulics
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg BRA5R005020

Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox 2011 ➤
Brake systems - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brake PR number correspondence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brake technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 General information on the Bosch 5.7 anti-lock braking system (ABS) . . . . . . . . . . . . . . . . 4
1.1 ABS Bosch 5.7 ..........................................................
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2 General
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3 oris General information on the Bosch 8.2 anti-lock
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braking system (ABS) . . . . . . . . . . . . . . . . 7
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4ss a General information on the Bosch 9.0 anti-lock ra
c braking system (ABS) . . . . . . . . . . . . . . . . 8
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5 Information on repair works on the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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6 Connect Vehicle diagnostic, testing and information system VAS 5051A /52 and select
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functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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7 Electrical/electronic components and installing locations . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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7.1 ABS Bosch 5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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7.2 ABS Bosch 8.0 (ABS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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7.3 ABS Bosch 8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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7.4 ABS Bosch 9.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Hydraulic unit, brake servo/brake master cylinder - assembly overview (Bosch 5.7) . . . . 18
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8.1 Hydraulic unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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8.2 Command unit for hydraulic unit - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

8.3 Brake pressure sensor 1 G201 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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9 Hydraulic unit, brake servo/brake master cylinder - assembly overview (Bosch 8.0 / 8.2)
........................................................................ 26
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9.1 Hydraulic unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9.2 ABS control unit J104 on ABS hydraulic unit N55 - remove and install . . . . . . . . . . . . . . . . 28
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10 Fault indication via control lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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10.1 Control lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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11 ABS system components on the front and rear axles - remove and install . . . . . . . . . . . . 37
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11.1 ABS system components on the front axle - remove and install . . . . . . . . . . . . . . . . . . . . 37
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11.2 Front axle speed sensor - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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11.3 Bosch 5.7 front speed sensor cables - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . .
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11.4 Bosch 8.0 / 8.2 front speed sensor cables - remove and install . . . . . . . . . . . . . . . . . . . . . . 41
11.5 ABS system components on rear axle (vehicles with drum brakes) - remove and install . . 42
11.6 Speed sensor on rear axle (drum brake) - remove and install . . . . . . . . . . . . . . . . . . . . . . 43
11.7 Rear speed sensor cables - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12 ESP system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12.1 Lateral tilting intensity sensor G202 and Lateral acceleration sensor G200 - remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12.2 Steering angle sensor G85 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Front wheel brake - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Front brake - Brake caliper FS II - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Brake pads - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 FS II brake caliper - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.4 Front wheel brake - FS II brake caliper - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.5 Brake pads, FS III disc brake cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . 56
1.6 FS III brake caliper - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.7 Brake disc - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.8 Brake disc - check (disc knocking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
1.9 Brake disc with visual check - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2 Rear wheel brake (drum brake) - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Rear wheel brake - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Brake drum - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Brake drum - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4 Brake shoes - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.5 Rear wheel brake cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Handbrake - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.1 Handbrake cable - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2 Handbrake cable (drum brake) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.3 Handbrake lever handle - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.4 Handbrake lever - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.5 Handbrake switch - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4 Brake pedal - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Brake pedal - separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2 Pedal set - remove gen Aand
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4.3 Brake pedaly Volk - remove and install . . . .no.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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4.4 Brake
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47 - Brakes
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1 Assembly overview: Brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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1.1 Master cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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1.2 Inspect the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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1.3 Brake servo - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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1.4 Vacuum pump for 4-cylinder diesel engines and with distribution injector pump (diesel
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vehicles) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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2 Vacuum system - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.1 Test instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Servo brake vacuum measurement device VAS 6721 - connect . . . . . . . . . . . . . . . . . . . . 100
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2.3 Vacuum generation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

2.4 Leak control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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2.5 Vacuum generation with the manual vacuum pump VAS 6213 . . . . . . . . . . . . . . . . . . . . 103
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3 Front brake caliper, FS II brake caliper - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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3.1 Plunger for front brake caliper - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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4 Front brake caliper, FS II brake caliper - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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4.1 Front brake caliper plunger - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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5 Vehicles without braking power adjustment - assembly overview . . . . . . . . . . . . . . . . . . . . 110

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6 Braking power adjustment - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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6.1 Braking power adjustment - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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6.2 Braking power adjustment - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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7 Bleed the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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7.1 Bleed the brake system with the filling and bleeding equipment . . . . . . . . . . . . . . . . . . . . 114
7.2 Brake system, only vehicles with ABS/EDS/ASR - bleed when the reservoir is empty . . . . 116
ii Contents
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1 Technical Data
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(VRL012724; Edition 02.2019)
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1.1 Brake PR number correspondence urposes, in part or in wh
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The type of brake installed in the vehicle is listed on the vehicle
ID tag with the corresponding PR number.
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Example of a vehicle identification tag
In this example, the following brake is installed in the vehicle:
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♦ -Arrow 1- Rear wheel brake (-1KB- Drum Brake)
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♦ -Arrow 2- Front wheel brake (-1LG- FS III Disc brake)
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Maintenance and Warranty book.
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The following table displays the PR number coding. This is im‐

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1.1.1 Font wheel brake (disc brake)

PR number Front wheel brake
1LM / 1LA / 1ZN FS II (13”)
1LG / 1ZF / 1ZR FS III (14”)
1.1.2 Rear wheel brake (drum brake)

PR number Rear wheel brake
1KB TB 200 X 40 CR 17 mm
1. Technical Data 1
1.2 Brake technical data

1.2.1 Front wheel brake FS II
PR number 1LM / 1ZN / 1LA
(without power steer‐
ing)
Brake master ∅ mm 19.05 without ABS
cylinder
Brake servo ∅ in 8.544′′
-1- Brake caliper FS II (13”)
-2- Brake pad, mm 12
thickness
-3- Brake disc ∅ mm 239
Brake disc, mm 18
thickness
-4- Brake caliper, ∅ mm 48
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1.2.2 Front wheel brake FS III

PR number 1LG / 1ZF / 1ZR
(with power steering)
Brake master ∅ mm 20.64
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-3- Brake disc ∅ mm 256

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Brake disc, mm 22
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-4- Brake caliper, ∅ mm 54

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Brake mas‐ ∅ mm 20.64

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-2- Brake shoe, mm 5

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Brake shoe, mm 38.8
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-3- Brake drum ∅ mm 200

1) Only for vehicles with 13” running gear without ABS
2 Rep. gr.00 - Technical data

1.2.4 Rear wheel brake (drum brake, with

ABS)
PR number 1KB
Brake mas‐ ∅ mm 20.64
ter cylinder
-1- Wheel brake ∅ mm 17.46
cylinder 19.05
-2- Brake pad, mm 5
thickness
Brake pad, mm 38.8
width
-3- Brake drum ∅ mm 200
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1. Technical Data 3
45 – Anti-lock brake system

1 General information on the Bosch 5.7
anti-lock braking system (ABS) kswagen AG. Volkswagen AG does
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Failures in the ABS influence the brake system and amplification.
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A different braking behaviour should be expected. After the ABS
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In case of complaint, ABS hydraulic unit - N55- and ABS control
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unit - J104- must be replaced together.
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unit - J104- .
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Location of ABS in a vehicle with left-hand drive:

1 - ABS hydraulic unit - N55- and ABS control unit - J104-
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2 - Brake servo.
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Location of the ABS in a vehicle with the steering wheel on the
right side:
1 - Brake servo.
Bosch 5.7 (ABS) :

Command device -1- and hydraulic system unit -2- constitute a
unit. In case of damage, replace both the command device and
hydraulic system unit. Do not separate hydraulic pump -3- from
the hydraulic system unit.
4 Rep. gr.45 - Anti-lock brake system

2 General information for the anti-lock

braking system (ABS) Bosch 8.0
The ABS Bosch 8.0 in this vehicle has the following configuration:
♦ ABS.
♦ ABS/EDS/ASR/ESP.
The ABS brake system is arranged diagonally. The braking power
amplification is carried out pneumatically through the vacuum
brake servo.
Note
Failures on the ABS do not influence the brake system and the
brake servo. The conventional braking system remains functional
even without the ABS. A difference in the behaviour of the brake
system is to be expected. After the ABS control light comes on,
the rear wheels may lock early.
Location of the ABS in vehicles with steering wheel on the left

side:
2 - Brake servo.
Location of the ABS in vehicles with steering wheel on the right

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1 - Brake servo.
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2 - ABSshydraulic
au unit - N55- and ABS control unit - J104-r ac
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ABS control unit - J104- -1- and ABS Hydraulic Unit - N55- -2-
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form one unit. In case of damage ABS hydraulic unit - N55- and
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ABS control unit - J104- must both be replaced. Do not separate

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ABS reflux pump - V39- -3- from ABS hydraulic unit - N55- .
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Bosch 8.0 (ABS) and (ABS/ASR):

ABS hydraulic unit - N55- and ABS control unit - J104-
rrectness of i
⇒ page 13 .
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2. General information for the anti-lock braking system (ABS) Bosch 8.0
AG.
Bosch 8.0 (ABS/EDS/ASR/ESP):

⇒ page 13 .
AG. Volkswagen AG d
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anti-lock braking system (ABS)
The ABS brake system (Bosch 8.2) is arranged diagonally. The
braking power amplification is carried out pneumatically through
the vacuum brake servo.
Note
Failures in the ABS do not influence the brake system and the
system is to be expected. After the ABS control light lights up, the
rear wheels may lock early!
ABS location:
1 - Hydraulic system unit and

ABS command device
2 - Brake servo
AG. Volkswagen AG d
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Bosch 8.2 (ABS) :

t to the co

rrectness of i

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⇒ page 15 .
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3. General information on the Bosch 8.2 anti-lock braking system (ABS)
AG. Volkswagen AG d
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Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFoxed2011by ➤ gu
ara
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Brake systems - Edition 02.2019 thor eo
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nl
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anti-lock braking system (ABS)
erm
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The ABS brake system (Bosch 9.0) is arranged diagonally. The
h re
hole
braking power amplification is carried out pneumatically through
spec
the vacuum brake servo.
es, in part or in w
t to the co
Note
rrectness of i
Failures in the ABS do not influence the brake system and the
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system is to be expected. After the ABS control light lights up, the
nform
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rear wheels may lock early!

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ABS location:
in t
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1 - Hydraulic system unit and
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2 - Brake servo t. C rig
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Bosch 9.0 (ABS) :

⇒ page 15 .

5 Information on repair works on the

ABS
Before repairing the antilock system, determine cause of damage
by using the “Assisted troubleshooting” in Vehicle diagnostic,
testing and information system - VAS 5051A /52- .
♦ Check whether the vehicle has a coded radio. If so, request
the anti-theft code before disconnecting the battery earth
strap.
♦ When the battery is reconnected, check the vehicle's equip‐
ment (radio, clock, electric door locks, power windows, etc.) gen AG
. Volkswagen AG
does
according to the repair manual and/or instructions of use. Volkswa not
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♦ Before starting to repair the antilock braking system, odeter‐
ris
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mine the cause of damage with the help of the “Assisted
auth or
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troubleshooting”. ss
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nl
pt
♦ Before working with an electric welding equipment, disconnect du
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the battery earth strap, with the ignition off.
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♦ Observe the effective measures and notes when handing the
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brake fluid, ⇒ page 114
, is n
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hole
♦ After services requiring opening of the brake system, bleed the
spec
brake system with the Brake filling and bleeding equipment -
es, in part or in w
t to the co
VAS 5234- or the Brake pedal pressing device - VAG 1869- ,
⇒ page 114
♦ During the test drive, ensure at least one brake adjustment is
rrectness of i
performed (a slight pulsing on the brake pedal should be felt).
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♦ While working on the ABS system, a high level of cleanliness

must be maintained, and under no circumstances can mate‐
nf
ercia
rials containing mineral oil, such as, for example, oils, grease,
or
etc., be used.
m
m
atio
m
♦ Carefully clean the union points and surrounding surfaces be‐

o
n in
or c
fore releasing them; however, no cleaning products should be
thi
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used, such as, for example, brake cleaning products, petrol,

t
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solvents, or similar products.
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♦ The components removed must be placed on a clean surface

t.
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and covered over. C py
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♦ If the repairs are not carried out immediately, carefully cover
p by
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the open components or place them in the proper location. Prote
cted AG.
agen
(Use the lid from repair set 1H0 698 311 A)
♦ Use cloths that do not fray.
♦ Only remove the replacement parts from their packages im‐
mediately before assembly.
♦ Use only parts in original packaging.
♦ Do not work with compressed air nor move the vehicle with the
system open.
♦ Make sure that no brake fluid comes into contact with the con‐
nectors.
♦ During painting, the command unit may be momentarily sub‐
mitted to a maximum temperature of 95 °C, and for longer
periods (approximately 2 hours) at an ambient temperature of
85 °C.
5. Information on repair works on the ABS 9

6 Connect Vehicle diagnostic, testing

and information system - VAS
5051A /52- and select functions
olkswagen AG
en AG. V
Special tools and workshop equipment requiredolkswag does
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♦ Vehicle diagnostic, testing and information
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system - VAS nte
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♦ Diagnosis cable - VAS 5051/1- or Diagnosis cable - VAS
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nl
5051/3-
pt
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WARNING
orm
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♦ During a test drive, the measuring and checking equip‐

o
n in
c
ment must always be fastened to the rear seat of the

or
thi
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vehicle.
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♦ During a test drive, only one person should operate this
o
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equipment.
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– Connect the diagnostic cable connector Diagnostic cable -
co Vo
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VAS 5051/1- or Diagnostic cable - VAS 5051/3- to the diag‐ Prote AG.
nostic connection -arrow-.
– Turn on Vehicle diagnostic, testing and information system -

VAS 5051A/52- and follow the on-screen instructions.

lkswage es n
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7 Electrical/electronic components and ir se
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7.1 ABS Bosch 5.7
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1 - ABS hydraulic unit - N55- is n
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spec
The hydraulic unit comprises
the following components:
t to the co
❑ ABS return pump - V39-
❑ may be checked by the
rrectne
“Assisted Troubleshoot‐
ing” with Vehicle diag‐
s
nostic, testing and infor‐
s o
mation system - VAS
cial p
f in
5051A /52-
form
mer
❑ Valve block (includes in‐
atio
m
take and exhaust

o
n
c
i
valves)
or
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❑ ABS reflux pump - V39-

iv
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pr
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and the valve block
um
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must not be separated
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❑ remove and install C py
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⇒ page 20
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2 - ABS control unit - J104- Prote
cted AG.
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mation system - VAS
5051A /52-
❑ do not disconnect the
command unit connec‐
tor before the self-diag‐
nosis
❑ remove and install
⇒ page 20
3 - Brake pressure sensor 1 -
G201-
ing” with Vehicle diagnostic, testing and information system - VAS 5051A /52-
❑ remove and install ⇒ page 25
4 - Brake light switch - F- or Brake pedal switch - F47-
❑ may be checked by the “Assisted Troubleshooting” with Vehicle diagnostic, testing and information sys‐
tem - VAS 5051A /52-
❑ remove and install ⇒ page 89 .
5 - ABS control lamp - K47-
❑ Installation location: dash panel.
Function: ⇒ page 35 .
6 - Brake system control lamp - K118-
❑ Installation location: dash panel
Function: ⇒ page 35
7. Electrical/electronic components and installing locations 11

7 - Diagnostic connector
❑ Installation location: Next to the fuse box, under the steering column.
8 - Steering angle sensor - G85-
tem - VAS 5051A /52-
❑ Installation location: on the steering column, between the steering wheel and the steering column switch.
❑ Observe the assembly procedure
⇒ page 47 .
9 - Lateral acceleration sensor - G200- and Lateral tilting intensity sensor - G202-
❑ Not available in the ABS Bosch 5.7.
10 - ESP button
❑ Not available in the ABS Bosch 5.7.
11 - Right front wheel rotation sensor - G45- / Left front wheel rotation sensor - G47-
tem - VAS 5051A /52-
12 - Right rear wheel rotation sensor - G44- / Left rear wheel rotation sensor - G46-
tem - VAS 5051A /52-
13 - Wheel hub/roller bearing assembly
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❑ the ABS sensor ringolks
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14 - Wheel hub/roller
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❑ the ABS au sensor ring is assembled in the wheel roller bearing.
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rrectness of i
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c
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ate
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7.2 ABS Bosch 8.0 (ABS/ESP)
1 - ABS control unit - J104-

mation system - VAS
5051A /52-
tor before the self-diag‐
nosis
⇒ page 28
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2 - ABS hydraulic unit y- VN55-
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The hydraulic unitthor comprises
is tee
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❑ may be checked on the

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and information system
hole
spec
- VAS 5051A /52-
es, in part or in w
❑ valve block (includes in‐

take and exhaust t to the co
valves)
rrectness of i

and the valves may not
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be separated.
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⇒ page 28 .
m
3 - Brake light switch - F- or

a
com
tio
Brake pedal switch - F47-

n in
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⇒ page 89 .
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❑ Installation location: dash panel. Cop py
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Function: ⇒ page 35 . p by
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AG.

