Service

Repair Manual
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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - General, Technical Data
45 - Antilock Brake System
46 - Mechanical Components
47 - Hydraulic Components

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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 © 2020 Volkswagen AG, Wolfsburg D4B806EC0D1

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Contents

00 - General, Technical Data . . . . . . . . . . . . . .G.. V.o.lk.sw.a.ge.n. . . . . . . . . . . . . . . . . . . . . . . 1

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1 Safety Precautions . . . . . . . . . . .V.o.lk.sw. a. . . . .
. . . . . . . . . . . .oe. s. n.o.t g. . . . . . . . . . . . . . . . . .
.. 1
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1.1 Safety Precautions during Road ed Test with Testing Equipment . . . . .ra.n. . . . . . . . . . . . . . .. 1
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2 Identification . . . . . . . . .au.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a. . . . . . . . . . .
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2.1 PR Number Allocation - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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3.1 Technical Data, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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4.2 FWD Vehicles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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4.3 AWD Vehicles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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4.4 Parking Brake, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

45 - Antilock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.1 Anti-Lock Braking System (ABS) Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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2 Component Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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2.1 Component Location Overview - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3 Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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3.1 Overview - Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 , Removing and Installing . . . . . . . . 15
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3.3 Control Module, Separating from Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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3.4 Control Module, Installing on Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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3.5 Brake Lines, Attaching to Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Overview - Front Axle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.2 Overview - Rear Axle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 Right/Left Front ABS Wheel Speed Sensor G45 / G47 , Removing and Installing . . . . . . 24
4.4 Right/Left Rear ABS Wheel Speed Sensor G44 / G46 , Removing and Installing . . . . . . . . 25
4.5 ABS Sensor Ring, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 ESP Sensor Unit G419 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

46 - Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 Overview - Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1 Overview - Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Component Location Overview - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Electromechanical Parking Brake Control Module J540 , Removing and Installing . . . . . . 47
3.3 Left/Right Parking Brake Motor V282 / V283 , Removing and Installing . . . . . . . . . . . . . . 47
4 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1 Overview - Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2 Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3 Brake Pedal, Disconnecting from Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4 Brake Pedal, Attaching to Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Contents i
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4.5 Brake Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

47 - Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Overview - Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Brake Caliper Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Overview - Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Dust Cap, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Brake Booster/Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.1 Overview - Brake Booster/Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2 Brake Lamp Switch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Brake Booster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 Brake Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.1 Overview - Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 Check Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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4.3 Vacuum Sensor G608 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5 Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1 Brake Lines, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Brake Fluid General Information . . . .w.ag.e.n.A.G.. V. o.lk.s.wa. g.e.n.A.G.do. e. . . . . . . . . . . . . . . . . . . . . . . 88
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6.2 Hydraulic System, Standard Bleeding Vol . . . . . . . . . . . . . . . . . . . o. t .gu. a. . . . . . . . . . . . . . . . . . 88
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6.3 Hydraulic System, Post-Bleeding ris
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6.4 Leak Test . . . . . . . . . . s.au. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . 89
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7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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8 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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ii Contents
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

00 – General, Technical Data

1 Safety Precautions
(Edition 06.2020)
⇒ “1.1 Safety Precautions during Road Test with Testing Equip‐
ment”, page 1

1.1 Safety Precautions during Road Test

with Testing Equipment
WARNING
There is a risk of injury caused by unsecured testing equipment.
If the front passenger airbag deploys during an accident, unse‐
cured testing equipment becomes a dangerous projectile.

– Secure the testing equipment on the rear seat.

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or
– Have a second technician operate the testing equipment on
the rear seat.

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1. Safety Precautions 1
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

2 Identification
⇒ “2.1 PR Number Allocation - Brakes”, page 2

2.1 PR Number Allocation - Brakes

⇒ “2.1.1 Front Brakes”, page 2
⇒ “2.1.2 Rear Brakes”, page 2

2.1.1 Front Brakes

The PR number on the vehicle data label describes which brake
system is installed in the vehicle among other things.
There is a vehicle data label in the spare wheel well and the
maintenance schedule.
– For relevant information regarding each brake installed. Refer
to ELSA/vehicle-specific notes.
In this example, the vehicle has “1LJ” front brakes.
♦ Refer to the Parts Catalog for the allocation.

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♦ The following tables explain the PR numbers. These are im‐
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Engine PR Number Fronty VBrakes
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system is installed in the vehicle among other things.

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– For relevant information regarding each brake installed. Refer

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In this example, the vehicle has “1KU” rear brakes.
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♦ Refer to the Parts Catalog for the allocation.

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♦ The following tables explain the PR numbers. These are im‐

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2 Rep. Gr.00 - General, Technical Data

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3 Technical Data
⇒ “3.1 Technical Data, Brakes”, page 3

3.1 Technical Data, Brakes

⇒ “3.1.1 Brake Master Cylinder and Brake Booster”, page 3
⇒ “3.1.2 Front Brakes”, page 3
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3.1.2 Front Brakes

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Front Brakes PC57 (17"):

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Item PR Number 1LI
1 Brake Caliper PC 45+48 (17”)
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Brake rotor, mm 27
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4 Brake caliper, diam‐ 45+48
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3. Technical Data 3
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3.1.3 Rear Brakes

Rear Brakes FNc M42 (17”):
Item PR Number 1KZ
1 Brake Caliper FNc-M42 (17”)
2 Brake Pad, mm 11
Thickness
Brake Pad, mm 2
Wear Limit with‐
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Plate
3 Brake Rotor diam‐ 310
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Brake Rotor, mm 22
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4 Rep. Gr.00 - General, Technical Data

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4 Brake Inspection
⇒ “4.1 General Information”, page 5
⇒ “4.2 FWD Vehicles, Checking”, page 5
⇒ “4.3 AWD Vehicles, Checking”, page 5
⇒ “4.4 Parking Brake, Checking”, page 6

4.1 General Information

♦ The operation takes place on a test stand.
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♦ Follow the instructions provided by the test stand manufactur‐

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The brake control systems do not function when the ignition is off.

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4.2 FWD Vehicles, Checking
The brake inspection is to be performed on a one-axle roller test

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stand.
Do not exceed a test speed of 6 km/h (4 mph).
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4.3 AWD Vehicles, Checking

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⇒ “4.3.1 On a Controlled Opposite-Running Test Stand for AWD

or

Vehicles”, page 5
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⇒ “4.3.2 Without Test Stand for AWD Vehicles”, page 6

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4.3.1 On a Controlled Opposite-Running Test

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Stand for AWD Vehicles

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Note

With AWD, Testing with a Controlled Opposite-Running One-Axle

Dynamometer

“Opposite-running” means: The rollers on the one-axle roller test

stand are rotated forward on one side and backward on the other
side.
During this test, the wheels of one axle are driven in opposite
directions, to prevent delivering power to the other axle.
“Regulated” means: The speed of the test stand rollers must be
regulated in such a way as to avoid any speed difference during
the brake test.
The transferring of a force to the rolling wheels in the roller set is
prevented by the stationary wheel (outside of the roller set) via
the drivetrain.
During testing, the wheel turning forward is measured, therefore
2 braking tests are necessary on each axle.
Do not exceed a test speed of 6 km/h (4 mph).

4. Brake Inspection 5
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Volkswagen approved test stands meet these requirements.

4.3.2 Without Test Stand for AWD Vehicles

Note

With AWD, Testing with Standard One-Axle Dynamometer

– Drive the vehicle forward onto the rollers.

– Turn off the engine and wait two seconds.
– Perform the brake inspection.
– Start the engine and wait approximately five seconds until
there is enough vacuum. agen
AG. Volkswagen AG d
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– Drive the vehicle forward until the rear wheels ared bstanding
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– Turn off the engine and wait two seconds.
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– Perform the brake inspection for the rear brakes.

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– Start the engine and wait approximately five seconds until
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there is enough vacuum.

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4.4 Parking Brake, Checking

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spec
⇒ “4.4.1 Electro-Mechanical Parking Brake, Checking, FWD Ve‐
es, in part or in w

t to the co
hicles”, page 6

4.4.1 Electro-Mechanical Parking Brake,

rrectness of i
Checking, FWD Vehicles
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Activating »TÜV mode«:

• The seat belt is buckled.

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• Rear axle in the one-axle roller test stand

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• The ignition remains on.
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• The front wheels must be stationary.

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»TÜV mode« is indicated when the yellow Electric Parking Brake
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Malfunction Indicator Lamp - K214- is displayed.
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Note

The electromechanical parking brake does not close completely

the first time the »TÜV mode« button is pressed.

Pressing the Electromechanical Parking Brake Button - E538-

four times in a row gradually increases the tension force.
Operating the Electromechanical Parking Brake Button - E538- a
fifth time loosens the electro-mechanical parking brake.
Ending »TÜV mode«:
• Front wheels, speed greater than 0 km/h (0 mph)
• Rear wheels, speed less than 2.5 km/h (2 mph) or greater than
9 km/h (6 mph)

6 Rep. Gr.00 - General, Technical Data

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

• Ignition off.

AG. Volkswagen AG d
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4. Brake Inspection 7
 AG. Volkswagen AG d
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Atlas 2017 ➤ , Atlas 2020 ➤ by V ol
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Brake System - Edition 06.2020orise nte
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45 – Antilock Brake System

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⇒ “1.1 Anti-Lock Braking System (ABS) Repair Information”, page
ole,

spec
8
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t to the co
1.1 Anti-Lock Braking System (ABS) Repair
Information

rrectness of i
Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234-
cial p

The ABS brake system is divided diagonally. The brake booster

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operates pneumatically via the vacuum brake booster.
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Vehicles with ABS do not have a mechanical brake pressure reg‐

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ulator. A specially coordinated software program in the control

or

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module determines brake pressure allocation at the rear axle.

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8 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Note

ABS malfunctions do not affect the brake system and the booster.
The conventional brake system remains operative even without
ABS. A change in braking behavior must be anticipated. When
the ABS indicator lamp comes on, the rear wheels may lock pre‐
maturely when braking!

ABS Layout
1 - Hydraulic Unit and Control Module
2 - Brake Booster
The control module and hydraulic unit form one component. Sep‐
aration is only possible when removed. The hydraulic pump must
also not be separated from the hydraulic unit.
♦ Before carrying out repair work on the ABS, determine the
cause of damage as well as the control module code using
“Guided Fault Finding”.
“Guided Fault Finding” is performed. Refer to Vehicle Diagnostic

cardiagn.com
Tester .
♦ Disconnect the battery ground cable when the ignition is
switched off.
♦ Before welding with an electric welding tool, observe the in‐
formation found here ⇒ General Information; Body Repairs,
Body Collision Repair .
♦ When handling brake fluid, observe the relevant safety pre‐
cautions and notes. Refer to . Volkswagen AG
⇒ “6.1 Brake Fluid General Information”, page gen.AG
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♦ After finishing any work that requirediseopening
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r
-VAS5234- . Refer to tee
or
⇒ “6.2 Hydraulic System, Standards au Bleeding”, page 88 . ac
s
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♦ During the final road test, make sure a controlled braking ma‐
nl

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neuver is performed at least one time (pulsing must be felt in

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brake pedal).
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♦ Absolute cleanliness is required when working on the ABS. Do

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not use any products which contain mineral oil, such as oils,
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greases etc.
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♦ Thoroughly clean all connection points and their surrounding

t to the co

areas before loosening. However, do not use aggressive

cleaning agents such as brake cleaner, gasoline, thinners or
similar compounds.
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♦ Place the removed parts on a clean surface and cover them.

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♦ Carefully cover or seal opened components if the repair is not

performed immediately. (Use plugs from repair set -1 H0 698
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311 A- )
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♦ Only use lint-free cloths.

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♦ The valve coils inside the control module cannot be readjus‐ Prote
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ted.
AG.

♦ The valve coils inside the control module cannot be replaced.

1. General Information 9
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ The pressure sensor must not be changed or damaged.

♦ The pressure sensor cannot be replaced.
♦ The sensor housing must not be under any mechanical load.
♦ No measurements may be performed on the contacts in the
control module.
♦ No measurements may be performed on the contacts in the
hydraulic unit.
♦ The valve bodies inside the hydraulic unit must not be dam‐
aged or bent.
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♦ Using contact sprays on the contacts and pressure sensorise
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♦ Make sure there are no foreign objects betweens the control

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module and the hydraulic unit.
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♦ When painting, electronic control module can be exposed to
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a maximum temperature of 95 °C (203 °F) only briefly, and to
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a maximum of 85 °C (185 °F) for longer periods (approximately
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two hours). Make sure that brake fluid cannot get into the con‐

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10 Rep. Gr.45 - Antilock Brake System

 AG. Volkswagen AG d
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2 Component Location Overview

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⇒ “2.1.1 Component Location Overview - ABS/ESP”, page 11

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2.1.1 Component Location Overview - ABS/ESP
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1 - ABS Control Module - J104-

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❑ Component location: in
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motor compartment on
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the front passenger

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❑ Do not disconnect the

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The following components are

integrated inside the control
module:
♦ Electromechanical Parking
Brake Control Module -
J540-
♦ Transverse Acceleration
Sensor - G200-
♦ Rotation Rate Sensor -
G202-
♦ Longitudinal Acceleration
Sensor - G251- (depending
on vehicle equipment)
♦ The components cannot be
replaced individually.
❑ Removing and instal‐
ling. Refer to
⇒ “3.2.1 ABS Control
Module and ABS Hy‐
draulic Unit, Removing
and Installing, Gasoline
Engine”, page 15 .
2 - ABS Hydraulic Unit - N55-
❑ Component location: in
the engine compartment on the front passenger side
The hydraulic unit consists of the components:
♦ ABS Hydraulic Pump - V64-
♦ Brake Pressure Sensor 1 - G201-
♦ Valve block (contains intake and exhaust valves)
❑ The ABS Hydraulic Pump - V64- and valve block must not be separated from one another.
❑ Removing and installing. Refer to
⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Removing and Installing, Gasoline Engine”, page
15 .

