Mecanica Skoda Fabia

Service 5
Workshop Manual
FABIA 2000 ³
Chassis
Edition 08.99
Service Department. Technical Information Printed in Czech Republic

S00.5303.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5303.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ Chassis
List of Supplements to Workshop Manual

FABIA 2000 ³
Chassis
Edition 08.99
Suppleme
Edition Subject Article Number
nt
08.99 Basic Edition S00.5303.00.20
1 12.99 Supplement to Basic Edition S00.5303.01.20
2 05.00 Axles, brakes, electrical inspection ABS, ABS/EDL/TCS S00.5303.02.20
3 07.00 Steering S00.5303.03.20
4 08.00 ABS, Brake mechanics, Brake hydraulics S00.5303.04.20
5 11.00 Repairing the front axle, repairing the wheel bearing S00.5303.05.20
6 01.01 Repairing front suspension strut, repairing drive shafts S00.5303.06.20
7 02.01 Removing and installing rear axle and coil spring S00.5303.07.20
8 03.01 Chassis with Brakes FS-II and C54-II S00.5303.08.20
9 08.01 ESP and Rep.-Gr. 48, solid nut (twelve point nut), brake- S00.5303.09.20
pressure reducer
10 11.01 Geometrical change S00.5303.10.20
11 03.02 Changes to the text in Rep. Gr. 00, 40, 42, 46 and 48 S00.5303.11.20
12 10.02 Brake pedal switch, control unit for the ABS (fault table, coding) S00.5303.12.20
13 02.03 1.2 ltr./47 kW Engine, Supplement to the text S00.5303.13.20
14 07.03 1.9 ltr./96 kW TDI PD Motor, 1.4 ltr./55 kW TDI PD Engine, S00.5303.14.20
Supplement to the text
15 04.04 Steering KOYO, Correction of the text, Updating of the steering S00.5303.15.20
coding
16 07.04 Supplement to Rep. Gr. 40, 44, 45, 46 and 47, ABS BOSCH 8.0 S00.5303.16.20
17 11.04 Supplement to Rep. - Gr. 45 and 48 TRW/KOYO steering S00.5303.17.20
18 04.05 Text adaptation, Supplement to the coding of ABS, TCS, ESP S00.5303.18.20
Edition 04.05 List of Supplements

S00.5303.18.20
List of Supplements Edition 04.05

S00.5303.18.20
Table of Contents
00 – Technical Data
Chassis ................................................................................................... 00-1 page 1
- Nominal values front axle ............................................................................ 00-1 page 1
- Nominal values rear axle ............................................................................. 00-1 page 2
- Vehicle data sticker and PR number ............................................................... 00-1 page 2
Steering ................................................................................................... 00-2 page 1
Brakes ..................................................................................................... 00-3 page 1
- Brake variants and their assignment ............................................................... 00-3 page 1
- Adjusting values for the load-dependent regulator ............................................... 00-3 page 5
- Pressure value of the distributor valve ............................................................. 00-3 page 5
- Brake fluid .............................................................................................. 00-3 page 5
Wheels, Tyres ........................................................................................... 00-4 page 1
- Possible wheel-tyre combinations .................................................................. 00-4 page 1
- Tyre legend ............................................................................................. 00-4 page 2
40 – Front wheel suspension

Repairing front axle .................................................................................... 40-1 page 1
- An overview of the front axle ........................................................................ 40-1 page 1
- I - Summary of components assembly carrier, console, axle link, anti-roll bar, coupling rod,
bracket, pendulum support ........................................................................... 40-1 page 2
- Inspecting the steering joint .......................................................................... 40-1 page 4
- Removing and installing the steering joint ......................................................... 40-1 page 4
- Release the assembly carrier and tighten (fix) .................................................... 40-1 page 6
- Removing and installing the track control arm .................................................... 40-1 page 8
- Removing and installing the console ............................................................... 40-1 page 10
- Disconnecting and assembling the track control arm and console ............................ 40-1 page 13
- Replacing the bonded rubber bush for track control arm ........................................ 40-1 page 13
- Replacing the bonded rubber bush for console - removal version 1 .......................... 40-1 page 13
- Replacing the bonded rubber bush for console - removal version 2 .......................... 40-1 page 15
- Removing and installing the anti-roll bar ........................................................... 40-1 page 17
- Removing and installing assembly carrier ......................................................... 40-1 page 19
Repairing front suspension strut ................................................................... 40-2 page 1
- II - Summary of components of suspension strut ................................................. 40-2 page 1
- Removing and installing the suspension strut .................................................... 40-2 page 2
- Repairing the suspension strut ...................................................................... 40-2 page 5
- Inspecting the shock absorber ...................................................................... 40-2 page 7
- Disposing of the shock absorber .................................................................... 40-2 page 8
Repairing the wheel bearing ......................................................................... 40-3 page 1
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FS-
III ......................................................................................................... 40-3 page 1
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FS-
II .......................................................................................................... 40-3 page 3
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake C54-
II .......................................................................................................... 40-3 page 5
- Removing and installing wheel bearing housing .................................................. 40-3 page 7
Edition 04.05 Table of Contents I

S00.5303.18.20
- Removing and installing the wheel hub with wheel bearing with the wheel-bearing housing
fitted ..................................................................................................... 40-3 page 10
Drive shafts with CV joints ........................................................................... 40-4 page 1
- Removing and installing a drive shaft .............................................................. 40-4 page 1
- Summary of components of drive shaft with CV joint ............................................ 40-4 page 2
- Repairing drive shaft with CV joint .................................................................. 40-4 page 5
- Inspecting a CV joint .................................................................................. 40-4 page 7
Drive shafts with tripod joint ........................................................................ 40-5 page 1
- Removing and installing a drive shaft .............................................................. 40-5 page 1
- V - Summary of components of drive shaft with AAR2000 tripod joint ........................ 40-5 page 1
- Inspecting outer CV joint ............................................................................. 40-5 page 3
- Repairing the drive shaft with AAR 2000 tripod joint ............................................. 40-5 page 3
- Removing and installing the outer CV joint ........................................................ 40-5 page 6
42 – Rear wheel suspension

Rear axle with drum brake ........................................................................... 42-1 page 1
- Summary of components of rear axle .............................................................. 42-1 page 1
- Removing and installing rear suspension ......................................................... 42-1 page 3
Servicing the rear axle with drum brakes ........................................................ 42-2 page 1
- Removing and installing coil spring ................................................................. 42-2 page 1
- Removing and installing shock absorber .......................................................... 42-2 page 2
- Disassembling and assembling shock absorber ................................................. 42-2 page 3
- Inspecting the shock absorber ...................................................................... 42-2 page 3
- Disposing of the shock absorber .................................................................... 42-2 page 3
- removing and installing rubber-metal bearing .................................................... 42-2 page 3
Rear suspension with disc brake ................................................................... 42-3 page 1
- Summary of components of rear suspension ..................................................... 42-3 page 1
- Removing and installing rear suspension ......................................................... 42-3 page 3
Servicing rear suspension with disc brake ...................................................... 42-4 page 1
Repairing the wheel bearing ......................................................................... 42-5 page 1
- Summary of components of wheel bearing - drum brake ....................................... 42-5 page 1
- Removing and installing the wheel hub with wheel bearing - drum brake .................... 42-5 page 1
- Summary of components of wheel bearing - disc brake ........................................ 42-5 page 4
- Removing and installing the wheel hub with wheel bearing - disc brake .................... 42-5 page 4
- Removing and installing axle studs ................................................................. 42-5 page 6
44 – Wheels, Tyres, Chassis Alignment

Wheels, Tyres ........................................................................................... 44-1 page 1
- General points ......................................................................................... 44-1 page 1
- Disc wheel .............................................................................................. 44-1 page 2
- Light-alloy wheel ....................................................................................... 44-1 page 3
Vehicle alignment ...................................................................................... 44-2 page 1
- General points ......................................................................................... 44-2 page 1
- Test requirements ..................................................................................... 44-2 page 2
- Measurement preliminaries .......................................................................... 44-2 page 3
- Chassis terms .......................................................................................... 44-2 page 4
- Nominal values for vehicle alignment .............................................................. 44-2 page 4
- Checking the transversal inclination of the vehicle ............................................... 44-2 page 4
Table of Contents Edition 04.05

II S00.5303.18.20
- Checking the camber on the front axle, if necessary take the mean .......................... 44-2 page 4
- Checking the camber on the rear axle ............................................................. 44-2 page 5
- Checking the track on the rear axle ................................................................ 44-2 page 5
- Checking the tracking on the front axle, adjusting if necessary ................................ 44-2 page 5
- Checking the left and right steering angle ......................................................... 44-2 page 6
- Calculation of the misalignment on the rear axle ................................................. 44-2 page 7
45 – Anti-Lock Brake System

Antilock braking system (ABS) ..................................................................... 45-1 page 1
- Safety precautions, basic information on fault finding and on repairing ...................... 45-1 page 1
- Instructions for repair work on Antilock braking system ........................................ 45-1 page 1
- Required technical information ...................................................................... 45-1 page 4
Distinguishing features of the ABS system ...................................................... 45-2 page 1
- General Instructions ................................................................................... 45-2 page 1
- Distinguishing features ............................................................................... 45-2 page 2
- Fitting position of the ABS systems BOSCH 5.7 and BOSCH 8.0 ............................. 45-2 page 3
Function of Self-diagnosis ........................................................................... 45-3 page 1
- General Instructions ................................................................................... 45-3 page 1
- Vehicle fitted with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 does not have an EDL
function .................................................................................................. 45-3 page 2
Vehicle diagnosis, measurement and information system -VAS 5051- .................... 45-4 page 1
- Connect vehicle diagnosis, measurement and information system -VAS 5051- and select
functions (ABS systems BOSCH 5.7 and BOSCH 8.0) ......................................... 45-4 page 1
Performing Self-diagnosis - ABS systems BOSCH 5.7 and BOSCH 8.0 ................... 45-5 page 1
- Connecting vehicle system tester -V.A.G 1552- and selecting function ...................... 45-5 page 1
- Interrogating control unit version .................................................................... 45-5 page 1
- Overview of selectable functions .................................................................... 45-5 page 2
- Interrogating fault memory ........................................................................... 45-5 page 2
- Erasing fault memory ................................................................................. 45-5 page 3
- Ending output .......................................................................................... 45-5 page 3
- Automatic test sequence ............................................................................. 45-5 page 4
Fault table - ABS systems BOSCH 5.7 ............................................................ 45-6 page 1
Fault table - ABS systems BOSCH 8.0 ............................................................ 45-7 page 1
Code control unit - ABS systems BOSCH 5.7 ................................................... 45-8 page 1
- Table of codes ......................................................................................... 45-8 page 1
Code control unit - ABS BOSCH 8.0 .............................................................. 45-9 page 1
- Table of codes ......................................................................................... 45-9 page 2
Reading measured value block - BOSCH 5.7 ................................................... 45-10 page 1
- Safety measures ....................................................................................... 45-10 page 1
- Test sequence and test tables with measured values ........................................... 45-10 page 1
Reading measured value block - BOSCH 8.0 .................................................... 45-11 page 1
- Safety measures ....................................................................................... 45-11 page 1
- Test sequence and test tables with measured values ........................................... 45-11 page 1
Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 ........................ 45-12 page 1
- Performing actuator diagnosis ....................................................................... 45-12 page 2
Basic setting - ABS systems BOSCH 5.7 ........................................................ 45-13 page 1
Edition 04.05 Table of Contents III

S00.5303.18.20
- Bleeding the hydraulic unit (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ................ 45-13 page 1
- Bleeding the hydraulic unit (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ................ 45-13 page 3
- Null balance of the steering angle sender -G85- ................................................. 45-13 page 4
- Perform ESP road and system test (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ...... 45-13 page 6
Basic setting - ABS systems BOSCH 8.0 ........................................................ 45-14 page 1
- Bleeding the hydraulic unit (vehicles with ABS/TCS/ESP BOSCH 8.0) ...................... 45-14 page 1
- Null balance of the steering angle sender -G85- (vehicles with ABS/TCS/ESP BOSCH 8.0) 45-14 page 3
- Perform ESP road and system test (vehicles with ABS/TCS/ESP BOSCH 8.0) ............ 45-14 page 5
Electrical Test - ABS systems BOSCH 5.7 ....................................................... 45-15 page 1
- Connecting test box -V.A.G 1598A- ................................................................ 45-15 page 1
- Multi-pin connector with contact assignment ...................................................... 45-15 page 1
- Overview of test steps ................................................................................ 45-15 page 3
- Test table ............................................................................................... 45-15 page 4
Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7
and BOSCH 8.0 ......................................................................................... 45-16 page 1
- Summary of components - Electrical/electronic components and fitting locations - ABS/ESP
systems BOSCH 5.7 .................................................................................. 45-16 page 1
- Summary of components - Electrical/electronic components and fitting locations - ABS/ESP
systems BOSCH 8.0 .................................................................................. 45-16 page 3
- Indication of faults by means of warning lights ................................................... 45-16 page 6
- Setting, removing and installing the brake light switch -F- ...................................... 45-16 page 8
- Removing and installing steering angle sender -G85- - vehicles with ABS/EDL/TCS/ESP
BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0 ....................................................... 45-16 page 10
- Removing and installing lateral acceleration sender -G200- and yaw rate sender -G202- or
ESP sensor unit -G419- - vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 or ABS/TCS/ESP
BOSCH 8.0 ............................................................................................. 45-16 page 13
Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo unit/Master brake
cylinder ................................................................................................... 45-17 page 1
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake
Cylinder ................................................................................................. 45-17 page 1
- Removing and installing the hydraulic control unit ............................................... 45-17 page 2
- Repairing the hydraulic control unit ABS or ABS/EDL/TCS BOSCH 5.7 ..................... 45-17 page 6
- Removing and installing brake pressure sender 1 -G201- - vehicles with ABS/EDL/TCS/
ESP BOSCH 5.7 ...................................................................................... 45-17 page 10
Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo unit/Master brake
cylinder ................................................................................................... 45-18 page 1
- Summary of Components of Hydraulic Control Unit Brake Servo Unit/Master Brake
Cylinder ................................................................................................. 45-18 page 1
- Removing and installing the hydraulic control unit ............................................... 45-18 page 3
- Removing and installing bracket for the hydraulic control unit ................................. 45-18 page 6
- Connecting the brake lines .......................................................................... 45-18 page 7
Removing and Installing Parts of the ABS System on the Front and Rear Axle ........ 45-19 page 1
- Removing and installing wheel speed sensor on the front axle - Vehicles with ABS systems
BOSCH 5.7 or BOSCH 8.0 .......................................................................... 45-19 page 1
- Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH
5.7 ....................................................................................................... 45-19 page 1
- Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH
8.0 ....................................................................................................... 45-19 page 4
- Sensor ring for ABS on the front and rear axle ................................................... 45-19 page 8

IV S00.5303.18.20
- Removing and installing wheel speed sensor on the rear axle ................................. 45-19 page 8
- Repairing rear wheel speed sensor cables - Vehicles with ABS systems BOSCH 5.7 and
BOSCH 8.0 ............................................................................................. 45-19 page 9
46 – Brakes, Brake mechanics

Repairing the front wheel brake .................................................................... 46-1 page 1
- Repairing front brake, the floating caliper disc brake FS-III ..................................... 46-1 page 1
- Removing and installing brake pads - Floating caliper disc brake FS-III ..................... 46-1 page 3
- Repairing front brake, the floating caliper disc brake FS-III ..................................... 46-1 page 6
- Removing and installing brake pads - Floating caliper disc brake FS-II ...................... 46-1 page 7
- Repairing the front brake - the floating caliper disc brake C54-II .............................. 46-1 page 10
- Removing and installing brake pads - the floating caliper disc brake C54-II ................. 46-1 page 12
Repairing a rear brake ................................................................................. 46-2 page 1
- Removing and installing rear brake - Drum brake ................................................ 46-2 page 1
- Resetting brake ........................................................................................ 46-2 page 3
- Repairing rear brake - drum brake .................................................................. 46-2 page 4
- Removing and installing brake shoe - Drum brake ............................................... 46-2 page 6
- Setting the hand-brake - drum brake ............................................................... 46-2 page 8
- Removing and installing rear brake - Disc brake ................................................. 46-2 page 9
- Removing and installing brake pads - Disc brake ................................................ 46-2 page 10
- Setting the hand-brake - disc brake ................................................................ 46-2 page 13
Handbrake ............................................................................................... 46-3 page 1
- Summary of components of hand brake ........................................................... 46-3 page 1
- Removing and installing the hand-brake cable ................................................... 46-3 page 2
Foot Controls, Brake Pedal .......................................................................... 46-4 page 1
- Summary of Components of Foot Controls, Brake Pedal ....................................... 46-4 page 1
- Separating the brake pedal from the brake servo unit and clipping onto brake servo unit . 46-4 page 2
- Removing and installing the foot controls .......................................................... 46-4 page 3
- Removing and installing brake pedal ............................................................... 46-4 page 4
47 – Brake, Brake Hydraulics

Repairing the brake caliper .......................................................................... 47-1 page 1
- Summary of Components of Brake Caliper FS-III ................................................ 47-1 page 1
- Removing and installing piston of brake caliper FS-III ........................................... 47-1 page 2
- Summary of Components of Brake Caliper FS-II ................................................. 47-1 page 4
- Removing and installing piston of brake caliper FS-II ........................................... 47-1 page 4
- Summary of components of brake caliper C54-II ................................................. 47-1 page 5
- Removing and installing piston of brake caliper C54-II .......................................... 47-1 page 5
- Summary of components of rear brake caliper ................................................... 47-1 page 6
- Removing and installing the rear brake caliper piston ........................................... 47-1 page 7
Brake Servo Unit, Master Brake Cylinder ......................................................... 47-2 page 1
- Summary of Components of Brake Servo Unit, Master Brake Cylinder ...................... 47-2 page 1
- Checking the master brake cylinder for tightness ................................................ 47-2 page 2
- Removing and installing the master brake cylinder .............................................. 47-2 page 3
- Removing and installing brake servo unit .......................................................... 47-2 page 5
- Removing and installing the vacuum pump for the brake servo unit .......................... 47-2 page 7
- Removing and installing tandem pump for fuel and vacuum supply .......................... 47-2 page 8
Brake-power regulator, brake-pressure reducer ................................................ 47-3 page 1
Edition 04.05 Table of Contents V

S00.5303.18.20
- Summary of Components of Brake-Power Regulator ........................................... 47-3 page 1

- Inspecting and adjusting the brake-power regulator ............................................. 47-3 page 2
- Removing and installing brake-power regulator .................................................. 47-3 page 3
- Inspecting the brake-pressure reducer ............................................................ 47-3 page 4
- Removing and installing the brake-pressure reducer ............................................ 47-3 page 5
Bleeding Brake System ............................................................................... 47-4 page 1
- Bleeding Brake System - vehicles without and with ABS, ABS/EDL/TCS or ABS/EDL/TCS/
ESP BOSCH 5.7 or ABS, ABS/TCS or ABS/ASR/ESP BOSCH 8.0 .......................... 47-4 page 1
- Bleeding the brake system of air using the brake filling and bleeding device, e. g.
-ROMESS S15- ........................................................................................ 47-4 page 2
- Bleeding the brake system of air without using the brake filling and bleeding device ...... 47-4 page 4
- Changing the brake fluid ............................................................................. 47-4 page 5
48 – Steering
Steering column ........................................................................................ 48-1 page 1
- Summary of components ............................................................................ 48-1 page 1
Inspecting steering column .......................................................................... 48-2 page 1
- Optical inspection ..................................................................................... 48-2 page 1
- Functional test ......................................................................................... 48-2 page 1
Removing and installing steering column ....................................................... 48-3 page 1
- Removing the steering column ...................................................................... 48-3 page 1
- Installing the steering column ....................................................................... 48-3 page 4
Removing and installing ignition lock housing ................................................. 48-4 page 1
- Removing ignition lock housing ..................................................................... 48-4 page 1
- Installing ignition lock housing ....................................................................... 48-4 page 1
Frequency link, bracket ............................................................................... 48-5 page 1
- Removing and installing frequency link ............................................................ 48-5 page 1
- Removing and installing bracket .................................................................... 48-5 page 1
Steering without servo unit (mechanical steering) ............................................. 48-6 page 1
- Summary of components ............................................................................ 48-6 page 1
Removing and installing mechanical steering gear ............................................ 48-7 page 1
- Removing steering gear .............................................................................. 48-7 page 1
- Installing steering gear ............................................................................... 48-7 page 4
Inspecting and adjusting mechanical steering gear ........................................... 48-8 page 1
- Check the centre position of the gear rack of the steering gear, if necessary adjust ....... 48-8 page 1
- Adjusting the steering gear (adjusting the pressure plate clearance) ......................... 48-8 page 1
Disassembling and assembling the steering gear ............................................. 48-9 page 1
Track rod ends, track rods ........................................................................... 48-10 page 1
- Play, correct attachment and joint boots ........................................................... 48-10 page 1
- Removing and installing track rod ends ............................................................ 48-10 page 1
- Removing and installing track rods ................................................................. 48-10 page 1
Power-assisted steering .............................................................................. 48-11 page 1
- Structure and function ................................................................................ 48-11 page 1
- Summary of components of power-assisted steering (TRW) .................................. 48-11 page 3
- Summary of components of power-assisted steering (KOYO) ................................. 48-11 page 5
- Summary of components of pressure line (hose) - power steering TRW or KOYO ........ 48-11 page 6
Removing and installing power-steering gear (TRW or KOYO) ............................. 48-12 page 1