6 - ASR and ESP control light - K155-

7 - Diagnosis connector
8 - Steering angle sensor - G85-
tem - VAS 5051A /52-
❑ Installation location: on the steering column, between the steering wheel and the steering column switch.
❑ Observe the assembly procedure.

⇒ page 47 .
9 - Lateral acceleration sensor - G200- and Lateral tilting intensity sensor - G202-
tem - VAS 5051A /52-
❑ packed in a case.
❑ Installation location: on the left seat cross member, on the floor plate.
❑ Follow assembly procedures
10 - Switch for the ASR/ESP electronic stability programw-aE256-
gen AG
. Volkswagen AG
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❑ Installation location: dash panel. d byV gu
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11 - Right front wheel rotation sensor - G45-ut/hoLeft front wheel rotation sensor - G47- eo
ra
sa c
s
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tem - VAS 5051A /52-

nl
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ab
ility
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tem - VAS 5051A /52-
hole
spec
es, in part or in w
t to the co
❑ the ABS sensor ring is assembled in the wheel roller bearing.
rrectness of i
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7.3 ABS Bosch 8.2

mation system - VAS
5051A /52-
tor before the self-diag‐ agen
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❑ remove and installrise d
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⇒ page 28 . aut ho eo
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2 - ABS hydraulic unit - N55-
ce
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- VAS 5051A /52-
rrectness of i
take and exhaust
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valves)
❑ ABS reflux pump - V39- nf
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be separated
atio
om

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⇒ page 28 .
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3 - Brake light switch - F- or

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f
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❑ remove and install Cop py
⇒ page 89 .
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❑ Installation location: dash panel

tem - VAS 5051A /52-
8 - Rear wheel hub/roller bearing assembly
9 - Front wheel hub/roller bearing assembly
❑ the ABS sensor ring is assembled in the wheel roller bearing

tem - VAS 5051A /52-
11 - Centrifuging disc
❑ Only for vehicles with ABS brakes.
7.4 ABS Bosch 9.0

mation system - VAS
5051A /52- agen
AG. Volkswagen AG d
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❑ do not disconnect the d by
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command unit connec‐ orise nte
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tor before the self-diag‐ aut
h
ra
nosis. ss c
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un
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⇒ page 28 .
itte
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ab
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, is n
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es, in part or in w
t to the co
rrectness of i
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- VAS 5051A /52-
nform
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take and exhaust

m
valves) a
com
tion in

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te o
thi

s
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be separated
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fo
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⇒ page 28 .
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Cop py
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3 - Brake light switch - F- or yri
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❑ remove and install Prote AG.
⇒ page 89 .
❑ installation location: dash panel


tem - VAS 5051A /52-
8 - Rear wheel hub/roller bearing assembly
9 - Front wheel hub/roller bearing assembly
❑ the ABS sensor ring is assembled in the wheel roller bearing
tem - VAS 5051A /52-
11 - Centrifuging disc
AG. Volkswagen AG d
❑ Only for vehicles with ABS brakes. agen oes
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es, in part or in w
t to the co
rrectness of i
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at
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8 Hydraulic unit, brake servo/brake

master cylinder - assembly overview
(Bosch 5.7)
The brake master cylinder and the brake servo may be replaced
independently of one another.
WARNING
Always replace self-locking nuts and bolts subject to angular

torque
asdasd

❑ Remove and install
⇒ page 20 .
❑ ABS hydraulic pump -
V64- and the intake and
exhaust valves are
checked through self-di‐
agnosis on the hydraulic
unit
❑ ABS hydraulic pump -
V64- and the valve block
may not be separated.
❑ When replacing the hy‐
draulic unit, seal the old
part with the plugs from
the repair set number
ET 1H0 698 311 A. AG. Volkswagen AG d
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❑ Remove and install ed byV gu
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⇒ page 20 . horis nte
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3 - External bolt ss c
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❑ 3 Nm
un
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4 - Brake pressure sensor 1 -

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ab
G201-
pe
ility
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wit

, is n
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⇒ page 25 .
hole
spec
5 - Brake pipe connection

es, in part or in w
t to the co
❑ Hydraulic unit for left

front brake caliper.
❑ Identification in the hy‐
rrectness of i
draulic unit -VL-.

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❑ 14 Nm
nform
ercia
❑ Hydraulic unit for right

m

com
tion in
❑ Identification in the hydraulic unit -VR-.

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❑ 14 Nm
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❑ Brake master cylinder/floating plunger circuit for the hydraulic unit.
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❑ Identification in the hydraulic unit -HZ2-.
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18
Prote AG.
Rep. gr.45 - Anti-lock brake system
❑ 14 Nm
❑ Brake master cylinder/push rod circuit for the hydraulic unit
❑ 14 Nm
AG. Volkswagen AG d
❑ for the left rear brake caliper. agen oes
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❑ Identification in the hydraulic unit -HL-. ise
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❑ 14 Nm auth eo
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❑ for the right rear brake caliper.
an
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❑ Identification in the hydraulic unit -HR-.
ab
pe
ility
❑ 14 Nm
ot
wit
, is n
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11 - Brake servo
hole
spec
❑ On petrol engines, the vacuum required is removed from the intake manifold.
es, in part or in w
t to the co
❑ In diesel engines, there is a vacuum pump to create vacuum.
❑ Check functioning:
rrectness of i
❑ Press the brake pedal all the way several times with the engine stopped (This eliminates any remaining
vacuum inside the device).
l purpos
❑ Keep the brake pedal depressed with medium foot pressure in the braking position, and start the engine.
If the brake servo is operating properly, the foot on the brake pedal goes down (amplification is active).
nform
ercia
❑ In case of faults, replace completely.

m
❑ Non-return valve (in the vacuum line) ⇒ page 93 .
a
com
tion in
❑ Disassemble from the brake pedal ⇒ page 86 .
r
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thi
❑ Remove and install ⇒ page 93 .
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12 - Sealing
um
fo
en
ng
t.
❑ to brake servo.
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Cop py
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13 - Self-locking hex head nut
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❑ 28 Nm.
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❑ Replace whenever removed
14 - Sealing ring
❑ 20 Nm.
16 - Brake master cylinder
❑ cannot be repaired. Where faults occur, replace completely.
17 - Retaining pin for the brake fluid reservoir
❑ insert through the brake master cylinder.
18 - Sealing plug
❑ moisten with brake fluid and press into the brake master cylinder.
19 - Sealing plug
❑ Connection for vacuum line.
8. Hydraulic unit, brake servo/brake master cylinder - assembly overview (Bosch 5.7) 19
20 - Brake fluid reservoir

21 - Sealing plug
❑ 20 Nm
23 - Mounting bracket
24 - Stud
❑ Stud welded to the body.
25 - Bolts
❑ 8 Nm.
27 - Bolts
❑ 8 Nm.
❑ 20 Nm.
29 - Stud
AG. Volkswagen AG d
❑ Stud welded to the body. agen oes
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8.1 Hydraulic unit connections ss c
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8.1.1 Connecting the brake pipes from brake

an
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master cylinder pipes (Tandem) to the

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hydraulic unit
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A - Hydraulic unit to the brake master cylinder pressure plunger

spec
circuit.
es, in part or in w
t to the co
- Identification in the hydraulic unit -HZ1-.

B - Hydraulic unit to the brake master cylinder floating pressure
rrectness of i
plunger circuit.
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1 - Hydraulic unit for left front brake caliper.
nform
ercia
- Identification in the hydraulic unit -VL-.

m
a
com
tio
2 - Hydraulic unit for right front brake caliper.

n in
r
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thi
- Identification in the hydraulic unit -VR-.

s
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3 - Hydraulic unit to right rear brake caliper.

um
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t.
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- Identification in the hydraulic unit -HR-.
Co
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4 - Hydraulic unit to left rear brake caliper.
ht
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- Identification in the hydraulic unit -HL-.
agen
Prote AG.
8.2 Command unit for hydraulic unit - re‐

move and install
Special tools and workshop equipment required

n AG. VoBrake
lkswagesystems
nA - Edition 02.2019
G do
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Volks ot g
♦ Torque wrench - 5 to 50Nm ( 1/2” drive) - VAGed1331-
by ua
ran
oris tee
th or
au ac
ss
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nl
pt
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
♦ Brake pedal pressing device - VAG 1869/2-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
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rig ht
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cted agen
Prote AG.
Plug repair set 1H0 698 311 A
After disconnecting the ABS hydraulic unit - N55- from ABS con‐
trol unit - J104- , always fit on the hydraulic unit the valve tube
transport protection.
ABS hydraulic units - N55- without the transport protection are not
covered by warranty.
1- Valve tube transport protection.
2- M 10 Plugs.
3- M 12 Plugs.
8.2.1 Removal
Installation location:
The command unit is screwed onto the hydraulic system unit and
is found in the right side of the engine compartment.
WARNING
The brake lines near ABS hydraulic unit - N55- cannot be bent.
– Note the coding in vehicles with code radio equipment, request

such coding if necessary.
– Disconnect the battery ⇒ Electrical system; Rep. gr. 27 ; lkswage es n
o ot g
Starter, alternator, battery . byV ua
d ran
ir se tee
o
3 cylinders, injection engine: auth or
ac
ss
– Disconnect the vacuum lines from the upper air filter case
ce
e
nl
pt
section.
du
an
itte
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erm
– Remove the cover by the points marked with -arrows-.
ab
ility
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4 cylinders, injection engine:
wit
, is n
h re
– Pull the hose from the oil separator and the non-return valve
hole
spec
on the upper air filter case section.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
3-cylinder diesel engine

or
thi
te
sd
a
– Pull the engine cover up and away from the fittings.

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Prote AG.
– Remove the intake hose -1-.

4-cylinder diesel engine with injector pump unit:
– Remove the intake hose and tube -1-.

4 cylinders, diesel engine with distribution injector pump:

– Remove the escape gas return valve -1-.

Continuation for all vehicles:
– Disconnect the connector for the braking pressure sensor
Brake pressure sensor 1 - G201- -2-.
– Unlock -arrow 1- and disconnect -arrow 3- the control unit

connector ABS hydraulic unit - N55- .
– Install the Brake pedal pressing device - VAG 1869/2- .
– Press the brake pedal with the actuator.
– Place the venting hose of the venting reservoir over the left
front brake caliper plug and open the plug.
– Close the left front venting plug.
– Place a sufficient amount of non-fraying cloths under ABS
control unit - J104- and ABS hydraulic unit - N55- .
WARNING AG. Volkswagen AG d

agen oes
olksw not
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d b ar
Make sure no brake fluid orisedoes not get on the contacts for ABS ante
control unit - J104- a.uth eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Loosen and hang the hydraulic unit brake pipes -1- to the
erm
ab
brake master cylinder.

ility
ot p
wit
, is n
– Release the remaining brake pipes for the ABS hydraulic unit
h re
- N55- .
hole
spec
– Close the brake pipes and threaded holes with plugs from the
es, in part or in w
t to the co
number 1H0 698 311 A repair set.

– Remove the hexagonal nuts -3- and -5- from the command
unit/hydraulic unit support.
rrectness of i
– Remove ABS hydraulic unit - N55- from ABS control unit -

l purpos
J104- .
– Unscrew the bolts -2- and -4- and remove the command unit/
nf
ercia
hydraulic unit support.

rm
m
atio
om
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Prote AG.
8.2.2 Installation
Note
Only remove the plugs from the new ABS hydraulic unit - N55-
when the respective brake pipe is assembled. If the plugs were n AG. Volkswagen AG do
already removed from ABS hydraulic unit - N55- , brake fluid may lkswage es n
Vo ot g
leak to the point that proper ventilation and filling can no longer
ed
by ua
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be guaranteed. thoris tee
or
au ac
ss
– Install the ABS unit on the support.
ce
le
un
pt
an
d
– Installation is performed in the reverse sequence of the re‐
itte
y li
moval. erm
ab
ility
ot p
– Bleed the brake system ⇒ page 114
wit
is n
h re
ole,
– Code the ABS control unit - J104- control unit.
spec
Connect the Vehicle diagnostic, testing and information system -
t to the co
VAS 5051A /52- and select the function ⇒ page 10 .
– Codify the radio.
rrectne
Brake line tightening torques:
s
ABS Bosch - (5.7)
s o
cial p
f
Positions Component Torque
inform
mer
-1- Brake lines 14 Nm
atio
om
-2- Brake pressure sensor 1 - 14 Nm
n
c
i
or
n
G201- .
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
Tightening torques for fastening the ABS unit and supports: cted agen
Prote AG.
ABS Bosch - (5.7)

Positions Nuts / Bolts Torque
-2 / 4- Bolt 8 Nm
-3- Hexagonal nut 20 Nm

8.3 Brake pressure sensor 1 - G201- - re‐

move and install
8.3.1 Removal
Depending on engine version, remove the air filter or the engine
cover, as described below:
♦ 3 cylinders, injection engine ⇒ page 22 .
♦ 4 cylinders, injection engine ⇒ page 22 .
♦ 3-cylinder diesel engine ⇒ page 22 .
♦ 4-cylinder diesel engine with injector pump unit ⇒ page 22 .
♦ 4 cylinders, diesel engine with distribution injector pump
⇒ page 22 .
. Volkswagen AG
a gen AG d
– Disconnect connector -3- from
Vol Brake pressure sensor 1 - ot gu
ksw
oes
n
G201- -2-. ed by ara
n is tee
or
– Place a sufficient amount
au
th of non-fraying cloths under ABS or
ac
control unit - J104-
s and ABS hydraulic unit - N55- .
s
ce
e
nl
pt
– Release brake pipes -1- from ABS hydraulic unit - N55- .
du
an
itte
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erm
ab
ility
ot p
wit
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– Remove Brake pressure sensor 1 - G201- .
h re
hole
spec
es, in part or in w
t to the co
8.3.2 Installation
rrectness of i
– Installation is carried out by reversing the removal order, con‐

l purpos
sidering the following:

– Tighten Brake pressure sensor 1 - G201- with a torque of 14
nf
ercia
Nm ⇒ page 24 .
rm
m
atio
m
– Bleed the brake system ⇒ page 114

o
n in
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thi
te
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Cop py
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Prote AG.
9 Hydraulic unit, brake servo/brake

master cylinder - assembly overview
(Bosch 8.0 / 8.2)
The brake master cylinder and the brake servo may be independ‐
ently replaced.
WARNING

torque

❑ Remove and install ABS
hydraulic unit - N55-
along with ABS control
unit - J104-
⇒ page 28 .
and the coupled valves
may not be separated.
❑ When replacing ABS
hydraulic unit - N55- ,
seal the old part with the
plugs from the repair set
number ET 1H0 698 311
A.
❑ Remove and install ABS
hydraulic unit - N55- AG. Volkswagen AG d
agen
along with ABS control olksw
oes
not
unit - J104- byV gu
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⇒ page 28 . horis nte
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aut ra
3 - Brake pipe connection ss c
ce
le
❑ Hydraulic unit for right

un
pt
an
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❑ Identification in the hy‐ ab

pe
draulic unit -VR-. ility

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❑ for the left rear brake

es, in part or in w
caliper.
t to the co

draulic unit -HL-.
rrectness of i

l purpos
❑ for the right rear brake

caliper.
nform
ercia

draulic unit -HR-.
m
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com
tio

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thi
❑ Hydraulic unit for left front brake caliper.

s
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❑ Identification in the hydraulic unit -VL-.