2. Component Location Overview 11

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3 - Brake Pad Wear Indicator Lamp - K32-

❑ Component location: in the instrument cluster
4 - ABS Indicator Lamp - K47-
❑ Component location: in the instrument cluster
5 - ASR/ESP Indicator Lamp - K155-
❑ Component location: in the instrument cluster
6 - Brake System Indicator Lamp - K118-
❑ Component location: in the instrument cluster
7 - Brake Lamp Switch - F-
❑ Component location: on the brake master cylinder
❑ Removing and installing. Refer to ⇒ “3.2.1 Brake Lamp Switch, Removing and Installing”, page 68 .
8 - ASR/ESP Button - E256-
❑ There are two versions, therefore there are two component locations:
♦ As a button in the center console
♦ Via the function keys in the Infotainment system menu
❑ ASR/ESP Button - E256- in Center Console, Removing and installing. Refer to ⇒ Electrical Equipment;

cardiagn.com
Rep. Gr. 96 ; Controls; ASR/ESP Button - E256- , Removing and Installing .
9 - Data Link Connector
❑ Component location: driver side footwell cover
10 - Steering Angle Sensor - G85-
❑ Component location: inside the steering gear
❑ The Steering Angle Sensor A-GG85-
. Volkswcannot
agen AGbe replaced separately.
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❑ Steering, Removing by V and installing. Refer to ⇒ Suspension,
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Wheels, Steering; Rep. Gr. 48 ; Steering
Gear; Steering
ris Gear, Removing and Installing .
ed
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11 - Right Front
ss
auABS Wheel Speed Sensor - G45- / Left Front ABS
r a Wheel Speed Sensor - G47-
c
❑ Removing and installing. Refer to ⇒ “4.1 Overview - Front Axle Speed Sensor”, page 22 .
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12 - Wheel Hub with Wheel Bearing

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❑ The ABS sensor ring is installed in the wheel bearing

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13 - Right Rear ABS Wheel Speed Sensor - G44- / Left Rear ABS Wheel Speed Sensor - G46-
h re
ole,

❑ Removing and Installing (FWD). Refer to ⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 23 .
spec
urposes, in part or in wh

14 - Wheel Hub with Wheel Bearing

t to the co

❑ The ABS sensor ring is installed in the wheel bearing

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12 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3 Control Module and Hydraulic Unit

⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
page 13
⇒ “3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 , Re‐
moving and Installing”, page 15
⇒ “3.3 Control Module, Separating from Hydraulic Unit”,
page 18
⇒ “3.4 Control Module, Installing on Hydraulic Unit”, page 19
Volkswa
⇒ “3.5 Brake Lines, Attaching sto
waHydraulic
gen AG
.
Unit”, page
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3.1 Overview - Control Module and Hydraul‐
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⇒ “3.1.1 Overview - Control Module and Hydraulic Unit”,

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3.1.1 Overview - Control Module and Hydraulic Unit

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1 - ABS Control Module - J104-

spec
es, in part or in w

❑ Removing and instal‐

t to the co
ling. Refer to
⇒ “3.2.1 ABS Control
Module and ABS Hy‐

rrectness of i
draulic Unit, Removing
and Installing, Gasoline
l purpos

Engine”, page 15 .
2 - ABS Hydraulic Unit - N55-
nf
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❑ Removing and instal‐

m
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atio

ling. Refer to
om

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⇒ “3.2.1 ABS Control

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Module and ABS Hy‐

h
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a

draulic Unit, Removing

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and Installing, Gasoline

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Engine”, page 15 .
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3 - TORX® Bolt
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TORX® bolts in two
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steps, switching back
and forth.
❑ 1. Step: Preliminary
tightening specification
1 Nm to 1.5 Nm (to in‐
stall the seal)
❑ 2. Step: final tightening
specification: 2.5 Nm
4 - Brake Line
❑ With standard tool: 14
Nm
❑ With special tools Mini
Torque Wrench -
VAS6854- , Torque
Wrench - Universal
Joint - VAG1410/7- and
Open Ring Spanner In‐
sert - AF 11mm - VAG1410/6- : 12 Nm
❑ To the right rear brake caliper
❑ Identification: 5.25 mm diameter and tube fitting with a M12 x 1 thread

3. Control Module and Hydraulic Unit 13

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

5 - Brake Line
❑ With standard tool: 14 Nm
❑ With special tools Mini Torque Wrench - VAS6854- , Torque Wrench - Universal Joint - VAG1410/7- and
Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm
❑ To the left front brake caliper
❑ Identification: 5.25 mm diameter and tube fitting with a M10 x 1 thread
6 - Brake Line
❑ With standard tool: 14 Nm
❑ With special tools Mini Torque Wrench - VAS6854- , Torque Wrench - Universal Joint - VAG1410/7- and
Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm
❑ To the right front brake caliper
❑ Identification: 5.25 mm diameter and tube fitting with a M12 x 1 thread
7 - Brake Line
❑ With standard tool: 14 Nm
❑ With special tools Mini Torque Wrench - VAS6854- , Torque Wrench - Universal Joint - VAG1410/7- and
Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm
❑ To the left rear brake caliper
❑ Identification: 5.25 mm diameter and tube fitting with a M10 x 1 thread

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8 - Brake Line by
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❑ With standard tool: 14 Nm rise nte
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❑ With special tools Mini Torque
ss a Wrench - VAS6854- , Torque Wrench - Universal ra
c Joint - VAG1410/7- and
Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm

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❑ Brake master cylinder/primary piston circuit to hydraulic unit

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❑ Identification: 6 mm diameter and pipe fitting with a M12 x 1 thread
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9 - Brake Line

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❑ With standard tool: 14 Nm
hole

spec
❑ With special tools Mini Torque Wrench - VAS6854- , Torque Wrench - Universal Joint - VAG1410/7- and
es, in part or in w

Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm t to the co

❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ Identification: 6 mm diameter and pipe fitting with a M12 x 1 thread
rrectness of i

10 - Brake Booster
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❑ Overview - Brake Booster/Brake Master Cylinder. Refer to

⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”, page 66 .
nf
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11 - Bracket
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❑ After installing, make sure it fits properly

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12 - TORX® Bolt
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❑ 8 Nm
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13 - Rubber Bushing
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14 - Heat Shield
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Refer to the Parts Catalog for the allocation.
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15 - Hex Nut
❑ 20 Nm
16 - Bracket
17 - Hex Nut
❑ 20 Nm

14 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3.2 ABS Control Module - J104- / ABS Hy‐

draulic Unit - N55- , Removing and In‐
stalling
⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Removing
and Installing, Gasoline Engine”, page 15

3.2.1 ABS Control Module and ABS Hydraulic

Unit, Removing and Installing, Gasoline
Engine
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Open Ring Spanner Insert - AF 11mm - VAG1410/6-
♦ Torque Wrench - Universal Joint - VAG1410/7-
♦ Mini Torque Wrench - VAS6854-
♦ Brake Pedal Actuator - VAG1869/2- .
♦ Torque Wrench - Assembly Tool - VAG1410/8-

cardiagn.com
Plugs Assembly Part 5Q0 698 311
1 - M10 Plug
2 - M12 Plug
Removing
Component Location:

The control module is bolted to the hydraulic unit and is located

at right in the engine compartment.

CAUTION
Risk of destroying the brake lines by bending. AG. Volkswagen AG d
agen oes
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– Never forcefully bend the brake linesby
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– Read and note the present control module code. s
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– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

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Gr. 27 ; Battery; Battery, Disconnecting and Connecting .

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3. Control Module and Hydraulic Unit
agen
Prote AG.
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– For vehicles with a heat shield, remove the heat shield -1-.

AG. Volkswagen AG d
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– Press the locking mechanism downward in direction of

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– Release the connector in direction of -arrow B-.

– Remove the connector -1-.

– Insert the -VAG1869/2- .

16 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Attach the bleeder bottle bleed hose -1- to the left front brake
caliper breather valve.
– Open the breather valve.

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– Attach the bleeder bottle bleed hose -1- to the left rear brake

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caliper breather valve.

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– Open the breather valve.
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– Push the brake pedal at least 60 mm using the -VAG1869/2- .
– Close the left front and left rear bleeder valves.

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– Do not remove the -VAG1869/2- .

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Note

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Make sure that no brake fluid gets into the contacts.

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– Unclip the brake lines from the brake lines as far as possible. his
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– First, mark both brake lines from the brake master cylinder and
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remove from the hydraulic unit.

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– Immediately seal the threaded holes with the plugs from the t. C
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assembly repair kit -5Q0 698 311- . copyri Vo
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cted
– Mark the remaining brake lines (brake calipers), remove them
agen
Prote AG.
and seal off the threaded holes.
– Place the dust caps for the bleeder valves on the brake lines.

– Pull the hydraulic unit with the control module upward out of
the shock absorbers in direction of -arrow-.
Installing
Install in reverse order of removal and note the following:

Note

♦ Only remove the plugs on the new hydraulic unit if the corre‐
sponding brake line is installed.
♦ If the plugs are removed too early from the hydraulic unit,
brake fluid can escape and the unit may not be sufficiently filled
or adequately bled.
♦ When installing the hydraulic unit, make sure that the rubber
bushings are not pushed out of the bracket.

– Before assembling the holder for the ABS Hydraulic Unit -

N55- in the bracket, spray the rubber bushings with Silicone
Lubricant Spray - D 007 000 A2- .

3. Control Module and Hydraulic Unit 17

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Install the brake lines carefully with the -VAG1410/8- .

Brake Line Tightening Sequence:

– Remove the -VAG1869/2- .
– Bleed the brake system. Refer to n AG. Volkswagen AG do
wage es n
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 88 . y Volks ot g
b ua
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– Code the radio. horis tee
t or
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– Code the ABS Control Module - J104- . Refer tossVehicle Di‐

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agnostic Tester in "Guided Fault Finding".

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While doing so, a basic setting for the Steering Angle Sensor -

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G85- , Transverse Acceleration Sensor - G200- , Longitudinal
pe

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Acceleration Sensor - G251- and Brake Pressure Sensor 1 -
ot

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G201- must be performed.

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Tightening Specifications

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Special Tool Assembly for Tightening the Brake Lines
♦ Refer to

rrectness of i
⇒ “3.1.1 Overview - Control Module and Hydraulic Unit”, page
13
l purpos

♦ Battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Bat‐

tery; Overview - Battery .

nform
ercia

♦ Front breather valve. Refer to

m

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⇒ “1.1 Overview - Front Brake Caliper”, page 58 .

ion in
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♦ Rear breather valves. Refer to thi

s
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⇒ “2.1 Overview - Rear Brake Caliper”, page 63 .

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3.3 Control Module, Separating from Hy‐ Cop o
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draulic Unit pyri Vo
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Special tools and workshop equipment required
AG.

♦ ESD Work Surface - VAS6613-

♦ TORX® insert T25
♦ If the control module is faulty, then the control module is to be
separated from the hydraulic unit and only the control module
replaced.
♦ If the hydraulic unit is faulty, the hydraulic unit and the control
module are to be replaced together.
♦ The ESP unit must be removed in order to separate the control
module and the hydraulic unit.

18 Rep. Gr.45 - Antilock Brake System

 AG. Volkswagen AG d
agen oes
olksw not Atlas 2017 ➤ , Atlas 2020 ➤
byV gu
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CAUTION

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There is a risk of destroying the hydraulic unit by removing the itte

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return flow pump.
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– Never separate the return flow pump from the hydraulic unit.

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CAUTION

t to the co
There is a risk of destroying the control module through the
electrostatic charge and reduced cleanliness.
– Discharge electrostatic charge: touch the electro-static dis‐

rrectness of i
charge work surface
– Protect the inner control module from moisture and dirt.
cial p

nf
– Touch a grounded object before working on electrical equip‐

o
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rm
ment -VAS6613- . Do not touch the connector terminals or

atio
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electronic components directly.

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– Position the hydraulic unit with the control module on the -

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VAS6613- .
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– Remove the three TORX® bolts from the control module and

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set aside immediately (risk of confusing them with new op o
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– Position the hydraulic unit with the control module from upward
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on the -VAS6613- .
AG.

– Pull the control module off from hydraulic unit without tilting in
direction of -arrow-.
– Cover the control module solenoid coils with a lint free cloth.
– Check the cleanliness of the hydraulic unit sealing surface if
necessary clean with mineral spirits and a lint-free cloth.
The hydraulic unit sealing surface must not be worked with a file,
metal scraper, sand paper or similar.
If the hydraulic unit sealing surface is damaged (for example
through grooves or scrapes) the hydraulic unit must be replaced
with the control module.
The seal on the control module must not be pulled out or raised
up.
The seal on the control module cannot be replaced.

3.4 Control Module, Installing on Hydraulic

Unit
Special tools and workshop equipment required
♦ ESD Work Surface - VAS6613-
♦ Torque Screwdriver - VAG1624-
♦ TORX® insert T25

3. Control Module and Hydraulic Unit 19

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Note

Excessive shaking (for example, dropping, impact) may destroy

the control module. The control module must then no longer be
used.

• Surfaces must be cleaned before assembling.

– Place the control module it onto hydraulic unit without tilting it.
– Install the hydraulic unit and control module with the new in‐
cluded TORX® bolts switching back and forth in two steps
according to the tightening specification.

Note

The hydraulic unit threads cannot be re-cut to secure the control

module. If the threads are damaged (bolts are difficult to install by
hand or the bolts cannot be tightened to the tightening specifica‐
tion), the hydraulic unit must be replaced.

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Tightening Specification AG. Volkswagen AG d
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♦ Refer to by Vol
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♦ A new control module may be installed a maximum of three

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seals sufficiently.

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♦ Do not install a used control module.
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3.5 Brake Lines, Attaching to Hydraulic Unit

rrectness of i
⇒ “3.5.1 Brake Lines, Attaching to Hydraulic Unit”, page 20

3.5.1 Brake Lines, Attaching to Hydraulic Unit

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On Tandem Master Brake Cylinder:

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A - Master Brake Cylinder Primary Piston Circuit to Hydraulic Unit
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- Identification: 6 mm diameter and pipe fitting with a M12 x 1

or

thread
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1 - Hydraulic Unit to Left Front Brake Caliper
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3 - Hydraulic Unit to Left Rear Brake Caliper

4 - Hydraulic Unit to Right Rear Brake Caliper

20 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

On the Hydraulic Unit:

1 - Hydraulic Unit to Right Rear Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
short thread
2 - Hydraulic Unit to Left Front Brake Caliper
- Identification: 5.25 mm diameter and tube fitting
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3 - Hydraulic Unit to Right Front
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- Identification: 5.25 mm diameter
ss and tube fitting with a M12 x 1
short thread

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4 - Hydraulic Unit to Left Rear Brake Caliper

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5 - Hydraulic Unit to Master Brake Cylinder Secondary Piston

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- Identification: 6 mm diameter and pipe fitting with a M12 x 1
thread

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6 - Hydraulic Unit to Master Brake Cylinder Primary Piston Circuit
- Identification: 6 mm diameter and pipe fitting with a M12 x 1
thread
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Tightening Specification

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♦ Refer to
om

⇒ “3.1.1 Overview - Control Module and Hydraulic Unit”, page

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3. Control Module and Hydraulic Unit 21

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4 Sensors
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 22
⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 23
⇒ “4.3 Right/Left Front ABS Wheel Speed Sensor G45ag/eG47 , olkswagen AG do
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Removing and Installing”, page 24 Volksw es n
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⇒ “4.4 Right/Left Rear ABS Wheel Speed hSensor
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Removing and Installing”, page 25 aut or
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⇒ “4.5 ABS Sensor Ring, Checking”, page 26

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⇒ “4.6 ESP Sensor Unit G419 , Removing and Installing”,

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page 27

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4.1 Overview - Front Axle Speed Sensor

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1 - ABS Speed Sensor

t to the co
❑ Before inserting the
sensor, clean the inner
surface of the hole and

rrectness of i

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coat with Hot Bolt Paste
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- G 052 112 A3- .