VI S00.5303.18.20
- Removing the power-assisted steering drive ...................................................... 48-12 page 2

- Installing the power-assisted steering drive ....................................................... 48-12 page 6
Power-assisted steering sensor -G250- and the hydraulic line for power steering .... 48-13 page 1
- Check power-assisted steering sensor -G250- (TRW or KOYO) .............................. 48-13 page 1
- Remving and installing power-assisted steering sensor -G250- (TRW or KOYO) .......... 48-13 page 1
- Removing and installing hydraulic lines (TRW or KOYO) ....................................... 48-13 page 4
Inspecting and adjusting the power-steering gear ............................................. 48-14 page 1
- Check the centre position of the gear rack of the power-steering gear, if necessary adjust 48-14 page 1
- Adjusting the power-steering gear (adjusting the pressure plate clearance) ................. 48-14 page 1
Disassembling and assembling the power-assisted steering gear ........................ 48-15 page 1
- Disassembling and assembling the power-assisted steering gear (TRW) ................... 48-15 page 1
- Disassembling and assembling the power-assisted steering gear (KOYO) .................. 48-15 page 3
Track rod ends, track rods for power steering and mechanical steering ................. 48-16 page 1
- Inspecting play, correct attachment and boots of track rod ends .............................. 48-16 page 1
- Removing and installing track rod ends ............................................................ 48-16 page 1
- Removing and installing track rods ................................................................. 48-16 page 2
Disposing of the power-steering gear ............................................................. 48-17 page 1
Engine pump aggregate .............................................................................. 48-18 page 1
- Summary of components of engine pump aggregate (TRW) ................................... 48-18 page 1
- Summary of components of engine pump aggregate (KOYO) ................................. 48-18 page 3
Inspecting engine pump aggregate ................................................................ 48-19 page 1
- Testing function of the engine pump aggregate .................................................. 48-19 page 1
- Check the feed pressure of the engine pump aggregate ........................................ 48-19 page 2
Removing and installing as well as disposing of engine pump aggregate .............. 48-20 page 1
- Removing and installing engine pump aggregate (TRW) ....................................... 48-20 page 1
- Removing and installing engine pump aggregate (KOYO) ..................................... 48-20 page 5
- Disposing of the engine pump aggregate .......................................................... 48-20 page 10
Replace reservoir of engine pump aggregate ................................................... 48-21 page 1
- Replace reservoir of engine pump aggregate (TRW) ............................................ 48-21 page 1
- Replace reservoir of engine pump aggregate (KOYO) .......................................... 48-21 page 4
Checking hydraulic oil level ......................................................................... 48-22 page 1
- Inspecting hydraulic oil level, if necessary topping up ........................................... 48-22 page 1
Filling and bleeding the power steering system, and checking tightness ................ 48-23 page 1
- Filling and bleeding the power steering system .................................................. 48-23 page 1
- Checking the power steering system for leaks .................................................... 48-23 page 3
Power steering noises ................................................................................ 48-24 page 1
- Notes for eliminating the noises ..................................................................... 48-24 page 1
Self-diagnosis on the power-assisted steering system ...................................... 48-25 page 1
- Indication of faults by means of warning light for Servotronic -K92- ........................... 48-25 page 1
- Connect vehicle system tester -V.A.G 1552- or fault read-out scan tool -V.A.G 1551- and
select functions. ........................................................................................ 48-25 page 1
- Overview of the selectable functions on the Vehicle system tester -V.A.G 1552- ........... 48-25 page 2
- Interrogating and erasing fault memory ............................................................ 48-25 page 3
- Fault table .............................................................................................. 48-25 page 5
- Coding control unit .................................................................................... 48-25 page 8
- Reading measured value block ..................................................................... 48-25 page 9
Edition 04.05 Table of Contents VII

S00.5303.18.20
- Connect vehicle diagnosis, measurement and information system -VAS 5051- and select
functions ................................................................................................ 48-25 page 11
Electrical Test of Power Steering ................................................................... 48-26 page 1
Checking the data BUS ............................................................................... 48-27 page 1
- Operation ............................................................................................... 48-27 page 1
- Test condition .......................................................................................... 48-27 page 1
- Test sequence ......................................................................................... 48-27 page 1
Electric/Electronic components and fitting locations ......................................... 48-28 page 1

VIII S00.5303.18.20
FABIA 2000 ³ Chassis 00
00 – Technical Data
00-1 Chassis
Nominal values front axle

♦ Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for
the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
Spring strut type axle

Standard suspen- Sport chassis Rough road suspen-
sion sion
1GA, 1GG G04 1GB
Running gear/PR No. G01, G02, G05 G03, G06
Explanations concerning this PR No. ⇒ 00-1 page 2
Overall track -adjustable- 0°10' ± 10' 0°10' ± 10' 0°10' ± 10'
Toe difference angle on turns of 20° of in- - 1° 30' ± 20' 1) - 1° 32' ± 20' - 1° 28' ± 20' 1)
side wheel -not adjustable- - 55' ± 20' 2) --- - 53' ± 20' 2)
Toe difference angle on turns at full lock of 6° 50' 1) 6° 45' 6° 50' 1)
inside wheel -not adjustable- 4° 5' 2) --- 6° 50' 2)
39° 14' 1) 38° 37' 39° 34' 1)
Max. wheel lock angle -not adjustable-
36° 59' 2) --- 39° 34' 2)
-30' ± 30'4) -39' ± 30' -15' ± 30'
Camber 3)
-28' ± 30' 5)
Max. difference between left and right 30' 30' 30'
side
Caster angle -not adjustable- 4° 28' ± 30' 1) 4° 42' ± 30' 4° 14' ± 30' 1)
2° 55' ± 30' 2) --- 2° 42' ± 30' 2)
Max. difference between left and right 30' 30' 30'
side
1) with electro-hydraulic steering
2) with mechanical steering
3) It is possible to adjust the camber within the tolerance range by shifting the engine-gearbox assembly carrier with console. Note: Always
replace the screws and washers of the engine-gearbox assembly carrier! After carrying out corrections of steering geometry, inspect position of
steering wheel and alter to correct position, if necessary.
4) up to 09.00
5) from 10.00
Edition 04.05 Chassis 00-1 page 1

S00.5303.18.20
00 FABIA 2000 ³ Chassis
Nominal values rear axle

♦ Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for
the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
Twist-beam rear axle

Standard suspen- Sport chassis Rough road suspen-
sion sion
The allocation of the adjusting values to the relevant running gear
occurs via the PR No. of the front axle damping.
20' ± 10' 1) 26' ± 10' 15' ± 10' 1)
Overall track -not adjustable-
21' ± 10' 2) --- 16' ± 10' 2)
-1° 25' ± 10' 3) -1° 33' ± 10' 4) -1° 25' ± 10' 3)
Camber -not adjustable-
-1° 33' ± 10'5) 4) -1° 30' ± 10' 6) -1° 33' ± 10'5) 4)
-1° 30' ± 10' 6) -1° 30' ± 10' 6)
Max. difference between left and 30' 30' 30'
right side
Max. misalignment of the rear axle 20' 20' 20'
1) up to 05.01
2) from 06.01
3) up to 12.02
4) up to 08.03
5) as of 01.03
6) from 09.03
Vehicle data sticker and PR number

Different running gears are fitted depending on the en-
gine type and equipment. These running gears are iden-
tified by PR numbers.
The PR number for the front axle on the vehicle data
sticker indicates which type of running gear has been fit-
ted.
The vehicle data sticker is located on the floor panel of
the boot and in the Service Schedule.
Example of a vehicle data sticker
In this example the vehicle is fitted with a standard damp-
ing running gear 1GA -arrow-.
These PR numbers are required to determine the nomi-
nal values for the vehicle.
S00-0151
00-1 page 2 Chassis Edition 04.05

S00.5303.18.20
00-2 Steering
Steering system: electro-hydraulic mechanical
(Electrically Powered Hydraulic
Steering - EPHS)
Steering gear: Rack pinion (input shaft) Zahnstange - Ritzel (Eingangswelle)
Rack pinion (input shaft)
Steering-wheel turns from turning an- 2,91 4,04
gle to the next:
Steering wheel diameter (mm): 370 370
Grease denomination for gear rack: TMS-L-10.482 1) SHELL STERAK
A0F 063 000 04 2)
Grease amount for gear rack in 11,0 +5,0 40,0
steering gear (g):
maximum clearance between pres- 0...0,08 0,04...0,09
sure plate and cover (mm):
authorised axial force for the dis- Displacement of the gear rack ---
placement of the gear rack (N):
♦ ± 40 mm: Axial force ≤ 200 N
♦ over 40 mm up to the stop: Axial
force ≤ 250 N
(Displacement speed 1 cm/s)
Pinion torque (Nm): --- ♦ Steering-wheel angle ±180°: Pin-
ion torque = 0.8...1.3 Nm
♦ Steering-wheel angle over 180°
up to the stop: Pinion torque
= 0.8...1.6 Nm
Rotating force of the steering tie rods 1,0...3,5 3) 1,0...3,5 3)
from rest position (N):
Denomination of the hydraulic oil: PENTOSIN CHF 11S ---
N 052 146 00
TL 52 146
or
PENTOSIN CHF 202
N 052 146 01
TL 52 146
Hydraulic oil amount (l): 0,80 ---
1) applies for TRW steering
2) applies for KOYO steering
3) after 2 rotations
Edition 04.04 Steering 00-2 page 1

S00.5303.15.20
00-2 page 2 Steering Edition 04.04

S00.5303.15.20
00-3 Brakes
Brake variants and their assignment
Engine litre/ 1,0/37 1,2/40 1,2/47

kW
Engine code letters: ARV, AQV AWY, BMD AZQ,BME
S = Manual gearbox
S - S - S - S -
A = Automatic gearbox
Master brake cylinder - ∅ mm 20,64
Brake booster - ∅ Inch Left-hand drive with and without ABS: 8,5
Right-hand drive with and without ABS: 8,5
♦ Front disc brake:
Front brake caliper (type denomination) FS-II FS-III FS-II FS-III
Front brake caliper, piston - ∅ mm 48,0 54,0 48,0 54,0
Front brake disc - ∅ mm 239,0 256,0 239,0 256,0
Brake disc - average effective di- mm 193,8 208,0 193,8 208,0
ameter
Brake disc, thickness mm 18,0 22,0 18,0 22,0
Brake disc, minimum thickness mm 15,0 19,0 15,0 19,0
Pad thickness with supporting mm 17,6 19,6 17,6 19,6
plate
Minimum thickness without sup- mm 2,0 2,0 2,0 2,0
porting plate
♦ Rear disc brake:
Rear brake caliper, piston - ∅ mm
Rear brake disc - ∅ mm
Rear brake disc - average effec- mm
tive diameter
Brake disc, thickness mm
Brake disc, minimum thickness mm
Pad thickness with supporting mm
plate
Minimum thickness without sup- mm
porting plate
♦ Rear drum brake:
Brake drum - ∅ mm 200,0 200,0 200,0 200,0
Brake drum - maximum diameter mm 201,0 201,0 201,0 201,0
∅
Wheel-brake cylinder - ∅ mm 19,05 19,05 19,05 19,05
Brake pad, width mm 40,0 40,0 40,0 40,0
Pad thickness without support- mm 5,4 5,4 5,4 5,4
ing shoe
porting shoe
Edition 04.05 Brakes 00-3 page 1

S00.5303.18.20
Engine litre/ 1,2/47 1,4/44 1,4/50

kW
Engine code letters: AZQ,BME AZE, AZF AME, ATZ,
AQW
S = Manual gearbox
S - S - S - S -
Front brake caliper (type denomination) FS-II FS-II FS-III FS-III
Front brake caliper, piston - ∅ mm 48,0 48,0 54,0 54,0
Front brake disc - ∅ mm 239,0 239,0 256,0 256,0
Brake disc - average effective di- mm 193,8 193,8 208,0 208,0
ameter
Brake disc, thickness mm 18,0 18,0 22,0 22,0
Brake disc, minimum thickness mm 15,0 15,0 19,0 19,0
Pad thickness with supporting mm 17,6 17,6 19,6 19,6
plate
porting plate
Rear brake caliper, piston - ∅ mm
Rear brake disc - ∅ mm
Rear brake disc - average effec- mm
tive diameter
Brake disc, thickness mm
Brake disc, minimum thickness mm
Pad thickness with supporting mm
plate
Minimum thickness without sup- mm
porting plate
Brake drum - ∅ mm 200,0 200,0 200,0 200,0
∅
Pad thickness without support- mm 5,4 5,4 5,4 5,4
ing shoe
porting shoe
00-3 page 2 Brakes Edition 04.05

S00.5303.18.20
Engine litre/ 1,4/55 1,4/74 2,0/85 1.9/47 SDI

kW
Engine code letters: AUA, BBY, AUB, BBZ AZL ASY
BKY
S = Manual gearbox
S A S - S - S -
Front brake caliper (type denomination) FS-III FS-III C54-II FS-III
Front brake caliper, piston - ∅ mm 54,0 54,0 54,0 54,0 54,0
Front brake disc - ∅ mm 256,0 256,0 256,0 288,0 256,0
Brake disc - average effective di- mm 208,0 208,0 208,0 244,0 208,0
ameter
Brake disc, thickness mm 22,0 22,0 22,0 25,0 22,0
Brake disc, minimum thickness mm 19,0 19,0 19,0 22,0 19,0
Pad thickness with supporting mm 19,6 19,6 19,6 18,6 19,6
plate
Minimum thickness without sup- mm 2,0 2,0 2,0 2,0 2,0
porting plate
Rear brake caliper, piston - ∅ mm 38,0 38,0
Rear brake disc - ∅ mm 232,0 232,0
Rear brake disc - average effec- mm 196,0 196,0
tive diameter
Brake disc, thickness mm 9,0 9,0
Brake disc, minimum thickness mm 7,0 7,0
Pad thickness with supporting mm 16,9 16,9
plate
Minimum thickness without sup- mm 2,0 2,0
porting plate
Brake drum - ∅ mm 200,0 200,0 200,0 200,0
∅
Pad thickness without supporting mm 5,4 5,4 5,4 5,4
shoe
porting shoe

S00.5303.18.20
Engine litre/ 1.9/74 TDI PD 1.9/96 TDI PD 1.4/55 TDI PD

kW
Engine code letters: ATD ASZ AMF
S = Manual gearbox
S - S - S -
Front brake caliper (type denomination) FS-III C54-II FS-III
Front brake caliper, piston - ∅ mm 54,0 54,0 54,0
Front brake disc - ∅ mm 256,0 288,0 256,0
Brake disc - average effective di- mm 208,0 244,0 208,0
ameter
Brake disc, thickness mm 22,0 25,0 22,0
Brake disc, minimum thickness mm 19,0 22,0 19,0
Pad thickness with supporting mm 19,6 18,6 19,6
plate
Minimum thickness without sup- mm 2,0 2,0 2,0
porting plate
Rear brake caliper, piston - ∅ mm 38,0 38,0
Rear brake disc - ∅ mm 232,0 232,0
Rear brake disc - average effec- mm 196,0 196,0
tive diameter
Brake disc, thickness mm 9,0 9,0
Brake disc, minimum thickness mm 7,0 7,0
Pad thickness with supporting mm 16,9 16,9
plate
porting plate
Brake drum - ∅ mm 200,0 200,0
Brake drum - maximum diameter mm 201,0 201,0
∅
Wheel-brake cylinder - ∅ mm 19,05 19,05
Brake pad, width mm 40,0 40,0
Pad thickness without supporting mm 5,4 5,4
shoe
porting shoe

S00.5303.18.20
Adjusting values for the load-dependent regulator
Note
♦ The adjusting values apply for the vehicle ready for driving.
♦ Vehicle weight ready for driving: Weight of the vehicle with full fuel tank and full water reservoir for windscreen wip-
er/washer and headlamp cleaning system, spare wheel, tool kit, jack and driver (75 kg). The spare wheel, tool kit
and jack must be located in the position prescribed by the vehicle manufacturer, the driver must be seated on the
driver seat.
Model/Version bar MPa bar MPa

Vehicles without electro-hydraulic Front axle 70 7,0 Front axle 100 10,0
steering - drum brakes on rear axle Rear axle 38 ± 3 3,8 ± 0,3 Rear axle 47 ± 3 4,7 ± 0,3
Vehicles with electro-hydraulic Front axle 70 7,0 Front axle 100 10,0
steering - drum brakes on rear axle Rear axle 43 ± 3 4,3 ± 0,3 Rear axle 56 ± 3 5,6 ± 0,3
Pressure value of the distributor valve

Pz(MPa)
1 MPa = 10 bar 6
Pz = output pressure at the distributor valve and left or
B
5 4,75
right rear wheel
Pp = input pressure at the distributor valve and left or right
4 A
3,1
front wheel 3
2,5
Part no.of the distributor valve: 6Y0°612°151 2
The colour marking on the main brake cylinder is not vis- 1

2,5
4,5
ible.
0 1 2 3 4 5 6 7 8 9 10 11
Pp(MPa)
Pressure values
S00-0183
Initial A B
setting
Pp (MPa) 2,5 4,5 5 6 7 8 9 10 11
Pz (MPa) 2,5 3,1 3,25 3,55 3,85 4,15 4,45 4,75 5,05
± 0,1 ± 0,2
Brake fluid
Classification N 052 766 X0 (USA standard FMVSS 571.116 DOT4)

TL 766 X0
Capacity 0.500 l Vehicles with rear disc brakes, with ABS
0.470 l Vehicles with rear drum brakes, with ABS
0.430 l Vehicles with rear drum brakes, without ABS
Replace every 2 years

S00.5303.18.20

S00.5303.18.20
00-4 Wheels, Tyres
Possible wheel-tyre combinations
Engine Wheel size 1) Light-alloy rim 2) Steel rim 2) Offset (mm) Snow chains
permitted
155/80 R13 79T 3) - 5J x 13 H2 35 yes
165/70 R14 81T - 5J x 14 H2 35 yes
1.0 l/37 kW
1.2 l/40 kW 43 yes
185/60 R14 82T 6J x 14 H2 6J x 14 H2
1.2 l/47 kW 38 no
1.4 l/44 kW
195/50 R15 82T 6J x 15 H2 6J x 15 H2 43 no
1.4 l/50 kW
185/55 R15 81T 6J x 15 H2 6J x 15 H2 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
165/70 R14 81T - 5J x 14 H2 35 yes
43 yes
185/60 R14 82T 6J x 14 H2 6J x 14 H2
1.4 l/55 kW 38 no
1.4 l/55 kW TDI PD 185/55 R15 81T 6J x 15 H2 6J x 15 H2 43 yes
195/50 R15 82V, T 6J x 15 H2 6J x 15 H2 43 no
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
43 yes
185/60 R14 82H 6J x 14 H2 6J x 14 H2
38 no
1.4 l/74 kW
195/50 R15 82V, H 6J x 15 H2 6J x 15 H2 43 no
1.9 l/74 kW TDI PD
185/55 R15 81H 6J x 15 H2 6J x 15 H2 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
195/50 R15 82V, H 6J x 15 H2 - 43 no
2.0 l/85 kW 185/55 R15 81H 6J x 15 H2 - 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
165/70 R14 81T - 5J x 14 H2 35 yes
43 yes
185/60 R14 82T 6J x 14 H2 6J x 14 H2
38 no
1.9 l/47 kW SDI
195/50 R15 82T 6J x 15 H2 6J x 15 H2 43 no
185/55 R15 81T 6J x 15 H2 6J x 15 H2 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
205/45 R16 83W 6.5J x 16 H2 - 37 no
1.9 ltr./96 kW TDI
185/55 R15 84H 6J x 15 H2 - 43 yes
PD
205/45 R16 83W, V - 6,5J x 16 H2 4) 42 no
1) Tyre inflation pressure ⇒ Inspection and Maintenance as well as sticker on the fuel-tank cap
2) 5-hole fixing, diameter of the bolt circle 100 mm, diameter of the central hole 57 mm
3) without power steering
4) it is only fitted as a spare wheel in series
Note
♦ Only use tyres of a same size and type on a vehicle,
however the tread pattern and manufacturer may dif-
fer per axle. It is exceptionally allowed to use a differ-
Edition 07.03 Wheels, Tyres 00-4 page 1

S00.5303.14.20
ent tyre temporarily in the event of breakdown. Take

into account a change in driving and braking behav-
iour.
♦ Use wheel bolts with spherical collar and a thread of
M14 x 1.5 - tightening torque: 120 Nm.
♦ Only use authorised rims on the relevant vehicle.
♦ When replacing rims always use wheel bolts that be-
long to these rims (different length and spherical cap
shape).
♦ Also observe the national legislation.
Caution!
Tyres that are more than 6 years old must only be
used in case of emergency and while driving very
carefully.
Tyre legend
Legend, Meaning
e.g. 155/80 R13 79 T
155/80 Tyre width (mm) section ratio between height - width (%)
R Tyre type (radial)
13 Rim diameter (inch)
79 Load rating-index
T Speed symbol
Manufacturing date Meaning