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7 - Brake master cylinder connection

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❑ Identification in the hydraulic unit -HZ1-. co Vo
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Prote AG.

8 - Brake master cylinder connection

9 - Sealing
❑ to brake servo.
10 - Brake servo
❑ On petrol engines, the vacuum required is removed from the intake manifold.
❑ On diesel engines, a vacuum pump is installed to create vacuum.
Operation checking:
– Press the brake pedal several times until the end with the engine stopped (This eliminates any remaining
vacuum inside the device).
– Now, keep the brake pedal pressed in the braking position with medium force and start the engine. When
the brake servo is working properly, this can be felt with a foot on the brake pedal (the amplification is
active).
❑ In case of faults, replace completely.
❑ Non-return valve (in the flexible vacuum line) ⇒ page 93 .
olkswagen AG
❑ separate from the brake en AG. V
agpedal ⇒ page 86 . does n
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yV ua
11 - Self-locking hexisehead
db nut ran
or tee
❑ Replace whenever
uth removed or
ac
sa
❑ 28 Nm. s
ce
e
nl
pt
du
12 - Sealing ring
an
itte
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erm

ab
ility
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wit
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hole
spec
❑ 20 Nm.
es, in part or in w
t to the co

❑ cannot be repaired. Where faults occur, replace completely.
rrectness of i

l purpos
15 - Retaining pin for the brake fluid reservoir

❑ insert through the brake master cylinder.
nform
ercia
16 - Sealing plug
m
at
❑ moisten with brake fluid and press into the brake master cylinder.
om
ion
c
in t
r
17 - Sealing plug
o
his
ate
❑ connection to flexible vacuum line.

do
priv
cum
or
18 - Brake fluid reservoir

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19 - Sealing plug
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20 - Bolts cop Vo
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❑ 8 Nm. Prote AG.

❑ 20 Nm.
23 - Stud
❑ Stud welded to the body.
9. Hydraulic unit, brake servo/brake master cylinder - assembly overview (Bosch 8.0 / 8.2) 27
❑ 20 Nm.
25 - Stud
❑ Stud welded to the body. AG. Volkswagen AG d
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26 - Mounting bracket d by
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9.1 Hydraulic unit connections
ce
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un
pt
an
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itte
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Connect the brake pipes and the brake master cylinder pipes to
erm
ab
the hydraulic unit:
ility
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h re
circuit (14 Nm).
ole,
spec
B - Hydraulic unit to the brake master cylinder pressure plunger
t to the co
circuit (14 Nm).
rrectne
ss o
cial p
f inform
mer
On the hydraulic system unit:
atio
om
n
c
i
or
n
circuit.
thi
te
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pr
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B - Hydraulic unit to the brake master cylinder floating pressure

t.
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op
plunger circuit. C py
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1 - Hydraulic unit for right front brake caliper.
Prote AG.
- Identification in the hydraulic unit -VR-.

- Identification in the hydraulic unit -HL-.
- Identification in the hydraulic unit -HR-.
- Identification in the hydraulic unit -VL-.
9.2 ABS control unit - J104- on ABS hy‐

draulic unit - N55- - remove and install

♦ Torque wrench - 5 to 50Nm ( 1/2” drive) - VAG 1331-
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
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itte
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erm
ab
ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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Plug repair set 1H0 698 311 A

iv
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pr
cum
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fo
After disconnecting ABS control unit - J104- from ABS hydraulic

en
ng
t.
yi
unit - N55- , always fit on the hydraulic unit the valve tube transport
Co
op py
protection. t. C rig
gh ht
pyri by
Hydraulic units without the transport protection are not covered
co Vo
by lksw
cted agen
by warranty. Prote AG.
1- Valve tube transport protection.

2- M 10 Plugs.
3- M 12 Plugs.
9.2.1 Removal
Installation location:
ABS control unit - J104- is fastened to ABS hydraulic unit - N55-
and is located in the engine compartment, right side -arrow-.
WARNING
The brake pipes in the hydraulic unit area must not be bent.

– Disconnect the battery ⇒ Electrical system; Rep. gr. 27 ;
Starter, alternator, battery .
– Disconnect the vacuum lines from the upper air filter case
section.

AG. Volkswagen AG d
agen o
– Pull the hose from the oil separatorolks and the non-return valves not g
w e
yV
on the upper air filter case section.
se
d b ua
ran
ri tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
3-cylinder diesel engine:

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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove the intake hose -1-.

4-cylinder diesel engine with injector pump unit:
– Remove hose -1- and intake tube -2- ⇒ Engine; Rep. gr. 23 ;
Supply system - fuel injection (diesel) .
or:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
ss c
ce
le
un
pt
– Remove flexible suction tube-1- and Motor for intake manifold
an
d
itte
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valve - V157- -2- ⇒ Engine; Rep. gr. 23 ; Supply system - fuel
erm
ab
injection (diesel) .
ility
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wit
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4 cylinders, diesel engine with distribution injector pump:
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Remove the escape gas return valve -1-.

mer
atio

om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
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Prote AG.
– Push down the connector safety lock -arrow- .
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
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itte
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rm
ab
pe
ility
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wit
– Release the connector for ABS control unit - J104- -arrow- and , is n
h re
remove it by pulling it forward
hole
spec
es, in part or in w
– Install the Brake pedal pressing device - VAG 1869/2- .
t to the co
– Press the brake pedal with the Brake pedal pressing device -
VAG 1869/2- already positioned.
rrectness of i
– Close the left front venting plug.
l purpos
– Place the hose from the bleeding reservoir over the left front
brake caliper plug and open the plug.
nform
mercia
a
com
tion in
r
te o
thi
– Place a sufficient amount of non-fraying cloths under ABS
s
iva
control unit - J104- and ABS hydraulic unit - N55- .
do
r
rp
cum
fo
en
ng
t.
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WARNING
Co
Cop py
ht. rig
rig ht
Make sure no brake fluid does not get on the contacts for ABS
py by
co Vo
by lksw
control unit - J104- . cted agen
Prote AG.
– Loosen and hang brake pipes-A-B-1-2-3-4- from the brake

master cylinder hydraulic unit.
Note
To avoid excessive leaking of brake fluid, use the exhaust valve

protection cover to seal brake lines -A and B-.

– Remove hexagonal nut -1- from the ABS control unit - J104- /
ABS hydraulic unit - N55- support
– Carefully remove ABS control unit - J104- / ABS hydraulic unit
- N55- , pulling it up -arrow-.
– Remove the command device / hydraulic unit support by re‐
moving bolts -2-.
There is no need to remove the lower ABS support by removing
nuts -3-. gen AG
. Volkswagen AG
d a oes
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b ara
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th
au ra
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ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
9.2.2 Installation
rrectness of i
Note
l purpos
♦ Only remove the plugs from the new hydraulic unit when the
respective brake pipe is assembled.
nform
ercia
♦ If the plugs were already removed from the hydraulic unit, the
m
a
brake fluid may leak to the point that proper venting and filling
com
tio
can no longer be ensured.

n in
r
te o
thi
s
iva
do
– Install the ABS unit on the support.

r
rp
cum
fo
– The rest of the installation is processed in the reverse order

en
ng
t.
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from removal. t. Cop py
rig
gh ht
– Remove the Brake pedal pressing device - VAG 1869/2- . pyri by
Vo
co lksw
by
cted agen
– Bleed the brake system ⇒ page 114 . Prote AG.
– Code ABS control unit - J104- .

Connect the Vehicle diagnostic, testing and information system -
VAS 5051A /52- and select the function ⇒ page 10 .
– Codify the radio.
Brake line tightening torques:
ABS Bosch - (8.0 / 8.2)
Brake pipes in the ABS set: -A-B-1-2-3-4-
Threads M 10 x 1 14 Nm
Threads M 12 x 1 14 Nm
Brake systems - Edition
wag02.2019
en AG. V
olkswagen AG
doe
ks s no
Vol t gu
by a
Tightening torques for ris fastening the ABS unit
e d
and supports: rante
utho eo
ra
ss ABS Bosch - (8.0 / 8.2)
a c
ce
e
Positions Nuts / Bolts Torque
nl
pt
du
an
itte
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erm
ab
ility
-2- Bolt 8 Nm
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
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or
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ate
do
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for
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Cop py
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Prote AG.

10 Fault indication via control lights

10.1 Control lights
Pos. Nomenclature
-1- ABS control light - K47- .
-2- Brake system control light - K118- .
-3- ASR and ESP control light - K155- .
ABS control light - K47- :
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
an
itte
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erm
ab
ility
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♦ If ABS control light - K47- for ABS -1- does not go off after the
wit
, is n
ignition is turned on and after the inspection is over, the fault
h re
hole
may have the following causes:
spec
es, in part or in w
-a- the voltage supply is below 10 Volt.
t to the co
-b- there is a fault in the ABS.
rrectness of i
In the case of a fault in the ABS -b-, the antilock braking system
is turned off, while the conventional brake system remains fully
l purpos
operational.
-c- there was a temporary fault in the speed sensor from the last
nf
ercia
time the vehicle was started. orm

m
atio
In the case of speed sensor -c- the ABS control light - K47- au‐
om
n in
tomatically goes off after the vehicle is started and at a speed

or c
higher than 20 km/h.

thi
te
sd
iva
o
r
-d- there is an interruption in the connection between the dash

rp
cu
o
panel and ABS control unit - J104- . ⇒ Electrical diagrams, diag‐

f
en
ng
t.
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nosis of electrical faults and installation locations .
Co
Cop py
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ABS control light - K47- and Brake system control light - K118- .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
10. Fault indication via control lights 35

♦ If ABS control light - K47- for ABS -1- turns off, while Brake
system control light - K118- for brake system -2- remains on,
the error may have the following causes:
-A- The handbrake is on.
wage es n
-B- The brake fluid level is too low. y Vo lks ot g
ua
b
ed ran
-C-: activation failure in of Brakehor system control light - K118- for
is tee
the brake system. ⇒ Electricals aut
diagrams, diagnosis of electrical or
ac
faults and installation locations
s
ce
e
nl
pt
du
♦ If ABS control light - K47- for ABS -1- and Brake system control
an
itte
y li
light - K118- for the brake system are lit -2- it means that the
erm
ab
ABS system and the EBV (electronic braking power distribu‐
ility
ot p
tion) have failed.
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
After the ABS control light - K47- from the ABS and Brake sys‐
tem control light - K118- from the brake system turn on, the
rear wheels may lock early during braking.
rrectness of i
l purpos
ASR and ESP control light - K155- :
nf
ercia
or
♦ If the ESP and ASR control light - K155- for the ASR/ESP sta‐
m
m
atio
bilization program -3- does not go off after the ignition is
om
switched on and after the inspection ends, the fault may have
n in
or c
the following causes:
thi
te
sd
iva
-a- Short-circuit to positive in Switch for the ASR/ESP electronic o

r
rp
cu
o
stability program - E256- .

f
en
ng
t.
yi Co
op
-b- A fault in switching the ESP and ASR control light - K155- for C py
t. rig
the stabilization program, ASR/ESP ⇒ Electrical diagrams, diag‐ gh ht
yri by
nosis of electrical faults and installation locations cop Vo
by lksw
cted agen
Prote AG.
-c- The Switch for the ASR / ESP electronic stability program -
E256- .
There is a fault exclusively related to the ASR/ESP. The vehicle's
ABS/EDS and EBV safety systems remain fully operational ⇒
Refer to the event memory.
If the ESP and ASR control light - K155- for the ASR/ESP stabi‐
lization program blinks during the drive, then the ASR or ESP
system is in adjustment mode.

11 ABS system components on the front

and rear axles - remove and install
11.1 ABS system components on the front axle - remove and install
1 - Wheel roller bearing case

2 - Internal hex head bolt
❑ 8 Nm
3 - ABS speed sensor
❑ is checked through self-
diagnosis.
❑ before putting the sen‐
sor, clean the internal
hole surface and coat
with lubricating putty - G
052 142 A2- or G 052
112 A3 - lubricating put‐
ty- around the sensor.
Refer to the ⇒ Chemi‐
cals Manual .
❑ remove and install lkswage es n
⇒ page 37 . d byV
o ot g
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e ran
ris tee
4 - Cover plate utho or
a ac
ss
5 - Hexagonal head bolt
ce
e
nl
pt
❑ 12 Nm.
du
an
itte
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6 - Wheel hub with roller bear‐

ab
ility
ing
ot p
wit
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❑ the ABS sensor ring is

h re
assembled in the wheel

hole
spec
hub.
es, in part or in w
t to the co
❑ remove and install ⇒

Running gear, axles,
steering; Rep. gr. 40 ;
rrectness of i
Front suspension .
l purpos
7 - Brake disc
8 - Bolt
nf
ercia
❑ 8 Nm.
orm
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atio
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thi
11.2 Front axle speed sensor - remove and

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install
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11.2.1 Removal
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– Jack the vehicle. Prote AG.
11. ABS system components on the front and rear axles - remove and install 37
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Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox
aut 2011 ➤ ra
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s
Brake systems - Edition 02.2019 s
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– Disconnect connector -2- from the speed sensor cable and
y li
erm
ab
from the speed sensor.
ility
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– Remove the bolt -1- from the wheel roller bearing case.
wit
is n
h re
ole,
– Remove the ABS speed sensor from the wheel bearing hous‐
spec
ing.
t to the co
For easier viewing, the brake disc is represented as removed.
rrectness o
cial p
f inform
mer
11.2.2 Installation
atio
om
n
– Before installing the speed sensor, clean the internal hole sur‐
c
i
or
n thi
face and coat with Lubricating putty - G 052 142 A2- or G 052
te
sd
a
112 A3 - Lubricating putty- around the sensor. Refer to the ⇒
iv
o
pr
c
Chemicals Manual .
um
r
fo
en
ng
t.
yi
– Place the speed sensor in the wheel bearing housing and
Co
op py
tighten the bolt to 8 Nm. t. C rig
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pyri by
– Connect the speed sensor to the speed sensor cable.
o Vo
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cted agen
Prote AG.
– Turn the steering wheel completely to the left and to the right
and control the space available for the speed sensor cable.
11.3 Bosch 5.7 front speed sensor cables -

remove and install
♦ Harness repair set - VAS 1978-
11.3.1 Removal

– Unlock and disconnect command unit -arrow 1- and pull it

-arrow 2-.
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ab
– Release the multiple connector cover cap with a screwdriver
ility
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and remove it.
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Unlock the secondary lock (purple) with a small screwdriver in

o
n
the arrow direction.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Contact assignment for connector -T42- ABS control unit - J104-