❑ Removing and instal‐
ling. Refer to

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⇒ “4.3 Right/Left Front

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ABS Wheel Speed Sen‐
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sor G45 / G47 , Remov‐

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ing and Installing”, page

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24 .
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2 - Bolt
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❑ Overview. Refer to ⇒ Prote
cted agen
AG.
Suspension, Wheels,
Steering; Rep. Gr. 40 ;
Drive Axle; Overview -
Drive Axle .
❑ Removing and instal‐
ling. Refer to ⇒ Suspen‐
sion, Wheels, Steering;
Rep. Gr. 40 ; Drive Axle;
Drive Axle, Removing
and Installing .
4 - Wheel Hub with Wheel
Bearing Unit
❑ The ABS sensor ring is
integrated in the wheel
bearing unit
❑ Removing and instal‐
ling. Refer to ⇒ Suspen‐
sion, Wheels, Steering;
Rep. Gr. 40 ; Wheel
Bearing; Wheel Bearing
Unit, Removing and Installing .

22 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4.2 Overview - Rear Axle Speed Sensor

⇒ “4.2.1 Overview - Rear Axle Speed Sensor, FWD”, page 23
⇒ “4.2.2 Overview - Rear Axle Speed Sensor, AWD”, page 24

4.2.1 Overview - Rear Axle Speed Sensor, FWD

1 - ABS Speed Sensor

❑ Before inserting the AG. Volkswagen AG d
sensor, clean the inner agen oes
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surface of the hole and d by V gu
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coat with Hot Bolt Paste orise nte
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- G 052 112 A3- . auth
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❑ Removing and instal‐

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ling. Refer to

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⇒ “4.4.1 Right/Left Rear

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ABS Wheel Speed Sen‐

ab
ility
sor G44 / G46 , Remov‐
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ing and Installing,
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FWD”, page 25 .
ole,

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urposes, in part or in wh

2 - Bolt

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❑ 8 Nm
3 - Wheel Hub with Wheel

rrectness of i
Bearing Unit
❑ The ABS sensor ring is
integrated in the wheel
bearing unit
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4. Sensors 23
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4.2.2 Overview - Rear Axle Speed Sensor, AWD

1 - ABS Speed Sensor

❑ Before inserting the
sensor, clean the inner AG. Volkswagen AG d
surface of the hole and agen oes
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coat with Hot Bolt Pasteed by
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- G 052 112 A3- . horis nte
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ut
❑ Removing and instal‐
ss a ra
c
ling. Refer to

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⇒ “4.4.2 Right/Left Rear

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ABS Wheel Speed Sen‐

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sor G44 / G46 , Remov‐

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ing and Installing,

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AWD”, page 26 .
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2 - Bolt

spec
es, in part or in w

❑ 8 Nm

t to the co
3 - Drive Axle
❑ Overview. Refer to ⇒

rrectness of i
Suspension, Wheels,

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Steering; Rep. Gr. 42 ;
l purpos

Drive Axle; Overview -

Drive Axle .

nf
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❑ Removing and instal‐

rm
m

ling. Refer to ⇒ Suspen‐

atio
m

sion, Wheels, Steering;

o

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c

Rep. Gr. 42 ; Drive Axle;

or

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Drive Axle, Removing

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and Installing .
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4 - Wheel Hub with Wheel

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Bearing Unit Cop o
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❑ The ABS sensor ring is opyri Vo
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bearing unit Prote AG.

4.3 Right/Left Front ABS Wheel Speed Sen‐

sor -G45- / -G47- , Removing and In‐
stalling

Note

The example describes the removal and installation of the left

front ABS wheel speed sensor. The removal and installation of
the right front ABS wheel speed sensor is identical.

Removing
– Raise the vehicle.

24 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Disconnect the connector -3- from the Left Front ABS Wheel
Speed Sensor - G47- -1-.
– Remove the bolt -2- and remove the Left Front ABS Wheel
Speed Sensor - G47- -1- from the wheel bearing housing.
Installing
Install in reverse order of removal and note the following:
– Before inserting the speed sensor, clean the inner surface of
the hole and coat speed sensor all-round with Hot Bolt Paste
- G 052 112 A3- .
Tightening Specification
♦ Refer to
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 22

4.4 Right/Left Rear ABS Wheel Speed Sen‐

cardiagn.com
sor -G44- / -G46- , Removing and In‐
stalling
⇒ “4.4.1 Right/Left Rear ABS Wheel Speed Sensor G44 / G46 ,
Removing and Installing, FWD”, page 25
⇒ “4.4.2 Right/Left Rear ABS Wheel Speed Sensor G44 / G46 ,
Removing and Installing, AWD”, page 26

4.4.1 Right/Left Rear ABS Wheel SpeedGSen‐

A . Volkswagen AG d
sor -G44- / -G46- , Removing Volksw and In‐
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The example describes the removal and installation of the left rear
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ABS wheel speed sensor. The removal and installation of the right
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rear ABS wheel speed sensor is identical.

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Left Rear ABS Wheel Speed Sensor - G46- -1-

es, in part or in w

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Removing
– Raise the vehicle.
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4. Sensors 25
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Disconnect the connector -2- from the Left Rear ABS Wheel
Speed Sensor - G46- .
– Remove the bolt -1- and remove the speed sensor from the
wheel bearing housing. wage
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Installing ed by ara
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Install in reverse order of removal and note
utho the following: eo
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ss
– Before inserting the speed sensor, clean the hole inner surface

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and coat speed sensor all-round with Hot Bolt Paste - G 052
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112 A3- .

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Tightening Specifications
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♦ Refer to

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⇒ “4.2.1 Overview - Rear Axle Speed Sensor, FWD”,

spec
page 23
es, in part or in w

t to the co
4.4.2 Right/Left Rear ABS Wheel Speed Sen‐

rrectness of i
sor -G44- / -G46- , Removing and In‐
stalling, AWD
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Note

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The example describes the removal and installation of the left rear

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ABS wheel speed sensor. The removal and installation of the right

th
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rear ABS wheel speed sensor is identical.

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Removing

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– Raise the vehicle.
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– Disconnect the connector -3- from the Left Rear ABS Wheel
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Speed Sensor - G46- -1-. Prote AG.

– Remove the bolt -2- and remove the Left Rear ABS Wheel
Speed Sensor - G46- -1- from the wheel bearing housing.
Installing
Install in reverse order of removal and note the following:
– Before inserting the speed sensor, clean the inner surface of
the hole and coat speed sensor all-round with Hot Bolt Paste
- G 052 112 A3- .
Tightening Specifications
♦ Refer to
⇒ “4.2.2 Overview - Rear Axle Speed Sensor, AWD”,
page 24

4.5 ABS Sensor Ring, Checking

Special tools and workshop equipment required
♦ Gauge - Sender Wheel - T10473-
Procedure
• The wheel bearing unit is removed.

26 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Check the entire circumference of the ABS sensor ring -2- with
the -T10473- as shown.
1 - Wheel Bearing Unit
2 - Seal with Integrated ABS Sensor Ring agen
AG. Volkswagen AG d
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ABS sensor ring test diagram.

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A - ABS Sensor Ring is OK
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B - ABS Sensor Ring is Faulty

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4.6 ESP Sensor Unit - G419- , Removing
and Installing
The Transverse Acceleration Sensor - G200- , the Rotation Rate
Sensor - G202- and the Longitudinal Acceleration Sensor - G251-
are installed together with the Electromechanical Parking Brake
Control Module - J540- in the ABS Control Module - J104- .
The components cannot be replaced individually.
– ABS Control Module - J104- , Removing and installing. Refer
to
⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Re‐
moving and Installing, Gasoline Engine”, page 15 .

4. Sensors 27
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

5 Special Tools

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
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♦ Torque Wrench 1331 5-50Nm - VAG1331-

or

his
ate

do
riv

♦ Open Ring Spanner Insert - AF 11mm - VAG1410/6-

p

cu
for

♦ Torque Wrench - Universal Joint - VAG1410/7-

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♦ Mini Torque Wrench - VAS6854- . C
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♦ Brake Pedal Actuator - VAG1869/2- .
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Prote AG.
♦ Torque Wrench - Assembly Tool - VAG1410/8-

28 Rep. Gr.45 - Antilock Brake System

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Gauge - Sender Wheel - T10473-

♦ Torque Screwdriver - VAG1624-

AG. Volkswagen AG d
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♦ Not Illustrated:
♦ Brake Charger/Bleeder Unit - VAS5234-

rrectness of i
♦ ESD Work Surface - VAS6613-
♦ TORX® insert T25
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5. Special Tools 29
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

46 – Mechanical Components
1 Front Brakes
⇒ “1.1 Overview - Front Brakes”, page 30
⇒ “1.2 Brake Pads, Removing and Installing”, page 32
⇒ “1.3 Brake Caliper, Removing and Installing”, page 35

1.1 Overview - Front Brakes

⇒ “1.1.1 Overview - Front Brakes”, page 30

1.1.1 Overview - Front Brakes

Note

♦ After every brake pad replacement, firmly press down on the

brake pedal several times with vehicle stationary so that the
brake pads are properly set in their respective operating po‐

cardiagn.com
sition.
♦ Use the Brake Charger/Bleeder Unit - VAS5234- to extract
brake fluid from the brake fluid reservoir.
♦ Install the Brake Pedal Actuator - VAG1869/2- before remov‐
ing a brake caliper or disconnecting a brake hose (doing so
reduces the pressure).

Overview - Front Brakes PC 45+48:

AG. Volkswagen AG d
agen oes
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30
copy Vo
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Rep. Gr.46 - Mechanical Components cted agen
Prote AG.
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

1 - Brake Hose with Ring Con‐

nection and Banjo Bolt
❑ 35 Nm
❑ Make sure it is in the in‐
stallation position
2 - Clip
3 - Bracket
4 - Bolt
❑ 8 Nm
5 - Brake Rotor
❑ Always replace on both
axles.
❑ Internally vented
❑ Wear limits. Refer to AG. Volkswagen AG d
⇒ “3.1.2 Front Brakes”, agen oes
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❑ Remove the brake cali‐ hor eo
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per and brake carrier s a ra
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before removing

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6 - TORX® Bolt
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❑ 12 Nm

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7 - Cover Plate
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8 - Wheel Bearing Housing

spec
urposes, in part or in wh

❑ With bolted brake carri‐

t to the co
er
Refer to the Parts Catalog for

rrectness of i
the allocation.

9 - Ribbed Bolt
❑ 200 Nm
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❑ Clean if using again

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10 - TORX® Bolt
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❑ 8 Nm th
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11 - Brake Carrier
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pr

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❑ Lightly grease the pad guide surfaces with Lithium Lubricating Grease G 052150 A2.
ng

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12 - Brake Pad Retaining Plate ht. C
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❑ The upper right and lower left are identical by copy Vo
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❑ The side tabs must point outward
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13 - Brake Pad Retaining Plate

❑ The upper left and lower right are identical
❑ The side tabs must point outward
14 - Brake Pads
❑ Always replace on both axles.
❑ With right front brake pad wear indicator
❑ When the wear limit is reached (limit: approximately 4 mm), the indicator lamp in the instrument cluster
will come on; the contact sensor can be replaced separately.
❑ Wear limit: 2 mm without backing plate
❑ Thickness, Checking. Refer to ⇒ Maintenance ; Booklet 42.1 ; Procedure Descriptions; Front and Rear
Brake Pad Thickness and Brake Rotor Condition, Checking .
❑ Removing and installing. Refer to
⇒ “1.2.1 Brake Pads, Removing and Installing, Front Brakes”, page 32 .

1. Front Brakes 31
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

15 - Brake Caliper
❑ Do not disconnect the brake hose when replacing a brake pad
❑ Removing and installing. Refer to
⇒ “1.3.1 Brake Caliper, Removing and Installing, Front Brakes”, page 35 .
❑ Servicing. Refer to ⇒ “1.1 Overview - Front Brake Caliper”, page 58 .
Refer to the Parts Catalog for the allocation.
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16 - Self-Locking Hex Bolt by Vol not
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❑ 35 Nm rise nte
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❑ Replace after removing. ss a ra
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1.2 Brake Pads, Removing and Installing
erm

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⇒ “1.2.1 Brake Pads, Removing and Installing, Front Brakes”,
, is n

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page 32
hole

spec
1.2.1 Brake Pads, Removing and Installing,
es, in part or in w

t to the co
Front Brakes

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Special tools and workshop equipment required

rrectness of i
♦ Torque Wrench 1331 5-50Nm - VAG1331-
l purpos

♦ Piston Resetting Tool - T10145-

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ercia

Removing

orm
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Note
or

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t

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iva

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Label the brake pads when removing if they are going to be used
r
rp

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o

again. Install in the same position, otherwise the braking effect

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ng

n
will be uneven.
yi
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– Remove the wheels on the front axle. cop Vo
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cted agen
– Disconnect the connector for the brake pad wear indicator if
Prote AG.

equipped.
The brake pad wear indicator if equipped is installed at the front
right.
– Counterhold the guide pin and remove the lower bolts from the
brake caliper.

32 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Fold up the brake caliper -1- and secure using a wire.

– Remove the brake pads -4 and 5- from the brake carrier -2-.

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es, in part or in w

– Remove the brake pad retaining plates -2 through 5- from the

t to the co

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brake carrier -1-.
Cleaning:

rrectness of i
WARNING
l purpos

Health risk due to toxic dust from the brake system.

nf
ercia

Irreversible deposit of dust particles in the lungs. Breathing im‐

orm
pairments may occur.
m

atio
m

– Never blow out the brake system with compressed air.

o

n in
or c

th
e

i
t

sd
iva

– Thoroughly clean contact surfaces for brake pads at brake

oc
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rp

carrier and remove corrosion.

fo
ng

yi
– Clean the brake caliper. . Cop o
ht g
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copy Vo
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Note cted agen
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Only use mineral spirits for cleaning the brake caliper.

Installing

Note

Before pressing the piston into the cylinder using the piston re‐
setting tool, the brake fluid must be extracted from the brake fluid
reservoir. Otherwise the brake fluid will overflow and cause dam‐
age, especially if the brake fluid was added intermittently.

1. Front Brakes 33
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Push back both pistons -1 and 2- using the -T10145- -A- in the
brake caliper -3-.
– Lightly grease the pad guide surfaces on the brake carrier with
Lithium Grease - G 052150 A2-

Note

♦ The upper left and lower right brake pad retaining plates
-2 and 4- as well as the upper right and lower left -3 and 5- are
identical.
♦ The brake pad retaining plate side tabs must point outward.

– Place the new brake pad retaining plates -2 through 5- on the

brake carrier -1-.

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– Place the brake pad -2- in the lower brake pad retaining plate

spec
-3- -arrow A-.
es, in part or in w

t to the co
– Then push the brake pad -2- rearward in direction of
-arrow B- until the tab of the brake pad is positioned in front of
the recess of the upper brake pad retaining plate -4-. rrectness of i

– Then push the brake pad -2- in the upper brake pad retaining
l purpos

plate -4- in direction of -arrow C-.

The installation of the inner brake pad is identical.
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ate

After installing the brake pads, ensure the proper seating of all
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brake pad retaining plates.

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– Place the brake caliper carefully on the brake carrier. gh
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Prote AG.