DOT up to 399 < Manufactured during week 39 of 1999
< = denomination of the decade (1990 … 1999)
DOT … 0300 Manufactured during week 3 of 2000
(03 = 3rd calendar week, 00 = year 2000)
79 = 437 kg
Load rating-indexes 81 = 462 kg
(Load index) 82 = 475 kg
83 = 500 kg
T = 190 km/h
H = 210 km/h
Speed symbols
V = 240 km/h
W = 270 km/h
00-4 page 2 Wheels, Tyres Edition 07.03

S00.5303.14.20
40 – Front wheel suspension
40-1 Repairing front axle
An overview of the front axle

I - Repairing front axle ⇒ 40-1
page 2 I II
II - Repairing the suspension
strut ⇒ Chapter 40-2
III - Repairing the wheel bearing
⇒ Chapter 40-3
IV - Drive shaft with constant ve-
locity joint ⇒ Chapter 40-4
V - Drive shaft with tripod joint
⇒ Chapter 40-5
IV III
S40-0153
Edition 04.05 Repairing front axle 40-1 page 1

S00.5303.18.20
I - Summary of components assembly carrier, console, axle link, anti-roll bar, cou-
pling rod, bracket, pendulum support
Note
♦ Welding and straightening work is not allowed on the bearing and wheel control components of the wheel suspen-
sion.
♦ Always replace the self-locking nuts and screws.
♦ Always replace corroded self-locking nuts and screws.
1 - Assembly carrier
T removing and installing
26
⇒ 40-1 page 19
T assignment ⇒ Spare part 1 2 3 4 5
catalogue 27
2 - Nut, 40 Nm 6
T assignment ⇒ Spare part
catalogue
25 7
3 - Anti-roll bar 20
T to remove and install lower 8
assembly carrier 24
⇒ 40-1 page 17 22
catalogue
4 - Rubber bearing
9
T assignment ⇒ Spare part 23 21 10 10
catalogue
5 - Clamp
11
T assignment ⇒ Spare part 19
catalogue 12
6 - Nut, 40 Nm 13
catalogue 14
7 - Coupling rod 18
catalogue
8 - Bracket
17
9 - Screw, 20 Nm + torque a fur-
ther 90° (1/4 turn) 16
T replace after each removal S40-0201
ther 90° (1/4 turn)
T replace after each removal
11 - Bonded rubber bush
T removing and installing - removal version 1 ⇒ 40-1 page 13
T removing and installing - removal version 2 ⇒ 40-1 page 15
12 - Axle link
T removing and installing ⇒ 40-1 page 8
T removing and assembling the track control arm and console ⇒ 40-1 page 13
T Bonded rubber bush -arrow- is a component part of the track control arm
13 - Lock washer
14 - Nut, self-locking, 20 Nm and torque a further 90° (1/4 turn)
40-1 page 2 Repairing front axle Edition 04.05

S00.5303.18.20
15 - Steering joint
T check ⇒ 40-1 page 4
16 - Screw, 20 Nm + torque a further 90° (1/4 turn)
17 - Air deflector
T assignment ⇒ Spare part catalogue
18 - Clip
20 - Console
T Can only be removed and fitted together with the track control arm
T Disconnecting and assembling the track control arm and console ⇒ 40-1 page 13
T note the order of use of the screws:
♦ first staple Pos. 22 (manual work)
♦ then staple Pos. 21
♦ subsequently tighten up positions 21 and 22 alternately
T note the order of use of the screws:
♦ first staple Pos. 22 (manual work)
♦ then staple Pos. 21
♦ subsequently tighten up positions 21 and 22 alternately
T position the screws in the elongated holes of the pendulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier
24 - Dowel screw, 40 Nm and torque a further 90° (1/4 turn)
25 - Hinged bracket
T do not disassemble
T position the screws in the elongated holes of the pendulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier
26 - Shield
T for drive shaft
27 - Screw, 35 Nm

S00.5303.18.20
Inspecting the steering joint

Inspecting axial play
– Pull the track control arm down with force and push up
again.
S40-0286
Inspecting radial play
– Forcefully push the wheel at the bottom towards the

inside and the outside.
Note
♦ For these two tests no „play“ may be felt or be visible.
♦ Observe the steering joint during the tests.
♦ Take into account possible wheel bearing play or
„play“ in top suspension strut bearing.
♦ Inspect rubber bellows for damage, if necessary re-
place.
S40-0287
Removing and installing the steering
joint
Special tools, test and measuring equipment and
auxiliary items required
♦ Engine/gearbox jack e.g. - V.A.G 1383- with
-V.A.G 1359/2-
♦ Fixing device -T 10096-
♦ Ball joint extractor -Matra V176-
♦ Polycarbamide grease -G 052 142 A2-
♦ Glue sealing mass -Loctite 601-
Removing
– Remove the drive shaft from wheel-bearing housing

⇒ Chapter 40-4 and tie up drive shaft to body. 1
– Swivel out the wheel-bearing housing with the sus-
pension strut and support with wooden insert -1-.
Note
♦ Position gearbox jack with adapter, (e.g. -V.A.G 1383/
A- with -V.A.G 1359/2-, (risk of accident: due to falling
parts while the steering joint is being pressed out).
♦ To protect the thread, screw the nut a couple of thread
turns onto the steering joint.
S40-0161

S00.5303.18.20
– Push out the steering joint with the ball joint extractor.
Installing
Note
♦ Note the installed position of the steering joint. Matra V176
♦ The castor changes if the fitting position is incorrect.
♦ Always replace plate nuts of drive shaft on both sides
by twelve-point nuts.
Fitting position
Left steering joint
L - means left
S40-0162
3 - means 13"
4 - means 14"
Right steering joint
R - means right
3 - means 13"
4 - means 14"
Arrow points in the driving direction on the 14" running
gear.
– Insert steering joint in the wheel-house bearing.

– Screw new nut onto the steering joint and tighten.
Secure against spinning while doing this.
Vehicles with 13" running gear
– Smear the drive shaft lightly with adhesive sealing

material -Loctite 601-.
Vehicles with 14” and 15” running gear
– Grease the serration on the propeller shaft with poly-

carbamide grease -G 052 142 A2-.
Do not grease thread on the outer joint of the drive
shaft.
– Grease the serration in the wheel hub with polycar-

bamide grease -G 052 142 A2-.
Continued for all vehicles
– Insert the drive shaft in the wheel hub and screw on

with new twelve-point nut.
– When inserting the drive shaft insert the steering joint
at the same time -1- into the track control arm -2-.
– Screw the steering joint -1- and the track control arm
-2- with new screws -arrows- and new lock washer in
the former position and to the marking.
Note
2
Make sure the steering joint boot is neither damaged nor
twisted.
1 S40-0338
– Fit front wheel.

S00.5303.18.20
Tightening torques:
Steering joint to wheel-bearing housing 20 Nm + 90°

♦ Use new nut!
Twelve-point nut of drive shaft to wheel hub 13" running gear 50 Nm
♦ Use new nut!
♦ Do not grease thread of the outer joint of the drive shaft.
Twelve-point nut of drive shaft to wheel hub 14" and 15" running gear 50 Nm + 45°
♦ Use new nut!
Steering joint to track control arm 20 Nm + 90°
♦ Use new screws!
♦ Use new lock washer!
Wheel bolts 120 Nm
Release the assembly carrier and tighten

(fix)
-V.A.G 1359/2-
♦ Fixing device -T 10096-
♦ Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2-
Removing
Vehicles with exhaust pipe under the assembly carri-
er 2
1
– Remove the front exhaust pipe with catalyst ⇒ Engine
- Mechanics; Rep. Gr. 26.
S48-0112
– Unscrew screws -1- and -2- from the pendulum sup-
port.
– Insert wooden insert -1- in the adapter, e.g.
-V.A.G 1359/2-.
– Position gearbox jack and support assembly carrier.
1
Note
♦ Note the following work steps and absolutely ensure
that you follow the sequence.
♦ The fixing bolts for -T10096- must only be tightened to
maximum 20 Nm as otherwise the fixing bolt thread
becomes damaged.
V.A.G 1359/2
V.A.G 1383A S40-0168

S00.5303.18.20
– Unscrew left screw -4- for assembly carrier -3-, screw
in a fixing bolt of -T10096- and tighten to 20 Nm.
– Unscrew right screw -4- for assembly carrier (not 5
shown in figure), screw in a fixing bolt of -T10096- and
tighten to 20 Nm.
– Release screws -1- on both sides.
4
– Unscrew the left screw -2- and remove support -5-. 1
– Screw in fixing bolts of -T10096- to 20 Nm.
2
– Unscrew the right screw -2- and remove support -5-.
The fixing of the assembly carrier is completed once all 4

screws (Pos. -2- and -4-) are consecutively replaced with 3
S48-0117
the fixing bolts.
Note
When lowering the assembly carrier make sure that the
pressure line, return hose and the line of the power-as-
sisted steering sensor -G250- are not exposed to traction.
– Lower assembly carrier approx. 4 cm.

Installing
– Raise assembly carrier until the console touches the

body.
Note
♦ Note the following work steps and absolutely ensure
that you follow the sequence.
♦ Unscrew the fixing bolts of -T10096- one at a time. It
should be subsequently replaced by a new bolt tight-
ened to the recommended torque.
– Unscrew fixing bolt -1- of -T10096- from the left and

screw in new bolt to the recommended tightening
torque.
– Unscrew fixing bolt -1- of -T10096- from the right

(shown in figure) and screw in new bolt to the recom- 2
mended tightening torque.
– Unscrew fixing bolt -2- of -T10096- from the left. 1
– Install left support.
– Screw in new bolts for the left support and tighten at
the rear by hand.
3
– Tighten new bolts for left console and support to the S48-0197
recommended tightening torque.
– Tighten the rear left support bolts to the recommend-
ed tightening torque.
– Unscrew right fixing bolts -2- of -T10096- (shown in
figure).
– Install right support.

S00.5303.18.20
– Screw in new bolts for the right support and tighten at

the rear by hand.
– Tighten new bolts for the console and screw in to the
– Tighten up the rear right support bolts to the recom-
– Remove gearbox jack with adapter.
– Mount pendulum support on the gearbox and tighten
up the new screws -1-.
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
er 1
– Install the front exhaust pipe with catalyst ⇒ Engine -
Mechanics; Rep. Gr. 26.
Tightening torques: 2 S10-0133
Console to body 70 Nm + 90°

♦ Use new screws!
Support to body 20 Nm + 90°
♦ Use new screws!
Pendulum support to gearbox 30 Nm + 90°
♦ Use new screws!
Fixing bolt of -T10096- 20 Nm
Removing and installing the track con-

trol arm
♦ Multi-purpose tool -MP 3-419-
Removing
– Raise the vehicle until the front axle is free of stress.

– Remove front wheel.
Vehicles on which the track control arm should not
be replaced
– Mark fitting position of screws -arrows- from steering

joint -1- to track control arm -2-.
– Mark installation position of the steering joint -1- for
the track control arm -2-.
Continued for all vehicles 2
– Turn steering to right lock (removal on the left side) or 1 S40-0338
to left lock (removal on the right side).

S00.5303.18.20
– Release screws -arrows-.
– Pull the wheel-bearing housing with steering joint out
of the track control arm.
– Mark the fitting position of the screw -1-.
2
– Release screw -1-. 1
Note
Only swivel the track control arm as far as necessary out
of the assembly carrier to avoid damaging the bonded
rubber mounting.
– Swivelling the track control arm -2- out of the assem- S40-0169
bly carrier.
– Pull out the track control arm -1- using the multi-pur-
pose tool -MP 3-419- from the console.
Note
When pulling out the track control arm ensure that the MP3-419
wheehouse trim panel and the noise insulation are not
damaged.
Installing
1
– Brush the track control arm studs with assembly slid-
ing oil -G 294 421 A1-.
Caution!
S40-0333
♦ When sliding in observe that the track control
arm is in the correct installed position relative to
the console. The surface of the track control arm
must correspond with the surfaces in the console
bearing ⇒ 40-1 page 13.
♦ The track control arm should form one level with
the assembly carrier.
♦ If the fitting position is not respected, this could
lead to damage at the bonded rubber bush of the
console and as a result to a shorter life of the
bonded rubber bush.
– Insert the track control arm by hand into the bonded

rubber bush of the console, if necessary use a rubber
hammer.
– Insert the track control arm -2- in the assembly carrier,
if necessary use a rubber hammer. 2
– Insert screw -1- and tighten to the former position/ 1
marking to a specified tightening torque.
– Insert steering joint in the track control arm.
– If the track control arm is not replaced, tighten screws
to former position/marking.
Note
Use new screws and new lock washer to screw the steer- S40-0169
ing joint/track control arm.

S00.5303.18.20
Vehicles on which the track control arm was replaced
– Position the track control arm -2- and steering joint -1-
relatively to each other in such a way that the holes
-arrows- of the track control arm and steering joint are
flush.
For better fixing use two drifts with 8.3 mm ∅ or as shown
in the figure, two drill bits with 8.3 mm ∅.
Further installation occurs in reverse order.
– Install and tighten the wheel ⇒ Chapter 44-1.

2
Tightening torques: 1 S40-0337
Track control arm to assembly carrier 70 Nm + 90°

♦ Use new screw!
♦ Use new screws!
Wheel bolts 120 Nm
Removing and installing the console
Note
♦ If the console is to be replaced, remove it together with
the track control arm.
♦ The bonded rubber bush in the console may also be
replaced in the vehicle, removal version 1 ⇒ 40-1
page 13 or removal version 2 ⇒ 40-1 page 15.
Removing
– Removing the track control arm ⇒ 40-1 page 8.

– Unscrew the left and right nut -1-.
2
– Pull out left and right coupling rod -3- from stabilizer
-2-.
1
S48-0113

S00.5303.18.20
– Unscrew clamp of the anti-roll bar from the console
-arrows-.
Note
The anti-roll bar clamp is located behind the console and
is not visible in the figure shown.
S40-0165
– Screw out the screws -1- and tie up the steering gear
with wire.
– Release the assembly carrier and lower ⇒ 40-1 1
page 6.
1
– Take the console out of the assembly carrier.
Installing
Note
♦ Observe the jointing and screw sequence of the
screwed connections assembly carrier/track control 1
arm ⇒ item 21 in 40-1 page 3 and assembly carrier/
console/steering gear ⇒ item 22 in 40-1 page 3.
♦ Tighten screwed connections assembly carrier/track S40-0166
control arm in unladen weight position ⇒ Chapter 44-
2.
♦ Before inserting the screws for the assembly carrier,
position the steering gear on the assembly carrier and
insert the screws for the steering gear.
– Insert console into the assembly carrier.

– Insert and tighten screws -1-.
– Tighten assembly carrier ⇒ 40-1 page 6. 1
1
S40-0166

S00.5303.18.20
– Screw the anti-roll bar to the console -arrows-.
S40-0165
– Insert left and right coupling rod -3- into the stabilizer
-2-.
2
– Tighten the left and right nut -1-.
– Installing the track control arm ⇒ 40-1 page 8.
1
– Perform a test drive.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight, 3
perform a chassis alignment.
– Carry out check of chassis alignment ⇒ Chapter 44-2

Tightening torques: S48-0113
Track control arm to assembly carrier 70 Nm + 90°

♦ Use new screw!
♦ observe the order of tightening up ⇒ item 22 in 40-1 page 3
♦ Use new screws!
♦ Use new screws!
Console to assembly carrier/body 50 Nm + 90°
♦ Use new screws!
Coupling rod to anti-roll bar 40 Nm
Clamp for anti-roll bar to console 20 Nm + 90°
♦ Use new screws!

S00.5303.18.20
Disconnecting and assembling the track
control arm and console
1
♦ Two-arm extractor -Kukko 20/10-
♦ Assembly sliding oil -G 294 421 A1-
Separating the track control arm from the console
– Push track control arm out of the console.

1 - Two-arm extractor -Kukko 20/10-
Assembling the track control arm and the console
– Brush the track control arm studs with assembly slid-

ing oil -G 294 421 A1-.
– Clamp console in a vice with protective jaws.
Fitting position of the track control arm in the S40-0343

console bearing
The surfaces -A- of the track control arm must corre-
spond with the surfaces -B- in the console rubber-metal
bearing.
2
1 - Axle link
1
2 - Console A B
– Insert the track control arm by hand up to the stop in

the bonded rubber mounting of the console.
Replacing the bonded rubber bush for

track control arm B
A 3
No provision is made for replacing the bonded rubber
S40-0171
bush.
In the event of damage to the bearing, the track control
arm must be completely replaced together with the bear-
ing ⇒ Spare Part Catalogue.

console - removal version 1
♦ Pressure plate -MP 3-413-
♦ Assembly device -MP 5-402-
♦ Assembly device -T10030-
♦ Pressure plate -T30035-

S00.5303.18.20
Pulling out the bonded rubber bush

6 7
– Screw in the screw -T10030/3- (-1-) into the console. 5
3 4
1 2
2- Nut of -T10030/3-
3- Washer of -T10030/3-
4- Axial bearing of -MP 5-402-
5- Pressure plate -MP 3-459-
6- Console
7- Pressure plate -T30035-
– Pulling out the bonded rubber bush.

Inserting the bonded rubber bush
S40-0172
Note
♦ Never use grease!
♦ Use assembly sliding oil -G 294 421 A1 - to insert.
♦ This leaves a slightly sticky film, which ensures a tight
fit of the bearing.
1
♦ Commercially available greases/oils are usually acidic
and leave behind a grease film.
♦ This could result in a corrosion of the bearing or during
compression and rebound of the vehicle the whole 2
bearing may turn in the track control arm and not the
actual rubber in itself.
Fitting position of the bonded rubber mounting in the
console
♦ The stud -1- of the bonded rubber bush must be flush
with marking -2- on the console.
♦ At the console on the left the marking points towards
the body.
S40-0173
♦ At the console on the right the marking points towards
the body.
– Arrangement of the special tools for installation with-

out console. 1
1- Nut of -T 10030/3-
2
3
2- Axial bearing of -MP 5-402-
3- Pressure plate -T 10030/6- 4
4- Bonded rubber bush 5
6
5- Pressure plate -MP 3-413- 7
6- Washer of -T 10030-
7- Spindle -T 10030/3-
S40-0174

S00.5303.18.20
– Brush the bonded rubber mounting with assembly
sliding oil -G 294 421 A1-.
– Mount the bonded rubber mounting in the console us-
6 7
ing the special tools.
4 5
– Align the bonded rubber mounting in the console ac- 3
cording to the prescribed installed position ⇒ 40-1 2
page 14. 1
– Position the bonded rubber mounting -5- parallel to
the console -4-.
Note
When inserting the bonded rubber mounting counterhold
at spindle.
– Do not twist the bonded rubber mounting and insert up S40-0175

to the stop.
– Remove the special tools.

console - removal version 2
♦ Spindle -MP 5-401/2-
♦ Pressure plate -MP 6-414/8-
♦ Pressure washer -T30047- 1
♦ Pressure plate -T40023-
Replacing the bonded rubber bush for installed

console

S40-0341
– Loosen underfloor trim panel -1- to approx. half.
– Press down the underfloor trim panel -1-.
– Insert the spindle -MP 5-401/2- using the pressure
1
plate -T40023- and the washer -1- from the rear into
the bush.
T40023
– Screw the spindle -MP 5-401/2- into the thread of the
console -arrow-, until the pressure plate -T40023- is
resting against the bush.
Inserting the bonded rubber bush MP5-401/2
Note
♦ Use assembly sliding oil -G 294 421 A1- to insert. S40-0334
fit of the bearing.

S00.5303.18.20

compression and rebound of the vehicle the whole
console
♦ The stud -1- of the bonded rubber bush must be flush
with marking -2- on the console.
♦ At the console on the left the marking points towards
the body. 1 2
♦ At the console on the right the marking points towards
the body.
– Transpose the position of the stud -1- on the long side

of the bonded rubber bush, in order to ensure the cor-
rect fitting position when inserting.
Use e.g a marker for this purpose.
S40-0335
– Insert special tools in opposite direction of travel.
2 - Washer
3 - Console
When inserting pay special attention to fitting position of
the bonded rubber bush -1-.
– Insert the bonded rubber bush -1-.

– Attach the underfloor trim panel.
Replacing the bonded rubber bush for removed

console
– Remove console ⇒ 40-1 page 10.

– Separating the track control arm and the console
⇒ 40-1 page 13.
– Clamp console -1- in a vice with protective jaws. 1
– Insert the spindle -MP 5-401/2- using the pressure MP5-401/2
plate -T40023- and the washer -2- from the rear into
the bush. T40023
– Screw the spindle -MP 5-401/2- into the thread of the
console -arrow-, until the pressure plate -T40023- is
resting against the bush.
2
Inserting the bonded rubber bush
S40-0339

S00.5303.18.20
Note
♦ Use assembly sliding oil -G 294 421 A1- to insert.
fit of the bearing.
compression and rebound of the vehicle the whole
console
1 2
The stud -1- of the bonded rubber bush must be flush with
marking -2- on the console.
– Transpose the position of the stud -1- on the long side

of the bonded rubber bush, in order to ensure the cor-
rect fitting position when inserting.
Use e.g a marker for this purpose.
S40-0335
– Insert special tools as shown in the figure.
1 - Console
3 - Washer
When inserting pay special attention to fitting position of
the bonded rubber bush -2-.
– Insert the bonded rubber bush -2-.