⇒ Electrical diagrams, diagnosis of electrical faults and installa‐
tion locations .
– With an extractor from the Harness repair set - VAS 1978- ,

pull out the respective contacts.
– Disconnect the connector from the speed sensor cable as well
as the speed sensor.
– Also disconnect the connector -1- in vehicles with the brake

pad wear indicator.
– Disengage the support cable -2-.
– Remove the speed sensor cable.
AG. Volkswagen AG d
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ara
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aut ra
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nl
pt
du
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11.3.2 Installation
ab
ility
ot p
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hole
– Fasten the speed sensor cable in the locations indicated by
spec
the -arrows-.
es, in part or in w
t to the co
WARNING rrectness of i
• Ensure that the speed sensor cable at point -A- passes

l purpos
behind the hydraulic brake lines and that the same at point
-B- passes in front of the hydraulic brake line.
nform
mercia
at
– Place the brake pad wear indicator connector on the suspen‐

om
io
sion support.
n
c
in t
or
his
e
– Connect the connectors.

at
do
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cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Push to the stop the individual cable insulation with the as‐
sembly tool from the Harness repair set - VAS 1978- .
– Lock the contacts with the secondary lock and place the mul‐
tiple connector cover cap.
11.4 Bosch 8.0 / 8.2 front speed sensor ca‐

bles - remove and install
AG. Volkswagen AG d
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pt
du
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ab
ility
ot p
11.4.1 Removal wit

, is n
h re
– Observe coding on vehicles equipped with code radio. If nec‐
hole
spec
essary, request coding.

es, in part or in w
t to the co

rrectness of i
– Unlock the connector for ABS control unit - J104- pushing the
-arrow-.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Release the connector for ABS control unit - J104- -arrow- and
remove it by pulling it forward.
– Release the multiple connector cover cap with a screwdriver
and remove it.
Contact assignment for the 38-pin connector - T38- / ABS control
unit - J104- ⇒ Electrical diagrams, diagnosis of electrical faults
and installation locations
– With an extractor from the Harness repair set - VAS 1978- ,
pull out the respective contacts.
– Also disconnect the connector -1- in vehicles with the brake

pad wear indicator.
– Disengage the support cable -2-.
– Remove the speed sensor cable.
AG. Volkswagen AG d
agen oes
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d by ara
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ut
11.4.2 Installation a ra
ss c
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– Fasten the speed sensor cable in the locations indicated by
rm
ab
pe
ility
the -arrows-.
ot
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hole
WARNING
spec
es, in part or in w
t to the co
• Ensure that the speed sensor cable at point -A- passes
behind the hydraulic brake lines and that the same at point
-B- passes in front of the hydraulic brake line.
rrectness of i
l purpos
– Place the brake pad wear indicator connector on the suspen‐

sion support.
nform
ercia
– Connect the connectors.

m
a
com
– Lock the contacts with the secondary lock and place the mul‐
ion in
tiple connector cover cap.

r
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thi
s
iva
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ng
t.
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Cop py
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11.5 ABS system components on rear axle
ht
pyri by
Vo
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by c lksw
(vehicles with drum brakes) - remove cted agen
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and install
WARNING

torque

1 - Axle beam
❑ 8 Nm
❑ is checked through self-
diagnosis
052 142 A2- or G 052 wagen AG. Volkswagen AG does
112 A3 - lubricatingy Vput‐olks not
gu
rise
d b ara
nte
Refer to theu⇒ tho Chemi‐ eo
ra
cals Manualss a . c
ce
le
4 - Brake tube
un
pt
an
d
itte
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5 - Shaft end
erm
ab
ility
ot p
6 - Handbrake cable
wit
is n
h re
ole,
spec
❑ with dish spring
t to the co
8 - Bolt
9 - Brake drum
rrectne
❑ Brake drum diameter,
200 mm.
ss
❑ Wear limit 201.5 mm.
o
cial p
f i
❑ Release the handbrake
nform
before removing the

mer
atio
brake drum.
om
n
c
❑ clean thoroughly and

i
or
n thi
check for wear, dam‐

te
sd
va
age, dimensional preci‐

i
o
pr
sion and braking sur‐

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face with no apparent

t.
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damages. Cop py
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10 - Cover p by
co Vo
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cted
❑ extract and insert ⇒ Running gear, axles, steering; Rep. gr. 42 ; Front suspension .
agen
Prote AG.
11 - Self-locking grooved nut

12 - Wheel hub with wheel roller bearing and rotor
❑ always replace completely.
❑ remove and install ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear suspension .
13 - Calliper body with brake shoes
❑ Release the handbrake before removing the brake drum.
11.6 Speed sensor on rear axle (drum brake)

- remove and install
11.6.1 Removal
– Jack the vehicle.
– Disengage connector -1- from the speed sensor.

AG. Volkswagen AG d
– Loosen the bolt -2- from the shaft end. agen oes
olksw not
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ara
– Disconnect speed sensor from the shaftris end.
ed
nte
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
o
11.6.2 Installation
rm
m
atio
om
– Before installing the speed sensor, clean the internal hole sur‐
n in
or c
face and coat with Lubricating putty - G 052 142 A2- or G 052
thi
te
112 A3 - Lubricating putty- around the sensor. Refer to the ⇒
sd
iva
o
r
Chemicals Manual .
rp
cu
o
m
f
en
ng
– Place the speed sensor in the shaft end hole and tighten the
t.
yi Co
op
bolt to 8 Nm. C py
ht. rig
rig ht
py by
– Remove the speed sensor cable. co Vo
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Prote
11.7 Rear speed sensor cables - remove and
AG.
install
11.7.1 Removal
– Observe coding on vehicles equipped with code radio. If nec‐
essary, request coding.
– Remove the back door sill lining.
– Pull back the carpeting around the seat area ⇒ Body - General
body assembly work, interior; Rep. gr. 70 ; Linings/insula‐
tions .

– Remove the rubber boot -1- and pull the speed sensor cable
-2- inside the internal compartment.
– Cut the speed sensor cable between -arrows- -A- and -B- us‐
ing the insulating pliers from the Harness repair set - VAS
1978- and remove the defective section -2- of cable.
wage
11.7.2 Installation byV
olks es n
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d ran
ir se
– Insert the new speed sensor cable. tho tee
or
au ac
s
– Strip 15 mm of the cable tip with the insulating pliers and turn
s
ce
e
the stripped cable halfway.

nl
pt
du
an
itte
y li
– Connect the speed sensor cable using a cable fastener from
erm
ab
the Harness repair set - VAS 1978- .
ility
ot p
wit
– Connect the speed sensor to its corresponding cable connec‐
, is n
h re
tor.
hole
spec
When installing the speed sensor cable, make sure it is not twis‐
es, in part or in w
t to the co
ted in the wheel housing.
rrectness of i
l purpos
– Fasten the rubber boot -1-.

nf
ercia
– Put the carpet in the seat area again. orm

m
atio
– Install the rear door sill lining ⇒ General body repairs, interior;
om
Rep. gr. 70 ; Lining / insulation .

n in
or c
thi
te
sd
iva
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r
rp
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f
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ng
t.
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Cop py
t. rig
gh ht
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Vo
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by
cted agen
Prote AG.
12 ESP system components - remove

and install agen
AG. Volkswagen AG d
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12.1 Lateral tilting intensity sensor
s
- G202- au
tho or
ac
and Lateral accelerations sensor - G200-
ce
le
un
pt
- remove and install
an
d
itte
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rm
ab
Lateral tilting intensity sensor - G202- and Lateral acceleration pe
ility
sensor - G200- are packed in a case and are located on the seat
ot
wit
, is n
cross member under the carpet.
h re
hole
spec
12.1.1 Removal
es, in part or in w
t to the co
– Remove the left seat ⇒ General body repairs, interior; Rep.
gr. 72 ; Seat framework .
rrectness of i
– Remove the left door sill lining ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Lining / insulation .
l purpos
– Pull away the floor carpet until Lateral tilting intensity sensor -
G202- and Lateral acceleration sensor - G200- become free.
nform
ercia
– Disconnect the connector for Lateral tilting intensity sensor -

m
a
com
t
G202- and Lateral acceleration sensor - G200- .
ion in
r
te o
– Loosen the two fastening nuts -1-.
thi
s
iva
do
– Remove Lateral tilting intensity sensor - G202- and Lateral
r
rp
cum
fo
acceleration sensor - G200- .
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ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
12.1.2 Installation
WARNING
Very strong vibrations may damage the Lateral tilting intensity

sensor - G202- and the Lateral acceleration sensor - G200- .
– Installation is performed in the reverse sequence of the re‐

moval.
When installing Lateral tilting intensity sensor - G202- and Lateral
acceleration sensor - G200- , correct, effortless seating on the
fittings must be guaranteed.
Under no circumstances may the Lateral tilting intensity sensor -
G202- and Lateral acceleration sensor - G200- be force-fitted by
means of the fastening nuts.
Tightening torques:
Fastening nuts for the Lateral tilting intensity sensor 6 Nm
- G202- and Lateral acceleration sensor - G200-

en AG. V
olkswagen AG Brake systems - Edition 02.2019
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12.2 Steering angle sensor - G85- - remove
b ara
ed nte
oris eo
and install th
au ra
c
ss
ce
e
The steering angle sensor is installed between the steering wheel
nl
pt
du
an
and the steering column switch.
itte
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erm
ab
12.2.1 Removal
ility
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– Position the wheels in a straight angle.
h re
hole
spec
– Remove the airbag unit, if fitted, and the steering wheel. ⇒
es, in part or in w
Running gear, axles, steering; Rep. gr. 48 ; Steering wheel .
t to the co
– Remove the Steering wheel angle sensor - G85- .
rrectness of i
12.2.2 Installation
l purpos
– Install Steering angle sensor - G85- and carry out the basic
adjustment.
nform
ercia
– Carry out basic adjustment with the Vehicle diagnostic, testing

and information system - VAS 5051A /52- in the “Assisted
m
at
om
i
troubleshooting”function.
on
c
in t
or
– Connect the Vehicle diagnostic, testing and information sys‐
his
ate
tem - VAS 5051A /52- and advance until the “Function/com‐
do
priv
c
ponent selection”is displayed.
um
for
en
ng
t.
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Cop py
t. rig
gh ht
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cted agen
Prote AG.
12. ESP system components - remove and install 47

46 – Brakes - mechanism
1 Front wheel brake - repair
1.1 Front brake - Brake caliper FS II - as‐

sembly overview
Note
♦ After replacing the brake pads, press the brake pedal

agerepeat‐
edly for their correct seating yV
olks
w es n
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b ua
ed ran
♦ To draw the braking fluid from its reservoir,
ho
ris always use the tee
Brake filling and bleeding equipments a-uVAS 5234- or the Ac‐
t or
ac
cessory set for bleeder - V.A.G 1869/4-
s .
ce
le
un
pt
♦ Before removing the brake caliper or pulling out a brake caliper
an
d
itte
hose, always install the Brake pedal pressing device - VAG
y li
erm
ab
1869/2- .
ility
ot p
wit
♦ Tightening torques for the wheel bolts ⇒ Chassis; Rep. gr.
is n
h re
44 ; Wheels, tyres, vehicle dimensions
ole,
spec
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.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
48 Rep. gr.46 - Brakes - mechanism

1 - Brake disc
❑ Brake disc thickness: 18
mm.
❑ Wear limit: 16 mm.
or
Brake discs with visual check

system, refer to ⇒ page 62 .
2 - Bolt
❑ 8 Nm.
3 - Brake pads
❑ with wear indication
❑ when the corresponding
wear is reached (limit: 2
to 3 mm), a control light
turns on in the dash pan‐
el.
❑ Thickness 12 mm, the agen
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pad with largest packing olksw not
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area is installed on the ed b ara
nte
is
outside. hor eo
aut ra
❑ Wear limit: 7 mm with ss c
the rear plate.
ce
le
un
pt
an
d
❑ Check thickness
itte
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⇒ Maintenance ; Book‐
rm
ab
pe
let ; .
ility
ot
wit
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❑ always replace from the
h re
same axle.
hole
spec
es, in part or in w
t to the co
⇒ page 50 .
4 - Brake caliper
rrectness of i
❑ repair ⇒ page 104 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
1. Front wheel brake - repair 49

⇒ page 52 .
5 - Lower sleeve
6 - Lower bushing
7 - Lower spacer sleeve
8 - Lower internal hex head bolt
❑ 23 Nm
9 - Air duct
❑ 10 Nm
❑ 23 Nm
❑ The upper bolt is longer than the lower bolt
12 - Upper spacer sleeve
13 - Upper bushing
14 - Upper sleeve
15 - Fastening sleeve
16 - Brake hose with annular nozzle and hollow bolt
. Volkswagen AG
❑ 35 Nm swa
gen AG does
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17 - Wheel hub by ua
ed ran
ris tee
❑ remove and install ⇒auRunning gear, axles, steering; Rep. gr. 40 ; Front
tho
or suspension .
ac
s
❑ knocking: 0.04 (vehicles without abs)
s
ce
le
un
pt
❑ knocking: 0.02 (vehicles with abs)

an
d
itte
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rm
ab
pe
ility
❑ 12 Nm.
ot
wit
, is n
h re
19 - Cover plate
hole
spec
20 - Wheel roller bearing case

es, in part or in w
t to the co

❑ before putting the sensor, clean the internal hole surface and coat with lubricating putty - G 052 142 A2-
rrectness of i
or G 052 112 A3 - lubricating putty- around the sensor. Refer to the ⇒ Chemicals Manual .
l purpos

❑ 8 Nm.
nform
mercia
a
com
1.2 Brake pads - remove and install

ion in
r
te o
thi

s
iva
do
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rp

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ng
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cted agen
Prote AG.

♦ Piston resetting tool - T 10145-
♦ Plunger re-fitter device
1.2.1 Removal
– Remove the wheels.
– For vehicles with brake pad wear indicator, disconnect the
connector -1-.
– Remove the cover caps.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
– Loosen the two bolts -arrows- of the brake caliper and remove
pt
an
d
them.
itte
y li
rm
ab
pe
– Remove the brake cylinder and fasten it with wire so that the
ility
ot
brake caliper weight does not stress and damage the brake
wit
, is n
flexible tube.
h re
hole
spec
– Remove the brake pads.

es, in part or in w
t to the co
Note
rrectness of i
For cleaning the brake cylinder you must only use alcohol.
l purpos
1.2.2 Installation
nform
mercia
Before installing new brake pads, press the plungers in the cyl‐
com
tion in
inder with the re-fitter device. Before pressing the plungers, col‐
r
te o
lect the reservoir brake fluid in a container. Otherwise, if brake

thi
s
iva
fluid recirculates during this interval it may leak and cause dam‐
do
r
rp
age.
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Reposition the plungers.

– Install the brake pads.
– The larger brake pad is installed on the outside.
– Assemble the brake caliper by placing its lower section first

-arrow-.
– The brake caliper tear must be positioned behind the brake
support guide.
– Thread the bolt into the wheel bearing housing and tighten to
23 Nm .
– In vehicles with brake pad wear indicator,
swa
fit. Vthe
gen AG connector
olkswagen AG
doeof
s no
the wear indicator. y Volk t gu
b ara
ed nte
– Install the wheels. thoris e or
au ac
ss
ce
le
un
Note
pt
an
d
itte
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rm
ab
♦ After replacing each brake pad, press the brake pedal repeat‐
pe
ility
edly and strongly with the vehicle stopped so that the brake
ot
wit
, is n
pads are perfectly seated for operation.

h re
hole
spec
♦ After replacing the brake pads, check the brake fluid level.
es, in part or in w
t to the co
1.3 FS II brake caliper - remove and install

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.