34 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Counterhold at the guide pin and mount the brake caliper on

the brake carrier with new self-locking bolts.
– Connect the connector for the brake pad wear indicator if
equipped.
– Install the wheels.
Tightening Specifications
♦ Refer to ⇒ “1.1.1 Overview - Front Brakes”, page 30
♦ Wheel Bolts. Refer to ⇒ Wheel and Tire Guide; Rep. Gr. 44 ;
Wheels and Tires; Wheel Bolts Tightening Specification .

Note

♦ After every brake pad replacement, firmly press down on the

brake pedal several times with vehicle stationary so that the
brake pads are properly set in their respective operating po‐
sition.
♦ Check the brake fluid level after replacing the brake pad.
♦ Make sure the brakes are working correctly before driving the

cardiagn.com
vehicle for the first time.

1.3 Brake Caliper, Removing and Installing

⇒ “1.3.1 Brake Caliper, Removing and Installing, Front Brakes”,
page 35

1.3.1 BrakelkCaliper,
swa
gen AG Removing
. Volkswagen AG
doeand
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Installing,
Front Brakes
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or
Special tools
au and workshop equipment required
th or
ac
ss
♦ Torque Wrench 1331 5-50Nm - VAG1331-
ce
le
un

pt
an
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♦ Brake Pedal Actuator - VAG1869/2- .

itte

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ility
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Note
h re
ole,

spec

The procedure only applies to the replacement of or subsequent

urposes, in part or in wh

repair work done on the brake caliper.

t to the co

Removing
rrectness of i

– Remove the wheel from the affected front side.

– Disconnect the brake pad wear indicator connector.
cial p

– Attach the bleeder bottle bleed hose -1- to the brake caliper
nfo

bleed valve.
mer

rmatio
m

– Open the bleeder valve.

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pr

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fo
ng

yi
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gh
pyri Vo
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cted agen
Prote AG.

1. Front Brakes 35
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Install the -VAG1869/2- .

– Close the bleeder valve and remove the bleeder bottle.
– Remove the brake hose.

– Counterhold the guide pin and remove both bolts from the
brake caliper.
– Remove the brake caliper from the brake carrier.
Installing
• The piston is pressed back.
• Both brake pads and their springs rest in the openings in the

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. Volkswagen AG
brake carrier. sw agen AG does
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– Place the brake caliper
se
db
y
carefully on the brake carrier. ara
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– Counterholdauat
th the guide pin and mount the brake caliper onor a
the brake carrier
ss with new self-locking bolts. c
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pt

– Attach the brake hose to the brake caliper.

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– Remove the -VAG1869/2- .

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– Connect the brake pad wear indicator connector.

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– Bleed the brake system. Refer to

hole

spec

⇒ “6.2 Hydraulic System, Standard Bleeding”, page 88 .

es, in part or in w

t to the co

– Install the wheels.

Tightening Specifications
rrectness of i

♦ Refer to ⇒ “1.1.1 Overview - Front Brakes”, page 30

l purpos

♦ Breather valve. Refer to

⇒ “1.1 Overview - Front Brake Caliper”, page 58 .
nform
ercia

♦ Wheel Bolts. Refer to ⇒ Wheel and Tire Guide; Rep. Gr. 44 ;

m

Wheels and Tires; Wheel Bolts Tightening Specification .

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tion in
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♦ With the vehicle stationary, firmly press the brake pedal sev‐
n
n

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eral times so that the brake pads in the operating condition Cop o
.
properly sit in their respective position.
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♦ Check the brake fluid level.
by lksw
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♦ Make sure the brakes are working correctly before driving the
vehicle for the first time.

36 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

2 Rear Brakes
⇒ “2.1 Overview - Rear Brakes”, page 37 agen
AG. Volkswagen AG d
oes
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⇒ “2.2 Brake yV
Pads, Removing and eInstalling”, page 39 gu
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⇒ “2.3 Brake Caliper, Removing
aut and Installing”, page 42
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2.1 Overview - Rear Brakes

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Overview - Rear Brakes:
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Note

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♦ Use the Brake Charger/Bleeder Unit - VAS5234- to extract
es, in part or in w

t to the co
brake fluid from the brake fluid reservoir.
♦ Install the Brake Pedal Actuator - VAG1869/2- to relieve pres‐
sure before removing a brake caliper or disconnecting a brake

rrectness of i
hose.
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1 - Brake Shield
❑ Allocation ⇒ Parts Cata‐
m

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com

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2 - TORX® Bolt

thi
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❑ 12 Nm
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3 - Brake Rotor

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❑ Replace both sides if t. C
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❑ Wear limits. Refer to cted agen
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⇒ “3.1.3 Rear Brakes”,
page 4 .
❑ Do not use excessive
force to separate the
brake rotor from the
wheel hub. Use rust re‐
mover, if necessary,
otherwise the brake ro‐
tor could be damaged.
❑ To remove, first remove
the brake caliper and
carrier
4 - TORX® Bolt
❑ 8 Nm
5 - Brake Caliper
❑ Do not remove the
brake hose when
changing the brake
pads.
❑ Removing and instal‐
ling. Refer to
⇒ “2.3 Brake Caliper,
Removing and Instal‐
ling”, page 42 .
❑ Servicing. Refer to
⇒ “2 Rear Brake Caliper”, page 63 .
❑ After servicing or replacing perform the “Basic Setting”. Refer to Vehicle Diagnostic Tester .

2. Rear Brakes 37
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

6 - Internal Multi-Point Bolt

❑ 90 Nm + 90°
❑ Replace after removing.
❑ Remove and install using Multipoint Socket - T10035- . Refer to
⇒ Fig. ““ Multipoint Socket -T10035- ”“ , page 39 .
7 - Brake Carrier
8 - Spring
9 - Outer Brake Pad
❑ Always replace on both axles.
❑ Wear limit: 2 mm without backing plate
❑ Thickness, Checking. Refer to ⇒ Maintenance ; Booklet 42.1 ; Procedure Descriptions; Front and Rear
Brake Pad Thickness and Brake Rotor Condition, Checking .
❑ Removing and installing. Refer to ⇒ “2.2 Brake Pads, Removing and Installing”, page 39 .
10 - Inner Brake Pad
❑ Always replace on both axles.
❑ With spring
❑ Wear limit: 2 mm without backing plate

cardiagn.com
❑ Thickness, Checking. Refer to ⇒ Maintenance ; Booklet 42.1 ; Procedure Descriptions; Front and Rear
Brake Pad Thickness and Brake Rotor Condition, Checking .
❑ Removing and installing. Refer to ⇒ “2.2 Brake Pads, Removing and Installing”, page 39 .
11 - Spring
❑ Installed on the inner brake pad only.
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❑ Pay attention to the installed position. es n
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12 - Brake Line ed nte
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❑ 14 Nm au ra
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13 - Bracket
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14 - Brake Hose Spring on the Bracket

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15 - Brake Hose with Ring Connection and Banjo Bolt

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❑ To the brake line: 14 Nm

h re
hole

❑ To the brake caliper: 35 Nm

spec
es, in part or in w

16 - Guide Pin
t to the co

❑ 35 Nm
17 - Caps
rrectness of i

❑ For the guide pins

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18 - Seal
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❑ Always replacing
❑ For the Parking Brake Motor
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19 - Hex Socket Bolt

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❑ 8 Nm
at

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20 - Parking Brake Motor

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❑ Removing and installing. Refer to op

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⇒ “3.3 Left/Right Parking Brake Motor V282 / V283 , Removing and Installing”, page 47 . t. C
gh g
pyri Vo
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cted agen
Prote AG.

38 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Multipoint Socket - T10035-

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2.2 Brake Pads, Removing and Installing
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester

rrectness of i
♦ Brake Bleeding Tool Set - VAS6564-
l purpos

♦ Torque Wrench 1331 Insert - Ratchet Head - VAS6784-

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nf
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♦ Hex Bit - 7mm - T10503-

orm
m

♦ Torque Wrench 1331 5-50Nm - VAG1331-

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om

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♦ Piston Resetting Tool - T10145-

or

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a

Removing
iv

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When removing, mark the brake pads that will be used again.
f
ng

Install in the same position, otherwise the braking effect will be

yi
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uneven. t. C
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Note
AG.

Do not disconnect the connectors from the parking brake motors.

• Electromechanical parking brake not actuated.

– Remove the rear axle wheels.
The pistons on the electro-mechanical parking brake must be
driven back. Refer to Vehicle Diagnostic Tester .

Note

Before pressing the piston back, extract the brake fluid from the
brake fluid reservoir. Otherwise the brake fluid will overflow and
cause damage, especially if the brake fluid was added intermit‐
tently.

– Drive back the piston. Refer to Vehicle Diagnostic Tester .

WARNING
There is a risk of injury because the spring is tensioned.
The spring can jump out and cause eye or skin injury.
– Hold the spring with a hand.

2. Rear Brakes 39
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Using the screwdriver -A-, pry off the brake pad spring -1- from
the brake caliper -arrow-, while doing so secure the spring with
the other hand.

– Remove the caps -arrows-.

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nl

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– Remove both guide pins from the brake caliper using the -
es, in part or in w

T10503- and -VAS6784- .

t to the co
rrectness of i
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– Remove the brake caliper -1- and secure with wire -A- so that
u
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the weight of the brake caliper does not stress or damage the
ng

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brake hose. op o
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Note cted agen
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Driving back the pistons. Refer to Vehicle Diagnostic Tester is not

necessary. The thrust nut in the piston is a slider so the piston
can only be pressed and cannot be pulled back. Only the spindle
with the thrust nut is moved back.

• The piston must first be reset. Refer to Vehicle Diagnostic

Tester .

40 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Use the -T10145- to press back the piston.

– Remove the brake pads -2 and 3-.

Cleaning:

WARNING
Health risk due to toxic dust from the brake system.
Irreversible deposit of dust particles in the lungs. Breathing im‐
pairments may occur.

cardiagn.com
– Never blow out the brake system with compressed air.

– Thoroughly clean contact surfaces for brake pads at brake

carrier and remove corrosion.
– Clean the brake caliper.

Note AG. Volkswagen AG d

agen oes
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byV gu
ara
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Only use mineral
orise spirits for cleaning the brake caliper.nte
eo
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Installing
s
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d
itte

– Install the inner brake pad -2- and outer -3- in the brake carrier.
y li
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ot

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hole

spec
es, in part or in w

t to the co
rrectness of i
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– Attach the brake caliper.

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tion in
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te o

thi
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n
n

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Cop o
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cted agen
Prote AG.

2. Rear Brakes 41
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Install the caps -arrows-.

AG. Volkswagen AG d
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urposes, in part or in wh

t to the co
– Install the brake pads spring in the brake caliper opening
-arrow-.

rrectness of i
Note

Make sure that the spring is seated correctly in the holes on the
cial p

brake caliper.

nfo
mer

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matio
m

After driving the pistons out using a basic setting of the brake
o

n in
c

system must be performed. Refer to Vehicle Diagnostic Tester .

or

th
e

is d
at

– Perform the basic setting of the brake system. Refer to Vehicle

iv

oc
pr

Diagnostic Tester .

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ng

n
– Install the wheels.
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Tightening Specifications
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♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 37 Prote
cted agen
AG.

♦ Wheel Bolts. Refer to ⇒ Wheel and Tire Guide; Rep. Gr. 44 ;

Wheels and Tires; Wheel Bolts Tightening Specification .

Note

♦ Check the brake fluid level after replacing the brake pad.
♦ Make sure the brakes are working correctly before driving the
vehicle for the first time.

2.3 Brake Caliper, Removing and Installing

Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester
♦ Brake Bleeding Tool Set - VAS6564-
♦ Torque Wrench 1331 Insert - Ratchet Head - VAS6784-
♦ Hex Bit - 7mm - T10503-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Piston Resetting Tool - T10145-
♦ Brake Pedal Actuator - VAG1869/2- .

42 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Removing

Note
olkswagen AG
en AG. V
The procedure only Vol
applies
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to the replacement
does
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ed
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Do not disconnect the connectors from the parking brake motors.
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– Remove the wheel from the affected rear side.

h re
hole

spec
The pistons on the electro-mechanical parking brake must be
es, in part or in w

driven back. Refer to Vehicle Diagnostic Tester .

t to the co
Note

rrectness of i
Before pressing the piston back, extract the brake fluid from the
l purpos

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brake fluid reservoir. Otherwise the brake fluid will overflow and
cause damage, especially if the brake fluid was added intermit‐

nform
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tently.
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com

tio
– Drive back the piston. Refer to Vehicle Diagnostic Tester .
n in
r
te o

thi

– Remove the bolts -arrows- for the parking brake motor.

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cu

– Remove the parking brake motor and set aside, without dis‐
fo

connecting the connectors.

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n

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Cop o
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cted agen
Prote AG.

– Attach the bleeder bottle bleed hose -1- to the brake caliper
bleed valve.
– Open the bleeder valve.
– Install the -VAG1869/2- .
– Close the bleeder valve and remove the bleeder bottle.
– Remove the brake hose.

WARNING
There is a risk of injury because the spring is tensioned.
The spring can jump out and cause eye or skin injury.
– Hold the spring with a hand.

2. Rear Brakes 43
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Using the screwdriver -A-, pry off the brake pad spring -1- from
the brake caliper -arrow-, while doing so secure the spring with
the other hand.

n AG. Volkswagen AG do
lkswage es n
o ot g
– Remove the caps -arrows-. byV ua
d ran
ir se tee
tho
u or
a ac
ss

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un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

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h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness of i
cial p

nfo
mer

rmatio
om

n in
or c

th
e

is d
at
iv

oc
pr

u
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fo
ng

yi
Cop o
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gh
pyri Vo
co lksw
by
cted agen
Prote AG.

44 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Remove both guide pins from the brake caliper using the -
T10503- and -VAS6784- .
– Remove the brake caliper from the brake carrier.
Installing AG. Volkswagen AG d
agen oes
olksw not
• Brake pads sit in springs ond bthe
y V brake carrier. gu
ara
ise nte
r
– Secure the brake caliperut on brake carrier using new self-lock‐
ho eo
ra
ing bolts. ss a c

ce
e
nl

pt
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an
itte

y li
Note
erm

ab
ility
ot p

Ring groove and contact surface of parking brake motor must be

wit
, is n

clean.

h re
hole

spec
es, in part or in w

– Install the new seal.

t to the co
– Turn the spindle back slightly using a E11 TORX® socket, until
the parking brake motor can be correctly positioned.

rrectness of i
– Carefully install the parking brake motor, while doing so pay
l purpos

attention to the seating of the seals.

cardiagn.com
– Rotate the parking brake motor until the bolt hole and threads

nform
ercia

are aligned.
m

at
om

ion
c

Note

in t
or

his
ate

do
riv

Make sure that the parking brake motor is seated flush against
p

cu
or

the brake caliper. Do not, under any circumstances, pull the park‐
g f

n
n

ing brake motor against the brake caliper using the bolts.
yi
Cop o
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gh
yri
– Install the new hex socket bolts by hand and then tighten. op Vo
by c lksw
cted agen
– Attach the brake hose on the brake caliper.
Prote AG.