– Install console ⇒ 40-1 page 10.
Removing and installing the anti-roll bar

-V.A.G 1359/2-
♦ Fixing device -T10096-
-V.A.G 1359/2-
Removing
– Removing noise insulation ⇒ Engine - Mechanics;

Rep. Gr. 10.
– Unscrew screws -1- and -2- from the pendulum sup- 2
port. 1
S48-0112

S00.5303.18.20
– Unscrew clamp of the anti-roll bar from the console

-arrows-.
Note
♦ The anti-roll bar clamp is located behind the console
and is not visible in the figure shown.
♦ The bottom screw of the right clamp can only be re-
moved once the assembly carrier has been lowered.
S40-0165
– Screw out the left and right nuts -1-.

– Pull out left and right coupling rod -3- from stabilizer 2
-2-.
S48-0113
with wire.
page 6.
1
– Remove the clamp from the anti-roll bar.
– Turn the anti-roll bar upwards and remove towards the
rear.
Installing
– Insert the anti-roll bar.

1
– Insert new screws for the clamps and tighten by hand.
Note S40-0166
Before inserting the screws for the assembly carrier, po-

sition the steering gear on the assembly carrier and insert
the screws for the steering gear.
– Raise the assembly carrier and fix ⇒ 40-1 page 6.

Further installation occurs in reverse order, while paying
attention to the following:

S00.5303.18.20
up the new screws -1-.
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
Tightening torques:
Console to body 70 Nm + 90° 1

♦ Use new screws!
2 S10-0133
♦ Use new screws!
♦ Use new screws!
♦ observe the order of tightening up
⇒ item 21 in 40-1 page 3
♦ Use new screws!
Clamp for anti-roll bar to console 20 Nm + 90°
♦ Use new screws!
Removing and installing assembly carri-

er
-V.A.G 1359/2-
♦ Extractor -MP 6-425-
-V.A.G 1359/2-
Removing
– Remove the drive shaft from wheel-bearing housing 1

⇒ Chapter 40-4 and tie up drive shaft to body.
S40-0161

S00.5303.18.20

-2-.
– Swivel the anti-roll bar upwards.
1
S48-0113
with wire.
page 6.
1
Installing
Note
♦ Before inserting the screws for the assembly carrier,
position the steering gear on the assembly carrier and
insert the screws for the steering gear.
1
– Raise the assembly carrier and fix ⇒ 40-1 page 6. S40-0166



shaft.


– Screw the steering joint and the track control arm with
new screws.

S00.5303.18.20
Caution!
ing straight ahead the steering wheel is off straight,

Tightening torques:

♦ Use new screws!
♦ Use new screws!
♦ Use new screws!
♦ Use new nut!
♦ Use new nut!
♦ Use new screws!
Wheel bolts 120 Nm

S00.5303.18.20

S00.5303.18.20
40-2 Repairing front suspension strut
II - Summary of components of suspension strut
Note
The figure represents the wheel-bearing housing for disc brake FS-III. The different versions of the wheel-bearing
housing do not influence the assembly of the suspension strut.
1 - Wheel-bearing housing
13
2 - Nut, 60 Nm + torque a further 12
90° (1/4 turn) 12
3- Screw 12
6
4- Shock absorber
⇒ 40-2 page 2 11
T can be replaced individually 5
T must be replaced completely
T check ⇒ 40-2 page 7 10
T disposing of ⇒ 40-2 page 8
catalogue 4
5- Stop buffer
6- Boot
7- Helical spring
8
T check colour coding
T The surface of the spring coil 3
must not be damaged
T replace axle-wise 2
T per axle only use helical
springs of the same make
T removing and installing 7
⇒ 40-2 page 6
catalogue
8- Axial grooved ball bearing 1
9- Suspension strut bearing S40-0185
10 - Self-locking nut, 60 Nm
11 - Suspension strut dome
T when mounting the suspension strut, first mount the screws on the inside of the vehicle
13 - Cap
T clipped into suspension strut dome
Edition 04.05 Repairing front suspension strut 40-2 page 1

S00.5303.18.20
Removing and installing the suspension

strut
♦ Gearbox jack with adapter e.g. - V.A.G 1383 A- with
-V.A.G 1359/2-
♦ Spreader -3424-
♦ Extractor -Matra V176-
Removing

– Unscrew plate nut (or the twelve-point nut) from the 2
drive shaft using a 19 mm Allen key.
– Remove wheel. 1 S40-0338
– Mark fitting position of screws -arrows- from steering
– Mark installation position of the steering joint -1- for B
– Screw out the screws.
– Unscrew the nut of the coupling rod -arrows B- from
the suspension strut.
– Unhook speed sensor cable from the suspension
strut.
A
S40-0342
– Screw up nut -1- sufficiently so that the puller

-Matra V176- is supported on the nut. Matra V176
– Use puller -Matra V176- to press track rod/track rod 1
end -2- off the steering arm.
– Screw off the nut from the track rod end.
– Pull track rod end out of steering arm.
– Tie up track rod.
⇒ Chapter 40-4 and tie up. 2
– Screw steering joint to the track control arm. To do so
use the removed screws and the removed lock wash-
er.
S40-0177
– Position the gearbox jack with adapter (e.g. - V.A.G
1383/A- with -V.A.G 1359/2-) under the wheel-bear-
ing housing.
40-2 page 2 Repairing front suspension strut Edition 04.05

S00.5303.18.20
– Separate the screwed connection wheel-bearing
housing/suspension strut -arrow-.
S40-0288
– Insert the spreader -3424- in the slot on the wheel-

bearing housing.
– Turn ratchet 90° and remove from spreader -3424-.
– Press the brake disc by hand towards the suspension
strut.
Otherwise the shock-absorber tube may tilt in the hole
of the wheel-bearing housing. 3424
– Pull wheel-bearing housing downwards away from the

shock-absorber tube and lower with gearbox jack until
the shock-absorber tube hangs free.
– Secure the wheel-bearing housing to the console/as-
sembly carrier. S40-0179
– Remove the gearbox jack with adapter.
– Unscrew the screws for the top shock-absorber fixture
-arrows-.
– Remove the suspension strut.
Installing
– Insert the suspension strut and secure to the suspen-

sion strut dome.
First mount the screws on the inner side of the vehicle.
– Tighten up the screws fully to the specified tightening

torque.
– Position the gearbox jack with adapter (e.g. - V.A.G
1383/A- with -V.A.G 1359/2-) under the wheel-bear-
ing housing. S40-0186
– Insert suspension strut in the wheel-house bearing.

– Loosen the wheel-bearing housing on the console/as-
sembly carrier.
– Raise up the wheel-bearing housing using the gear-
box jack to the point where the screws for the suspen-
sion strut/wheel-bearing housing can be inserted.
Note
Never press on the steering joint with the gearbox jack.

S00.5303.18.20
– With one's hand on the brake disc press in the direc-

tion of the suspension strut making sure that the
shock-absorber tube in the bore hole of the wheel-
bearing housing does not become tilted.
– Remove spreader -3424-.
– Screw on the new nuts and tighten up fully -arrow-.
Note
Remove possible corrosion, grease or adhesive sealing
material from the thread and from the serration of the out-
er joint as well as from the serration of the wheel hub.

S40-0288
shaft.

shaft.

– Insert the drive shaft in the serration of the wheel hub.

– When inserting the drive shaft insert at the same time
the steering joint -1- into the track control arm -2- in
accordance with the former positions and markings.
– Secure the outer joint of the drive shaft with a new
twelve-point nut.
Note
♦ Replace nut on both sides. 2
– Screw the track control arm -1- with the steering joint
-2- with new screws -arrows- and new lock washer in 1 S40-0338
– Tighten the new screws -arrows- in accordance with
the markings and the former positions to the specified
tightening torque.

S00.5303.18.20
Caution!

Tightening torques:
Suspension strut to suspension strut dome 15 Nm + 90°

♦ Use new screws!
Wheel-bearing housing to suspension strut 60 Nm + 90°
♦ Use new screws and nuts!
Track rod end/track rod to steering arm 20 Nm + 90°
♦ Use new nuts!
The anti-roll bar on the suspension strut 40 Nm
♦ Use new nuts!
♦ Use new nuts!
♦ Use new screws!
Wheel bolts 120 Nm
Repairing the suspension strut

♦ Spring tensioning device, e.g. -V.A.G 1752/1 -
♦ Spring holder with protective lining, e.g. - V.A.G 1752/
4-
♦ Socket wrench insert OK 21 -MP 6-427-

S00.5303.18.20
Removing the helical spring

V.A.G 1752/1 1
– Removing the suspension strut ⇒ 40-2 page 2
– Preload the helical spring with the spring tensioner un-
til the suspension strut bearing -3- is relieved.
MP 6-427
– Unscrew the nut from the piston rod using socket
wrench insert OK 21 -MP 6-427- and counterhold with 2
an hexagonal wrench -2-.
1 - Ratchet or torque wrench
3
V.A.G
1752/4
– Remove component parts of the suspension strut and S40-0187

preloaded helical spring with the clamping fixture.
– Check correct seating of the helical spring in the
spring tensioning device, e.g. -V.A.G 1752/4- -arrow-.
V.A.G
1752/1
Installing the helical spring

V.A.G 1752/4 S40-0290
– Position the preloaded helical spring with spring ten-

sioning device, e.g. -V.A.G 1752/4- on the bottom
spring washer.
The extremity of the spring coil must lie against the
stop -arrow-.
Tightening torque:
Nut for suspension strut bearing on the 60 Nm

piston rod
– Assembling the shock absorber ⇒ 40-2 page 1 S40-0259

S00.5303.18.20
Inspecting the shock absorber
Leaks on the shock absorber
Minor oil leakage (sweating) on the piston rod seal does
not entail the replacement of the shock absorber.
If an oil leak is visible (but blunt, dull, possibly dried by
dust) and does not propagate any further than from the
top shock-absorber plug (piston rod seal) to the bottom
spring cap -arrow-, the shock absorber is deemed to be
O.K.
Note
A slight oil leak is beneficial as the gasket is lubricated
and this increases the life time. This applies for shock ab-
sorbers on the front as well as the rear axle.
Shock absorber noises
There is reason to believe that in the event of noise com-
plaints the shock absorbers are all too often considered
as the source.
Possible causes of noise may be e.g.:
♦ Defective shock absorber
♦ Loose fixation of the suspension strut/body
♦ Defective axial grooved ball bearing
♦ Insufficient clearance of the suspension strut
♦ The outer joint is defect S40-0071
♦ Defective wheel bearing
♦ Cracked welding points on body
♦ Loose parts or parts fitted under stress (exhaust sys-
tem, attachments, flaps, etc.)
Note
In the event of complaints about noises interpreted as
knocking or cracking noises, always first perform a test
drive with the customer to determine where, when and
how these noises occur (preferably on a bumpy dry road).
Inspecting the removed shock absorber without gas
pressure
Defective shock absorbers become noticeable while driv-
ing because of the knocking noises caused by wheel hop-
ping, more specifically on poor road surfaces and they
must be replaced. The main cause of defect is oil leak-
age. The shock absorber then compresses and/or ex-
pands in jolts. It has an „idle travel“ before taking effect.
Note
Shock absorbers are maintenance-free. It is not possible
to top up the shock absorber oil.
Inspecting the removed shock absorber with gas
pressure
Defective shock absorbers with gas pressure are also no-
ticeable because of loud knocking noises caused by

S00.5303.18.20
wheel hopping and externally usually exhibit considera-

ble oil leakage.
Check by hand whether or not the shock absorber is
defective as follows:
– Compress the shock absorber by hand.

The piston rod must move evenly over the entire
stroke without jolting.
– Release the piston rod. On sufficiently pressurized

shock absorbers it will automatically return to its orig-
inal position.
If this is not the case, the shock absorber need not
necessarily be replaced, as it will still operate as a
conventional shock absorber (see instructions below).
Note
♦ The absorbing function is still fully present without suf-
ficient gas pressure as long as the oil leakage is not
too large. However, the noise level may increase. On
older vehicles it is possible to continue using an oper-
ational yet pressureless shock absorber without prob-
lem.
♦ Adequate gas pressure in the shock absorber im-
proves the noise behaviour and function when driving
over poor road surfaces.
Disposing of the shock absorber

♦ Drill ∅ 3 mm (commercially available)
♦ Drill ∅ 6 mm (commercially available)
♦ Safety goggles (commercially available)
♦ Oil catch container (commercially available)
♦ Pipe cutter, e.g. Stahlwille Express -150/3- (commer-
cially available)
Note
There are two ways of disposing of shock absorbers.
Degassing the front and rear pressurized shock ab-
sorbers
Possibility A: Degassing by drilling open
I - Front pressurized shock absorber
II - Rear pressurized shock absorber
– Clamp the pressurized shock absorber in the vice in

such a way tbat the piston points downwards.
Caution!
Wear safety goggles during the drilling procedure.

S00.5303.18.20
– Drill a hole ∅ 3 mm -arrow A- through the outer pipe
of the shock absorber. I II
Note
Gas will escape during drilling.
– Drill further until the inner pipe has been drilled A
60
A
60
20
through (approx. 25 mm deep).
20
– Drill a second hole ∅ 6 mm -arrow B- through the out-
er and inner pipe of the shock absorber. B B
– Hold the shock absorber over an oil catching pan,
move the piston rod sevral times up and down over its
entire stroke until no more oil escapes.
Degassing the front and rear pressurized shock ab-
sorbers
Possibility B: Open with pipe cutter
I - Front pressurized shock absorber
II - Rear pressurized shock absorber
– Clamp the pressurized shock absorber in the vice in

such a way that the piston points upwards.
S40-0188
Caution!
Wear safety goggles during the drilling procedure.
– Drill a hole ∅ 3 mm -arrow A- through the outer pipe I

of the shock absorber.
Note
Gas will escape during drilling.
– Position a pipe cutter, e.g. Stahlwille Express -150/3-,

as shown in the figure, and cut through the outer pipe
of the shock absorber.
– Pull the piston rod upwards and while doing so grip the
inner pipe with pipe pliers and press it down in such a
way that it remains in the outer pipe when the piston
rod is slowly pulled up. II
– Pull the piston rod out of the inner pipe.
– Empty the shock absorber pipe.
S40-0189

S00.5303.18.20

S00.5303.18.20
40-3 Repairing the wheel bearing
III - Summary of components of the wheel bearing, suspension strut, drive shaft,
brake FS-III
Note
♦ Welding and straightening work is not allowed on the bearing and wheel control components of the front wheel
suspension.
1 - Suspension strut
⇒ Chapter 40-2
1
T repair ⇒ Chapter 40-2
catalogue
28 6
2 - Drive shaft with CV joint 7
⇒ Chapter 40-4
T inspect ⇒ Chapter 40-4
3
T repair ⇒ Chapter 40-4 27 4
catalogue 24 25
3 - Shim
catalogue 23
20
4 - Fillister head screw with inter-
nal serrations
19
T replace after each removal 22
8
catalogue 9
T M8 x 48
initially tighten all screws to
10 Nm, then tighten screws
crosswise 17
Tightening torque: 40 Nm 18
T M10 x 52 21 10
initially tighten all screws to 12
16
crosswise 11
Tightening torque: 70 Nm 15 14 13 S40-0202
5 - Drive shaft with tripod joint
T removing and installing ⇒ Chapter 40-5
6 - Shim
T only replace along with a cylindrical screw with internal serrations M8 x 28 head, ⇒ item 7
7 - Fillister head screw with internal serrations
T M8 x 18
initially tighten all screws to 10 Nm, then tighten screws crosswise
Tightening torque: 40 Nm
T M8 x 28
Edition 04.05 Repairing the wheel bearing 40-3 page 1

S00.5303.18.20

T M10 x 23
8- Brake disc, internally ventilated
9- Wheel bolt, 120 Nm
10 - Plate nut
T replace after each removal against twelve-point nut ⇒ item 11
11 - 50 Nm + 45°
T Do not grease thread of the outer joint of the drive shaft.
12 - Screw, 4 Nm
13 - Brake pad
14 - Brake caliper
T do not release brake hose when working on the front wheel suspension
T tie up with wire or anything similar
15 - Guide bolts, 28 Nm
16 - Cap
T removing
17 - Screw, 10 Nm
18 - Wheel hub with wheel bearing
T for vehicles with ABS the sensor ring is built into the wheel hub
T The wheel hub and the wheel bearing are a single unit; it does not need servicing and is free of play; it is not
possible to undertake any kind of adjustment or repair work on it.
T The sensor ring for ABS cannot be replaced individually
T replace after each removal, is destroyed during removal
T Removing and installing the wheel hub with wheel bearing ⇒ 40-3 page 10
19 - Cover plate
20 - Nut, 20 Nm + torque a further 90° (1/4 turn)
21 - Track rod and track-rod ends
24 - Screw
T the tip of bolt must point in the direction of travel
25 - Speed sensor ABS
26 - Allan screw, 8 Nm
T for speed sensor ABS
27 - Nut, 40 Nm
40-3 page 2 Repairing the wheel bearing Edition 04.05

S00.5303.18.20
28 - Coupling rod
brake FS-II
Note
suspension.
⇒ Chapter 40-2
T repair ⇒ Chapter 40-2 2
1
catalogue
27
2 - Drive shaft with CV joint
⇒ Chapter 40-4
26 4
25
T assignment ⇒ Spare part 23 24
catalogue
3 - Shim
19
catalogue
18
nal serrations
T replace after each removal 17 5
T assignment ⇒ Spare part 21 16 6
catalogue
T M8 x 48
crosswise
Tightening torque: 40 Nm 20 14 7
T M10 x 52 9
13
10 Nm, then tighten screws 8
crosswise
12 10
11 S40-0203
5 - Brake disc, internally ventilat-
ed
6 - Wheel bolt, 120 Nm
7 - Plate nut
8 - 50 Nm

S00.5303.18.20
9 - Screw, 4 Nm
10 - Brake pad
11 - Brake caliper
12 - Fillister head screw with internal serrations, 25 Nm
T M8 x 49
13 - Fillister head screw with internal serrations, 25 Nm
T M8 x 59
14 - Air deflector
15 - Screw, 10 Nm
T for air deflector
17 - Screw, 10 Nm
18 - Cover plate
23 - Screw
26 - Nut, 40 Nm
27 - Coupling rod

S00.5303.18.20
brake C54-II
Note
suspension.
⇒ Chapter 40-2 1
catalogue 31 6
2 - Drive shaft with CV joint 7
⇒ Chapter 40-4 3
T repair ⇒ Chapter 40-4 30 4
29
catalogue 27 28
3 - Shim
catalogue 23
25 22
nal serrations 21
T assignment ⇒ Spare part 24 8
catalogue 9
T M8 x 48
17
10 Nm, then tighten screws 19
crosswise
Tightening torque: 40 Nm 15 14
T M10 x 52
12 10
crosswise
18 13 11
17 14
Tightening torque: 70 Nm 16 S40-0204
5 - Drive shaft with tripod joint
6 - Shim
T only replace along with a cylindrical screw with internal serrations M8 x 28 head, ⇒ item 7
7 - Fillister head screw with internal serrations
T M8 x 18
T M8 x 28

S00.5303.18.20
T M10 x 23
8- Brake disc, internally ventilated
9- Wheel bolt, 120 Nm
10 - Plate nut
11 - 50 Nm + 45°
12 - Screw, 4 Nm
13 - Brake pad
14 - Pad retaining plate
T always replace when changing the brake pads
T brake pads contained in repair kit
15 - Brake carrier with guide bolts and protective caps
16 - Heat shield
17 - Brake caliper
18 - Screw, 30 Nm
T Removing and installing the wheel hub with wheel bearing ⇒ 40-3 page 10
21 - Screw, 10 Nm
22 - Cover plate
24 - Screw, 125 Nm
T clean ribbing on underside each time removed
27 - Screw

S00.5303.18.20
30 - Nut, 40 Nm
31 - Coupling rod
Removing and installing wheel bearing

housing
Note
♦ The running gears have different versions of wheel
bearing housings and floating caliper brakes.
♦ The special tools, test and measuring equipment as
well as aids required for removing and installing the
wheel bearing housing of running gears with FS-II,
FS-III or C54-II brakes are identical.

♦ Gearbox jack with adapter e.g. -V.A.G 1383 A- with
-V.A.G 1359/2-
♦ Spreader -3424-
Removing

– Unscrew twelve-point nut (or the plate nut) from the
– Remove wheel.
Vehicles fitted with anti-roll bar
– Unscrew nut -1-.

2
– Pull out coupling rod -3- from the anti-roll bar -2-.
Vehicles with ABS
1
– Removing the speed sensor.
Vehicles fitted with FS-III floating caliper brake
S48-0113

S00.5303.18.20
– Removing the caps from the brake caliper guide bolts.

– Unscrew and remove the two guide bolts -arrow- from
the brake caliper.
Vehicles fitted with FS-II floating caliper brake
– Unscrew cylinder bolts with hexagon socket head

from brake caliper and take out (not shown).
Vehicles fitted with C54-II floating caliper brake
S40-0176
– Release screws -1-.

– Remove brake caliper or brake carrier with brake cal-
iper and secure with wire in such a way that the weight
of the brake caliper does not pull on or damage the
brake hose.
⇒ Chapter 40-4 and tie up.
– Remove the track rod end from the steering-knuckle
arm with extractor -Matra V176- and tie up the track
rod. 1
– Position the gearbox jack with adapter (e.g. -V.A.G
1383/A- with -V.A.G 1359/2-) under the wheel-bear- S40-0197
ing housing.
– Separate the screwed connection wheel-bearing
housing/suspension strut -arrow-.
S40-0288

S00.5303.18.20
– Insert the spreader -3424- in the slot on the wheel-
bearing housing.
– Turn ratchet 90° and remove from spreader -3424-.
strut.
of the wheel-bearing housing. 3424
– Remove the wheel-bearing housing from the shock-
absorber tube and lower with gearbox jack.
Installing
– Raise the wheel-bearing housing with gearbox jack.