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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♦ Brake pedal pressing device - VAG 1869/2-s au ra
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
1.3.1 Removal
nform
ercia
The following sequence is related only to brake caliper replace‐

ment or repair tasks:
m
at
om
ion
Remove the wheels.
c
in t
or
his
te
Disconnect the brake pad wear indicator connector.

a
do
priv
cum
or
Insert a flexible tube in the caliper bleeder valve, and then open
f
en
g
it.
n
t.
yi Co
Cop py
Install the Brake pedal pressing device - VAG 1869/2- .
ht. rig
rig ht
py by
co Vo
Close the bleeder valve and remove the bleeder container.
by lksw
cted agen
Prote AG.
Remove the brake flexible tube.
Remove securing bolts -arrows- from the brake caliper.
Remove the caliper from the brake support.
Remove the brake pads from the brake caliper.
1.3.2 Installation
• The plunger should be retracted:
– Install the pads in the caliper cup and install the plunger.

Pads with larger dimensions are seated on the outside.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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– Assemble the brake caliper by placing
aut
h
its lower section first ra
-arrow-. ss c
ce
e
nl
pt
du
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support guide.
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ility
– Install the flexible hose to the brake caliper with 35 Nm of tor‐
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– Remove Brake pedal pressing device - VAG 1869/2- .
spec
es, in part or in w
– In vehicles with brake pad wear indicator, fit the connector of
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the wear indicator.
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– Tighten bolts -arrows- with 23 Nm of torque.
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The bolt with the smaller dimension should be mounted onto the
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lower brake caliper section. thi

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– Bleed the brake system.

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Install the wheels.
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For tightening torques, refer to: ⇒ Chassis, axles, steering; Rep.
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gr. 44 ; Vehicle wheels, tires, vehicle measurement . by c lksw
cted agen
Prote AG.
Note
♦ Rapidly and vigorously press the brake pedal so that the pads
seat properly according to their normal operating condition.
♦ Check the brake fluid level and replenish if necessary.

1.4 Front wheel brake - FS II brake caliper -

repair
Note
♦ After replacing the brake pads, press the brake pedal repeat‐
edly for their correct seating
♦ To draw the braking fluid from its reservoir, always use Brake
filling and bleeding equipment - VAS 5234- or the Accessory
set for bleeder - V.A.G 1869/4-
♦ Before removing the brake caliper or pulling out a brake caliper
hose, always install the Brake pedal pressing device - VAG
1869/2-
1 - Brake disc
❑ vented, ∅ 256 mm.
❑ Thickness 22 mm.
❑ Wear limit: 19 mm.
or
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on brake discs with visuallkswagen A oes
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⇒ page 62 . ris
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2 - Bolt ss c
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❑ 8 Nm.
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3 - Brake pads
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❑ with wear indication.

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❑ when the corresponding

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wear is reached (limit:

spec
approx. 4 mm) a control

light turns on in the dash

t to the co
panel.
❑ Thickness: 14 mm.
rrectne
❑ Wear limit: 7 mm with

the rear plate.
ss
❑ Check thickness
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⇒ Maintenance ; Book‐
inform
let ; .
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❑ always replace from the

atio
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same axle.
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⇒ page 56 .
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4 - Brake caliper
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brake flexible tube.

❑ repair ⇒ page 107 .
5 - Guide pin
❑ 30 Nm.
6 - Cover cap
7 - Fastening sleeve
8 - Brake hose with annular nozzle and hollow bolt
❑ 35 Nm.
9 - Wheel hub
❑ extract and press ⇒ Running gear, axles, steering; Rep. gr. 40 ; Front suspension .
❑ knocking: 0.04 (vehicles without abs)
❑ knocking: 0.02 (vehicles with abs)
❑ 12 Nm. n AG. Volkswagen AG do
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11 - Cover plate d byV ua
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12 - Wheel roller bearinguth case
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or G 052 112 A3 - lubricating putty- around the sensor. Refer to the ⇒ Chemicals Manual . y li
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❑ 8 Nm.
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es, in part or in w
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1.5 Brake pads, FS III disc brake cylinder -

remove and install
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1.5.1 Removal
– For vehicles with brake pad wear indicator, disconnect the n AG. Volkswagen AG
connector -1-. olks
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– Remove the cover caps. rise nte
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t to the co
– Loosen the guide pins -arrows- of the brake caliper and re‐
move them.
rrectne
– Remove the brake cylinder and fasten it with wire so that the
s
flexible tube.
s o
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– Remove the pads from the brake cylinder.
nform
mer
For cleaning the brake caliper case, use alcohol only.

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1.5.2 Installation
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Before installing new brake pads, press the plungers in the cyl‐
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inder with the re-fitter device. Before pressing the plungers, col‐ Prote AG.
lect the reservoir brake fluid in a container. Otherwise, if brake
fluid recirculates during this interval it may leak and cause dam‐
age.

– Press the plungers back.

– Place the pads in the brake caliper housing.
– Pad -1- should be mounted on the plunger, and Pad -2- should
be mounted on the housing.
AG. Volkswagen AG d
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support guide.
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– Install guide pins -arrows- on the brake caliper and fasten them
to 30 Nm of torque ⇒ Item 5 (page 56) .
m
at
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ion

c
in t
or
the wear indicator.

his
ate
do
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– Install the wheels

p
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♦ After replacing each brake pad, press the brake pedal repeat‐
t.
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edly and strongly with the vehicle stopped so that the brake C py
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pads are perfectly seated for operation.
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♦ After replacing the brake pads, check the brake fluid level. cted agen
Prote AG.
1.6 FS III brake caliper - remove and install


♦ Torque wrench - V.A.G 1331-
♦ Brake pedal actuator - V.A.G 1869/2-
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1.6.1 Removal
t to the co
The following sequence is related only to brake caliper replace‐
ment or repair tasks.
rrectne
Remove the wheels.
In vehicles with brake pad wear indicator, fit the connector of the
ss
wear indicator.
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cial p
f inform
Insert a flexible tube in the caliper bleeder valve, and then open
mer
it.
atio
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n
c
Install the Brake pedal actuator - V.A.G 1869/2- . i

or
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Close the bleeder valve and remove the bleeder container.

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Remove the brake flexible tube -arrow-.

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Remove both guide pin covers. C py
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Remove the brake caliper guide pins.
p by
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Remove the caliper from the brake support.
Prote AG.
Remove the brake pads from the brake caliper.
1.6.2 Installation
• The plunger should be retracted:
– Install the pads in the caliper body


-arrow-.
support guide.
– Install the flexible hose to the brake caliper with 35 Nm of tor‐
que.
– Install guide pins arrows on the brake caliper and fasten them
to 30 Nm of torque .
– Remove the Brake pedal actuator - V.A.G 1869/2- .
the wear indicator.
– Mount the guide pin covers.
– Bleed the brake system ⇒ page 114 .
Install the wheels.
gr. 44 ; Vehicle wheels, tires, vehicle measurement .
Note
♦ Rapidly and vigorously press the brake pedal so that the pads
seat properly according to their normal operating condition.
♦ Check the brake fluid level.
1.7 Brake disc - remove and install
1.7.1 Removal
– For vehicles with brake pad wear indicator, disconnect the
connector of the wear indicator. agen
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– Loosen the two guide pins -arrows- from ed
the
by brake caliper and
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pull them out. ho
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– Remove the brake cylinder and sfasten
s it with wire so that the
ce
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un
pt
flexible tube.
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t to the co
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Rep. gr.46 - Brakes - mechanism
agen
Prote AG.
– Remove the bolt fastening the brake disc to wheel hub

-arrow-, and remove the disc.
Note
♦ Do not remove the brake discs from the wheel hub with ex‐
cessive force, use a rust remover if necessary, otherwise the
discs may be damaged.
♦ Always replace both discs of the same axle.
1.7.2 Installation
swage es n
– Install the brake disc, fastening the bolt -arrow-bto y V the torque
o lk ot g
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of 8 Nm. ir se
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– Return plunger to resting position.
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– Install the pads properly in the caliper.
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– Install the brake caliper, fastening the guide pins -arrows- to
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30 Nm of torque. Prote
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1.8 Brake disc - check (disc knocking)

– Remove brake disc ⇒ page 60 .
– Clean the wheel hub surface properly.
– Check for clearance in the hub with a dial gauge.

The dial gauge should be positioned 90° over the wheel hub sur‐AG. Volkswagen AG d
face, and in the indicated place -arrow-. lksw
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The value should be less than or equal to 0.04mm ris
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The value should be less than or equal to 0.02mm
s
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Otherwise, replace the wheel hub (for vehicles with abs).
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Otherwise, replace the wheel hub (for vehicles with abs).
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- If the wheel hub value is within the specified value, replace the
hole
spec
discs.
es, in part or in w
t to the co
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nform
ercia
1.9 Brake disc with visual check - check

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Note
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♦ The wear indicators on the front brake discs (visual check) in‐
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dicate when the brake discs must be replaced. This check is
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brake discs. p by
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♦ Always check both discs on the same axle and, if necessary,
Prote AG.
replace them.
1.9.1 Vehicles with light-alloy wheels

Position the vehicle so that the brake disc wear indicators (visual
check) can be seen.

AG. Volkswagen AG d
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If the front brake disc wear indicator markings (visual check) can‐
not be visualized due to wheel design, the wheels must be re‐
moved.
rrectne
Conditions for front brake disc wear checking:

ss
1- Wear indicators -1- and -2- are visible:

o
cial p
f inform
The brake discs need not be replaced.

mer
atio
2- Only wear indicator -2- is visible:

om
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The brake discs do not require replacement, but be aware that

thi
te
the next replacement is close.

sd
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3- No wear indicator is visible on the brake disc.

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Replace the brake discs. t. Cop py
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Remove and install the front brake discs. pyri by
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1.9.2 Vehicles with steel wheel
Note
In order to see the brake disc wear indicators (visual check) on

vehicles with steel wheels, the front wheels must be removed.
AG. Volkswagen AG d
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es, in part or in w
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nform
mercia
Conditions for front brake disc wear checking:

a
com
tion in
1- Wear indicators -1- and -2- are visible:

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The brake discs need not be replaced.

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2- Only wear indicator -2- is visible:

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The brake discs do not require replacement, but be aware that C py
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3- No wear indicator is visible on the brake disc cted agen
Prote AG.
Replace the brake discs.

Remove and install the front brake discs.

2 Rear wheel brake (drum brake) - re‐

pair
2.1 Rear wheel brake - assembly overview
Special tools and workshop

equipment required
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or
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ate
do
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♦ "Torque wrench - 40 to 200Nm ( 1/2” drive) - VAG 1332-
2. Rear wheel brake (drum brake) - repair 65

AG. Volkswagen AG d
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After replacing thes awheel brake cylinder, the brake support and
h
♦ ut ra
the brake shoe, it is absolutely necessary to strongly press the
s c
ce
le
brake pedal once so that the brake shoes are properly seated.
un
pt
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♦ To draw the braking fluid from its reservoir, always use the
y li
erm
ab
Brake filling and bleeding equipment - VAS 5234- or the Ac‐
ility
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cessory set for bleeder - V.A.G 1869/4- .
wit
is n
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♦ Before removing a cylinder or brake support and before dis‐
ole,
spec
connecting a brake cylinder tube, the Brake pedal pressing
device - VAG 1869/2- must be installed.
t to the co
WARNING
rrectne
ss
torque.
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f inform
mer
atio
asda
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1 - Axle beam
sd
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❑ 8 Nm
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AG.

052 142 A2- or G 052
112 A3 - lubricating put‐
cals Manual .
4 - Brake tube
5 - Shaft end
6 - Handbrake cable
❑ adjust the handbrake
⇒ page 74 .
⇒ page 76 .
❑ 60 Nm.
❑ with spring dish.
8 - Bolt
❑ 8 Nm
9 - Brake drum
❑ Brake drum diameter,
200 mm.
❑ Wear limit 201.5 mm.
❑ clean thoroughly and
check for wear, dam‐

age, dimensional preci‐

sion and braking surface with no impairments.
10 - Cover
❑ extract and insert ⇒ Running gear, axles, steering; Rep. gr. 42 ; Front suspension .
11 - Self-locking grooved nut
❑ 70 Nm + 30°.
❑ refer to ⇒ Chassis, axles, steering; Rep. gr. 42 ; Rear suspension .
12 - Wheel hub with wheel roller bearing and rotor
❑ refer to ⇒ Chassis, axles, steering; Rep. gr. 42 ; Rear suspension .
13 - Calliper body with brake shoes
Reposition the brake

– Press the wedge upward through one of the threaded holes in
the brake drum wheel bolts with a screwdriver.
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2.2 Brake drum - repair

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After working on the rear wheel brake:

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♦ Release the handbrake.

l purpos
♦ Strongly press the brake pedal once.

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1 - Spring dish
❑ to remove, press
against the compres‐
sion spring and turn 90°
2 - Compression spring
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3 - Brake shoe with handbrake agen oes
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❑ remove and install hor eo
ut
⇒ page 70 . ss a ra
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❑ adjust the handbrake
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⇒ page 74 .
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4 - Upper return spring
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❑ disengage using Hook -
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3438- .
h re
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spec
5 - Lower return spring
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❑ Lubricate the support
points with grease num‐
ber ET G 052 150 A2.
rrectne
6 - Extension spring
7 - Brake shoe
ss o
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⇒ page 70
form
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❑ Minimum pad thickness
atio
m
2.5 mm.
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n
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❑ Check the thickness ⇒
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Maintenance with Accu‐

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The pads are also supplied
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8 - Sealing cap
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❑ remove to check the
brake shoe thickness.
9 - Spring pin
10 - Brake support
❑ 8 Nm
12 - Wheel brake cylinder
❑ Check the sealing ⇒ page 69
13 - Wedge
14 - Operating rod
❑ Lubricate the support points with grease number ET G 052 150 A2.
15 - Support spring
❑ disengage using Hook - 3438- .

Check the tightness of the brake cylinder.

– Remove the sealing boot with the aid of Wedge - 3409- .
– If there is brake fluid in the dust protection boot, replace the
brake cylinder.
While lifting the dust protection boot, make sure that it is not dam‐
aged.
Apply Tectyl - AKR 329 060 BL- to the wheel hub joint and brake
drum -arrow-.
WARNING
Tectyl must not be applied to the wheel holes, as this may af‐
fect the torque application of wheel bolts.
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2.3 Brake drum - remove and install

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2.3.1 Removal
hole
spec
es, in part or in w
– Remove the wheel.

t to the co
– Loosen the bolt -arrow- and remove the brake drum.

rrectness of i
Note
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To do this, the handbrake cannot be engaged.

nform
mercia
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com
tion in
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2.3.2 Installation
t. C rig
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– Installation is carried out in the reverse order of removal.
Prote
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– Install the brake drum, fastening the bolt -arrow- to the torque
of 8 Nm.
Note
To assemble the brake drum, the handbrake cannot be engaged.
2.4 Brake shoes - remove and install

AG. Volkswagen AG d
♦ Hook - 3438- agen oes
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2.4.1 Removal
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– Remove the brake drum. ⇒ page 69

nf
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– Remove the spring dish with the compression springs.

rm
m
atio
m
– Uncouple the brake shoes in the arrow direction behind the

o
n in
c
lower support plate with the help of a screwdriver.

or
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– Support the brake shoes on the lower support plate.

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– Uncouple the lower return spring.
– Release the handbrake cable.