– Bleed the brake system. Refer to

⇒ “6.2 Hydraulic System, Standard Bleeding”, page 88 .
After driving the pistons a basic setting of the brake system must
be performed. Refer to Vehicle Diagnostic Tester .
– Perform the basic setting of the brake system. Refer to Vehicle
Diagnostic Tester .
– Install the wheels.
Tightening Specifications
♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 37
♦ Breather valve. Refer to
⇒ “2.1 Overview - Rear Brake Caliper”, page 63 .
♦ Wheel Bolts. Refer to ⇒ Wheel and Tire Guide; Rep. Gr. 44 ;
Wheels and Tires; Wheel Bolts Tightening Specification .

Note

♦ Check the brake fluid level.

♦ Make sure the brakes are working correctly before driving the
vehicle for the first time.

2. Rear Brakes 45
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3 Parking Brake
⇒ “3.1 Component Location Overview - Parking Brake”,
page 46
⇒ “3.2 Electromechanical Parking Brake Control Module J540 ,
Removing and Installing”, page 47
⇒ “3.3 Left/Right Parking Brake Motor V282 / V283 , Removing
and Installing”, page 47

3.1 Component Location Overview - Parking Brake

1 - -AUTO HOLD- Indicator

Lamp - K237-
❑ Component location: in
the -AUTO HOLD- But‐
ton - E540-
❑ Depending on vehicle
equipment
2 - -Auto Hold- Button - E540-

cardiagn.com
❑ Component location: in‐
side the center console
❑ Removing and instal‐
ling. Refer to ⇒ Electri‐ n AG. Volkswagen AG do
cal Equipment; Rep. Gr. lkswage es n
o ot g
96 ; Controls; Compo‐ byV ua
d ran
nent Location Overview ir se tee
tho
or
- Controls in Center au ac
ss
Console .

ce
le
un

pt
❑ Depending on vehicle

an
d
itte

equipment

y li
erm

ab
ility
3 - Electromechanical Parking
ot p

wit
Brake Button - E538-
is n

h re
ole,

❑ Component location: in‐

spec
side the center console
urposes, in part or in wh

t to the co
❑ Removing and instal‐
ling. Refer to ⇒ Electri‐
cal Equipment; Rep. Gr.
96 ; Controls; Compo‐ rrectness of i
nent Location Overview
- Controls in Center
Console .
cial p

nf

4 - Electromechanical Parking
o
mer

rm

Brake Indicator Lamp - K213-

atio
m

❑ Component location: in‐

o

n in
or c

side the Electrome‐

th
e

is d
t

chanical Parking Brake

iva

oc
r

Button - E538-
p

u
r
fo
ng

5 - Instrument Cluster op
yi o
❑ With the Brake System Indicator Lamp - K118-
t. C
gh g
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❑ With the Electric Parking Brake Malfunction Indicator Lamp - K214- cop Vo
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Prote
6 - Electromechanical Parking Brake Control Module - J540-
AG.

❑ Integrated in the ABS Control Module - J104- and cannot be replaced separately.
❑ ABS Control Module - J104- , Removing and installing. Refer to
⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Removing and Installing, Gasoline Engine”, page
15 .

46 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

7 - Seal
❑ Always replacing
8 - Left Parking Brake Motor - V282-
❑ Component location: on the left rear brake caliper
❑ Removing and installing. Refer to
⇒ “3.3 Left/Right Parking Brake Motor V282 / V283 , Removing and Installing”, page 47 .
9 - Hex Socket Bolt
❑ 8 Nm
10 - Right Parking Brake Motor - V283-
❑ Component location: on right rear brake caliper.
❑ Removing and installing. Refer to
⇒ “3.3 Left/Right Parking Brake Motor V282 / V283 , Removing and Installing”, page 47 .

3.2 Electromechanical Parking Brake Con‐

trol Module - J540- , Removing and In‐
stalling

cardiagn.com
The Electromechanical Parking Brake Control Module - J540- is
integrated in the ABS Control Module - J104- and cannot be re‐
placed separately.
– ABS Control Module - J104- , Removing and installing. Refer
to
⇒ “3.2.1 ABS Control Module and ABS Hydraulic Unit, Re‐
moving and Installing, Gasoline Engine”, page 15 .

3.3 Left/Right Parking Brake Motor -V282- /

-V283- , Removing and Installing
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
ksw
♦ Torque Wrench 1331 5-50Nm - VAG1331- by Vol not
gu
ara
d
ise nte
♦ Vehicle Diagnostic Tester thor eo
au ra
c
Removing ss

ce
e
nl

pt
du

an
itte

Note y li
erm

ab
ility
ot p

wit
Ignition must be switched off for at least 30 seconds before dis‐
, is n

h re
connecting the connector.
hole

spec
es, in part or in w

– Remove the connector -2- from the parking brake motor -1-.
t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

th
e

i
t

sd
iva

oc
r
rp

u
fo
ng

yi
Cop o
t. g
gh
pyri Vo
co lksw
by
cted agen
Prote AG.

3. Parking Brake 47
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020 agen AG. Volkswagen AG do
lksw es n
o ot g
yV ua
– Remove both hex socket boltri-arrows-
se
db from the parking brake ran
tee
motor. utho
or
sa ac
– Remove the parking brakes
motor from the brake caliper, while

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e
nl
doing so turn the parking brake motor back and forth.

pt
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an
itte

y li
– Remove the seal.
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
es, in part or in w

Make sure that the ring groove of the seal and the contact surface

t to the co
of the parking brake motor do not become damaged.

– Clean the parking brake motor ring groove and contact sur‐

rrectness of i
face.
l purpos

Installing

nf
ercia

– Lightly grease the seal and install, while doing so do not twist

orm
or damage the seal.
m

atio
om

n in
– Completely grease the TORX® socket on the parking brake
or c

t
motor drive axle.

h
e

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i
t

sd
iva

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ng

Note

n
yi
Cop o
ht. g
Do not remove the gasket when assembling the parking brake
rig
py Vo
motor.
co lksw
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cted agen
Prote AG.

– Carefully push the parking brake motor on the brake caliper

while doing so pay attention that the seals are seated correctly.

Note

If necessary slightly turn back the drive shaft using a E11

TORX® socket -A- so that the parking brake motor can be cor‐
rectly positioned.

– Rotate the parking brake motor until the bolt hole and threads
are aligned.

Note

Make sure that the parking brake motor is seated flush against
the brake caliper. Do not, under any circumstances, pull the park‐
ing brake motor against the brake caliper using the bolts.

48 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020
en AG and thenn AG doe . Volkswage
– Set the hex socket bolts -arrows- in placeksw
by
aghand s no
l
tighten. by
Vo t gu
a
ed ran
ris
– Install the connector -1-. tho tee
or
au ac
– ss brake system. Refer to Vehicle
Perform the basic setting of the

ce
e
Diagnostic Tester .

nl

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itte

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Tightening Specification
erm

ab
ility
ot p
♦ Refer to

wit
, is n

⇒ “3.1 Component Location Overview - Parking Brake”, page

h re
46
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

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n in
or c

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t

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n
yi
Cop o
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gh
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co lksw
by
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Prote AG.

3. Parking Brake 49
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4 Brake Pedal
⇒ “4.1 Overview - Brake Pedal”, page 50
⇒ “4.3 Brake Pedal, Disconnecting from Brake Booster”,
page 54
⇒ “4.4 Brake Pedal, Attaching to Brake Booster”, page
agen
54
AG. Volkswagen AG
do w es n
olks ot g
⇒ “4.5 Brake Pedal, Removing and Installing”,
ed
by page 55
V ua
ran
ris tee
⇒ “4.2 Mounting Bracket, Removingauand
tho Installing”, page 51 or
ac
ss
4.1 Overview - Brake Pedal

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itte

⇒ “4.1.1 Overview - Brake Pedal”, page 50

y li
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pe

ility
4.1.1 Overview - Brake Pedal
ot

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, is n

h re
hole

spec
Note
es, in part or in w

t to the co
♦ Do not shorten the path for the brake pedal with additional
carpets.

cardiagn.com
rrectness of i
♦ Do not lubricate or grease the mounting pin. The mounting pin
l purpos

must remain dry.

nform
ercia

1 - Pedal Assembly/Mounting
m

a
Bracket
com

tion in
❑ Removing and instal‐
r
te o

thi
ling. Refer to

s
iva

do
⇒ “4.2 Mounting Brack‐
r
rp

et, Removing and Instal‐ cu

g fo

n
n

ling”, page 51 . op
yi o
. C
2 - Self-Locking Hex Nut
ht g
rig
py Vo
❑ 25 Nm
co lksw
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cted agen
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❑ Replace after removing.
AG.

❑ Bolt tightening se‐

quence. Refer to
⇒ Fig. ““Tightening Se‐
quence:”“ , page 51 .
3 - Mounting Pin
❑ Remove the mounting
bracket to remove.
❑ Do not lubricate or
grease the mounting
pin. The mounting pin
must remain dry.
4 - Bearing Bushing
❑ Not replaceable; check
for proper installation
position
5 - Bearing Bushing
❑ Not replaceable; check
for proper installation
position
6 - Lock Washer
❑ Pressed on, not detach‐
able

50 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

7 - Brake Pedal
❑ Brake Pedal, Removing from Brake Booster. Refer to
⇒ “4.3 Brake Pedal, Disconnecting from Brake Booster”, page 54 .
. Volkswagen AG
❑ Brake Pedal, Attaching to Brake Booster. swaRefer
gen AGto does
⇒ “4.4 Brake Pedal, Attaching to Brake
by V Booster”, page 54 .
olk not
gu
ara
d
❑ Removing and installing. Refer se ⇒ “4.5 Brake Pedal, Removing and Installing”,
rito nte page 55 .
ho e t or
au ac
8 - Cap ss

ce
e
nl
9 - Bearing Shell

pt
du

an
itte

y li
10 - Mount
erm

ab
ility
ot p

❑ For the brake booster push rod ball head

wit
, is n

h re
hole

spec
Tightening Sequence:
es, in part or in w

t to the co
rrectness of i
l purpos

cardiagn.com
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cu
or

4.2 Mounting Bracket, Removing and Instal‐

g f

n
n

yi
ling Cop o
t. g
gh
yri
⇒ “4.2.1 Mounting Bracket, Removing and Installing”, page 51 cop Vo
by lksw
cted agen
Prote AG.
4.2.1 Mounting Bracket, Removing and Instal‐
ling
– Remove the driver side instrument panel side cover. Refer to
⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument
Panel Side Cover, Removing and Installing .
– Remove the footwell cover on the driver side. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Storage Compartments and Covers .
– Remove the driver side footwell trim center console panel.
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Front
Footwell Center Console Trim Panel, Removing and Instal‐
ling .
– Remove the driver side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
ers .
– Remove the driver side instrument panel cover. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
ers; Driver Side Instrument Panel Cover, Removing and In‐
stalling .

4. Brake Pedal 51
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Remove the knee airbag -1-. Refer to ⇒ Body Interior; Rep.

Gr. 69 ; Knee Airbags; Overview - Knee Airbag .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
– Remove the driver side footwell vent. Refer to ⇒ Heating,

ility
ot p

Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Duct; Over‐

wit
, is n

view - Air Routing and Air Distribution in Vehicle Interior .

h re
hole

spec
es, in part or in w

t to the co

cardiagn.com
rrectness of i
l purpos

nf
ercia

orm
m

atio
– Remove the bolt -1- and fold the footwell trim panel -2- in the
om

n in
direction of the -arrow- into the vehicle interior.
or c

th
e

i
t

sd
iva

oc
r
rp

u
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ng

yi
Cop o
t. g
gh
pyri Vo
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by c lksw
cted agen
Prote AG.

– Unlock and disconnect the connector -2- from the accelerator

pedal module.
– Remove the bolt -1-.
– Remove the accelerator pedal module -3- from the mounting.

52 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Remove the brake pedal crash bolster -1- disengage -2- and
push to the side. Refer to ⇒ Body Interior; Rep. Gr. 70 ; In‐
strument Panel Crossmember; Overview - Instrument Panel
Crossmember .

– Remove the Headlamp Range Control Module - J431- / Cor‐

nering Lamp and Headlamp Range Control Module - J745-
-1- and move to the side. Refer to ⇒ Electrical Equipment;
Rep. Gr. 94 ; Automatic Headlamp Range Control; Cornering
Lamp and Headlamp Range Control Module - J745- , Remov‐
ing and Installing .
– Disconnect the brake pedal from the brake booster. Refer to
⇒ “4.3 Brake Pedal, Disconnecting from Brake Booster”, page

cardiagn.com
54 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

– Remove the nuts -1 to 4-. h re

hole

spec
es, in part or in w

– Carefully remove the pedal assembly.

t to the co

Installing
Install in reverse order of removal. Note the following:
rrectness of i

– Connect the brake pedal with the brake booster. Refer to

l purpos

⇒ “4.4 Brake Pedal, Attaching to Brake Booster”, page 54 .

nf
ercia

orm
m

atio
om

n in
or c

th
e

i
t

sd
iva

oc
r
rp

u
fo
ng

yi
Cop o
ht. g
rig
copy Vo
by lksw
cted agen
Prote AG.

4. Brake Pedal 53
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

Nut Tightening Sequence:

Tightening Specifications
♦ Refer to ⇒ “4.1.1 Overview - Brake Pedal”, page 50
♦ Crash bolster. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instru‐
ment Panel Crossmember; Overview - Instrument Panel
Crossmember .
♦ Footwell Vent. Refer to ⇒ Heating, Ventilation and Air Condi‐
tioning; Rep. Gr. 87 ; Air Duct; Overview - Air Routing and Air
Distribution in Vehicle Interior .
♦ Knee Airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee
Airbags; Overview - Knee Airbag
♦ Driver Side Covers. Refer to ⇒ Body Interior; Rep. Gr. 68 ;
Storage Compartments and Covers; Component Location
Overview - Storage Compartment and Covers .

4.3 Brake Pedal, Disconnecting from Brake

Booster
Special tools and workshop equipment required

cardiagn.com
♦ Release Tool - T10159B-
– Press and hold the brake pedal in the direction of the braken AG. Volkswagen A
booster. olks
wage
G do
es n
o
yV t gu
2 - Push Rod db ara
ir se nte
ho eo
ut
3 - Retaining Tabs ss
a ra
c

ce
e

– Insert the -T10159B- and pull in the direction of the driver seat.
nl

pt
du

an
While doing so, counterhold on the brake pedal (at this mo‐
itte

y li
ment the pedal must not move to the driver seat). The mount
erm

ab
retaining tabs -3- will thereby be pressed off the ball head of

ility
ot p

the push rod -2-.

wit
, is n

h re
For clarity, the process of separating the brake pedal from the
hole

spec
brake booster is shown with the pedal assembly removed.
es, in part or in w

t to the co
– Pull the -T10159B- and brake pedal together in the direction
of the driver seat. (This will pull the brake pedal off of the
pushrod ball head).
rrectness of i
l purpos

nform
ercia

4.4 Brake Pedal, Attaching to Brake Booster

m

at
om

ion
c

– Hold the pushrod ball head in front of the mount and push the
in t
or

his
e

brake pedal toward the brake booster so that the ball head
at

do
riv

engages audibly.
p

cu
for

– Check the engagement by pulling briefly on the brake pedal.

g

n
n

yi
op o
Further installation is the reverse order of removal. t. C
gh g
pyri Vo
co lksw
by
cted agen
Prote AG.