S40-0179
– Insert the suspension strut/wheel-bearing housing
screw.
strut.
of the wheel-bearing housing.
– Remove spreader -3424-.


shaft.

shaft.


Note
Always replace plate nuts of drive shaft on both sides by
twelve-point nuts.
– Screw the steering joint and track control arm with the
new screws in the former positions.

S00.5303.18.20
Caution!

Tightening torques:
Wheel-bearing housing to suspension strut 60 Nm + 90°

♦ Use new nuts!
♦ Use new nuts!
Track-rod end to steering lever 20 Nm + 90°
♦ Use new nuts!
♦ Use new screws!
FS-III brake caliper to wheel bearing housing 28 Nm
FS-II brake caliper to wheel bearing housing 25 Nm
Brake carrier with C54-II brake caliper to wheel bearing housing 125 Nm
Speed sensor to wheel-bearing housing 8 Nm
Wheel bolts 120 Nm
Removing and installing the wheel hub

with wheel bearing with the wheel-bear-
ing housing fitted
Note
♦ The FS-II chassis uses another size of wheel hub with
wheel bearing compared to the FS-lll chassis or the
C54-ll type.
♦ The special tools, test and measuring equipment as
well as aids required for removing and installing the
wheel bearing housing of chassis with the FS-II, FS-III
or C54-II brake are identical.
♦ When drawing in the wheel hub and wheel bearing at
the chassis fitted with an FS-II brake, pay attention to
the modified installed position of the assembly device
- T10064/4-. On a chassis fitted with the FS-II brake
use grips -T10064/5- and on chasses with FS-III or
C54-II brakes use grips -T10064/6-.

S00.5303.18.20
♦ Gearbox jack with adapter e.g. -V.A.G 1383 A- with
-V.A.G 1359/2-
♦ Assembly device -MP 6-414-
♦ Side door removal tool -MP 8-605/1- or e.g. supple-
mentary tool kit -V.A.G 1459 B/2-
♦ Assembly device -T10064-
2
♦ Molykote grease -G 052 723 A2-
1
Removing the wheel hub with wheel bearing

drive shaft using a 19 mm Allen key. 3
– Remove wheel.
Vehicles fitted with anti-roll bar
S48-0113
– Unscrew nut -1-.
– Pull out coupling rod -3- from the anti-roll bar -2-.
Vehicles with ABS
– Removing the speed sensor.

Vehicles fitted with FS-III floating caliper brake
– Removing the caps from the brake caliper guide bolts.

– Unscrew and remove the two guide bolts -arrows-
from the brake caliper.
Vehicles fitted with FS-II floating caliper brake
– Unscrew cylinder bolts with hexagon socket head

from brake caliper and take out (not shown).
S40-0176
Vehicles fitted with C54-II floating caliper brake
– Release screws -1-.

S40-0197

S00.5303.18.20
– Remove brake caliper or brake carrier with brake cal-

iper and secure with wire in such a way that the weight
of the brake caliper does not pull on or damage the
brake hose.
⇒ Chapter 40-4 and tie up.
– Remove the track rod end from the steering-knuckle
arm with extractor -Matra V176- and tie up the track 1
rod.
– Screw out the Phillips head screws of the brake disc
and remove brake disc.
– Remove the cover plate of the brake disc.
– Place the gearbox jack with adapter, e.g. -V.A.G
1383/A- with -V.A.G 1359/2- below (danger of having
an accident): from parts which are falling when pulling
out the wheel hub).
S40-0161
Note
♦ The illustration shows the process of pulling out the
wheel hub and wheel bearing at a wheel bearing
housing for vehicle fitted with an FS-III brake.
♦ The procedure for pulling out the wheel hub and wheel
bearing of the chassis fitted with an FS-II or C54-II
brake is similar to that for a chassis fitted with an FS-
III brake even when the wheel bearing housing has a
different appearance.
♦ Mount the assembly device -MP 6-414- at right angles
to the centre axle of the wheel hub with wheel bearing.
Do not tilt the wheel hub with wheel bearing when re-
moving and installing.
♦ Three different variants are described below for pull-
ing out the wheel bearing with wheel hub.
– Insert the side door removal tool -3- between the 3

wheel-bearing housing and the wheel hub as support
for the assembly device -2-.
– Pull the wheel hub with wheel bearing out of the 2
wheel-bearing housing.
4
1- -MP 6-414/2- with -MP 6-414/5-
2- -MP 6-414/1-
3- -MP 8-605/1-
4- -MP 6-414/10- 1
5- -MP 6-414/6- 5
Note
S40-0181
♦ Instead of the side door removal tool -MP 8-605/1-
use 2 bases with a thickness of approx. 25 mm, a
height of approx. 40 mm and a length of approx. 220
mm between the wheel-bearing housing and the

S00.5303.18.20
wheel hub as support for the assembly device
-MP 6-414-. The arrangement is similar to separating 3
device - E-37- ⇒ 40-3 page 13.
♦ If the separating device -E-37- from the supplementa-
ry tool kit -V.A.G 1459 B/2- is available then this can 2
also be used as a support. Please note the correct in-
stalled position while doing this. The straight surfaces 4
of the cutting edges must point towards the wheel
hub.
– Insert separating device -3- between the wheel-bear-

ing housing and the wheel hub and take up the weight. 1
– Pull the wheel hub with wheel bearing out of the 5
wheel-bearing housing.
1- -MP 6-414/2- with -MP 6-414- S40-0182
2- -MP 6-414/1-
3- Separating device -E-37- from -V.A.G 1459 B/2-
4- -MP 6-414/10-
5- -MP 6-414/6-
Inserting a wheel hub with wheel bearing
Note
♦ Figure S40-0180 shows the wheel bearing housing for
the chassis with the FS-III brake. The procedure for
cleaning and greasing the holes on wheel bearing
housings for a chassis with FS-II or C54-II brakes is
similar to that on a chassis with an FS-III brake.
♦ Clean the bore holes on the wheel bearing housing.
♦ Coat the bore with molykote grease -G 052 723 A2-
S40-0180
over the entire surface.
♦ Screw the grippers -1- to the wheel hub with wheel

bearing -2-.
1
Grippers -1- 1
Chassis with an FS-II brake -T10064/5-
Chassis with an FS-III or -T10064/6- 3
C54-II brake
Note
The wheel bolts -3- must not protrude from the rear of the
grippers -1-.
Chassis with an FS-II brake
2
S40-0194
Note
Do not tilt the wheel hub with wheel bearing while insert-
ing.

S00.5303.18.20
– Pull the wheel hub with wheel bearing into the wheel-
bearing housing.
1- -MP 6-414/5-
3
2- -T10064/1-
3- -T10064/5-
4- -MP 6-414/10-
4 2
5- -T10064/4-
Chassis with an FS-III or C54-II brake
1
Note 5
♦ Figure S40-0183 shows the procedure for pulling in
the wheel hub and wheel bearing on a wheel bearing
housing for a chassis fitted with an FS-III brake. S40-0195
♦ The selection and arrangement of special tools for

pulling in the wheel hub with wheel bearing into the
wheel bearing housing of a chassis fitted with an C54-
II brake is similar to that for a chassis fitted with an FS-
III brake.
♦ Do not tilt the wheel hub with wheel bearing while in-
serting. 3
– Pull the wheel hub with wheel bearing into the wheel-
bearing housing. 4 2
1- -MP 6-414/5-
2- -T10064/1-
3- -T10064/6- 1
4- -MP 6-414/10- 5
5- -T10064/4-
S40-0183
– Pull in the wheel hub with wheel bearing until the cir-
clip is heard to click into position.
– Screw out the grippers -1- from the wheel hub with 1
wheel bearing -2-.
3 - Wheel bolts
Further installation occurs in reverse order, while paying 3
2
– Smear the drive shaft lightly with adhesive sealing 1
shaft.
Vehicles with 14” and 15” running gear S40-0196

carbamide grease -GG 052 142 A2-.
shaft.


S00.5303.18.20

Note
Always replace plate nuts of drive shaft on both sides by
twelve-point nuts.
– Screw the steering joint and track control arm with the
new screws in the former positions.
Caution!

Tightening torques:
Cover plate to wheel-bearing housing 10 Nm

Phillips head screw of brake disc to wheel hub with wheel bearing 4 Nm
♦ Use new nuts!
♦ Use new nuts!
Track rod/track rod end to steering lever 20 Nm + 90°
♦ Use new nuts!
♦ Use new screws!
FS-III brake caliper to wheel bearing housing 28 Nm
FS-II brake caliper to wheel bearing housing 25 Nm
Brake carrier with C54-II brake caliper to wheel bearing housing 125 Nm
Wheel bolts 120 Nm

S00.5303.18.20

S00.5303.18.20
40-4 Drive shafts with CV joints
Removing and installing a drive shaft

♦ A steel cylinder - max. ∅ 18 mm, length 20 mm
Removing

– Removing noise insulation ⇒ Engine - Mechanics;
Rep. Gr. 10.
– Unscrew the drive shaft from the flange shaft - gear-
box, if necessary remove the heat shield below the in-
ner joint.
– Mark fitting position of screws -arrows- from steering 2
– Mark installation position of the steering joint -1- for 1 S40-0338
– Release screws -arrows-.
– Press out drive shaft with -MP 6-425-.
– Remove the drive shaft.
Installing
Note
Remove possible corrosion, grease or adhesive sealing
material from the thread and from the serration of the out-
er joint as well as from the serration of the wheel hub.
MP 6-425
– Smear the gearing of the outer joint of the drive shaft
lightly with adhesive sealing material -Loctite 601-.
S40-0178
shaft.

shaft.

Edition 04.05 Drive shafts with CV joints 40-4 page 1

S00.5303.18.20
– Insert the drive shaft in the serration of the wheel hub.

– When inserting the drive shaft insert at the same time
the steering joint -1- into the track control arm -2- in
– Screw the drive shaft onto the flange shaft - gearbox
and initially tighten to 10 Nm.
– Secure the outer joint of the drive shaft with a new
twelve-point nut.
Note
Always replace plate nuts of drive shaft on both sides by 2
twelve-point nuts. Replace nut on both sides.
– Tighten the drive shaft on the flange shaft - gearbox to 1 S40-0338

the prescribed torque.
– Screw the track control arm -1- with the steering joint
-2- with new screws -arrows- and new lock washer in
– Tighten the new screws -arrows- in accordance with
the markings and the former positions to the specified
tightening torque.
Tightening torques:
Drive shaft to flange shaft/gearbox M 8 = 40 Nm

M 10 = 70 Nm
♦ Use new screws!
♦ Use new nut!
♦ Use new nut!
♦ Use new screws!
Wheel bolts 120 Nm
Summary of components of drive shaft

with CV joint
Grease quality and grease quantity
Note
♦ The outer joints of the drive shaft are filled with grease
for operating at normal temperatures, e.g.
-N 052 738 00-.
♦ Only use the appropriate high-temperature grease
from the relevant repair kit for the grease filling of the
CV joint ⇒ Spare Parts catalogue.
40-4 page 2 Drive shafts with CV joints Edition 04.05

S00.5303.18.20
Grease of which in:

Total Joint Joint boot
Outer joint amount
∅ mm [g] [g] [g]
90 80 +10 80 +10 ---
100 100 +10 100 +10 ---
Inner joint
∅ mm
90 80 +10 40 +5 40 +5
100 110 +10 55 +5 55 +5
Note
♦ Assignment of the drive shafts ⇒ Spare part catalogue.
♦ Grease joint if necessary, when replacing the joint boot.
♦ Spread the grease mass evenly in the joint boot.
1 - Right joint boot (tubular shaft)

catalogue
2 - Screw
T initially tighten to 10 Nm,
subsequently tighten cross-
wise to final torque:
M 10 = :
For vehicles ³ 04.03
70 Nm
For vehicles 05.03 ³
Tighten 50 Nm + 45°
M8=:
40 Nm
catalogue
3 - Shim
catalogue
4 - Warm-type clamp
T replace
T tensioning ⇒ 40-4 page 5
5 - Joint boot for inner CV joint
T Material: Hytrel (Polyelas-
tomere)
T inspect for tears and chafing
points
T remove from CV joint with
drift
T before installation coat the inside of the cap with sealant -D 454 300 A2-

S00.5303.18.20
6 - Disc spring
T Fitting position ⇒ 40-4 page 6
7 - Inner CV joint
T pressing off ⇒ 40-4 page 6
T pressing on ⇒ 40-4 page 6
T grease ⇒ 40-4 page 2
8 - Gasket
T The adherend must be free of grease and oil!
T replace
T Pull off protective foil and stick in housing
9 - Circlip
T replace
T use circlip pliers, e.g. -VW 161 A- for removing and installing
10 - Left drive shaft (solid shaft)
11 - Warm-type clamp
T replace
12 - Joint boot
T Material: Hytrel (Polyelastomere)
T inspect for tears and chafing points
T replace
T tension with tensioning pliers, e.g. -V.A.G 1682 - ⇒ 40-4 page 5
14 - Disc spring
15 - Thrust ring
16 - Circlip
T replace
T insert in the shaft groove
17 - Outer CV joint
T removing ⇒ 40-4 page 5
T before installing grease the serration with polycarbamide grease -G 052 142 A2-
T Installing: drive onto the shaft with a plastic hammer until the compressed circlip expands
18 - Thrower ring
T 13" chassis - black
T 14" and 15" chassis - white
19 - Twelve-point nut
T 13" chassis - black, 50 Nm
T 14" and 15" chassis - silvery, 50 Nm + 45°

S00.5303.18.20
Repairing drive shaft with CV joint
♦ Thrust piece -MP 3-448-
♦ Strutting bushing -MP 6-428-
♦ Clamping device -MP 6-429-
♦ Workshop press, e.g. -V.A.G 1290 A-
♦ Tensioning pliers, e.g. -V.A.G 1682-
♦ Sealant -D 454 300 A2-
Removing outer CV joint
– Removing drive shaft ⇒ 40-4 page 1.

– Remove the joint boot.
– Drive the CV joint off the drive shaft with a strong blow
of a plastic hammer.
– Remove circlip ⇒ item 16 in 40-4 page 4.
– Remove the disc spring and thrust ring from the drive
shaft.
Installing the inner CV joint
– Push the new joint boot onto the drive shaft.

– Fit the disc spring -1- and the thrust ring -2- onto the
drive shaft.
Check fitting position.
– Insert new circlip in the groove of the drive shaft.

– Carefully drive CV joint onto the drive shaft with a
plastic hammer until the compressed circlip expands.
– Grease the CV joint and the joint boot ⇒ 40-4
page 2.
– Fit joint boot on the outer joint.
– Install drive shaft ⇒ 40-4 page 1.
Note
♦ In view of the hard material (as opposed to rubber) of
the joint boot, which requires the use of a stainless
steel-open warm-type clamp, the latter can only be
tightened with tensioning pliers, e.g. -V.A.G 1682-.
♦ Tightening torque 20 Nm.
♦ Make sure the thread of spindle -A- of the pliers is
smooth. If necessary grease with molykote grease,
e.g. MoS2.
♦ If it is not smooth, e.g. if the thread is dirty, the neces-
sary clamping force of the open warm-type clamp is
not reached at the given torque.
– Tighten the open warm-type clamp on the outer joint

(at the large diameter).

S00.5303.18.20
– Apply tensioning pliers, e.g. -V.A.G 1682- as shown.

Make sure the cutting edges of the pliers are posi-
tioned in the corners -arrows B- of the warm-type
clamp.
V.A.G 1682
– Tighten the warm-type clamp by turning the spindle
with a torque wrench. Do not tilt the pliers during this A
process.
A - Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
C
– Tighten the warm-type clamp at the small diameter
– Apply tensioning pliers, e.g. -V.A.G 1682- as shown.
Make sure the cutting edges of the pliers are posi-
tioned in the corners -arrows B- of the warm-type
clamp.
– Tighten the warm-type clamp by turning the spindle
with a torque wrench. Do not tilt the pliers during this B S40-0078
process.
A - Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
C - Torque wrench
MP 3-448
Removing inner CV joint
– Removing drive shaft ⇒ 40-4 page 1.

MP 3-407
– Open warm-type clamp.
– Remove joint boot from CV joint with drift.
– Remove the circlip from the drive shaft.
– Press CV joint off the drive shaft.
– Do this while supporting the ball joint.
– Remove the disc spring from the drive shaft. S40-0098
Installing the inner CV joint
– Fit the disc spring -1- onto the drive shaft.

Check fitting position.

S00.5303.18.20
– Push the new joint boot onto the drive shaft.
– Press CV joint onto the drive shaft up to the stop.
Note MP 6-428
Chamfer on inner diameter of the ball hub (serration)
MP 6-429
must point towards the bearing collar of the drive shaft.
– Fit new circlip on the drive shaft. For this use e.g. the
circlip pliers -VW 161 A-.
MP 3-407 MP 3-406
– Coat the edge of the inner joint boot cap with sealant
-D 454 300 A2-.
– Fit joint boot on the constant velocity joint.
Note S40-0099
♦ In view of the hard material (as opposed to rubber) of

the joint boot, which requires the use of a stainless
steel-open warm-type clamp, the latter can only be
tightened with tensioning pliers, e.g. -V.A.G 1682-.
♦ Tightening torque 20 Nm.
♦ Make sure the thread of spindle -A- of the pliers is
smooth. If necessary grease with molykote grease,
e.g. MoS2.
♦ If it is not smooth, e.g. if the thread is dirty, the neces-
sary clamping force of the open warm-type clamp is
not reached at the given torque.
Inspecting a CV joint
Disassembling and inspecting the outer CV joint
Disassemble the joint to replace badly soiled grease or if
the contact surfaces of the balls must be inspected for
wear and damage.
– With an electric stylus or rubstone mark the position of

the ball hub relatively to the ball cage and housing be-
fore disassembling -arrow-.
– Rotate the ball hub and ball cage.
– Remove the balls one after the other.

S00.5303.18.20
– Turn the cage until two rectangular cage windows -ar-

row- rest on the joint part.
– Remove cage with hub.
– Turn the hub segment in opening of the cage.

– Tilt hub out of cage.
Note
♦ The 6 balls of each joint belong to a tolerance group.
Inspect the axle studs, hub, cage and balls for small
depressions (pitting = point erosion) and seizing
marks. Load alteration shocks indicate too much tor-
sional clearance in the joint. If this is the case, replace
the joint. Smoothing and bearing marks do not justify
a joint replacement.
♦ Inspect the cage for tears.
Assembling the outer CV joint

– Press the required grease mass into the joint part
⇒ 40-4 page 2
– Insert the cage and hub in the joint body.
Note
The cage must be inserted in the correct position.
– Press in opposite balls one after the other, during this

process observe the prior position of the ball hub rel-
atively to the ball cage and to the joint part.
– Insert new circlip in the groove of the shaft.
– Spread any residual grease in the joint boot ⇒ 40-4
page 2.
– Installing the joint boot ⇒ 40-4 page 5.
Disassembling and inspecting the inner CV joint
Disassemble the joint to replace badly soiled grease or if
the contact surfaces of the balls must be inspected for
wear and damage.

S00.5303.18.20
Note
The ball hub and joint piece are paired and must be
marked before disassembly. Do not interchange the
bearing track assignment.
– Rotate the ball hub and ball cage.

– Press the ball hub and ball cage out of the joint part in
the direction of the arrow.
– Press out the balls from the cage.
– Tilt the ball hub out of the ball cage over the ball bear-
ing track -arrows-.
– Inspect the joint part, ball hub, ball cage and balls for
small broken out depressions (pitting = point corro-
sion) and seizing marks.
Note
Load alteration shocks indicate too much torsional clear-
ance in the joint. If this is the case, replace the joint.
Smoothing and bearing marks do not justify a joint re-
placement.
Assembling the inner CV joint
– Insert the ball hub in the ball cage over the two cham-
fers. The fitting location is random. Press the balls into
the cage.
– Insert the hub with cage upright into the joint part.

S00.5303.18.20
Note
When inserting make sure the greatest distance -a- on
the joint part is close to the short distance -b- on the hub
after it has been swivelled in -arrow-.
– Swivel in the ball hub, to do so swivel the hub out of

the cage -arrows- until the balls are at bearing track
distance.
– Lock the hub with the balls into position by exerting

considerable pressure on the cage -arrow-.
Inspecting the operation of the CV joint
The CV joint is correctly assembled if the ball hub can be
rolled by hand up and down the entire linear compensa-
tion.

– Press the required grease mass into the joint part
⇒ 40-4 page 2
– Spread any residual grease in the joint boot ⇒ 40-4
page 2.
– Installing the joint boot ⇒ 40-4 page 5.