– Remove rear wheel brake cylinder ⇒ page 73 .
AG. Volkswagen A
– Remove the brake shoes between wathe
gen wheel hub and the
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– Fasten the brake shoes
ut in a vise.
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ility
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– Remove the drawspring -1- to the wedge -2-.
es, in part or in w
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– Remove the upper return spring -3- with Hook - 3438- .
rrectness of i
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– Remove the return spring -1- with Hook - 3438- .

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– Remove the operating rod -2- and the wedge -3- from the
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brake shoe.
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Use only alcohol to clean the brake system. co Vo
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Prote AG.

2.4.2 Installation
– Engage the support spring -1- with the Hook - 3438- on the
operating rod -2-.
– Simultaneously place the wedge -3-. AG. Volkswagen AG d
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The bump -arrow- must remainaut visible when installing. ra
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– Place the brake shoe with the lever on the operating rod.
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– Fit return spring -3- with Hook - 3438- .
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t to the co
– Engage the drawspring -1- on the wedge -2-.
– Insert the brake shoes between the wheel hub and the brake
rrectness of i
support.
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– Install rear wheel brake cylinder ⇒ page 73 .

– Place the shoes in the brake cylinder plunger.
nform
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ate
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– Couple the handbrake cable to the brake lever. cum

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– Place the lower return spring and couple the brake shoe be‐
hind the lower support.
– Press the compression spring with the spring dish.
– Install the brake drum ⇒ page 69 .
– Install the wheels.
– Strongly press the brake pedal once.
– Adjust the handbrake ⇒ page 74 .

2.5 Rear wheel brake cylinder - remove and

install
2.5.1 Removal
– Remove the brake drum ⇒ page 69 .
– Remove the rear wheel brake cylinder, loosening the bolt -1-
and hydraulic connection -2-.
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2.5.2 Installation
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– Install the rear wheel brake cylinder, fastening the bolt -1- to
8Nm of torque, and the hydraulic connection -2- with 14 Nm.

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3 Handbrake - assembly overview
1 - Handbrake lever trim

❑ remove by pulling for‐ agen
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❑ Uncouple the unlocking rise
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3 - Adjusting nut
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❑ Adjust the handbrake
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⇒ page 74 .
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spec
❑ Vehicles with drum
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brake
4 - Hexagonal nut
rrectness of i
❑ 20 Nm + 90°.
❑ Replace whenever re‐
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moved
6 - Right-hand guide tube
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7 - Left-hand guide tube

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8 - Handbrake lever support
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9 - Handbrake cables thi

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⇒ page 84 .
11 - Handbrake lever
3.1 Handbrake cable - adjust
3.1.1 Adjustment
– Remove the handbrake finishing adjustment lid.
Note
To perform this operation, the brake must be in ideal conditions

of functioning.
– Remove rear wheels.

– Loosen and remove the handbrake cables from the lever com‐
pensator.
– Raise the vehicle.
– Turn the brake drums until being able to see the wedges
through the wheel securing holes.

– Raise the wedge to its maximum limit with a screwdriver.
Note
♦ Be careful to not release the wedge drive spring.

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♦ If the spring releases, the brake
db
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install the spring. ris
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– Turn the engine on, and accelerate once.
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– Keep the engine in idle and press brake pedal three times,
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3. Handbrake - assembly overview 75

– Assemble the cables and tighten the nut -arrow A- until it is no

longer possible to turn the wheels manually.
Note
To do this, the handbrake cannot be engaged.
– Loosen the nut -arrow A- until the wheel turns freely. A slight
interference is allowed.
The adjusting nut -arrow A- should be screwed above the drawbar
end -1-. n AG. Volkswagen A ge G do
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– Activate the brake lever and check if it is not possible
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With this procedure, the vehicle will be completely immobilized by
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activating the lever between the 3rd and 4th tooth.
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– Release the handbrake and check that the wheels turn freely,
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spec
otherwise slightly loosen the nut -arrow A-.
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t to the co
– With the lever button pressed, raise the lever to just before the
stop for 10 times, keeping it in the position for 1 sec.
– Check the handbrake adjustment again.
rrectness of i
In this condition, make sure that the wheel cannot move with the
l purpos
handbrake on the 4th tooth.

Otherwise, redo the adjustment until the wheel cannot move with
nf
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the handbrake on the 4th tooth.
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A slight interference of the linings against the drum is allowed.
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– Make a test-drive and check the wheels' temperature with your
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front and rear wheels, and cannot be sensible from one side to
another in the same axle.
3.2 Handbrake cable (drum brake) - remove

and install
3.2.1 Removal
– Remove the handbrake finishing adjustment lid.
– Release the handbrake.

– Loosen the nut -arrow- until the handbrake cable can hang out
of the compensator.
– Jack the vehicle.
– Release nuts -1- and remove the floor protection to access the
guide tube -2-.
– Remove the wheel.
– Remove the brake drum ⇒ page 69 .
– Remove the spring dish with the compression springs.
– Uncouple the brake shoes in the arrow direction behind the

lower support plate with the help of a screwdriver.
– Support the brake shoes on the lower support plate.
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– Uncouple the lower return spring.

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Prote AG. 3. Handbrake - assembly overview
– Release the handbrake cable.

– Detach the handbrake cable from the supports on the rear axle
beam -arrows B and C- and supports -arrows A-.
– Pull the handbrake cable in the direction of the arrow, out of

the guide tube -1-.
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3.2.2 Installation
– Pull the handbrake cable in the direction of the -arrow- into the
guide tube -1-.

– Couple the handbrake cable to the brake lever.
– Place the lower return spring and couple the brake shoe be‐
hind the lower support.
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– Press the compression
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– Install the
ss au brake drum ⇒ page 69 . ra
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Fasten the handbrake cable in the following sequence:

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Fox 2004 ➤ , iFoxsed b 2010 ➤ , Fox 2014 ➤ , SpaceFox a2011
ran ➤
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au ra
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A - On the handbrake cable
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support.
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B - On the handbrake cable
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support on the rear axle beam,
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depending on the version:
h re
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♦ Version -1- Support.
spec
es, in part or in w
t to the co
♦ Version -2- Support with
securing bolt -3- with torque
of 5 Nm.
rrectness of i
C - On the rear axle beam
handbrake fastening clip.
♦ The handbrake cable fas‐ l purpos
tening ring must be in the
nf
ercia
o
middle of the clip.
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– Fit the handbrake cable to the compensator.

– Previously tighten the handbrake cable with the nut -arrow-.
– Adjust the handbrake ⇒ page 74 .
– Fasten the floor protection.
– Install the handbrake finishing adjustment cover.
3.3 Handbrake lever handle - remove and

install
Removal:

AG. Volkswagen AG d
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aut ra
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– Pull the handbrake lever handle -2- up. rig ht
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– Fit a small screwdriver in the lever opening and press against cted agen
Prote AG.
the handle -arrow A-.
– Remove the handle -1- from the handbrake lever -2- by pulling
towards the front -arrow B-.
Installation:
Installation is performed in the reverse sequence to the removal.
3.4 Handbrake lever - remove and install
3.4.1 Removal
– Remove the lid to access the handbrake adjustment nut.
Note
To perform the next operation, the handbrake lever cannot be

engaged.

– Loosen the nut -arrow- until the handbrake cable can hang out
of the compensator.
– Engage the handbrake lever.
AG. Volkswagen AG d
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– Remove the nut -1- with an articulated wrench.
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– Release (disengage) the handbrake lever.
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is n
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t to the co
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mer
– Remove the nut -2- through the access to the handbrake ad‐
atio
m
justment nut.
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– Disengage the handbrake sensor connector.

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– Remove the lever.

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3.4.2 Installation
– Installation is carried out in the reverse order of removal.
– Fasten the bolts -arrows- to the handbrake lever with the tor‐
que of 20 Nm + 90°.
Note
The nuts must be replaced whenever removed.

3.5 Handbrake switch - remove and install
3.5.1 Removal
– Remove the handbrake lever handle ⇒ page 81 .
– Remove the cover -1- from the access to the handbrake ad‐
justment.
– Disengage the handbrake switch connector.
– Remove the handbrake switch by releasing the locks -1-

through the access to the handbrake adjustment, if necessary.
AG. Volkswagen AG d
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3.5.2 Installation
spec
es, in part or in w
t to the co
The installation is performed in the reverse sequence from the

removal.
rrectness of i
Note
l purpos
♦ Only use the access to the handbrake adjustment if necessa‐

nf
ercia
ry.
orm
m
atio
♦ The assemble is easier with the operator on the passenger

om
seat.
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Fox 2004 ➤ , Fox 2010 ➤
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tee systems - Edition 02.2019
ut or
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4 Brake pedal - assembly overview
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WARNING
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The brake pedal travel should not be shortened with additional
hole
spec
floor linings.
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t to the co
Before the assembly, all support points must be lubricated with
Grease - G 000 602- . Refer to the ⇒ Chemicals Manual .
rrectness of i
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WARNING
nform
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torque
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Prote AG.
❑ 28 Nm
4 - Brake pedal switch - F47-
❑ before assembling the
Brake pedal switch -
F47- , the brake pedal
must be fitted with the
brake servo selector rod
⇒ page 87
⇒ page 89
5 - Accelerator pedal
6 - Brake pedal
7 - Bearing bush
8 - Cover
9 - Support pin
moved
❑ 25 Nm
11 - Brake servo
12 - Front panel
13 - Module support
14 - Crash bar anchor
❑ 10 Nm
4. Brake pedal - assembly overview 85

olkswagen AG
ag en AG. V
Fox 2004 ➤ , Fox ol2010
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does
not 2011 ➤
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Brake systems
sed - Edition 02.2019
b ara
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ut or
4.1 Brake pedal - separate
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4.1.1 Separate brake pedal from brake servo
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ility
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♦ Wrench - T 10006A-
spec
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– Remove the bolts -1-.
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– Remove the cover -2-.
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– Remove the Brake pedal switch - F47- , turning it 45º to the rig ht
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left.
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– Then, press and hold the brake pedal towards the brake servo.
1 - Brake pedal
2 - Brake cylinder selector rod
3 - Fastening shoulders
– Position Wrench - T 10006A- and pull towards the driver's
seat, at the same time hold the brake pedal (at this time, the
pedal cannot move backwards). With this, the fastening
shoulders -3- of the operating rod ball head seat are pressed
away from the operating rod -2-.
The picture displays a better way to represent the brake servo
pedal separation without representing the pedals.
– Pull Wrench - T 10006A- together with the brake pedal towards
the driver's seat. (With this, the brake pedal is pulled out of the
operating rod ball head).

AG. Volkswagen AG d
4.1.2 Fasten brake pedal
Vol
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swabrake servo
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– Hold the selector rod ball head
oris in front of the seat and press
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the brake pedal towardsauthe
th brake servo until the ball head eo
ra
coupling is heard. ss c
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Installation is performed in the reverse sequence to the removal
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– Install and adjust the Brake pedal switch - F47- ⇒ page 89 .
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4.2 Pedal set - remove and install
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nform
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4.2.1 Removal
m
a
com
t
– Remove dash panel ⇒ Electrical system; Rep. gr. 90 ; Instru‐
ion in
ment case, indicators .
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thi
s
iva
– Remove the driver's side cover ⇒ General body repairs, inte‐
do
r
rior; Rep. gr. 68 ; Internal equipment .

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– Remove heating baffle ⇒ Heating, air conditioning; Rep. gr.
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– Remove the Brake pedal switch - F47- , turning it 45º to the
left.
– Disconnect the accelerator cable.
– On vehicles with accelerator pedal position sensor, release
the connector under the dash panel.
– Separate the brake pedal from the brake servo ⇒ page 86 .
– Remove the pedal set, loosening the nuts -arrows-.

4.2.2 Installation
removal.
4.3 Brake pedal - remove and install agen

AG. Volkswagen AG d
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4.3.1 Removal th
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– Remove the bolts -1-. pe
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– Remove the Brake pedal switch - F47- , turning it 45º to the
spec
left.
es, in part or in w
t to the co
– Disengage the accelerator cable.
– On vehicles with accelerator pedal position sensor, release
rrectness of i
the connector under the dash panel.
l purpos
– Separate the brake pedal from the brake servo ⇒ page 86 .
nform
mercia
a
com
t
– Unscrew the hexagonal nut -1- and remove the hexagonal
ion in
head bolt -arrow-.
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– Remove the brake pedal -2-.
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4.3.2 Installation
Installation is performed in the reverse sequence of the removal.
– The tightening torque for the hexagonal nut -1-is 25 Nm.

4.4 Brake pedal switch - F47- - remove and

install
4.4.1 Removal swage

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– Disconnect the brake light connector. b yV ua
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– Remove the Brake pedal switch - F47- , rotating
auth
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4.4.2 Install and adjust
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– Before installing, apply Lubricating putty - G 052 142 A2- on pe
ility
the rod tip, area -A-. Refer to the ⇒ Chemicals Manual .
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spec
Note
es, in part or in w
t to the co
The installation of the Brake pedal switch - F47- must be carried
out with the brake pedal in rest position. The brake pedal may not
rrectness of i
be activated before the end of the procedure
l purpos
nform
mercia
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t
– Inset the Brake pedal switch - F47- in its respective housing
ion in
and press it slightly against the brake pedal -arrow 1- and fas‐
r
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ten by turning it (45°) to the right -arrow 2-.
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– Connect the connector for the Brake pedal switch - F47- .
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– Depress the brake pedal and check whether the brake light
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47 – Brakes - hydraulics
1 Assembly overview: Brake servo/
brake master cylinder
The brake master cylinder and the brake servo can be independ‐
ently replaced.
WARNING

torque
1 - Brake servo
❑ On petrol engines, the
vacuum required is re‐
moved from the intake
manifold.
❑ On diesel engines, a
vacuum pump is instal‐
led to create vacuum.
❑ Check the operation
❑ Press the brake pedal
several times with the AG. Volkswagen AG d
engine stopped (this olkswagen oes
not
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❑ Now, holds the brake
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pressure and start the

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ility
engine. When the brake

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ly, this can be felt with a

hole
spec
foot on the brake pedal

es, in part or in w
(the amplification is ac‐

t to the co
tive).
❑ in case of faults, replace
completely
rrectness of i
❑ Non-return valve (in the

l purpos
vacuum line). Check the

operation ⇒ page 93
nform
ercia
❑ separate from the brake

pedal ⇒ page 86
m
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on in
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90 Rep. gr.47 - Brakes - hydraulics

⇒ page 93 .
2 - Brake oil level warning
wagecontact - F34-
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3 - Sealing pluged by ara
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4 - Brake fluid
au
th reservoir ra
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5 - Sealing plug
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❑ moisten with brake fluid and introduce into the brake cylinder
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❑ 20 Nm
ole,
spec
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❑ cannot be repaired. In case of faults, replace completely
8 - Retaining pin
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❑ insert through the brake cylinder
s
9 - Seal
s o
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f
inform
mer
10 - Sealing plug
atio
m
11 - Vacuum line
o
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❑ Install in the brake servo
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12 - Bellows
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❑ ensure proper seating, aspiration noises may occur

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❑ Replace whenever removed cop Vo
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❑ 28 Nm
Prote AG.
14 - Sealing
❑ to brake servo
1. Assembly overview: Brake servo/brake master cylinder 91

1.1 Master cylinder - remove and install

equipment required
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♦ Clamps (diameter 25 mm) - 3094-
♦ Torque wrench - 5 to 50Nm ( 1/2” drive) - VAG 1331- rrectness of i
l purpos
♦ Brake filling and bleeding equipment - VAS 5234-
1.1.1 Removal
nform
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– Place an adequate number of lint-free cloths in the area

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around the water reservoir, engine and transmission. Cop py
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rig ht
– Draw as much brake fluid as possible from the reservoir by py by
co Vo
using Brake filling and bleeding equipment - VAS 5234- or Ac‐
by lksw
cted agen
Prote
AG.
– Close the clutch cylinder return hose with the clamps (diam.
25 mm) - 3094- .