54 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4.5 Brake Pedal, Removing and Installing

⇒ “4.5.1 Brake Pedal, Removing and Installing”, page 55

4.5.1 Brake Pedal, Removing and Installing

Removing the brake pedal separately is not possible.

cardiagn.com
n AG. Volkswagen AG do
lkswage es n
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byV ua
d ran
ir se tee
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a ac
ss
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itte

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erm

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ility
ot p

wit
, is n

h re
hole

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es, in part or in w

t to the co
rrectness of i
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ercia

orm
m

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om

n in
or c

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i
t

sd
iva

oc
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u
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ng

yi
Cop o
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gh
pyri Vo
co lksw
by
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Prote AG.

4. Brake Pedal 55
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

5 Special Tools

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
ksw

cardiagn.com
ol not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness of i
cial p

nfo
mer

rmatio
om

n in
c

♦ Vehicle Diagnostic Tester

or

th
e

is d
at

♦ Brake Bleeding Tool Set - VAS6564-

iv

oc
pr

u
r
fo

♦ Torque Wrench 1331 Insert - Ratchet Head - VAS6784-

ng

yi
op o
♦ Hex Bit - 7mm - T10503- gh
t. C
g
yri
♦ Torque Wrench 1331 5-50Nm - VAG1331- cop Vo
by lksw
cted agen
Prote
♦ Piston Resetting Tool - T10145-
AG.

56 Rep. Gr.46 - Mechanical Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Release Tool - T10159B-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
♦ Brake Pedal Actuator - VAG1869/2- .

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

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t to the co
rrectness of i
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m

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i
t

sd
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oc
r
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u
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ng

yi
Cop o
t. g
gh
pyri Vo
o
by c lksw
cted agen
Prote AG.

5. Special Tools 57
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

47 – Hydraulic Components
1 Front Brake Caliper
⇒ “1.1 Overview - Front Brake Caliper”, page 58
⇒ “1.2 Brake Caliper Piston, Removing and Installing”,
page 59

1.1 Overview - Front Brake Caliper

⇒ “1.1.1 Overview - Front Brake Caliper”, page 58

1.1.1 Overview - Front Brake Caliper

♦ Install the entire repair kit when servicing.
♦ Only use mineral spirits to clean the brakes.
♦ Apply a thin coat of Assembly Paste G 052 150 A2 to brake
cylinders, pistons and seals.
AG. Volkswagen AG d
agen oes

cardiagn.com
olksw not
1 - Brake Carrier ed by
V gu
ara
is nte
❑ Is assembled with the ut
hor eo
guide pins and caps as ss a ra
c
well as with sufficient

ce
le
un

grease on the guide pins

pt
an
d
itte

as a replacement part.

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❑ Install the repair kit if the
pe

ility
caps or guide pins are
ot

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damaged. Use grease

h re
hole

packet supplied to lubri‐

spec
cate guide pins.
es, in part or in w

t to the co
2 - Protective Cap
❑ Lubricate the groove
with the grease that

rrectness of i
comes with the repair kit
l purpos

and then install the cap

into the groove on the
brake carrier and the
nform
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guide pin.
m

3 - Guide Pin
com

tion in
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4 - Hex Bolt
thi
s
iva

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❑ 35 Nm
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❑ Replace after removing.

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op
5 - Breather Valve
o
t. C
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❑ 10 Nm by c
opyri Vo
lksw
❑ Lightly grease the cted agen
Prote AG.
threads with Assembly
Paste - G 052 150 A2 -
before installing.
6 - Dust Cap
❑ Install onto breather
valve.
7 - Brake Caliper
8 - Seal
❑ For piston with 48 mm diameter

58 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020
❑ Removing and installing. Refer to
AG. Volkswagen
⇒ “1.2.1 Front lBrake
ksw
agenCaliper Piston,AG
Removing
does
n and Installing”, page 59 .
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9 - Seal ris
ed
b ara
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❑ For apiston
ut
h
with 45 mm diameter ra
ss c
❑ Removing and installing. Refer to

ce
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nl

⇒ “1.2.1 Front Brake Caliper Piston, Removing and Installing”, page 59 .

pt
du

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itte

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10 - Piston
erm

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ility
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❑ 48 mm diameter

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❑ Removing and installing. Refer to

h re
hole

⇒ “1.2.1 Front Brake Caliper Piston, Removing and Installing”, page 59 .

spec
es, in part or in w

❑ Apply thin coat of Assembly Paste - G 052 150 A2 - on the piston before inserting.

t to the co
11 - Piston
❑ 45 mm diameter

rrectness of i
❑ Removing and installing. Refer to
l purpos

⇒ “1.2.1 Front Brake Caliper Piston, Removing and Installing”, page 59 .

❑ Apply thin coat of Assembly Paste - G 052 150 A2 - on the piston before inserting.

nform
ercia

12 - Protective Cap
m

❑ For piston with 48 mm diameter

at
om

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ion
❑ Removing and installing. Refer to
c

in t
or

⇒ “1.2.1 Front Brake Caliper Piston, Removing and Installing”, page 59 .

his
ate

do
riv

❑ Do not damage the piston when inserting it.

p

cu
for
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13 - Protective Cap
n
n

yi
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❑ For piston with 45 mm diameter . C
ht g
rig
❑ Removing and installing. Refer to copy Vo
by lksw
⇒ “1.2.1 Front Brake Caliper Piston, Removing and Installing”, page 59 .
Prote
cted agen
AG.
❑ Do not damage the piston when inserting it.

1.2 Brake Caliper Piston, Removing and In‐

stalling
⇒ “1.2.1 Front Brake Caliper Piston, Removing and Installing”,
page 59

1.2.1 Front Brake Caliper Piston, Removing

and Installing
Special tools and workshop equipment required
♦ Piston Resetting Tool - T10145-
♦ Trim Removal Wedge - 3409-
Removing

Note

♦ Place a wooden board into the recess so the piston is not

damaged.
♦ Only one piston can be pressed out respectively, at the same
time hold the other pistons in the brake caliper using the piston
resetting tool.

1. Front Brake Caliper 59

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Use compressed air to push the piston out of the brake caliper.

– Remove the protective cap Afrom the piston using the -3409- .
G. Volkswagen n AG do
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– Remove the piston.
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ed ran
oris tee
th or
au
Notess ac

ce
e
nl

pt
du

When removing, make sure that the cylinder surface is not dam‐
an
itte

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aged.
erm

ab

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ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Remove the protective cap using the -3409- .

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cu
for
g

n
n

yi
– Remove the seal with the -3409- . op o
. C
ht g
rig
copy Vo
by lksw
Note cted agen
Prote AG.

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

Installing
– Only clean the surfaces of the pistons and seal with mineral
spirits and then dry.
– Apply a thin coat of Assembly Paste G 052 150 A2 on the
piston and the seal before inserting.

60 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020
AG . Volkswagen AG
– Insert the seal into the brake caliper.
ksw
agen does
not
ol
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pt
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erm

ab
ility
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wit
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hole

spec
es, in part or in w

t to the co
– Place the cap with the outer sealing lip on the piston.

rrectness of i
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at
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io

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n
c

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or

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ate

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Cop o
– Insert the inner sealing lip into the cylinder groove using the
t. g
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-3409- . cop Vo
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cted agen
At the same time hold the piston in front of brake caliper.
Prote AG.

– Push the piston by hand as far back as possible in the brake

caliper.

1. Front Brake Caliper 61

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Press the piston into the brake caliper using the piston reset‐
ting tool.
Outer sealing lip of protective cap will then engage in the piston
groove.

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ss

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du

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ab
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
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ion
c

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or

his
ate

do
priv

cu
for
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n
n

yi
Cop o
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gh
pyri Vo
co lksw
by
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Prote AG.

62 Rep. Gr.47 - Hydraulic Components

 n AG. Volkswagen AG do
lkswage Atlas 2017 ➤ , Atlas es n2020 ➤
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2 Rear Brake Caliper

ce
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nl

pt
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an
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⇒ “2.1 Overview - Rear Brake Caliper”, page 63

y li
erm

ab
⇒ “2.2 Dust Cap, Removing and Installing”, page 63

ility
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2.1 Overview - Rear Brake Caliper

h re
hole

spec
♦ Install the entire repair kit when servicing.

es, in part or in w

t to the co
♦ Only use mineral spirits to clean the brakes.
♦ New brake calipers are filled with brake fluid and are pre-bled.

rrectness of i
l purpos
1 - Brake Caliper
2 - Damping Sleeves

nform
ercia
3 - Guide Pin
m

at
om

io
4 - Caps

n
c

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5 - Hex Socket Bolt

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❑ 8 Nm
or

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6 - Parking Brake Motor . Cop o
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7 - Seal
gh
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❑ Always replace
by lksw
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Prote AG.
8 - Thrust Nut
❑ Removing and installing
is not possible.
9 - Seal
❑ Removing and installing
is not possible.
10 - Piston
❑ Removing and installing
is not possible.
11 - Protective Cap
❑ Removing and instal‐
ling. Refer to
⇒ “2.2 Dust Cap, Re‐
moving and Installing”,
page 63 .

Note

To change the protective cap the

brake caliper does not need to be
removed, do not remove the brake
hose.

12 - Breather Valve
❑ 10 Nm
❑ Lightly grease the threads with Assembly Paste - G 052 150 A2 - before installing.
13 - Dust Cap

2.2 Dust Cap, Removing and Installing

Special tools and workshop equipment required

2. Rear Brake Caliper 63

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Trim Removal Wedge - 3409-

♦ Piston Resetting Tool - Caps /1,/2,/3,/4,/5 - T10146/5- for the
rear brakes FNc-M42
♦ Piston Resetting Tool - T10145-
Removing
It is possible to only replace the protective cap.

Note

To change the protective cap the brake caliper does not need to
be removed, do not remove the brake hose.

• The piston is driven back. agen

AG. Volkswagen AG d
oes
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• The parking brake motor is removed. ed by gu
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ut
CAUTION ss a ra
c

ce
e

There is a risk of destroying the ball thread by removing from

nl

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an
the piston and thrust nut.

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itte

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ab
– Never completely remove the piston and thrust nut.

ility
ot p

wit
, is n

h re
– Remove the piston maximum 20 mm -dimension a- with a E11
hole

TORX® socket in the direction of -arrow-.

spec
es, in part or in w

t to the co
rrectness of i
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orm
m

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th
e

– Pry up the protective cap with the -3409- from the brake caliper
i
t

sd
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-arrows-.
r
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ng

Installing
n

yi
Cop o
– The surface on the piston and the brake caliper must only be
t. g
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cleaned with mineral spirits and then dried. op Vo
by c lksw
cted agen
Prote AG.

64 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Place the protective cap in the groove -arrow- on the piston.

– Reinstall the piston in the direction of -arrow-.

cardiagn.com
– Push the protective cap on the brake caliper with the -T10502-
-2- and the -T10145- -1- so that it is all around the brake
caliper.

n AG. Volkswagen AG do
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ce
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nl

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ab
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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mercia

at
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ion
c

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or

his
ate

do
priv

cu
for
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n
n

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Cop o
t. g
gh
pyri Vo
co lksw
by
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Prote AG.

2. Rear Brake Caliper 65

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

3 Brake Booster/Brake Master Cylin‐

der
⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”,
page 66
⇒ “3.2 Brake Lamp Switch, Removing and Installing”, page 68
⇒ “3.4 Brake Master Cylinder, Removing and Installing”,
page 73
⇒ “3.3 Brake Booster, Removing and Installing”, page 69

3.1 Overview - Brake Booster/Brake Master

Cylinder
⇒ “3.1.1 Overview - Brake Booster/Brake Master Cylinder”, page
66

3.1.1 Overview - Brake Booster/Brake Master

Cylinder lksw
agen
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Only use new brake fluid conforming to VW standard (VW 501

un

pt
an
d

14).
itte

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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness of i
cial p

nfo
mer

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om

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or c

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at
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pr

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ng

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copy Vo
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cted agen
Prote AG.

66 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

1 - Self-Locking Hex Nut

❑ 25 Nm
❑ Tightening sequence.
Refer to
⇒ Fig. ““Tightening Se‐
quence:”“ , page 68 .
❑ Replace after removing.
2 - Mounting Bracket/Pedal
Assembly
3 - Bulkhead
4 - Self-Locking Hex Nut
❑ 23 Nm
❑ Replace after removing.
5 - Brake Master Cylinder
❑ Cannot be serviced. Re‐
place as a complete unit
if malfunctioning.
❑ Removing and instal‐

cardiagn.com
ling. Refer to
⇒ “3.4.1 Brake Master
Cylinder, Removing and
Installing”, page 73 .
6 - Brake Lamp Switch - F-
❑ Removing and instal‐
ling. Refer to
⇒ “3.2.1 Brake Lamp
Switch, Removing and
Installing”, page 68 .
olkswagen AG
en AG. V
7 - Bolt olks
wag does
not
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❑ 8 Nmise
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8 - Brake
au Line
t ra
c
ss
❑ With standard tool: 14
ce
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nl

pt

Nm
du

an
itte

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❑ With special tools Mini Torque Wrench - VAS6854- , Torque Wrench - Universal Joint - VAG1410/7- and
erm

ab

Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm

ility
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wit

❑ Brake master cylinder/secondary piston circuit to hydraulic unit

, is n

h re
hole

9 - Brake Line
spec
es, in part or in w

❑ With standard tool: 14 Nm

t to the co

❑ With special tools Mini Torque Wrench - VAS6854- , Torque Wrench - Universal Joint - VAG1410/7- and
Open Ring Spanner Insert - AF 11mm - VAG1410/6- : 12 Nm
rrectness of i

❑ Brake master cylinder/primary piston circuit to hydraulic unit

l purpos

10 - Plugs
❑ Coat with brake fluid and press into brake fluid reservoir
nf
ercia

11 - Brake Fluid Level Warning Switch - F34-

rm
m

atio
m

12 - Brake Fluid Reservoir

o

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❑ Bolt: 8 Nm
th
e

i
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sd
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13 - Vacuum Hose
oc
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❑ With check valve

f
ng

yi
❑ Insert in the brake booster op o
t. C
gh g
❑ On some vehicles with a gasoline engine, the Vacuum Sensor - G608- is installed. Refer to
pyri Vo
⇒ “4.3 Vacuum Sensor G608 , Removing and Installing”, page 79 .
co lksw
by
cted agen
Prote AG.