S00.5303.18.20
40-5 Drive shafts with tripod

joint
Removing and installing a drive shaft

⇒ Chapter 40-4
V - Summary of components of drive

shaft with AAR2000 tripod joint
Grease quality and grease quantity
Note
♦ The outer joints of the drive shaft must be filled with
grease for operating at normal temperatures, e.g.
-N 052 738 00-.
♦ Only use high-temperature grease from the relevant
repair kit for filling the CV joint ⇒ Spare Parts cata-
logue.
Grease of which in:

Total Joint Joint boot
Outer joint amount
∅ mm [g] [g] [g]
100 100 +10 100 +10 ---
Tripod joint
∅ mm
108 110 +5 110 +5 ---
Note
♦ Assignment of the drive shafts ⇒ Spare part cata-
logue
♦ Grease joint if necessary, when replacing the joint
boot.
♦ On tripod joints only apply grease in the joint; the
grease should never let in the grease boot. Of all of
the grease used, half should be pressed into the front
side of the joint and the other half on the rear side of
the tripod joint.
Edition 04.05 Drive shafts with tripod joint 40-5 page 1

S00.5303.18.20
1 - Joint boot for the joint

T inspect for tears and chafing
points
catalogue
2 - Warm-type clamp
T replace
T tensioning ⇒ Chapter 40-4
3 - Screw
T initially tighten to 10 Nm,
subsequently tighten cross-
wise to final torque:
M 10 = :
70Nm
M8=:
40Nm
catalogue
4 - Shim
catalogue
5 - Joint part
catalogue
6 - Tripod spider with rollers
T Chamfer -arrow- points towards the drive shaft serration
7 - Circlip
T replace
8 - O-ring seal
T replace
9 - Cover
T replace
10 - Hose clamp
T for tripod joint
T replace
11 - Joint boot for tripod joint
T inspect for tears and chafing points
12 - Drive shaft
T replace
40-5 page 2 Drive shafts with tripod joint Edition 04.05

S00.5303.18.20
14 - Disc spring
T Fitting location ⇒ Chapter 40-4
15 - Thrust ring
16 - Circlip
T replace
17 - Outer CV joint
T removing ⇒ Chapter 40-4
T Installing: carefully drive onto the shaft with a plastic hammer until the compressed circlip expands
T greasing ⇒ Chapter 40-4
18 - Thrower ring
T 13" chassis - black
T 14" and 15" chassis - white
19 - Twelve-point nut
T 13" chassis - black, 50 Nm
T 14" and 15" chassis - silvery, 50 Nm + 45°
Inspecting outer CV joint

⇒ Chapter 40-4
Repairing the drive shaft with AAR 2000

tripod joint
♦ Distance sleeve -MP 3-458/2-
♦ Strutting bushing -MP 6-428-
♦ Clamping device -MP 6-429-
♦ Pliers -3340-
♦ Circlip pliers (commercially available)
♦ Workshop press, e.g. -V.A.G 1290 A-
Disassembling the AAR 2000 tripod joint

– Removing the drive shaft ⇒ Chap. 40-4.
– Open hose clamp on joint part.

S00.5303.18.20
– Straighten the metal tabs -arrows- with a screwdriver

and lever off cover.
S40-0145
– Remove O-ring seal -arrow- from the slot.

– Mark the fitting position of parts -1...3-.
1 - Joint part
2 - Tripod spider
3 - Drive shaft
Note
♦ If parts -1...3- are not marked and if they are not fitted
in their original position again this could cause noises
during driving at a later stage.
♦ Use a waterproof marker for marking.
– Clamp the drive shaft in a vice with protective jaws.

– Removing the circlip.
1
1 - Circlip pliers (commercially available)
S40-0148

S00.5303.18.20
– Hold the joint part and remove drive shaft from the
vice.
– Insert the drive shaft in the press.
– Hold the drive shaft and push tripod spider off the MP 6-405
drive shaft.
– Remove the tripod spider with rollers and lay aside on
a clean surface.
– Remove the joint part from the drive shaft. MP 3-406
– Remove the joint boot from the drive shaft.
– Clean the drive shaft and the joint part.
Assembling the AAR 2000 tripod joint

– Insert the joint boot on the drive shaft.
– Insert the joint part on the drive shaft.
MP 6-428
Note
Chamfer on the tripod spider must point towards the drive
shaft. Chamfer serves as an assembly aid ⇒ item 6 in
40-5 page 2.
S40-0144
– Position the tripod spider on the drive shaft according

to the markings and press on up to the stop.
MP 3-408
– Insert new circlip and pay attention to correct position.
– Slide the joint part over the rollers and hold down.
– Remove the drive shaft from the special tool and MP 3-458/2
clamp in the vice.
MP 3-407
MP 3-406 MP 6-429
S40-0143

S00.5303.18.20
– Press 60 grams of -Hochtemperaturfett- from the re-

pair kit into the tripod joint (on the tripod spider side) A
-arrow A-.
– Press 60 grams of -Hochtemperaturfett- from the re-
pair kit in the rear of the tripod joint -arrow B-.
– Installing the joint boot.
Note
The bead in the joint boot must fit into the groove of the
joint part.
– Remove drive shaft from the vice and clamp the joint B S40-0106
part.
– Insert new gasket ring -arrow- from the repair kit in the
groove.
– Fit the new cover on the joint part.
Note
The bores of the cover and joint part must be flush.
– Fit the hose clamp.
Removing and installing the outer CV

joint
⇒ Chapter 40-4

S00.5303.18.20
42 – Rear wheel suspension
42-1 Rear axle with drum brake
Summary of components of rear axle
Note
♦ Welding and straightening on axle body and axle studs not allowed.
♦ Always replace the self-locking nuts and bolts.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
1 - Wheel bolt, 120 Nm 32

T Allocation ⇒ Spare parts 33
catalogue 31
2 - Screw, 4 Nm 30 34
3 - Brake drum
T reset brake before removing 28
the brake drum ⇒ Chapter
46-2
29
4 - Cap 27 23
T pressing off and inserting 26 21
20
⇒ Chapter 42-5 25
5 - Twelve-point nut, self-lock- 24 19
ing, 70 Nm and turn a further
30° (1/12 turn)
15
12 18
T for vehicles with ABS the
sensor ring is built into the 14 16 17
wheel hub 13
T wheel hub and wheel bearing 12 8 7
form one unit; it does not 11
need servicing.
T the sensor ring for ABS can-
not be replaced individually
⇒ Chapter 42-5 1
T Allocation ⇒ Spare parts
catalogue
2
7 - Screw, 30 Nm + torque a fur- 10 9 6 5 4 3
S42-0122
8 - Brake carrier with brake shoe
T repairing ⇒ Chapter 46-2
9 - Holder for hand-brake cable
10 - Hand-brake cable
Edition 03.02 Rear axle with drum brake 42-1 page 1

S00.5303.11.20
11 - Bracket
T for brake-power regulator
T attached to the vehicle body
12 - Screw, 20 Nm
13 - Brake-power regulator
T load dependent
T for vehicles without ABS
T inspecting and setting ⇒ Chapter 47-3.
14 - Screw, 16 Nm
15 - Screw, 16 Nm
16 - Holder for hand-brake cable
18 - Axle body
T Allocation ⇒ Spare parts catalogue
T The locating face and the threaded holes for axle studs must be free from enamel and dirt
19 - Axle stud
T Straightening work is not allowed!
T Re-cutting the thread is not allowed!
20 - Brake line
T Tightening torque of the pipe screws: 14 Nm
21 - Axle body
T The locating face and the threaded holes for axle studs must be free from enamel and dirt
22 - Self-locking nut
T insert from the inside of the vehicle
T For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight ⇒ Chapter 44-2, then
place a weight of 90 kg in the luggage compartment, immediately behind the rear seat.
This operation can be skipped if the shock absorber and rear suspension are preassembled ⇒ Chapter 42-2.
25 - Plug
T to plug the hole in the axle stud
27 - Bottom spring base
T inspect for damage (visual inspection)
T insert from the outside of the vehicle
T For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight ⇒ Chapter 44-2, then
place a weight of 90 kg in the luggage compartment, immediately behind the rear seat.
29 - Self-locking nut
30 - Mount for rear axle
T attached to the vehicle body
42-1 page 2 Rear axle with drum brake Edition 03.02

S00.5303.11.20
31 - Helical spring
T check for paint damage, if necessary eliminate paint damage
T replace axle-wise
T per rear axle only use helical springs of the same make
32 - Top spring base
T installing ⇒ Chapter 42-2
34 - Shock absorber
T inspecting ⇒ Chapter 40-2
T disposal ⇒ Chapter 40-2
T can be replaced individually
T per rear axle only use shock absorbers of the same make
Fitting location of the shock absorber on the

rear axle
♦ If shock absorber -1- is preassembled to the rear ax-
les -2-, pay attention to the installed angle -α- = 97°.
♦ Tighten up the screws fully to the specified tightening
torque.
♦ It is not necessary to initially tighten the bolt and to 1
place a weight of 90 kg in the vehicle.
Removing and installing rear suspen- α

sion
♦ Torque wrench
♦ Brake pedal arrester, e.g. -V.A.G 1238 B- or brake
pedal load-V.A.G 1869/2-
♦ Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
-V.A.G 1359/2-
♦ Spring tensioning device, e. g. -V.A.G 1752/1-
♦ Spring holder with protective lining, e. g. -V.A.G 1752/ 2
3-
♦ Securing strap, e. g. -T10038- S42-0145
♦ Brake filling and bleeding device, e. g.
-ROMESS S15-
♦ Wooden block 490 x 270 x 50 mm for attachment
-V.A.G 1359/2-
♦ Assembly paste -G052 150 A2-
Removing
– Remove wheels.

S00.5303.11.20
– Removing the centre console ⇒ Body Work;

Rep. Gr. 68.
– Actuate the brake pedal and insert the brake pedal de-
pressor.
This prevents the brake line and the ABS hydraulic unit
from running empty of brake fluid.
– Release adjusting nut -arrow- and unhook hand-brake

cable from compensating clamp.
– Pull hand-brake cables out of guide tubes.
Caution!
♦ Before removing the rear suspension, the vehicle S46-0096
must be lashed securely on both sides at the sup-
porting arms of the lift platform.
♦ If the vehicle is not lashed, there is a risk of the
vehicle toppling off the lift platform.
– Remove the plugs from the frame side rail and the pull 2
in the securing strap
1 - Supporting arm of lift platform
2 - Securing strap, e. g. -T10038-
1
– Lash the vehicle on both sides to the supporting arms
of the lift platform.
– Pull out the plug connector from the oil pressure
switch. N42-0390
– Unclip cable for wheel speed sensor from the fixture.
– Unhook handbrake cable from the holders -arrows-.
– Detach clip -2- from brake hose fixture.
2
– Separate brake line.
Note
Seal brake lines with plugs.
1
Only on vehicles equipped with Xenon head-
lights
– Disconnect the tension rod for the sender at the rear
of the assembly carrier ⇒ Electrical System;
Rep. Gr. 94.
S42-0147

S00.5303.11.20
Only on vehicles fitted with load-sensitive brake
pressure regulator (without ABS)
– Screw out bolt -1-. 1

– Remove coil spring ⇒ Chapter 42-2.
– Slacken the front attachment of the wheelhouse liner S42-0148
at the rear ⇒ Body Work; Rep. Gr. 66.
– Insert wooden block -A- into attachment, e. g.
- V.A.G 1359/2-.
V.A.G 1359/2
– Support rear axle with gearbox jack and attachment.
Note A
A second person is required for the further removal oper-
ations.
– Unbolt rear suspension from shock absorbers -ar-

rows-.
– Secure rear suspension at attachment, e. g. with strap V.A.G 1383 A N42-0130
of attachment V.A.G 1359/2.
– Screw out the bolts -1- of the bearing bracket of the
rear axle and lower the rear axle.
2
Installing
Installation is carried out in the reverse order. Pay atten-
tion to the following:
– Before inserting the rear suspension, grease the kid- 1

ney-shaped cavities of the bonded rubber bushes with
assembly paste - G052 150 A2 -.
S42-0147

S00.5303.11.20
Note
♦ The bolts of the bearing bracket of the rear suspen-
sion must not be inserted into the profiles of the inner
core -arrows- of the bonded rubber bush. If this is
done, the rear suspension will be installed skewed
and the bush will be damaged. In this case, the bush
must be replaced.
♦ To provide a clearer illustration, the bonded rubber
bush is shown with the rear suspension removed.
♦ The axle beam should be moved into the horizontal
position when tightening the bolts and nuts of the
bearing bracket of the rear suspension and the shock
absorber. Place the vehicle onto its wheels for this
step, ensure vehicle is at unladen weight ⇒ Chapter
44-2 and place a weight of 90 kg in the luggage com-
partment, immediately behind the rear seat. S42-0150
– Install shock absorber ⇒ Chapter 42-2.

– Install new nuts and bolts on the front axle mounting
but do not tighten up completely.
– Install coil spring ⇒ Chapter 42-2.
– Install a new clamp for attaching the brake line.
– Adjust handbrake ⇒ Chapter 42-2.
– Bleed brake system ⇒ Chapter 47-4.
– If fitted, inspect the load-sensitive brake pressure reg-
ulator and set if necessary ⇒ Chapter 47-3.
– If fitted, adjust the upper position of the tension rod in
such a way before tightening up so that the sender le-
ver points towards the rear when whipping the rear
axle and does not turn upwards.
– Tighten up the screw of the bearing bracket of the rear
axle fully to the specified tightening torque. Place ve-
hicle onto its wheels and ensure it is at its unladen
weight ⇒ Chapter 44-2. Then place a 90 Kg weight in
the luggage compartment immediately behind the rear
seat.
Tightening torques:
Brake line to brake hose 14 Nm

Shock absorber to rear suspension 40 Nm +90°
Rear suspension to bearing bracket 45 Nm +90°
Brake pressure regulator to rear sus- 16 Nm
pension
The sender at the rear on the rear axle 16 Nm
Wheel bolts 120 Nm

S00.5303.11.20
42-2 Servicing the rear axle

with drum brakes
Removing and installing coil spring

♦ Spring tensioning device, e. g. -V.A.G 1752/1-
♦ Spring holder with protective lining, e. g. -V.A.G 1752/
3-
Removing V.A.G
1752/1
Note
The rear silencer must be taken off in order to remove the
left coil spring.
– Removing the rear silencer ⇒ Engine - Mechanics;

Rep. Gr. 26.
Note
♦ Ensure that the spring holders are positioned as close V.A.G 1752/3 S42-0149
as possible to the spring coils -arrow-.
♦ During the tensioning operation, ensure that the
spring holder is correctly located at the spring coils.
♦ Do not use impact screw drivers. 2
– Insert spring tensioning device. 1
– Tension coil spring sufficiently until it can be removed. V.A.G 1752/3
– Remove coil spring.
1 - top base
2 - Mount for top base
Installing
– Check to ensure that the zinc base (bottom base) is
not damaged. V.A.G 1752/1 S42-0146
Replace if necessary.
– Install the helical spring along with the top base.

The beginning of the spring -arrow- must be positioned at
the stop at the top of the base.
– Release the tension of the coil spring and remove the

spring tensioner (do not damage surface protection
for the coil spring).
Edition 04.04 Servicing the rear axle with drum brakes 42-2 page 1
S00.5303.15.20
Removing and installing shock absorber

♦ Torque wrench
-V.A.G 1359/2-
Removing
– Remove wheel.
– Place gearbox jack with attachment below and sup-
port rear suspension at shock absorber mounting.
Only on vehicles equipped with an Xenon head-

lights
of the assembky carrier ⇒ Electrical System;
Rep. Gr. 94.

– Remove bolts -1- and -2-.
– Take out shock absorber.
1
Installing
– Install a bolt on the shock absorber for the rear axle

and tighten by hand.
such away before tightening up so that the sender le-
– Place vehicle onto its wheels and ensure it is at its un-
laden weight ⇒ Chapter 44-2. 2
– Then place a 90 kg weight in the luggage compart-
ment immediately behind the rear seat bench.
– Tighten up the screws fully to the specified tightening
torque.
V.A.G 1383A V.A.G 1359/2
S42-0040
Tightening torques:
Shock absorber to body 30 Nm + 90°

♦ Use new screws!
Shock absorber to rear suspension 40 Nm + 90°
Wheel bolts 120 Nm
42-2 page 2 Servicing the rear axle with drum brakes Edition 04.04
S00.5303.15.20
Disassembling and assembling shock absorber
Note
The shock absorbers must not be disassembled and repaired.
1 - Shock absorber
⇒ 42-2 page 2
catalogue
T disposal ⇒ Chapter 40-2
2 - Protective cap
3 - Protective tube 5
4 - Stop buffer
5 - Shock absorber bushing
T counterhold the piston rod of 4
the shock absorber at the tip
in order to slacken and tight-
en the nut
7 - Cover
3
1
S42-0152
Inspecting the shock absorber

⇒ Chapter 40-2
Disposing of the shock absorber

⇒ Chapter 40-2
removing and installing rubber-metal

bearing
♦ Universal tool -MP 3-419-
♦ Axial bearing -MP 5-402-
S00.5303.15.20
♦ Assembly device, e. g. -MP 5-400-

♦ Torque wrench
-V.A.G 1359/2-
♦ Wooden block 490 x 270 x 50 mm for attachment
-V.A.G 1359/2-
♦ Securing strap, e. g. -T10038-
Removing
Note
It is only possible to replace the bonded rubber bush
when the rear suspension is lowered.
– Remove wheels.
Caution!
♦ Before removing the rear suspension, the vehicle
must be lashed securely on both sides at the sup-
porting arms of the lift platform.
♦ If the vehicle is not lashed, there is a risk of the
vehicle toppling off the lift platform.
– Remove the plugs from the frame side rail and the pull
in the securing strap
1 - Supporting arm of lift platform
2 - Securing strap, e. g. - T10038-
– Lash the vehicle on both sides to the supporting arms

of the lift platform.
– Unhook handbrake cable from the holders -arrows-.
– Detach clip -2- from brake hose fixture. 2
– Release brake line from fixture, on no account sepa-
rate.
Only on vehicles equipped with an Xenon head-

lights 1
of the assembky carrier ⇒ Electrical System;
Rep. Gr. 94.
S42-0147
S00.5303.15.20
Only on vehicles fitted with load-sensitive brake
pressure regulator (without ABS)
– Release screw -1-. 1
– Slacken the front attachment of the wheelhouse liner
at the rear ⇒ Body Work; Rep. Gr. 66.
– Remove coil spring ⇒ 42-2 page 1.

– Insert wooden block into attachment, e. g.
-V.A.G 1359/2-.
– Support rear axle with gearbox jack and attachment.
S42-0148
Note
A second person is required for the further removal oper-
ations.
– Secure the rear axle with the strap of the attachment. 2

– Screw out bolts -1- on the bearing bracket of the rear
axle.
– Swivel rear suspension on both sides down and out of
the bearing brackets.
1
Note
♦ When lowering the rear axle, ensure that the brake
lines and handbrake cables are not tensioned.
♦ Lower rear suspension only sufficiently to gain clear
access to the rubber-metal bearing. S42-0147
– Lower rear suspension.