AG. Volkswagen AG d
agen oes Brake systems - Edition 02.2019
olksw not
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– Disconnect
ho
ris the clutch cylinder return hose. nte
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t
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– Disconnect
ss the Brake oil level warning contact - F34-c .
ce
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un
pt
– Release the brake pipes from the brake cylinder and close
an
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them with the plugs from the number ET 1H0 698 311 A repair
y li
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ab
set.
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– Release the brake cylinder nuts.
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– Carefully remove the brake servo master cylinder.
spec
es, in part or in w
1.1.2 Installation
t to the co
Both vehicles
rrectness of i
– The installation is performed in the reverse sequence from the
removal.
l purpos
When installing, pay special attention to the following points:
nform
ercia
– When joining the brake master cylinder to the brake servo,

ensure the selector rod is properly seated in the brake master
m
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cylinder.
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– Screw the brake cylinder nuts to 20 Nm.
s
iva
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– Tightening torque for the brake pipes 14 Nm.

rp
cum
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en
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– Connect the brake pipes.

t.
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Cop py
t. rig
Vehicles without ABS
opyri
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ht
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♦ -1- Right front break tube
by
cted agen
Prote AG.
♦ -2- Left front break tube
♦ -3-Rear break tube for breaking power adjuster ⇒ page 111
♦ -4-Rear break tube for breaking power adjuster ⇒ page 111
Vehicles with ABS 5.7 ⇒ page 20
Vehicles with ABS 8.0 ⇒ page 28
1.2 Inspect the non-return valve

– Inspect the non-return valve
-A-.
Air must pass through the valve in the arrow direction.
The valve must remain closed in the opposite direction.
Pay attention to the correct assembly position.
1.3 Brake servo - remove and install

AG. Volkswagen AG d
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Fox 2004 ➤ , Fox 2010 ➤ , Fox r2014ise
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➤ , SpaceFox 2011 ➤ ara
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equipment required
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spec
t to the co
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cial p
f inform
mer
atio
om
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or
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te
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Cop py
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♦ Clamps (diameter 25 mm) - 3094-

♦ Break bleeding device - V.A.G 1869-
♦ Wrench - T 10006A-
1.3.1 Removal
– Remove the driver's side cover ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Internal equipment .


80 ; Heating .
– Remove air filter ⇒ Engine - Supply and ignition system ; Rep.
gr. 24 ; Supply system - fuel injection .
– Place an adequate number of lint-free cloths in the area
around the water reservoir, engine and transmission.
– Draw as much brake fluid as possible from the reservoir by
using Brake filling and bleeding equipment - VAS 5234- or Ac‐
– Close the clutch cylinder return hose with the tool 3094.
– Disconnect the clutch cylinder return hose.
– Disconnect the Brake oil level warning contact - F34- .
– Release the brake pipes from the brake cylinder and close
them with the plugs from the number ET 1H0 698 311 A repair
set.
– Disconnect the vacuum line from the brake servo.
– Remove the lining underneath the dash panel.
AG. Volkswagen AG d
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– Remove the cover -2-. olksw
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– Disconnect the brake light connector.
orise nte
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– Remove the Brake pedal sswitch - F47- , turning it 45º to the
s a c
left.
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– Then, press and hold the brake pedal towards the brake servo.
1 - Brake pedal
rrectness of i
2 - Brake cylinder selector rod

l purpos
3 - Fastening shoulders
– Position Wrench - T 10006A- and pull towards the driver's
nform
ercia
seat, at the same time hold the brake pedal (at this time, the
m
pedal cannot move backwards). With this, the fastening

com
tio
shoulders -3- of the selector rod ball head seat are pressed
n in
r
away from the selector rod -2-.

te o
thi
s
iva
do
The figure displays a better way to represent the separation be‐

r
rp
cum
tween the brake pedal and the brake servo without representing
fo
en
ng
the pedal set.

t.
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Cop py
. rig
– Pull Wrench - T 10006A- together with the brake pedal towards
ht ht
rig by
py
the driver's seat. (With this, the brake pedal is pulled out of the co Vo
by lksw
operating rod ball head). cted agen
Prote AG.

– Loosen the hexagonal nuts -arrows-.

– Uncouple the brake servo with the brake master cylinder for‐
ward and remove.
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1.3.2 Installation
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removal.
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spec
– Tightening torque for the hexagonal nuts -arrows- to 28 Nm.
t to the co
Fasten the brake pedal to the brake servo
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mer
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– Hold the operating rod ball head in front of the seat and press
p
cum
r
fo
the brake pedal towards the brake servo until the ball head
en
ng
t.
yi
coupling is heard.
Co
Cop py
t. rig
– Before installing, remove the rod completely.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Insert the Brake pedal switch - F47- in its respective housing

and press it slightly against the brake pedal -arrow 1- and fas‐
ten by rotating it (45°) to the right -arrow 2-.
– Here, the brake pedal always remains at rest position.
– Connect the connector for the Brake pedal switch - F47- .
– Check the brake light operation.
After adjusting, check whether the Brake pedal switch - F47- is at
the final stop (loose position).

1.4 Vacuum pump for 4-cylinder diesel en‐

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gines and with distribution
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(diesel vehicles)hor-iseremove and install
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1.4.1 Removal
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– Loosen the fastening clamp -arrow A- from the vacuum line,
ility
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disconnect the hose.
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– Loosen the bolt -arrow B- on the head flange.
ole,
spec
– Remove the vacuum pump.
t to the co
rrectness o
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mer
atio
Seal the vacuum pump
om
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2 - Cap
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3 - 0-Ring
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- change
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4 - Vacuum pump cop Vo
by lksw
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5 - 0-Ring
- change
6 - Hexagonal head bolt, 20 Nm
♦ It is impossible to repair the vacuum pump.
♦ To seal, replace the two rear O-Rings. 3 and 5.
1.4.2 Installation
When installing the vacuum pump, ensure the proper fitting to the
driving gear.
– Fasten the bolt -arrow B- to the flange and install the vacuum
line with the clamp -arrow A-.

1.4.3 Vacuum pump for 3-cylinder diesel en‐

gines
Tandem pump -1- (vacuum pump and fuel pump).
Vacuum line -2- to brake servo with non-return valve.
Fuel tube -3- and -4-
– Remove and install⇒ Rep. gr. 20 ; Fuel supply system com‐
ponents - remove and install .
1.4.4 Vacuum pump for 4-cylinder diesel en‐

gines with injector pump unit
Tandem pump -1- (vacuum pump and fuel pump).
Vacuum line -2- to brake servo with non-return valve.
Fuel tube sets -3- and -4-.
– Remove and install⇒ Rep. gr. 20 ; Fuel supply system com‐
ponents - remove and install; .
AG. Volkswagen AG d
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es, in part or in w
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nform
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ate
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priv
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98
AG.
Rep. gr.47 - Brakes - hydraulics
2 Vacuum system - Check
2.1 Test instructions

Inspection instructions
In case of complaints regarding the servo brake or the so-called
»hard brake pedal«, they must be used as support and guide for
an effective and objective search for faults.
This control covers the following components:
♦ Brake servo
♦ Sealing ring between the master cylinder of the brake and
servo brake
♦ Non return valve
♦ Vacuum hoses with fitting connections
♦ Vacuum pump (if applicable)
The results of measurement procedures are influenced by geo‐
graphical position. The higher the altitude (compared to sea
level), the lower the air pressure.
Observe verification conditions:
♦ Visual inspection of all vacuum hoses for damages (e.g.
cracks or “ruptures”) as well as proper fitting.
AG. Volkswagen
♦ Ensure proper cleanliness
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gen vacuum system
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♦ Clean the engine
risecompartment before initiating
db activities,
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♦ Servo brake vacuum measurement device - VAS 6721-

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ate
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en
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Vacuum system - Check 99

2.2 Servo brake vacuum measurement de‐

vice - VAS 6721- - connect
– Remove the vacuum hose -1- from the servo brake -2-.
To facilitate the vacuum hose disassembly procedure, press the
brake pedal several times with the engine switched off.
– Insert the servo brake vacuum measurement device - VAS

6721- -check the following figures-.
Posi‐ Com‐ Clarification
tion po‐
nent
A Clos‐ towards the vacuum hose, retention valve, and
ing vacuum pump, if applicable
valve
B Clos‐ ♦ Open to easily disassemble the servo brake
ing vacuum measurement device - VAS 6721-
valve
♦ Open to simulate an error source
♦ Connect the main vacuum pump - VAS 6213-
C Clos‐ towards the servo brake

ing
valve agen
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– Insert hose -A- of the servo brake vacuum measurement de‐
uthor eo
vice - VAS 6721- in the vacuum hose. ss a ra
c
ce
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– Press adaptor -C- in the servo brake.

un
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2.3 Vacuum generation control
Note
♦ Atmospheric air pressure is 1013 mbar at sea level (N.N.).

♦ Air pressure lowers as altitude increases (approx. 100 mbar/
1000 m altitude).
♦ Local and climate variations also affect vacuum generation.
♦ Cold engines, activated air conditioning systems, or simply an
idling engine negatively affect vacuum generation.
– Previously test all vacuum hoses for damages (e.g. cracks or

“ruptures”) as well as to proper fitting.
– Connect the servo brake vacuum measurement device - VAS
6721- ⇒ page 100
– Open closing valve -A- . wage
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Vo
– Close closing valves -B- and -C-. d by ua
ran
ir se tee
o
– Run the engine at service temperature (>60auth ºC); briefly press or
ac
the gas pedal once (engine rotation in sexcess
s of 2,000 rpm).
ce
le
un
pt
– Read the indicated measurement.
an
d
itte
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In normal circumstances (check indications), the generated vac‐
erm
ab
ility
uum must be between 600 and 950 mbar (depending on the
ot p
wit
engine).
is n
h re
ole,
If such values are not reached, despite meeting all requirements
spec
(check indications), the vacuum system must initially be tested for
t to the co
leaks.
– Comparatively, generate vacuum with the manual vacuum
pump - VAS 6213- ⇒ page 103 .
rrectne
To facilitate disassembly of adaptor and hose connections, open
the closing valve -B- .
ss o
cial p
f inform
2.4 Leak control
mer
atio
om
n
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i
or
Note
thi
te
sd
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o
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♦ Atmospheric air pressure is 1013 mbar at sea level (N.N.).

um
r
fo
en
ng
t.
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♦ Air pressure lowers as altitude increases (approx. 100 mbar/
Co
op py
1000 m altitude). t. C rig
gh ht
pyri by
♦ Local and climate variations also affect vacuum generation.
co Vo
by lksw
cted agen
Prote AG.
♦ Cold engines, activated air conditioning systems, or simply an
idling engine negatively affect vacuum generation.
– Previously test all vacuum hoses for damages (e.g. cracks or

“ruptures”) as well as to proper fitting.
– Connect the servo brake vacuum measurement device - VAS
6721- ⇒ page 100
– Open closing valve -A- .

– Close closing valves -B- and -C-.

– Run the engine at service temperature (>60 ºC); briefly press
the gas pedal once (engine rotation in excess of 2,000 rpm).
In normal circumstances (check indications), the generated vac‐
uum must be between 600 and 950 mbar (depending on the
engine).
AG. Volkswagen AG d
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– Open closing valve -C- to evacuate the servo brake. s
ce
le
un
pt
– Switch the engine off.
an
d
itte
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erm
ab
– Read and register the indicated measurement.
ility
ot p
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Vacuum must lower by 400 mbar in 12 hours.
is n
h re
ole,
In case of greater vacuum drop, you must test the leakage point
spec
located in the region of the ...
t to the co
1- Brake servo
or
rrectne
2- Retention valve, vacuum hoses with connectors and intake
manifold/vacuum pump
ss o
cial p
f
.
inform
mer
In case of major leaks, vacuum drops abruptly within a few sec‐
atio
onds.
om
n
c
i
or
n
Perform vacuum control in the servo brake region:
thi
te
sd
iva
o
pr
c
– After generating vacuum, close the closing valve -A- , to test
um
r
fo
en
ng
the servo brake vacuum system.

t.
yi Co
op py
Check the vacuum in the retention valve area, vacuum hose with
t. C rig
gh ht
yri
connectors and suction tube/vacuum pump: p by
co Vo
by lksw
cted agen
Prote AG.
– After generating vacuum, close the closing valve -C-, to check

the vacuum system of the servo brake vacuum measurement
device - VAS 6721- until the suction tube or vacuum pump.
To facilitate disassembly of adaptor and hose connections, open
the closing valve -B- .

2.5 Vacuum generation with the manual

vacuum pump - VAS 6213-
♦ Manual vacuum pump - VAS 6213-
AG. Volkswagen AG d
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In some cases vacuum may also be generated by the manual
h re
hole
vacuum pump - VAS 6213- , instead of the vacuum pump or the
spec
engine.
es, in part or in w
t to the co
– Switch the sliding ring -1- of the manual vacuum pump - VAS
6213- from position -A- to “vacuum”.
rrectness of i
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tion in
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– For such, insert the manual vacuum pump - VAS 6213- in the Cop py
t. rig
vacuum hose of connection -B- in the servo brake vacuum gh ht
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measurement device - VAS 6721- .
op Vo
by c lksw
cted agen
Prote AG.
– Open closing valve -B- .
– Generate vacuum with the manual vacuum pump - VAS
6213- , until the servo brake vacuum measurement device -
VAS 6721- reads between 600 and 950 mbar.
– Next, execute corresponding controls.

3 Front brake caliper, FS II brake cali‐

per - repair
♦ In case of repairs, install the full repair set.
♦ New brake calipers are filled with brake fluid and previously
bled.
♦ Apply a light coat of Grease - G 052 150 A2- on the brake
cylinder, plungers and sealing ring. Refer to the ⇒ Chemicals
Manual .
1 - Brake caliper case

2 - Protective cap
❑ couple to the bleederwagen AG. Volkswagen AG does
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3 - Bleeder valvetho
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❑ 10 Nmss a ac
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❑ before installing, apply a

un
pt
an
thin coat of Assembly
d
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paste - G 052 150 A2- to
erm
the thread. Refer to the ab

ility
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⇒ Chemicals Manual . wit

is n
h re
ole,
4 - Spacer sleeve, upper spec

❑ assemble with Assem‐

t to the co
bly paste - G 052 150

A2- . Refer to the ⇒
Chemicals Manual .
rrectne
5 - Sleeve, upper
❑ cut
ss o

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f in

form
mer
A2- . Refer to the ⇒

atio
Chemicals Manual .
om
n
c
i
or
6 - Bushing, upper
thi
te
sd
va
❑ couple to the brake cali‐

i
o
pr
per
um
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en
ng
t.
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7 - Bushing, lower
Co
Cop py
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gh ht
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per cop Vo
by lksw
cted agen
Prote AG.
8 - Sleeve, lower
❑ cut
A2- . Refer to the ⇒ Chemicals Manual .
9 - Spacer sleeve, lower
❑ assemble with Assembly paste - G 052 150 A2- . Refer to the ⇒ Chemicals Manual .
10 - Sealing ring
❑ remove with the help of a plastic wedge ⇒ page 105
11 - Piston
❑ first apply a light coat of Assembly paste - G 052 150 A2- to the plunger. Refer to the ⇒ Chemicals
Manual .