3. Brake Booster/Brake Master Cylinder 67

 Atlas 2017 ➤ , Atlas 2020 ➤ AG. Volkswagen AG d
Brake System - Edition agen
ksw 06.2020
oes
ol not
V gu
by ara
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14 - Cap oris eo
th
au ra
c
15 - Seal ss

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❑ Vacuum hose/brake booster

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itte

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16 - Seal
erm

ab
ility
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❑ Brake master cylinder/brake booster

wit
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h re
17 - Brake Booster
hole

spec
❑ Function Test:
es, in part or in w

t to the co
– With the engine switched off, press the brake pedal firmly several times (to reduce the vacuum in the
device).

rrectness of i
– Hold the brake pedal with average foot pressure and start the engine. If the brake booster is working
properly, the brake pedal will be felt to give noticeably under foot (booster becomes effective).
l purpos

❑ Replace completely if there are malfunctions (check the brake booster vacuum system first; refer to
⇒ “4.4 Vacuum System, Checking”, page 79 .)

nf
ercia

or
❑ Removing and installing. Refer to ⇒ “3.3.1 Brake Booster, Removing and Installing”, page 69 .

m
m

atio
m

18 - Gasket
o

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❑ Always replace

th
e

i
t

sd
iva

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❑ Bonded, only at the factory

oc
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❑ The bonding on the brake booster and bulkhead must not be replaced
f
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Cop o
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py
Tightening Sequence:
co Vo
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cted agen
Prote AG.

3.2 Brake Lamp Switch, Removing and In‐

stalling
⇒ “3.2.1 Brake Lamp Switch, Removing and Installing”,
page 68

3.2.1 Brake Lamp Switch, Removing and In‐

stalling
Removing
– Remove the air duct hose from the air filter housing.

68 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Disconnect the connector -2- from the Brake Lamp Switch - F-

-1-.
– Remove the bolt -3-.
– Remove the lower Brake Lamp Switch - F- -1- from the brake
master cylinder.
Installing
Install in reverse order of removal. Note the following:

– Pay attention that the Brake Lamp Switch - F- -1- is positioned n AG. Volkswagen AG do
wage

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correctly on the edge -arrow- of the brake master cylinder.
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Tightening Specification oris tee
th or
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♦ Refer to ss
⇒ “3.1.1 Overview - Brake Booster/Brake Master Cylinder”,

ce
le
un

pt
page 66

an
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es, in part or in w

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rrectness of i
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mercia

3.3 Brake Booster, Removing and Installing

a
com

tion in
r

⇒ “3.3.1 Brake Booster, Removing and Installing”, page 69

te o

thi
s
iva

do

3.3.1 Brake Booster, Removing and Installing

r
rp

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n
n

Special tools and workshop equipment required

yi
Cop o
t.
♦ Brake Charger/Bleeder Unit - VAS5234-
gh g
pyri Vo
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by
♦ Torque Wrench 1331 5-50Nm - VAG1331- cted agen
Prote AG.

♦ Sealing Tool - T10249-

♦ Hot air gun, for example Wiring Harness Repair Set - Hot Air
Blower - VAS1978/14A- .

Note

First check the brake booster vacuum system in case of com‐

plaints regarding the brake booster. Refer to
⇒ “4.4 Vacuum System, Checking”, page 79 .

3. Brake Booster/Brake Master Cylinder 69

 n AG. Volkswagen AG do
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Atlas 2017 ➤ , Atlas 2020 ➤ ho
ir se tee
t or
Brake System - Edition 06.2020 au ac
ss

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Removing

pt
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d
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– On vehicles with a coded radio, note the code. Retrieve it if

rm

ab
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necessary.

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– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

h re
hole
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .

spec
es, in part or in w
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.

t to the co
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the engine cover.

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– Loosen the hose clamp -2- and remove the air guide hose and

l purpos
air filter housing. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .

nform
mercia

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cted
– Remove the battery tray. Refer to ⇒ Electrical Equipment;
agen
Prote AG.
Rep. Gr. 27 ; Battery; Battery, Removing and Installing .
– Place enough lint-free cloths near the engine and transmis‐
sion.

– Extract as much brake fluid as possible from the brake fluid

reservoir with the -VAS5234- .

70 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

For Vehicles with Manual Transmission:

– Remove the clutch slave cylinder return hose -1-, close using
the -T10249- tie up or using a commercially available tool,
disconnect and remove the clutch slave cylinder return hose
-1-.

AG. Volkswagen AG d
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Continuation for All Vehicles: du

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– Remove the connectors from the -3- Brake Fluid Level Warn‐

ility
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ing Switch - F34- ,if equipped from the -2- Vacuum Sensor -

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G608- and from the -1- Brake Lamp Switch - F- .

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spec
– Reduce the vacuum in the brake booster by pressing the brake
es, in part or in w

pedal repeatedly.

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rrectness of i
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– Pull the vacuum hose -1- from the brake booster -2-.
m

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om

– Remove the brake lines on the brake master cylinder and seal

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c

the holes using the Plugs - 1H0 698 311 A- .

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ate

– Place the dust caps for the bleeder valves on the brake lines.

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For Vehicles with 7-Speed Dual Clutch Transmission:

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– Remove the selector lever cable and cable bracket from the
o
t. C
transmission. Refer to ⇒ Rep. Gr. 34 ; Selector Mechanism; gh g
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Overview - Selector Mechanism . cop Vo
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Prote AG.
Continuation for All Vehicles:
– Remove the driver side instrument panel side cover. Refer to
⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument
Panel Side Cover, Removing and Installing .
– Remove the footwell cover on the driver side. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Storage Compartments and Covers .
– Remove the driver side footwell trim center console panel.
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Front
Footwell Center Console Trim Panel, Removing and Instal‐
ling .
– Remove the driver side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
ers .
– Remove the driver side instrument panel cover. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
ers; Driver Side Instrument Panel Cover, Removing and In‐
stalling .

3. Brake Booster/Brake Master Cylinder 71

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Remove the knee airbag -1-. Refer to ⇒ Body Interior; Rep.

Gr. 69 ; Knee Airbags; Overview - Knee Airbag .

– Remove the driver side footwell vent. Refer to ⇒ Heating,

Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Duct; Over‐
view - Air Routing and Air Distribution in Vehicle Interior .
– Disconnect the brake pedal from the brake booster. Refer to
⇒ “4.3 Brake Pedal, Disconnecting from Brake Booster”, page
54 .

cardiagn.com
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Prote AG.

72 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020
olkswagen AG
en AG. V
– Remove the nuts -3 and
olk4-
swafrom the brake booster.
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no
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by a
– Pull the brake booster
ris
ed off of the bonded seal of the bulkhead.
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te
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– Carefully remove
ss
a the brake booster from the vehicle. ra
c

ce
le
– Remove the nuts for the brake master cylinder.
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– Remove any heat shield.
rm

ab
pe

ility
– Carefully remove the brake master cylinder from the brake
ot

wit
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booster.

h re
hole

Installing

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ The brake booster is also bonded with the seal at the factory
only.
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♦ The bonding on the brake booster and bulkhead must not be

replaced, but replace the seal.

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– Remove any bonded joint residue from the brake booster and

ion in

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the bulkhead.
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thi
s
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– Using a hot air gun, warm the adhesive residue at a low setting

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and remove it.
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– Clean the surfaces thoroughly.

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– Replace the gasket.
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– Install in reverse order of removal. Prote
cted agen
AG.

Note the following points when installing:

– Attach the brake pedal to the brake booster. Refer to
⇒ “4.4 Brake Pedal, Attaching to Brake Booster”, page 54 .
– After installing, bleed the brake system (refer to
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 88 ) and
the clutch.
Tightening Specifications
♦ Refer to
⇒ “3.1.1 Overview - Brake Booster/Brake Master Cylinder”,
page 66
♦ Footwell Vent. Refer to ⇒ Heating, Ventilation and Air Condi‐
tioning; Rep. Gr. 87 ; Air Duct; Overview - Air Routing and Air
Distribution in Vehicle Interior .
♦ Knee Airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee
Airbags; Overview - Knee Airbag
♦ Driver Side Covers. Refer to ⇒ Body Interior; Rep. Gr. 68 ;
Storage Compartments and Covers; Component Location
Overview - Storage Compartment and Covers .

3.4 Brake Master Cylinder, Removing and

Installing
⇒ “3.4.1 Brake Master Cylinder, Removing and Installing”,
page 73

3.4.1 Brake Master Cylinder, Removing and

Installing
Special tools and workshop equipment required

3. Brake Booster/Brake Master Cylinder 73

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Brake Charger/Bleeder Unit - VAS5234-

♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Sealing Tool - T10249-
Removing
– On vehicles with a coded radio, note the code. Retrieve it if
necessary.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the engine cover.
– Remove the air duct -1- from the lock carrier.

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erm

– Loosen the hose clamp -1- and remove the air duct hose and ab
ility
ot p

air filter housing. Refer to ⇒ 6-Cylinder Direct Injection (3.6L wit

is n

Engine, 4V); Rep. Gr. 24 ; Air Filter; Air Filter Housing, Re‐ h re
ole,

moving and Installing .

spec
urposes, in part or in wh

t to the co
rrectness of i
cial p

nfo
mer

rmatio

– Remove the battery tray. Refer to ⇒ Electrical Equipment;

om

n in

Rep. Gr. 27 ; Battery; Battery, Removing and Installing .

or c

th
e

is d
t

– Place enough lint-free cloths near the engine and transmis‐

iva

oc
r

sion.
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Prote AG.

74 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Extract as much brake fluid as possible from the brake fluid

reservoir with the -VAS5234- .
For Vehicles with Manual Transmission:

– Remove the clutch slave cylinder return hose -1-, close using

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the -T10249- tie up or using a commercially available tool,
disconnect and remove the clutch slave cylinder return hose
AG. Volkswagen AG d
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Continuation for All Vehicles: edb ran
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spec
– Remove the connectors from the -3- Brake Fluid Level Warn‐
urposes, in part or in wh

ing Switch - F34- ,if equipped from the -2- Vacuum Sensor -
G608- and from the -1- Brake Lamp Switch - F- . t to the co
rrectness of i
cial p

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– Remove the TORX® bolt -1- and pull the brake fluid reservoir
r
fo
ng

-2- from the sealing plugs. op

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Prote AG.

3. Brake Booster/Brake Master Cylinder 75

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Remove the brake lines -1- on the brake master cylinder and
seal the holes using the Plugs - 1H0 698 311 A- .
– Place the dust caps for the bleeder valves on the brake lines.
– Remove the nuts -2- from the brake master cylinder.
– Remove the heat shield, if equipped.
– Carefully take the brake master cylinder out of the brake boos‐
ter.
– Remove the Brake Lamp Switch - F- from the brake master
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– Install in reverse order of removal.
ss
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Note the following points when installing:

nl

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– When assembling the brake master cylinder with the brake
erm

ab
booster, make sure that the pushrod is correctly seated in the

ility
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brake master cylinder.

wit
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h re
The seals must be located in the return hose for the clutch master
hole

spec
cylinder.

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es, in part or in w

t to the co
– Bleed the brake system. Refer to
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 88 .
Tightening Specifications

rrectness of i
♦ Refer to
l purpos

⇒ “3.1.1 Overview - Brake Booster/Brake Master Cylinder”,

page 66

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76 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4 Vacuum System
⇒ “4.1 Overview - Vacuum Pump”, page 77
⇒ “4.2 Check Valve, Checking”, page 78
⇒ “4.3 Vacuum Sensor G608 , Removing and Installing”,
page 79
⇒ “4.4 Vacuum System, Checking”, page 79
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⇒ “4.1.1 Brake Booster Vacuum Pump, 3.6L
ris Gasoline
e Engine”, nte
page 77 tho eo
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⇒ “4.1.2 Brake Booster Vacuum Pump, 2.0L Gasoline Engine”,

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page 77

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4.1.1 Brake Booster Vacuum Pump, 3.6L

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Gasoline Engine
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Must not be disassembled.

spec
es, in part or in w

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A - Vacuum Hose to Brake Booster with Check Valve

t to the co
B - Vacuum Pump

rrectness of i
– Vacuum pump, removing and installing. Refer to ⇒ Rep. Gr.
15 ; Cylinder Head; Vacuum Pump, Removing and Installing .
l purpos

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tion in
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4.1.2 Brake Booster Vacuum Pump, 2.0L Gasoline Engine
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4. Vacuum System 77
 Atlas 2017 ➤ , Atlas 2020 ➤ agen
AG. Volkswagen AG d
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Brake System - Edition 06.2020 by Vol
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1 - Gasket auth
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❑ Replace after removing.

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nl

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2 - Vacuum Pump

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❑ Disassembling the vac‐

ility
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uum pump is not possi‐

wit
ble.

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h re
hole
❑ Removing and instal‐

spec
ling. Refer to ⇒ Rep.

es, in part or in w
Gr. 15 ; Cylinder Head;

t to the co
Vacuum Pump, Remov‐
ing and Installing .

rrectness of i
3 - Vacuum Hose
l purpos

❑ To the Brake Booster

4 - Bolts

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❑ Tightening specifica‐
m

tion. Refer to ⇒ Rep.

at
om

i
Gr. 15 ; Cylinder Head .

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4.2 Check Valve, Checking

Inspection Process
– Carefully remove the check valve with the vacuum line -1- from
the brake booster.
– Blow some air first in one then in the other direction through
the check valve -1-.
• The check valve -1- must allow air through in direction of
-arrow-.
• The check valve -1- must remain locked in the opposite direc‐
tion of the -arrow-. If this is not the case, replace the check
valve or the complete vacuum line.

Note

Pay attention when installing that the vacuum line with the check
valve is on correct installation position on the brake booster.

78 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4.3 Vacuum Sensor - G608- , Removing

and Installing

Note

The Vacuum Sensor - G608- is only installed on some gasoline

engines.

Removing
– Disconnect the connector -3- from the Vacuum Sensor - G608-
-1-.
– Unclip the Vacuum Sensor - G608- -1- from the vacuum line
-2-.
Installing
Install in reverse order of removal. Note the following:
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♦ Pay attention
ss a that before installing the Vacuum Sensor - G608- c
is checked for leaks and damage. ce
le
un

pt
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d

♦ Replace the vacuum sensor if the seal is damaged.

itte

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ab
ility
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wit
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ole,

spec
urposes, in part or in wh

4.4 Vacuum System, Checking

t to the co

⇒ “4.4.1 Brake Servo Tester VAS6721 , Connecting”,

page 80
rrectness of i

⇒ “4.4.2 Vacuum, Checking”, page 80

⇒ “4.4.3 Leak Test”, page 81
cial p

⇒ “4.4.4 Vacuum, Creating with Hand Vacuum Pump VAS6213 ”,

fo
mer

page 83
rmatio
om

n in
c

Special tools and workshop equipment required

or

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at

♦ Brake Servo Tester - VAS6721-

iv

oc
pr

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The following checks will be helpful when performing fault finding

ng

if there are complaints regarding the brake booster or the so-

yi
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called »hard brake pedal«. t. C
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The following components are included in the check:
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♦ Brake Booster
♦ Gasket between the brake master cylinder and the brake
booster
♦ Check Valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if equipped)
Keep the geographical surrounding in mind when evaluating the
measurement results. The higher above sea level, the lower the
air pressure.
Always observe all test requirements before checking the vacuum
system:

4. Vacuum System 79
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Visually inspect all of the vacuum hoses for damage (for ex‐
ample, tears or damage caused by animals) and secure fit
♦ Maintain clean working conditions when working on the vac‐
uum system
♦ Clean the engine compartment before starting work, if neces‐
sary

4.4.1 Brake Servo Tester - VAS6721- , Con‐

necting
Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAS6213-
♦ Brake Servo Tester - VAS6721-
– Remove the vacuum hose from the brake booster.
Pressing the brake pedal a few times beforehand makes it easier
to remove the vacuum hose.
– Connect the -VAS6721- -see following illustrations-.
Item Com‐ Explanation

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num‐ po‐
ber nent
A Shut- In the direction gtoward
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off check valve l wa evacuum pump (if dequipped)
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B Shut- ♦uth Opening makes the -VAS6721- removal eas‐
o eo
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off s s a
ier. c
valve
ce
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un

♦ Open to simulate a malfunction source

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♦ Connect the -VAS6213- .

erm

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ility
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wit

C Shut- In the direction toward the brake booster

is n

h re

off
ole,

valve
spec
urposes, in part or in wh

t to the co

– Connect the -VAS6721- hose -A- to the vacuum hose and

rrectness of i

push the adapter -C- into the brake booster.

cial p

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om

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4.4.2 Vacuum, Checking
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Special tools and workshop equipment required
AG.