– Insert special tools as shown and pull out rubber-met-
al bearing.
Note
A second mechanic must counterhold at the rear axle
when pulling out the rubber-metal bearing.
MP 5-400/2
MP 3-419
S42-0143
S00.5303.15.20
Installing
Fabia RS
1
The axle -1- must be aligned with the edge -arrow- of the
trailing arm -2-.
2 S42-0160
Other vehicles (except Fabia RS)

The rubber-metal bearing has a marking -1- on the inside.
This marking must be aligned with the edge -arrow- of the
trailing arm -2-.
– Mark the position of the marking -1- on the rubber-

metal bearing.
1
2 S42-0151
Fabia RS
– Insert special tools together with rubber-metal bearing

as shown.
S00.5303.15.20
Other vehicles (except Fabia RS)
– Insert special tools together with rubber-metal bearing

as shown.
For all vehicles
– Ensure that the marking or the axle is aligned with the

edge of the trailing arm.
– Pull the rubber-metal bearing -2- onto the spindle by
turning.
– Verify the installed position of the mounting once the
installation is complete.
If the marking or the axle is not aligned with the edge of
the trailing arm, it is then necessary to repeat removal
and installation.
Further installation occurs in reverse order. Pay attention
to the following:
– Before inserting the rear suspension, grease the kid-

ney-shaped cavities of the rubber-metal bearing with
assembly paste -G 052 150 A2-.
Note
♦ The bolts of the bearing bracket of the rear suspen-
sion must not be inserted into the profiles of the inner
core -arrows- of the rubber-metal bearing. If this is
done, the rear suspension will be installed skewed
and the bush will be damaged. In this case, the rub-
ber-metal bearing must be replaced.
♦ To provide a clearer illustration, the rubber-metal
bearing is shown with the rear suspension removed.
– Install new nuts and bolts on bearing bracket of the

rear axle and tighten by hand.
Note
The axle beam should be moved into the horizontal posi- S42-0150
tion when tightening the bolts and nuts. Place the vehicle
onto its wheels for this step, ensure vehicle is at unladen
weight ⇒ Chapter 44-2 and place a weight of 90 kg in the
luggage compartment, immediately behind the rear seat
bench.
– Install coil spring ⇒ 42-2 page 1.

such away before tightening up so that the sender le-
– Install a new clamp for attaching the brake line.
– Tighten up the screw of the bearing bracket of the rear
axle fully to the specified tightening torque. Place ve-
hicle onto its wheels and ensure it is at its unladen
weight ⇒ Chapter 44-2. Then place a 90 kg weight in
the luggage compartment immediately behind the rear
seat bench.
S00.5303.15.20
Tightening torques:
Rear suspension to bearing bracket 45 Nm + 90°

Brake pressure regulator to rear sus- 16 Nm
pension
The sender at the rear on the rear axle 16 Nm
Wheel bolts 120 Nm
S00.5303.15.20
42-3 Rear suspension with disc brake
Summary of components of rear suspension
Note
♦ Welding and straightening on axle beam and axle stubs not allowed.
♦ Always replace the self-locking nuts and bolts.
♦ Always replace corroded self-locking nuts and bolts.
♦ Always tighten pipe connections of brake lines to a torque of 14 Nm.
1 - Brake caliper 27
T repairing ⇒ Chap. 47-1 28
2 - Wheel bolt, 120 Nm 26
T Assignment ⇒ Spare part
25 29
catalogue
3 - Cross-head screw, 4 Nm 23
4 - Brake disc
5 - Cap 24 18
T replace each time removed 22 19
17
T pressing off and inserting
⇒ Chap. 42-5 21 16
6 - Twelve-point nut, self-lock-
ing, 70 Nm + torque a further 20 15
30° (1/12 turn)
T replace each time removed
T for vehicles with ABS the 14
sensor ring is built into the
wheel hub 12 13
T Wheel hub and wheel bear-
ing form one unit. The unit is
maintenance-free. Adjusting
and repairs are not possible.
1
T The sensor ring for ABS can-
not be replaced individually
⇒ Chap. 42-5 2
catalogue 3
8 - Hexagon bolt + washer, 11 10 9 8 7 6 5 4
30 Nm + torque a further 90° S42-0123
(1/4 turn)
9 - Cover plate
10 - Fixture for handbrake cable
T Fitting location ⇒ Chap. 46-3
11 - Handbrake cable
T removing and installing ⇒ Chap. 46-3
12 - Fixture for handbrake cable
14 - Axle beam
T Assignment ⇒ Spare part catalogue
Edition 02.01 Rear suspension with disc brake 42-3 page 1

S00.5303.07.20
T The locating face and the threaded holes for axle stubs must be free from enamel and dirt
15 - Axle stub
T Straightening work is not allowed!
T Re-cutting the thread is not allowed!
16 - Hexagon bolt, 30 Nm + torque a further +30° (1/12 turn)
17 - Brake line with connection, banjo bolt and seals
T must not be disassembled, must be replaced completely
T Tightening torque of banjo bolt: 35 Nm
T do not unscrew when replacing the brake pad
18 - Self-locking hexagon nut
19 - Hexagon bolt, 40 Nm + torque a further 90° (1/4 turn)
T insert from the inside of the vehicle
T For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight ⇒ Chap. 44-2, then place
a weight of 90 kg in the luggage compartment, immediately behind the rear seat.
This operation can be deleted if shock absorber and rear suspension are preassembled, while maintaining
the correct installation angle ⇒ Chap. 42-2.
21 - Hexagon socket bolt, 8 Nm
22 - Bottom spring base
T inspect for damage (visual inspection)
T insert from the outside of the vehicle
T For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight ⇒ Chap. 44-2, then place
a weight of 90 kg in the luggage compartment, immediately behind the rear seat.
24 - Self-locking hexagon nut
25 - Mount for rear suspension
T welded to body
26 - Coil spring
T check for paint damage, if necessary eliminate paint damage
T always replace on both sides of axle
T use only coil springs of the same make on an axle
27 - Top spring base
T installing ⇒ Chap. 42-4
29 - Shock absorber
T inspecting ⇒ Chap. 40-2
T disposal ⇒ Chap. 40-2
T use only shock absorbers of the same make on an axle
42-3 page 2 Rear suspension with disc brake Edition 02.01

S00.5303.07.20
Fitting location of shock absorber of rear sus-

pension
⇒ Chap. 42-1
Removing and installing rear suspen-

sion
⇒ Chap. 42-1
Edition 02.01 Rear suspension with disc brake 42-3 page 3

S00.5303.07.20
42-3 page 4 Rear suspension with disc brake Edition 02.01

S00.5303.07.20
42-4 Servicing rear suspension

with disc brake
⇒ Chap. 42-2
Edition 02.01 Servicing rear suspension with disc brake 42-4 page 1
S00.5303.07.20
42-4 page 2 Servicing rear suspension with disc brake Edition 02.01
S00.5303.07.20
42-5 Repairing the wheel bearing
Summary of components of wheel bearing - drum brake

1 - Phillips screw, 4 Nm
2 - Brake drum
3 - Cap 6 7
T extracting and inserting
⇒ 42-5 page 1
4 - Self-locking twelve-point nut,
70 Nm and tighten a further
30°
8
T Wheel hub with wheel bear-
ing form one unit. The unit is 9
⇒ 42-5 page 1
T Assignment ⇒ Spare Part
Catalogue
6 - Axle body
7 - Brake carrier with brake shoe
⇒ Chap. 46-2
8 - Tighten combination hexagon
screw 30 Nm and 90°
9 - Axle stud 4
T Straightening work is not al-
3
lowed! 2
T Re-cutting the thread is not 1
allowed! S42-0124
⇒ 42-5 page 6

with wheel bearing - drum brake
♦ Drive bushing -MP 3-427-
♦ Hub cap extractor -MP 5-404-
♦ Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
♦ Torque wrench, e.g. - V.A.G 1756-
Removing
– Raise vehicle.

S00.5303.05.20
– Unscrew rear wheel.

– Resetting brake.
– To this end use a screwdriver to push the wedge up
through a hole for the wheel screws in the brake drum.
– Unscrew the Phillips head screws of the drum brake
and remove drum brake.
S42-0031
– Release cap from its position by gently tapping the

claw of the hub cap extractor.
MP 5-404
S42-0125
– Press off cap.

– Release twelve-point nut.
– Remove wheel hub with wheel bearing from axle stud.
Caution!
On vehicles with ABS make sure the sensor ring is
not damaged. MP 5-404
Installing
– Carefully slide the wheel hub with wheel bearing onto
the axle stud up to the stop.
S42-0126

S00.5303.05.20
Caution!
not damaged.
Note
♦ Do not tilt the wheel hub with wheel bearing on the
axle stud.
♦ Use new twelve-point nuts.
♦ Replace cap after each removal.
♦ Damaged caps allow moisture to penetrate.
– Drive in new cap.
Tightening torques:
Twelve-point nut to axle stud 70 Nm + 30°

♦ Use new nut!
Drum brake to wheel hub 4 Nm
Wheel bolts 120 Nm
MP 3-427
S42-0127

S00.5303.05.20
Summary of components of wheel bearing - disc brake

1 - Phillips screw, 4 Nm
2 - Brake disc 6 7 8 9
3 - Cap
T extracting and inserting
⇒ 42-5 page 4
30°
T Wheel hub with wheel bear-
ing form one unit. The unit is
10
⇒ 42-5 page 4
T Assignment ⇒ Spare Part
Catalogue
6 - Axle body
7 - Allan screw, 30 Nm +30°
8 - Cover plate
9 - Brake carrier with brake cali-
per
10 - Axle stud
T Straightening work is not al- 5
lowed! 4
T Re-cutting the thread is not
3
allowed! 2
⇒ 42-5 page 6 S42-0128
11 - Tighten combination hexagon
screw 30 Nm and 90°

with wheel bearing - disc brake
Removing
– Raise vehicle.
– Unscrew rear wheel.

S00.5303.05.20
– Release cap from its position by gently tapping the
claw of the hub cap extractor.
MP 5-404
S42-0060
– Press off cap.
MP 5-404
S42-0061
– Unscrew screws -A-, remove brake caliper and tie up

with wire or anything similar.
Note
Do not unscrew the brake hose to remove the brake cal-
iper.
– Unscrew the Phillips head screws of the brake disc

and remove brake disc. A
– Unscrew the twelve-point nut.
– Remove wheel hub with wheel bearing from axle stud.
S42-0062

S00.5303.05.20
Caution!
not damaged.
Installing
– Carefully slide the wheel hub with wheel bearing onto
the axle stud up to the stop.
Caution!
not damaged.
Note
♦ Do not tilt the wheel hub with wheel bearing on the
axle stud.
♦ Use new twelve-point nuts.
♦ Replace cap after each removal.
♦ Damaged caps allow moisture to penetrate.
– Drive in new cap.
Tightening torques:
Brake carrier with brake caliper to axle 30 Nm +30°

body
Twelve-point nut to axle stud 70 Nm +30°
♦ Use new nut!
Brake disc to wheel hub 4 Nm
Wheel bolts 120 Nm
MP 3-427
S42-0129
Removing and installing axle studs
The following special tools and aids are only required for
vehicles with drum brakes.
♦ Vehicle system tester -V.A.G 1552- (only for vehicles
with ABS/TCS)
♦ Diagnostic cable -V.A.G 1551/3-
pedal load device, e.g. -V.A.G 1238 B-

S00.5303.05.20
♦ Brake filling and bleeding device. -ROMESS S15-
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ Chap. 00-3
Note
♦ Straightening work on axle studs is not allowed!
♦ Re-cutting the axle stud thread is not allowed!
Removing and installing the axle stud - Drum

brake
– Removing the wheel hub with wheel bearing ⇒ 42-5
page 1.
– Release hexagon screws -arrows-.
– Removing the brake carrier with brake shoe ⇒ Chap.
46-2.
– Remove the axle stud.
The installation occurs in reverse order.
– Bleeding brake system ⇒ Chap. 47-4.
Tightening torques:
Axle stud to axle body 30 Nm + 90°

♦ Use new screws! S42-0130
♦ Use new nut!
Drum brake to wheel hub 4 Nm
Brake line to wheel brake cylinder 14 Nm
Wheel bolts 120 Nm
Removing and installing the axle stud - Disc

brake
– Removing the wheel hub with wheel bearing ⇒ 42-5
page 4.
– Remove cover plate and axle stud.
S42-0131

S00.5303.05.20
Tightening torques:
Axle stud to axle body 30 Nm + 90°

♦ Use new screws!
♦ Use new nut!
Brake disc to wheel hub 4 Nm
Brake carrier with brake caliper to axle 30 Nm +30°
body
Wheel bolts 120 Nm

S00.5303.05.20
44 – Wheels, Tyres, Chassis Alignment
44-1 Wheels, Tyres

Wheel/tyre combinations ⇒ Chap. 00-4
Further information can be found in the instructions for
use.
General points
For safety reasons never change tyres individually but at
least in axle pairs.
Tyres with the greatest tread depth must always be fitted
at the rear.
It is recommended to fit tyres of the same make, same
type and tread pattern on all wheels.
When replacing the disc wheel or the tyre always replace
the rubber valve.
Note
Before installing the wheel, coat the centering of the hub
with grease -G 052 753 A2-.
Mount the tyre with the DOT marking pointing towards the
outside of the wheel. This applies only to the left side of
the vehicle for directional tyres.
For directional tyres mount a wheel/tyre combination for
the right side of the vehicle as spare wheel.

S00.5303.15.20
Disc wheel
Note
♦ Because of design variations the disc wheel and wheel trim cap may differ from the figure.
♦ When using anti-theft wheel bolts, the anti-theft bolt must be as close as possible to the valve.
1 - Tyres
2 - Wheel rims
T 5J x 13, ET 35
T 5J x 14, ET 35
T 6J x 14, ET 43
T 6J x 15, ET 43 1
2
Note
3
When using anti-theft wheel
bolts for steel rims, the anti-theft 4
bolt must be mounted in direc- 5
tion of the valve.
4 - Remove wheel trim cap
T remove with pull-off hook
⇒ item 5.
Note
When using anti-theft wheel
bolts for steel rims, first assem-
ble the wheel trim cap onto the
anti-theft bolt (at valve).
5- Pull-off hook
T included in tool kit
6- Wheel bolt key
7 8 9 8 7 6
7- Balancing weights
T max. 60 g allowed per rim
flange
8- Retaining spring for balanc-
ing weights S44-0010
9- Valve
T only use valve in accordance with spare part catalogue

S00.5303.15.20
Light-alloy wheel
Light-alloy rim 6J x 14, ET 43
Note
Because of design variations the light alloy rim and wheel trim cap may differ from the figure.
1 - Tyres
2 - Light-alloy rim
T 6J x 14, ET 43
3 - Anti-theft wheel bolt, 120 Nm
4 - Cap
1
T for anti-theft wheel bolt
⇒ item 3
T Remove with pull-off hook 2
⇒ item 5.
3
4
5 - Pull-off shackle 5
6
6 - Wheel bolt key
7 - Adapter for anti-theft wheel
bolt
8 - Wheel trim cap
T can only be removed once 7
the wheel has been removed
Note
Do not use a pull-off hook or oth-
er tools, e.g. screwdriver as this 8
could damage the wheel trim
cap.
Removing: 11 12 13 12 11 10 9
Push the wheel trim cap towards
the outside from the inside of the
rim.
Installing:
Push-in the wheel trim cap from S44-0011
the outside of the rim, it clicks
audibly.
9- Cap
T for wheel bolt ⇒ item 10
T Remove with pull-off hook ⇒ item 5.
11 - Balancing weights
T max. 60 g allowed per rim flange
12 - Retaining spring for balancing weights
13 - Valve
T only use valve in accordance with spare part catalogue

S00.5303.15.20
Light-alloy rim 6J x 15, ET 43
Note
Because of design variations the light alloy rim and wheel trim cap may differ from the figure.
1 - Tyres
2 - Light-alloy rim
T 6J x 15, ET 43
3 - Anti-theft wheel bolt, 120 Nm
4 - Adapter for anti-theft wheel
bolt
1
2
3
6 - Wheel trim cover 4
T remove with pull-off hook
⇒ item 7.
7 - Pull-off hook
5
8 - Wheel bolt key 6
9 - Balancing weights
T max. 60 g allowed per rim
flange
10 - Retaining spring for balanc-
ing weights
11 - Valve
T only use valve in accordance
with spare part catalogue
9 10 11 10 9 8 7
S44-0012

S00.5303.15.20
44-2 Vehicle alignment
General points
The vehicle must only be aligned using an alignment
gauge released by the manufacturer!
We recommend you align both the front and rear axles
during each chassis alignment procedure.
Otherwise correct vehicle driving behaviour cannot be
guaranteed!
Note
♦ Only perform a vehicle alignment after the first 1000 to
2000 km to allow the helical springs to fully settle.
♦ During adjustment work try to approximate the nomi-
nal values.
If the fitting position of the rear axle and hence the run-
ning direction of the vehicle are not considered this could
result in a skew steering wheel.
Note
♦ Before removing mark the steering wheel position rel-
atively to the steering column.
♦ This position must not be changed! Otherwise the
central position of the gear rack cannot be guaran-
teed!
♦ Steering columns supplied as spare parts do not have
dotting marks. These steering columns must be dot
marked after chassis alignment and a subsequent test
drive.
♦ vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 If the
steering wheel is offset on these vehicles, a null bal-
ance of the steering angle sender -G85- is carried out
(either using the vehicle system tester -V.A.G 1552-
⇒ Chapter 45-13 or using the vehicle diagnosis,
measurement and information system -VAS 5051-
⇒ Chapter 45-4).
♦ vehicles with ABS//TCS/ESP BOSCH 8.0 If the steer-
ing wheel is offset on these vehicles, a null balance of
the steering angle sender -G85- is carried out (either
usng the vehicle system tester -V.A.G 1552-
⇒ Chapter 45-14or using the vehicle diagnosis,
⇒ Chapter 45-4).
Edition 07.04 Vehicle alignment 44-2 page 1

S00.5303.16.20
It is necessary to perform a vehicle alignment in the event of:

♦ incorrect driving behaviour
♦ damage caused by accident and if parts have been replaced
♦ axle parts have been removed
♦ there is unilateral tyre wear
Front axle part replaced Chassis alignment Rear axle part replaced Chassis alignment re-
required quired
yes no yes no
Axle link X Shock absorber X
Wheel-bearing housing X Helical spring X
Track rod/track-rod ends X Complete rear axle X
Steering gear X
Assembly carrier X
Suspension strut or shock ab- X
sorber or helical spring
Console for engine-gearbox X
assembly carrier
Anti-roll bar X
Test requirements
• Determining the running gear version according to the
vehicle data sticker ⇒ Chap. 00-1.
• Check the wheel suspension, steering and steering
linkage for unauthorised clearance and damage, if
necessary repair.
• Check tyre inflation pressure, if necessary correct
⇒ Inspection and Maintenance or ⇒ fuel-tank cap
sticker.
• Check the tyre tread depth. The difference between
the left and right tyres on an axle must not exceed 2
mm.
• The unladen weight of the vehicle must correspond
with the vehicle documents.
Unladen weight:
Weight of the vehicle with full fuel tank and full water
reservoir for windscreen wiper/washer and headlamp
cleaning system, spare wheel, tool kit, jack and with-
out driver. The spare wheel, tool kit and jack must be
located in the position prescribed by the vehicle man-
ufacturer.
• Vehicle must be aligned, with the springs having been

repeatedly deflected and having returned to their orig-
inal position.
• Make sure that during alignment no sliding base and
no rotating plate touches the limit stop.
Note!
• The measuring device must be positioned and adjust-

ed in compliance with the specifications; follow the
manufacturer's instructions!
44-2 page 2 Vehicle alignment Edition 07.04

S00.5303.16.20
If necessary obtain information on your alignment gauge
from the manufacturer.
In the course of time the alignment platform and align-
ment gauge/alignment computer may deviate from their
original adjustment/setting.
The alignment platform and alignment gauge/align-
ment computer must be tested and adjusted during a
maintenance operation at least once a year or follow-
ing the manufacturer's instructions and if necessary
be adjusted!
Treat these precision instruments with great care.
Measurement preliminaries
♦ Brake pedal arrester, e.g. -V.A.G 1238/B- or
-V.A.G 1869/2-
♦ Open-jawed wrench insert waf 22, e.g. -V.A.G 1332/
12-
♦ Alignment/measuring gauge
♦ Weights, e.g. sand bags approx. 10 kg
The lateral runout on the rims must be balanced (com-

pensated). Otherwise the alignment result will be distort-
ed.
Correct toe-in adjustment is impossible if the rim run-
out has not been compensated!
To this end comply with the instructions of the alignment
gauge manufacturer.
– Perform a rim runout compensation.

– Lower vehicle and deflect the springs.
– Fit Brake pedal arrester, e.g. -V.A.G 1238/B- or
-V.A.G 1869/2- and activate the brake pedal with
Brake pedal arrester.
Overview of the work sequence for vehicle alignment
The following sequence of work steps must always
be respected!
1 - Find out what chassis has been mounted in the ve-
hicle. This information can be found on the vehicle
data sticker ⇒ Chap. 00-1
2 - Check camber on front axle, if necessary take the
mean ⇒ 44-2 page 4
3 - Check camber on rear axle ⇒ 44-2 page 5
S45-0016
4 - Check track on rear axle ⇒ 44-2 page 5
5 - Check track on front axle, if necessary adjust
⇒ 44-2 page 5
The following always applies!
Always check the transversal inclination of the vehicle be-
fore adjustment if one of the measuring values is outside
the tolerance ⇒ 44-2 page 4.

S00.5303.16.20
Chassis terms
⇒ Chapter 00-1
Nominal values for vehicle alignment

♦ Front axle nominal values ⇒ Chap. 00-1.
♦ Rear axle nominal values ⇒ Chap. 00-1.
Checking the transversal inclination of

the vehicle
Transversal inclination of the vehicle: „Straight-
ahead position“
It is possible the vehicle is skew if the measured val-
ues lie outside the tolerance for the front and rear
axle nominal values ⇒ Chap. 00-1.
RHD vehicles or e. g. vehicles with an automatic gearbox
may be slightly skew.
This is normal and is due to the fitting locations of the as-
semblies and the related weight transfer.
– Deflect the vehicle repeatedly and allow the springs to

return to their original position.
Note
Only determine dimension -a- on the rear axle.
Determining dimension -a- for the left and right vehicle
side.
aleft - left vehicle side
aright - right vehicle side
α = 90°
– Compare dimensions aleft and aright.

a
The deviation between aleft and aright must neither ex-
ceed nor fall short of ± 5.0 mm.
– Correct any deviations outside tolerance ± 5.0 mm.

If the deviation is exceeded, e.g. +8.0 mm, correct the S44-0013
difference on the rear axle on the relevant side by
placing weights in the boot.
If the deviation falls short of e.g. -8.0 mm, correct the
difference on the front axle by placing weights on the
relevant suspension strut dome.
Suitable weights are e.g. sand bags approx. 10 kg
Checking the camber on the front axle, if

necessary take the mean
The camber cannot be adjusted, it can only be centered.

S00.5303.16.20
If the values lie outside the tolerance the transversal incli-
nation must be checked and if necessary adjusted
⇒ 44-2 page 1.
It is only possible to evenly center the camber within the
tolerance range by shifting the complete engine-gearbox
assembly carrier.
– Release screws -1- and -2-.

– Move the engine-gearbox assembly carrier with con-
sole until the camber is equal on both sides.
– Subsequently check the castor.
When moving the engine-gearbox assembly carrier
with console the castor may change.
2
– Tighten the console with the engine-gearbox assem-
bly carrier with new screws.
Tightening torque:
Console for engine-gearbox assembly Tighten 70 Nm 1

carrier on body. + 90° S44-0014
♦ Use new screws!
Checking the camber on the rear axle

The camber cannot be adjusted.
⇒ 44-2 page 1.
If the measured values still lie outside the tolerance,
check the axle body for damage and if necessary replace.
Checking the track on the rear axle

The track cannot be adjusted.
⇒ 44-2 page 1.
If the measured values still lie outside the tolerance,
check the axle body for damage and if necessary replace.
Checking the tracking on the front axle,

adjusting if necessary 1
⇒ 44-2 page 1.
– Release counternut -1 -.
– Adjust track by turning the left and/or right track rod.
Use an open-jawed spanner on the hexagon bolt -ar-
row- of the track rod.
Check that the bellows have not become twisted after S44-0015
turning the track rods!