12 - Protective cap
❑ do not damage when inserting the plunger
. Volkswagen AG
gen AG
3.1 Plunger for front brake ksw caliper - removees not
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and install db ara
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Special tools and workshopss aequipment required ac
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♦ Wedge - 3409-
pt
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Cop py
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Prote AG.
3.1.1 Removal
– Remove the plungers from brake caliper case with com‐
pressed air.
Place a wooden plate in the area so that the plunger is not dam‐
aged.
3. Front brake caliper, FS II brake caliper - repair 105

– Remove the sealing ring with the Wedge - 3409- .

While removing, make sure that the cylinder surface is not dam‐
aged.
AG. Volkswagen AG d
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3.1.2 Installation
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The plunger and sealing ring surfaces can only be cleaned with
wit
, is n
alcohol.
h re
hole
spec
– Apply a light coat of Assembly paste - G 052 150 A2- to the
es, in part or in w
plunger and sealing ring. Refer to the ⇒ Chemicals Manual .
t to the co
– Install the sealing ring in the brake caliper case.
– Place the protection cover with the external sealing lip over the
rrectness of i
piston.
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Cop py
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rig ht
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– Install the internal lip in the cylinder groove using the Wedge copy Vo
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- 3409- . cted agen
Prote AG.
Keep the plunger in front of the brake caliper case.
– Press the plunger with the repositioning device into the brake
caliper case.
The external protection cover lip fits into the plunger groove.

4 Front brake caliper, FS II brake cali‐

per - repair
♦ In case of repairs, install the full repair set.
♦ New brake calipers are filled with brake fluid and previously
bled.
♦ Apply a light coat of Assembly paste - G 052 150 A2- on the
brake cylinder, plungers and sealing ring. Refer to the ⇒
Chemicals Manual .
1 - Dust protection cover n AG. Volkswagen AG do

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❑ couple to the bleeder byV
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2 - Bleeder valve ss
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❑ before installing, apply a
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thin coat of Assembly
erm
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ility
paste - G 052 150 A2- .
ot p
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cals Manual .
hole
spec
3 - Support sleeve
es, in part or in w
t to the co
per
rrectness of i
4 - Guide pin
❑ 30 Nm
l purpos

moved
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ercia
or
5 - Cover cap
m
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atio
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❑ assemble in support
o
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6 - Brake caliper
iv
o
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7 - Sealing ring
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❑ remove and install Cop py
. rig
⇒ page 107
t
gh ht
pyri by
Vo
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8 - Piston
by
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Prote AG.
❑ first apply a light coat of
Assembly paste - G 052
150 A2- to the plunger.
cals Manual .
⇒ page 107
9 - Sealing ring
4.1 Front brake caliper plunger - remove

and install

wage es n
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tee
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♦ Wedge - 3409-ss
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t to the co
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cial p
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Cop py
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4.1.1 Removal
– Remove the plungers from the brake caliper case with com‐
pressed air.
Place a wooden plate in the area so that the plunger is not dam‐
aged.
– Remove the sealing ring with the Wedge - 3409- .

While removing, make sure that the cylinder surface is not dam‐
aged.

kswage es n
4.1.2 Installation ol ot g
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The plunger and sealing
auth ring surfaces can only be cleaned with or
ac
alcohol. ss
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– Apply a light coat of Assembly paste - G 052 150 A2- to the
an
d
itte
plunger and sealing ring. Refer to the ⇒ Chemicals Manual .
y li
erm
ab
ility
– Install the sealing ring in the brake caliper case.
ot p
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– Install the protection cover with the external lip over the plung‐
h re
ole,
er.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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e
– Install the internal lip in the cylinder groove using the Wedge
t
sd
va
- 3409- .
i
o
pr
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Keep the plunger in front of the brake caliper case.
en
ng
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Cop py
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gh ht
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Vo
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by
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Prote AG.
– Press the plunger with the repositioning device into the brake
caliper case.
The external protection cover lip fits into the plunger groove.

5 Vehicles without braking power ad‐

justment - assembly overview
WARNING AG. Volkswagen AG d

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Always replace oself-locking
ris
e nuts and bolts subject to angular nte
torque. h eo
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an
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– Points for removing the flexible rear break line-arrows-: torque

itte
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of 14 Nm.
rm
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WARNING
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Whenever removed, bleed the break system ⇒ page 114 .
es, in part or in w
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Cop py
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Prote AG.

6 Braking power adjustment - assem‐

bly overview
Braking power adjustment on vehicles without ABS.
WARNING

torque. en AG. V
olkswagen AG
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When performing any repair on the brake pressure adjustment
du
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valve, never apply grease or lubricants on the valve's spring,
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nor in any other brake system component.
ility
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1 - Braking force adjustment
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❑ Adjust ⇒ page 112 .
❑ Check ⇒ page 112 .
2 - Mounting bracket rrectness of i
l purpos
3 - Self-locking hex head bolt

nf
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orm
❑ 17 Nm.
m
atio
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or
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❑ Right rear wheel brake

t
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cylinder.
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❑ Tightening torque for

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the brake pipes 14 Nm.
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5 - Brake pipe connection yri
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❑ Left rear wheel brake cted agen
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cylinder.
❑ Brake master cylinder/
floating plunger circuit
for the hydraulic unit.
❑ Brake master cylinder/
push rod circuit for the
hydraulic unit
8 - Retaining support
❑ 20 Nm.
6. Braking power adjustment - assembly overview 111

10 - Nut
❑ 20 Nm.
12 - Extension spring
13 - Brake hose olkswage es n
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14 - Axle beam ir se
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15 - Hexagonal head bolt ss
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❑ 16 Nm.
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ab
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6.1 Braking power adjustment - adjust
ot p
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Excessively high testing pressure on the rear axle:
hole
spec
es, in part or in w
– Relieve the adjustment spring.
t to the co
Excessively low testing pressure on the rear axle:
– Tension the adjustment spring.
rrectness of i
l purpos
Note
nform
ercia
Never relieve or tension the valve spring with the brake pedal
pressed
m
at
om
ion
c
in t
or
Follow the sequence:
his
ate
do
riv
– Check the amounts ⇒ page 112

p
cum
for
en
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– Adjust the spring.

n
t.
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Cop py
– Check the amounts again ⇒ page 112
t. rig
gh ht
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Vo
co
– If necessary, re-make the adjustment.
by lksw
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6.2 Braking power adjustment - check

♦ Control equipment for brake systems - V.A.G 1310 A-
Follow the conditions:
• The fuel tank must be full
• Driver weighing approximately 75 Kg
• The spare wheel and tools are in their respective assembly
positions in the vehicle
• The water reservoir for the windscreen/headlight washer sys‐
tem must be full
– Lift the vehicle on a board-type elevator or use an inspection
pit.

– Remove the cylinder bleeding bolts and install the adapters for
the Control equipment for brake systems - VAG 1310A- diag‐
onally, the front left wheel cylinder with the right rear wheel
cylinder, or the right frontgewheel
n AG. Vocylinder
lkswagenwith
AG dothe left rear wheel
+cylinder. lkswa es n
Vo ot g
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db ar
– Bleed the equipment
or
ise through the regulator valves. antee
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ss
WARNING
ce
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Do not allow fluid shortage in the reservoir
erm
ab
ility
ot p
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– Press the brake pedal until the front wheel pressure gauge
ole,
indicates 70 bar and compare to the values to be obtained on
spec
the left wheel according to table ⇒ page 113 .
t to the co
– Repeat the reading and checking with 100 bar and check the
table ⇒ page 113 .
rrectne
6.2.1 Braking power adjustment specifica‐
s
tions depending on the load
s o
cial p
f inform
Version Axle Pressure (Bar)
mer
atio
m
Drum brake in Front 70 100

o
n
c
the rear axle

i
or
Rear 35.7 ... 41.7 48.6 ... 54.6 n thi

te
sd
iva
– If the values found do not correspond to the ones indicated

pr
cum
r
fo
and the system has no leaks or other irregularities, readjust

en
ng
t.
the valve or replace it.
yi Co
Cop py
t. rig
gh ht
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WARNING
cop Vo
by lksw
cted agen
Prote AG.
Never reuse drained fluid.

Use factory recommended brake fluid only.
– Remove the pressure gauges and bleed the brake system

⇒ page 114 .
6. Braking power adjustment - assembly overview 113

AG. Volkswagen AG d
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7 Bleed the
s
brake system au
tho or
ac
s
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un
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WARNING
an
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rm
ab
pe
♦ Use only new brake fluid, in accordance with standard US
ility
ot
FMVSS 116 DOT 4.
wit
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hole
♦ The original VW/Audi brake fluid corresponds to this spec‐
spec
ification.
es, in part or in w
t to the co
♦ The brake fluid is toxic. Due to its acidic properties it
should not come into contact with painted surfaces.
rrectness of i
♦ The brake fluid is hygroscopic, which means it absorbs
humidity from the atmosphere and, therefore, must always
l purpos
be stored in hermetically sealed containers.

♦ Any brake fluid losses must be rinsed with water.
nform
mercia
a
com
tio
Particularities in the vehicles with ABS/EDS/ASR
n in
r
te o
thi
♦ When a brake fluid compensation reservoir chamber is com‐
s
iva
do
pletely empty (e.g. brake system leaks), the brake system
r
rp
cum
must be bled.
fo
en
ng
t.
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Particularities on vehicles with steering wheel on the right side: ht. Cop py
rig
rig ht
♦ When a brake fluid compensation reservoir chamber is com‐ py by
co Vo
pletely empty (e.g.: brake system leaks), or an ABS hydraulic
by lksw
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unit - N55- is replaced, after the basic adjustment the brake
AG.
cylinder must be bled by the plugs -arrows-.
7.1 Bleed the brake system with the filling

and bleeding equipment
or

♦ Brake filling and bleeding equipment - V.A.G 1869-

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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an
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ab
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spec
t to the co
♦ Bleeder accessory set - V.A.G 1869/4-
rrectne
Note
ss
On vehicles equipped with ABS/EDS/ASR brake systems, the
o
cial p
f
system must be bled when the brake fluid reservoir is empty
inform
⇒ page 116
mer
atio
om
– Connect the
n
c
i
or
n
Brake filling and bleeding equipment - VAS 5234- or Brake
thi
te
sd
a
filling and bleeding equipment - V.A.G 1869- .

iv
o
pr
cum
r
fo
– Open the plugs in the sequence determined and bleed the
en
ng
t.
brake cylinder/caliper.
yi Co
Cop py
ht. rig
Bosch 5.7 and 8.0 bleeding sequence rig ht
py by
co Vo
by lksw
1 - Right rear brake cylinder/caliper Prote
cted AG.
agen
2 - Left rear brake cylinder/caliper

3 - Right front brake caliper
4 - Left front brake caliper
– Keep the plugs open with the hose connected until fluid comes
out free of air bubbles.
A test drive must be carried out after the bleeding. At least one
ABS-controlled braking must occur in this test.
7.1.1 Later bleeding

After the test, the brake system must be bled with the filling and
bleeding device connected. For this, a second operator is neces‐
sary:
– Strongly press and hold the brake pedal with your foot.
– Open the plug on the right side of the rear brake caliper.
– Press deeply the brake pedal to the stop.
– Close the plug while still holding the brake pedal.
– Slowly release the brake pedal.
This bleeding procedure must be carried out 5 times per brake
caliper.
– Remove the plugs in the sequence determined and ventilate
the brake cylinder/caliper.
Bleeding sequence
1 - Right rear brake cylinder/caliper
7. Bleed the brake system 115

2 - Left rear brake cylinder/caliper

3 - Right front brake caliper
4 - Left front brake caliper
A test drive must be carried out after the bleeding. This drive must
include at least one ABS-controlled braking!
7.2 Brake system, only vehicles with ABS/

EDS/ASR - bleed when the reservoir is
empty
or
♦ Brake filling and bleeding equipment - V.A.G 1869-

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
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un
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an
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ab
ility
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ole,
spec
t to the co
♦ Bleeder accessory set - V.A.G 1869/4-

rrectne
– Connect the Brake filling and bleeding equipment - VAS 5234-

or Brake filling and bleeding equipment - V.A.G 1869- .
ss
– Open the plugs in the sequence determined and bleed the

o
cial p
brake cylinder/caliper.
inform
mer
1 - Simultaneously bleed the left front and right front rear brake
atio
m
caliper
o
n
c
i
or
2 - Simultaneously bleed the left rear and right rear brake caliper/
thi
te
sd
a
cylinder
iv
o
pr
cum
r
fo
– Keep the plugs open with the hose connected to the bleeding
en
ng
t.
container until the fluid exits free from air bubbles.
yi Co
Cop py
t. rig
Then, the hydraulic unit must be bled once again, by means of
gh ht
pyri by
the Vehicle diagnostic, testing and information system - VAS
co Vo
by lksw
cted
5051A /52- ⇒ page 10 in the function “Basic adjustment”.
agen
Prote AG.
– Then, bleed the brake system ⇒ page 114

A test drive must be carried out after the bleeding. At least one
ABS-controlled braking must occur in this test.
Note
AG. Volkswagen AG d
agen oes
ksw
Change the brake fluid every y V2 years
ol not
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ise nte
or eo
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aut ra
ss c
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nl
pt
du
an
itte
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ab
ility
ot p
wit
, is n
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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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Bleed the brake system 117

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Service

Service Department. Technical Information

45 - Anti-lock brake system

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg BRA5R005020

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 Information on repair works on the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 Electrical/electronic components and installing locations . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.3 ABS Bosch 8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8.1 Hydraulic unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

8.2 Command unit for hydraulic unit - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9.1 Hydraulic unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Fault indication via control lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10.1 Control lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.9 Brake disc with visual check - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1 Assembly overview: Brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.1 Master cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

1.2 Inspect the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1.3 Brake servo - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

vehicles) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 Vacuum system - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.3 Vacuum generation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3 Front brake caliper, FS II brake caliper - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4 Front brake caliper, FS II brake caliper - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.1 Front brake caliper plunger - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5 Vehicles without braking power adjustment - assembly overview . . . . . . . . . . . . . . . . . . . . 110

6 Braking power adjustment - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

♦ -Arrow 2- Front wheel brake (-1LG- FS III Disc brake)

The following table displays the PR number coding. This is im‐

portant for the combination caliper/disc/drum and brake pads/

1.1.1 Font wheel brake (disc brake)

1.1.2 Rear wheel brake (drum brake)

1.2 Brake technical data

1.2.2 Front wheel brake FS III

-3- Brake disc ∅ mm 256

-4- Brake caliper, ∅ mm 54

1.2.3 Rear wheel brake (drum brake, without

Brake mas‐ ∅ mm 20.64

ter cylinder 19.051)

Brake servo ∅ in 8.5′′

-1- Wheel ∅ mm 17.46

brake cylin‐ 19.05

-2- Brake shoe, mm 5

-3- Brake drum ∅ mm 200

2 Rep. gr.00 - Technical data

1.2.4 Rear wheel brake (drum brake, with

45 – Anti-lock brake system

Failures in the ABS influence the brake system and amplification.

A different braking behaviour should be expected. After the ABS

In case of complaint, ABS hydraulic unit - N55- and ABS control

Location of ABS in a vehicle with left-hand drive:

Bosch 5.7 (ABS) :

4 Rep. gr.45 - Anti-lock brake system

2 General information for the anti-lock

Location of the ABS in vehicles with steering wheel on the left

Location of the ABS in vehicles with steering wheel on the right

ABS control unit - J104- must both be replaced. Do not separate

Bosch 8.0 (ABS) and (ABS/ASR):

Bosch 8.0 (ABS/EDS/ASR/ESP):

6 Rep. gr.45 - Anti-lock brake system

3 General information on the Bosch 8.2

1 - Hydraulic system unit and

Bosch 8.2 (ABS) :