♦ Brake Servo Tester - VAS6721-

♦ Hand Vacuum Pump - VAS6213-

80 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
n AG. Volkswagen AG do
lkswage es n Brake System - Edition 06.2020
o ot g
byV ua
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ir se tee
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Note au ac
ss

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nl

pt
♦ The average earth atmospheric air pressure at sea level (N.

du

an
itte
N.) is 1013 mbar (14.69 psi) and it decreases dramatically at

y li
erm

ab
higher altitudes (approximately 100 mbar (1.45 psi) every

ility
ot p
1000 meters higher) Local and time fluctuations also influence

wit
, is n

the vacuum.

h re
hole

♦ A cold engine, the A/C switched on as well as the engine sim‐

spec
ply idling can negatively influence the vacuum.
es, in part or in w

t to the co
– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damage caused by animals) and secure fit.

rrectness of i
– Connect the -VAS6721- . Refer to
l purpos

⇒ “4.4.1 Brake Servo Tester VAS6721 , Connecting”,

page 80 .

nf
ercia

o
– Open the shut-off valve -A-.

rm
m

atio
m

– Close the shut-off valves -B and C-.

o

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– Start the warm (above 60 °C (140 °F)) engine and press the

th
e

i
t

sd

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a

accelerator pedal once briefly (engine speed higher than

iv

oc
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2,000 RPM).

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ng

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– Read the displayed measured value.
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Normally (see note), the vacuum should be between 600 and 950
gh g
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mbar (8.7 and 13.77 psi) (depending on the engine installed).
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Check the vacuum system for leaks if the measured value is not
reached, even though all requirements (see notes) are met.
– Create a vacuum using the -VAS6213- for comparison. Refer
to
⇒ “4.4.4 Vacuum, Creating with Hand Vacuum Pump
VAS6213 ”, page 83 .
Opening the shut-off valve -B- makes it easier to remove the hose
connections and the adapter.

4.4.3 Leak Test

Special tools and workshop equipment required
♦ Brake Servo Tester - VAS6721-

Note

♦ The average earth atmospheric air pressure at sea level (N.

N.) is 1013 mbar (14.69 psi) and it decreases dramatically at
higher altitudes (approximately 100 mbar (1.45 psi) every
1000 meters higher) Local and time fluctuations also influence
the vacuum.
♦ A cold engine, the A/C switched on as well as the engine sim‐
ply idling can negatively influence the vacuum.

– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damage caused by animals) and secure fit.
– Connect the -VAS6721- . Refer to
⇒ “4.4.1 Brake Servo Tester VAS6721 , Connecting”,
page 80 .
– Open the shut-off valve -A-.

4. Vacuum System 81
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Close the shut-off valves -B and C-.

– Start the warm (above 60 °C (140 °F)) engine and press the
accelerator pedal once briefly (engine speed higher than
2,000 RPM).
Normally (see note), the vacuum should be between 600 and 950
mbar (8.7 and 13.77 psi) (depending on the engine installed).

– Open the shut-off valve -C- to evacuate the brake booster.

– Turn off the engine.
– Read the displayed measured value and write it down.
The vacuum may drop 400 mbar (5.8 psi) within 12 hours.
If the drop in vacuum is greater, check for leaks in the area of
the....

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2- Check Valve, the Vacuum Hoses with Connectors
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are present.

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The vacuum will drop considerably within a few seconds if there

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are large leaks.

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Vacuum, Checking near Brake Booster:

h re
ole,

spec
urposes, in part or in wh

– Close the shut-off valve -A- after creating the vacuum to test

t to the co
the brake booster vacuum.
Vacuum, Checking near Check Valve, Vacuum Hoses with Con‐
rrectness of i
nectors and Vacuum Pump/Intake Manifold
cial p

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– Close the shut-off valve -C- after creating the vacuum to check
ng

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Opening the shut-off valve -B- makes it easier to remove the hose by c lksw
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connections and the adapter.
Prote AG.

82 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

4.4.4 Vacuum, Creating with Hand Vacuum

Pump - VAS6213-
Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAS6213-
♦ Brake Servo Tester - VAS6721-
In certain situations, the vacuum can also be created using the -
VAS6213- instead of using the engine or a vacuum pump.
– To do so, connect the -VAS6213- to the vacuum hose of the
connection -B- on the -VAS6721- .
– Open the shut-off valve -B-.
– Create the vacuum using the -VAS6213- until a vacuum be‐
tween 600 and 950 mbar (8.7 and 13.77 psi) is displayed on
the -VAS6721- .
– Then perform the relevant tests.

cardiagn.com
AG. Volkswagen AG d
agen oes
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es, in part or in w

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Prote AG.

4. Vacuum System 83
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

5 Brake Lines
⇒ “5.1 Brake Lines, Repairing”, page 84

5.1 Brake Lines, Repairing

⇒ “5.1.1 Overview - Flanging Tool”, page 84
⇒ “5.1.2 Flanging Tool, Instructions”, page 85

5.1.1 Overview - Flanging Tool

Special tools and workshop equipment required
♦ Brake Line Tool Kit - VAS6056-
♦ Brake Charger/Bleeder Unit - VAS5234-
Flare the brake lines with 5 mm outer diameter using the -
VAS6056- without damaging the coating. This allows for partial
sections of the brake lines to be inexpensively replaced in certain
cases.

cardiagn.com
Note

♦ Brake lines must not be bent more than 90°, otherwise they
kink or deform causes unacceptable constriction in the wire
cross-section.
♦ Disconnect the brake lines preferably at the underbody.
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♦ The position of intermediate pieces should be selected so kthat
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they cannot rub against moving parts. ed
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♦ Do not lubricate the spindle, clean only with mineral
au
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List of Individual Tools:

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es, in part or in w

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tion in
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84 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

1 - -VAS6056/1- gen AG
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❑ The -VAS6056/6- yV
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VAS6056/1-
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2 - -VAS6056/2-
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3 - -VAS6056/3-

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❑ The threaded pins (in

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set and must not be ad‐
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spec
4 - -VAS6056/4-
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t to the co
5 - -VAS6056/5-
6 - 6 mm Offset Screwdriver

rrectness of i
7 - -VAS6056/6- or -
l purpos

VAS6056/7-
❑ -VAS6056/6- for black

nform
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brake lines
❑ -VAS6056/7- for green
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brake lines

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stalled toward spindle, otherwise
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the flared head will not be formed
AG.

correctly.

5.1.2 Flanging Tool, Instructions

– Remove the affected brake line from the brake caliper or brake
cylinder. Be sure to catch any leaking brake fluid and dispose
of it correctly.
– Cut the brake line at a suitable place (straight, easily accessi‐
ble piece) with the pipe cutter -2-.
– Remove the piece to be exchanged.
– Grease the brake line surface.

5. Brake Lines 85
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Clamp the brake line in the locking pliers -4- so that approxi‐ wagen AG. Volkswagen AG doe
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– Remove the locking pliers and push the pipe fitting -D- onto
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The brake line must contact the stop when tightening the hex
socket bolts, otherwise the flanged head will not be formed cor‐
rectly.

– Clamp the brake line in the flaring tool until it cannot be moved
any more. Fold the stop -A- up and tighten the hex socket bolts
diagonally with the offset screwdriver -C-.

– Turn the spindle all the way in the flanging tool.

– Turn the spindle back.
– Loosen the hex socket bolts diagonally.
– Remove the brake line from the flanging tool, clean and check
the brake line and flared head.
Briefly rinse the part of the brake line remaining in the vehicle:
– Connect the -VAS5234- , place the bleeder bottle hose on the
flared head of the brake line and run the -VAS5234- briefly until
some brake fluid runs through.
– Clean the new brake line to be inserted with compressed air.

86 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

– Join the brake lines with the connecting piece -E-.

– Assemble the brake line.
– Bleed the brake system. Refer to
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 88 .

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5. Brake Lines 87
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⇒ “6.1 Brake Fluid General Information”, page 88
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⇒ “6.3 Hydraulic System, Post-Bleeding”, page 89
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⇒ “6.1.2 Brake Fluid, Changing”, page 88

6.1.1 Brake Fluid General Information

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♦ Rinse any spilled brake fluid with plenty of water.

6.1.2 Brake Fluid, Changing

Refer to ⇒ Maintenance ; Booklet 42.1 ; Procedure Descriptions;
Brake and Clutch System, Changing Brake Fluid .

6.2 Hydraulic System, Standard Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234-
♦ Brake Bleeding Tool Set - VAS6564-
♦ Brake Bleeding Tool Set - Insert Tool - VAS6564/9-

Note

♦ Bleeding the hydraulic system using the -VAS5234- is descri‐

bed.
♦ An initial pressure of 2 bar (29 psi) is required to bleed the ABS
Hydraulic Unit - N55- .

Perform the Following Procedures:

Note

Adhere strictly to the procedure when bleeding the brake system.

– Connect the -VAS5234-

– Open the bleeder valves in the specified sequence and bleed
the brake calipers.
1 - Left front brake caliper

88 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

2 - Right front brake caliper

3 - Left rear brake caliper
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6.3 Hydraulic System, Post-Bleeding
Special tools and workshop equipment required

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♦ Brake Charger/Bleeder Unit - VAS5234-
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– Open the bleeder valve on the brake caliper.
– Press the brake pedal down until it stops.
– Close the bleeder valve with the pedal depressed.
– Release the brake pedal slowly.

Note

This bleeding procedure must be performed five times per brake

caliper.

Bleeding sequence:
1 - Left front brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper

Note

A road test must be performed after bleeding. During this, at least

one ABS control must be performed!

6.4 Leak Test

Special tools and workshop equipment required
♦ Brake Pressure Gauge - VAG1310A-

6. Hydraulic System 89
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-

Test Requirement:
• Brake system (hydraulic unit, brake hoses, brake lines and
brake calipers) operating properly and free of leaks.
Perform the Following Procedures:
Checking
– Remove the bleeder valve at one of the front brake calipers.
– Connect the -VAG1310A- and bleed.
– Apply pressure to the brake pedal until the pressure gauge
indicates a pressure of 50 bar (725.18 psi). The pressure must
not drop more than 4 bar (58.01 psi) during the test period of
45 seconds. Replace the brake master cylinder if the pressure
decrease is too high.
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90 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

7 Special Tools
Special tools and workshop equipment required
♦ Piston Resetting Tool - T10145-

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♦ Sealing Tool - T10249-

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♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-

7. Special Tools 91
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Torque Wrench 1331 5-50Nm - VAG1331-

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♦ Brake Line Tool Kit - VAS6056-

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♦ Hand Vacuum Pump - VAS6213-

92 Rep. Gr.47 - Hydraulic Components

 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

♦ Brake Bleeding Tool Set - VAS6564-

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♦ Brake Bleeding Tool Set - Insert Tool - VAS6564/9-
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♦ Trim Removal Wedge - 3409-

♦ Not Illustrated:
♦ Hot air gun, for example Wiring Harness Repair Set - Hot Air
Blower - VAS1978/14A- .

7. Special Tools 93
 Atlas 2017 ➤ , Atlas 2020 ➤
Brake System - Edition 06.2020

8 Revision History
DRUCK NUMBER: K0059320721
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
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06.2 06/1 Fac‐ N/A Eric P.
020 8/20 tory
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08.2 04/2 Lo‐ N/A Basic edits Tom
019 3/20 cal Perry
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08.2 10/0 Fac‐ N/A Eric P.
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94 Rep. Gr.47 - Hydraulic Components

 Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair
work. You must answer that you have read and you understand these WARNINGS and
CAUTIONS before you will be allowed to view this information.

 If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual,
we suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially
urge you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be
covered wholly or in part by any of the extensive warranties issued by Volkswagen.

 Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

 Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
olkswpart
are made applicable to earlier models.agTherefore, agennumbers listed in this manual are for reference only.
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Always check with your authorized ol sw
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Any time the battery hasaubeen disconnected on an automatic transmission or vehicle, it will be necessary to
ac
ss Control Module (TCM) basic settings using the Volkswagen
reestablish Transmission Factory Approved Scan

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Tool (ST).

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 Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not

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support a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never

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work under a vehicle that is supported solely by a jack. Never work under the vehicle while the engine is
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running.
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 For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting
the battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock

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up and become inoperable, even if the correct code is used in a later attempt.

 If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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starting the vehicle while you are under it

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 Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you
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from being fully alert.

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 Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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 Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid.
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 Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work
near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery,
severe injury could result.

 Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners
with new parts where indicated, and any other time it is deemed necessary by inspection.

Page 1 of 3
© 2018 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without
notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0
 Cautions & Warnings
 Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the
vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can
ignite spilled fuel or oil.

 Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

 Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or
be crushed by heavy parts.

 Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.

 Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills
. Volkswagen AG
at once, but do not store the oily rags, wagen AG
which can ignite and dburn
oes spontaneously.
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Use pneumatic and electricthotools only to loosen threaded parts and fasteners.
eo Never use these tools to tighten
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fasteners, especially onsslight alloy parts. Always use a torque wrench to tightenc fasteners to the tightening

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torque listed.
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 Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.

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 Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose
hole

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of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local
es, in part or in w

ordinances that govern the disposal of wastes. t to the co

 The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should
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be serviced only by trained automotive service technicians using approved refrigerant recovery/recycling
l purpos

equipment, trained in related safety precautions, and familiar with regulations governing the discharging and
disposal of automotive chemical refrigerants.
nform
ercia

 Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
m

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om

negative terminal (ground strap) and the ABS control module connector.
ion
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 Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will
at

do
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increase system pressure and may cause the system to burst.

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 When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission . Cop o
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these ht g
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 Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.

Page 2 of 3
© 2018 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without
notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0
 Cautions & Warnings
 Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at
the battery with the boosting cables attached. Wait at least one minute before boosting the battery a second
time.

 Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the Volkswagen Factory Approved Scan Tool (ST) or an approved
equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.

 Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have
been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the
tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely
remove the tire from the rim before attempting any repair.

 When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings.

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Page 3 of 3
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© 2018 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without
notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0