S00.5303.16.20
Twisted bellows wear fast.
– Tighten counternut -1- with 50 Nm and again check

track value.
After tightening counternut -1- the set value may change
slightly.
Make sure this value remains within the tolerance for the
nominal value. If this is not the case repeat the track ad-
justment operation.
Checking the left and right steering an-

gle
This check is only required if
♦ the steering angles differ by more than 2° from the
steering centre.
♦ at full steering angle the tyres come into contact with
components on the front axle or body on one side,
♦ the left/right turning clearance circle differs.
The distance between the components on the front axle

and the tyres -arrow- must be the same on both sides at
maximum steering angle.
If the distance is unequal it is possible to correct the dis-
tance by turning the left and right track rod.
Example:
The distance between the front axle components and the
tyres is smaller on the left than on the right.
– Release the counternuts on the track rods.

– Turn the track rod on the left (unscrew from track-rod
end).
S44-0016
– Turn the track rod on the right to the same extent
(screw into track-rod end).
– Check overall track.
After this adjustment procedure the overall track
must correspond with the specified nominal value!
– Tighten counternuts with 50 Nm.

After tightening the counternuts the set value may
change slightly.
Make sure this value remains within the tolerance for the
nominal value. If this is not the case repeat the overall
track adjustment operation.
Check that the bellows have not become twisted after
turning the track rods!

S00.5303.16.20
Calculation of the misalignment on the rear axle
Note
The indicated values are only given as an example.
– For track values with the same preceding sign (+/+ or -/-) subtract the smaller value from the greater value and
divide by 2.
Track value on the rear left wheel Track value on the rear right wheel
+15' +5'
15' - 5' = 10'
10' : 2 = 5'
Deviation from the running direction = 5'
– Value with a different preceding sign (+/-) are added up and the sum is divided by 2.
Track value on the rear left wheel Track value on the rear right wheel
+15' -5'
15' + 5' = 20'
20' : 2 = 10'
Deviation from the running direction = 10'

The relevant result is the actual deviation of the running direction from the longitudinal vehicle axis.

S00.5303.16.20

S00.5303.16.20
45 – Anti-Lock Brake System
45-1 Antilock braking system

(ABS)
Safety precautions, basic information on

fault finding and on repairing
♦ The ABS and ESP are vehicle safety systems; de-
tailed system knowledge is required for working on
such systems.
♦ Testing and replacement or repairs should be carried
out only by personnel specially trained for ABS.
Dash panel insert up to model year 2004 4
S45-0184
1 2 3
Dash panel insert as of model year 2005
♦ Faults are indicated by the ABS warning light -K47-
(-3-), the red dual circuit and hand brake system warn-
ing light -K7- (-4-) and the traction control system
warning light -K86- or ESP and TCS warning light
-K155- (-2-). Certain faults are not detected until after
a minimum speed of 20 km/h has been exceeded
(conduct a road test).
♦ The brake pad warning light -K32- (-1-) indicates the
condition of the brake pads. If the warning light does
not go out after the ignition is switched on or it comes
on when driving, the brake pads could be worn down.
0
♦ If the ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- do not light up 4
and if in spite of this the brake system is not fully op- S45-0187
erational, look for the fault in the conventional brake
1 2 3
system ⇒ Chap. 46-1 and ⇒ Chap. 47-1.
♦ Notes on rectifying sudden faults ⇒ Technical Service
Handbook.
Instructions for repair work on Antilock

braking system
ABS systems BOSCH 5.7 and BOSCH 8.0
♦ The hydraulic unit of the systems ABS, ABS/EDL/TCS
BOSCH 5.7 and ABS, ABS/TCS BOSCH 8.0 can be
disassembled and repaired.
♦ The hydraulic unit ABS/EDL/TCS/ESP BOSCH 5.7
and ABS/TCS/ESP BOSCH 8.0 must not be disas-
sembled and repaired. In the event of faults or de-
fects, replace the complete hydraulic control unit.
♦ A repair of the hydraulic control unit is only possible in
an unmounted condition.
Edition 07.04 Antilock braking system (ABS) 45-1 page 1

S00.5303.16.20
♦ The separation of the hydraulic unit for ABS -N55- and

the return flow pump for ABS -V39- (-a-) from the ABS
control unit -J104- (-b-) is possible.
♦ The separation of the return flow pump for ABS -V39-
from the hydraulic unit for ABS -N55- is not permitted. a
ABS BOSCH 5.7
b
S45-0068
ABS, ABS/TCS BOSCH 8.0
a
b
S45-0181
ABS/TCS/ESP BOSCH 8.0

Continued for ABS systems BOSCH 5.7 and BOSCH
8.0 a
♦ Carefully cover or close opened components if the re-
b
pair is not completed immediately (use plugs repair kit
-1H0 698 311 A-).
♦ After separating the control unit/hydraulic unit use the
transport protection for valve domes.
♦ Before commencing work on the ABS systems it is
necessary to interrogate the fault memory in order to
check complaints and conduct specific fault finding.
♦ The interrogation of the fault memory can be per-
formed within the framework of:
S45-0182
the self diagnosis with the vehicle system tester
-V.A.G 1552- or
with the vehicle diagnosis, measurement and informa-
tion system -VAS 5051-.
45-1 page 2 Antilock braking system (ABS) Edition 07.04

S00.5303.16.20
♦ Do not separate plug connections unless the ignition
is switched off.
♦ Before commencing work on the ABS systems, switch
off the ignition and disconnect the earth strap at the
battery ⇒ Electrical System; Rep. Gr. 27. On models
fitted with a coded radio set, pay attention to the cod-
ing; determine if necessary.
♦ Welding work using electric welding equipment may
affect the ABS or ESP systems.
♦ Before commencing welding work using electrical
welding tool:
– Disconnect the cable form the negative terminal of the

battery and cover the negative terminal.
– Connect the earth connection of the electric welding
tool directly to the part to be welded. There must not
be any electrically insulated parts between the earth
connection and the welding point.
– Electronic control units and electrical wiring must not
touch the earth connection or the welding electrode.
♦ During paintwork, the electronic control unit can be
loaded for a short time at a maximum of 95 °C and for
longer period (approx. 2 hours) at a maximum of 85
°C.
♦ Do not drive the vehicle if the connector is unplugged
from the control unit.
♦ When carrying out work on the antilock brake system,
ensure scrupulous cleanliness, on no account use
agents containing mineral oils, such as oil, greases,
etc.
♦ Thoroughly clean connection points and the surround-
ing area before disconnecting, but do not use any ag-
gressive cleaning agents, such as brake cleaner,
petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or seal opened components if the re-
pairs are not carried out immediately (use plugs from
repair kit 1HO 698 311 A).
♦ Do not use fluffy clothes.
♦ Remove spare parts from their wrapping immediately
before fitting.
♦ Use only genuine wrapped parts.
♦ If the system is opened, avoid working with com-
pressed air and avoid moving the vehicle.
♦ Ensure that no brake fluid is able to flow into the con-
nectors.
♦ Observe the relevant instructions when handling
brake fluid ⇒ Chap. 47-4.
♦ After completing work which involved opening the
brake system, bleed brake system with brake filling
and bleeding device, e. g. -ROMESS S15-,
⇒ Chap. 47-4.
♦ During the subsequent road test, ensure that at least
one controlled brake application is performed (pulsing
must be felt on the brake pedal).
Edition 07.04 Antilock braking system (ABS) 45-1 page 3

S00.5303.16.20
Required technical information

♦ Binder „Current Flow Diagrams, Electrical Fault Find-
ing and Fitting Locations“
♦ Self-study programme ABS or ESP
♦ Technical Service Handbook
♦ Operating instructions for the vehicle diagnosis,
measuring and information system -VAS 5051-
45-1 page 4 Antilock braking system (ABS) Edition 07.04

S00.5303.16.20
45-2 Distinguishing features of

the ABS system
General Instructions
♦ The ABS prevents the wheels from locking during a
brake application initiated by the driver.
♦ The electronic differential lock (EDL) is a starting-off
aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven
wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhe-
sion. This also applies when reversing.
♦ The traction control system (TCS) prevents the driving
wheels from slipping when accelerating while reduc-
ing the engine power output. This is possible over the
entire vehicle speed range. EDL and TCS are mutual-
ly supportive when accelerating the vehicle.
♦ The engine drag torque control (EDC) prevents that
the drive gears are blocked by the engine because of
the braking ratio, if suddenly the accelerator pedal is
released or when braking with a gear engaged.
♦ The electronic stability program (ESP) recognizes crit-
ical driving conditions and stabilizes the vehicle by in-
dividual wheel braking and by intervention in the
engine control. This occurs independently of the brake
or accelerator pedal activation.
♦ The ESP is active over the entire speed range. If the
ESp is in regulating mode the ESP warning lamp
flashes three times per second.
♦ The description of the structure and function of the
ESP can be found in self-study programme No. 42.
♦ The brake system is split diagonally. Brake servo as-
sistance is provided pneumatically by the vacuum
brake servo unit.
♦ Vehicles fitted with ABS, ABS/EDL/TCS or ABS/EDL/
TCS/ESP BOSCH 5.7 as well as vehicles with ABS, or
ABS/TCS or ABS/TCS/ESP BOSCH 8.0 do not have
a mechanical brake pressure regulator. Specifically
matched software in the control unit, the electronic
brake pressure distribution (EBD) regulates the brake
pressure on the rear axle.
♦ The return flow pump for ABS -V39-, the hydraulic unit
for ABS -N55- and the ABS control unit -J104- form
the hydraulic control unit.
♦ New control units supplied through the Parts Division
are not coded. They must be coded after installation.
♦ Code ABS systems BOSCH 5.7 with the vehicle sys-
tem tester -V.A.G 1552- ⇒ Chap. 45-8 or with the ve-
hicle diagnosis, measurement and information system
-VAS 5051- ⇒ Chap. 45-4.
♦ Code ABS systems BOSCH 8.0 with the vehicle sys-
tem tester -V.A.G 1552- ⇒ Chap. 45-9 or with the ve-
- VAS 5051- ⇒ Chap. 45-4.
Edition 07.04 Distinguishing features of the ABS system 45-2 page 1

S00.5303.16.20
Distinguishing features
Note
Identification and assignment of the ABS systems
⇒ Spare parts catalogue.
ABS BOSCH 5.7
a
♦ Dimension -a-: 102 mm
♦ 8 valve domes: The protective sleeves for the valves
are visible if the control unit is separated from the hy-
draulic unit ⇒ Chap. 45-17.
♦ Control unit identification: The control unit version can
be displayed with the -V.A.G 1552- via the function 01
„Interrogating control unit version“ ⇒ Chapter 45-5 or S45-0108
with the vehicle diagnosis system, measurement and
information system -VAS 5051- ⇒ Chapter 45-4.
♦ List of available functions ⇒ Chap. 45-5.
ABS/EDL/TCS BOSCH 5.7

draulic unit ⇒ Chap. 45-17.
♦ Control unit identification: The control unit version can a
„Interrogating control unit version“ ⇒ Chapter 45-5 or
S45-0114
ABS/EDL/TCS/ESP BOSCH 5.7

♦ Dimension -a-: 130 mm 1
♦ 12 valve domes
♦ Brake pressure sender 1 -G201- (-1-)
a
Note
S45-0105
45-2 page 2 Distinguishing features of the ABS system Edition 07.04

S00.5303.16.20
♦ Inscription „ABS“ on the hydraulic unit for ABS -N55-
draulic unit.
S45-0175

The hydraulic control unit ABS/TCS/ESP BOSCH 8.0
must not be disassembled. It must be replaced as a
complete unit in the case of repairs.
♦ Inscription „ESP“ on the hydraulic unit for ABS -N55-
♦ 12 valve domes
S45-0176
Fitting position of the ABS systems
BOSCH 5.7 and BOSCH 8.0
ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH
5.7
In the engine compartment, to the right on the lateral part
of the engine compartment
Note
The Fig. shows the ABS or ABS/EDL/TCS BOSCH 5.7
hydraulic control unit.
S45-0104
Edition 07.04 Distinguishing features of the ABS system 45-2 page 3

S00.5303.16.20
ABS, ABS/TCS or ABS/TCS/ESP BOSCH 8.0

In the engine compartment, to the right on the lateral part
of the engine compartment 1 2
Note
The Fig. shows the ABS or ABS/TCS BOSCH 8.0 hy-
draulic control unit.
3
S45-0183
45-2 page 4 Distinguishing features of the ABS system Edition 07.04

S00.5303.16.20
45-3 Function of Self-diagno-

sis
General Instructions
ABS systems BOSCH 5.7 and BOSCH 8.0
As the control units are interlinked over two data BUS
lines, always start fault finding by interrogating the con-
tents of the fault memories of all the control units fitted to
the vehicle.
The interrogation of the fault memory can be performed
with the vehicle system tester -V.A.G 1552- by the „auto-
matic test sequence“ (activation with the key function 0
0 ) ⇒ Chap. 45-5 or with the vehicle diagnosis system,
⇒ Chap. 45-4.
When doing so check whether a possibly stored fault
might affect the ABS system.
The ABS control unit -J104- together with the hydraulic
unit for ABS -N55- forms a compact unit. The unit is locat-
ed in the right of the engine compartment. The control
unit is equipped with a fault memory. The connection for
self-diagnosis is located in the storage compartment on
the driver's side.
Self-diagnosis relates to the electrical/electronic part of
the ABS, i. e. faults are detected only over the electrical
connection to the control unit, e.g. open circuit of a wheel
speed sensor.
The control unit detects faults during the operation of the
vehicle and stores them in a permanent memory, whose
information is retained even if the battery voltage is dis-
connected.
Faults which occur sporadically (isolated) are likewise
detected and stored. If this fault no longer occurs during
40 vehicle starts and driving-off procedures, it is erased
from the fault memory (fault delete counter), with the ex-
ception of the fault „Control unit defective“.
After the ignition is switched on the ABS warning light
-K47-, the red dual circuit and hand brake system warn-
ing light -K7- and the traction control system warning light
-K86- or the ESP and TCS warning light -K155- light up
for approx. 2 seconds.
During this period a test sequence (self-check) is per-
formed in the control unit with the following functions:
♦ Test of supply voltage, min. 11.0 Volts.
♦ Test of control unit including valve coils.
♦ Electrical test of wheel speed sensors, not fully com-
pleted until vehicle reaches 20 km/h.
♦ Check of control unit coding.
♦ Test of electric motor for the return flow pump (hy-
draulic pump).
Before starting fault finding, always initiate self-diagnosis
and retrieve the stored information using vehicle system
Edition 07.04 Function of Self-diagnosis 45-3 page 1

S00.5303.16.20
tester -V.A.G 1552- ⇒ Chap. 45-5 or using vehicle diag-

nosis system, measurement and information system
-VAS 5051- ⇒ Chap. 45-4.
Note
♦ The description ⇒ Chap. 45-5 only relates to the ve-
hicle system tester -V.A.G 1552- using the current
program card.
♦ The use of fault reader -V.A.G 1551- with integrated
printer is similar. A minor deviation on the display
read-out is possible.
Vehicle fitted with ABS/EDL/TCS or ABS/

EDL/TCS/ESP BOSCH 5.7 does not have
an EDL function
Complaint: „Vehicle EDS system does not operate“
When dealing with this complaint a possible fault cause
may be that the brake light switch is incorrectly set or is
not operating ⇒ Chap. 45-10, read measured value
block, display group numbers 002 and 004.
45-3 page 2 Function of Self-diagnosis Edition 07.04

S00.5303.16.20
45-4 Vehicle diagnosis, meas-

urement and information
system -VAS 5051-
Connect vehicle diagnosis, measure-

ment and information system -VAS 5051-
and select functions (ABS systems
BOSCH 5.7 and BOSCH 8.0)
The self-diagnosis of the ABS systems BOSCH 5.7
and BOSCH 8.0 can be performed using the vehicle
diagnosis, measurement and information system
-VAS 5051-.

♦ Vehicle diagnosis, measurement and information sys-
tem -VAS 5051-
♦ Diagnostic cable -VAS 5051/5A- or Diagnostic cable
-VAS 5051/6A-
WARNING!
♦ For test drives, test and measuring equipment
must always be fastened to the rear seat.
♦ The equipment must be operated by an assist-
ant during test drives.
– Mount the plug of the diagnostic cable -VAS 5051/5A-

or the diagnostic cable -VAS 5051/6A- on the diag-
nostic connection in the storage compartment on the
driver's side.
– Switch on the vehicle diagnosis, measurement and in-
formation system -VAS 5051- -arrow-.
The vehicle diagnosis, measurement and information
system -VAS 5051- is operational, if it shows the key-
boards of its operating modes.
– Switch on ignition.
– On the screen, select the Geführte Fehlersuche .
– Select the following one after the other:
♦ Brand
♦ Type
♦ Model year
♦ Variant
♦ Engine identification characters
– Confirm the data entered.

Wait until the vehicle diagnosis, measurement and infor-
mation system -VAS 5051- has communicated with all
the control units in the vehicle (vehicle system test).
– Press the Sprung and choose the „Selected Func-

tions/Components“ option.
Edition 07.04 Vehicle diagnosis, measurement and information system 45-4 page 1
S00.5303.16.20 -VAS 5051-
– Select on the display „chassis“

– Select on the display „brake system“
– Select on the display the indicated „01-self-diagnosa-
ble system…“.
– Select on the display the indicated „Antilock braking
system …“.
Now all possible components and functions of the anti-
lock braking system in the vehicle are indicated.
– Select on the display the desired component or the

desired function.
45-4 page 2 Vehicle diagnosis, measurement and information system

-VAS 5051-
Edition 07.04
S00.5303.16.20
45-5 Performing Self-diagnosis

- ABS systems BOSCH 5.7
and BOSCH 8.0
Test requirements
• Approved tyre size fitted to all wheels; tyres inflated to
the specified pressure.
• Mechanical/hydraulic part of the brake system togeth-
er with the brake light switch and brake lights operat-
ing properly.
• No leaks in hydraulic connections and lines (visual in-
spection of hydraulic unit, brake calipers, wheel brake
cylinders, tandem brake master cylinder).
• Wheel bearings and wheel bearing play O.K.
• Control unit correctly bolted to the hydraulic unit.
• Plug connection on ABS control unit -J104- correctly
plugged in (lock is engaged).
• Inspect plug contacts of ABS components for damage
and correct fitting.
• All fuses must be OK in compliance with the current
flow diagram.
• Battery voltage at least 11 V.
Connecting vehicle system tester

-V.A.G 1552- and selecting function
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3-, -V.A.G 1551/3A-,
-V.A.G 1551/3B- or -V.A.G 1551/3C-
Note
♦ During self-diagnosis the ABS function is disconnect-
ed in the control unit.
♦ TheWarning lights -K47-, -K7- and -K86/K155- light up
during self-diagnosis.
The diagnostic connection is located in the storage com- V.A.G 1552
partment on the driver's side.
– Connect vehicle system tester -V.A.G 1552- with the V.A.G 1551/3
diagnostic cable -V.A.G 1551/3-.
– Switch on the ignition.
S01-0087
Interrogating control unit version

Vehicle system test HELP
Readout on display: Enter address word XX
– Press 0 and 3 for the address word „brake electron-
ics“ and confirm the entry with Q .
6Q0614117 ABS 5.7 FRONT X00 ->
After approx. 5 seconds the display will show: Coding 00036 WSC xxxxx
Edition 07.04 Performing Self-diagnosis - ABS systems BOSCH 5.7 and 45-5 page 1
S00.5303.16.20 BOSCH 8.0
The display shows:

♦ the control unit identification number, e.g. 6Q0614117
♦ the system designation, e. g. ABS 5.7 Front
♦ the version number, e.g. X00
♦ the code No. of the control unit, e.g. 00036
♦ the workshop code (WSC ⇒ Operatinginstructions
vehicle system tester V.A.G. 1552)
Assignment of the control unit ⇒ Spare part catalogue
If the control unit identification number is not displayed:
⇒ 45-5 page 2.
– Press →.
Readout on display: Select function XX
Overview of selectable functions

01 - Interrogating control unit version ⇒ 45-5 page 1
02 - Interrogating fault memory ⇒ 45-5 page 2
03 - Final control diagnosis ⇒ Chap. 45-12
04 - Basic setting BOSCH 5.7 ⇒ Chap. 45-13, BOSCH
8.0 ⇒ Chap. 45-14 1)
05 - Erasing fault memory ⇒ 45-5 page 3
06 - Ending output ⇒ 45-5 page 3
07 - Code control unit BOSCH 5.7 ⇒ Chap. 45-8,
BOSCH 8.0 ⇒ Chap. 45-9
08 - Reading measured value block BOSCH 5.7
⇒ Chap. 45-10, BOSCH 8.0 ⇒ Chap. 45-11
Interrogating fault memory

– Press 0 and 2 for the function „Interrogate fault
memory“ and confirm with Q . X faults detected!
The number of faults stored appears on the display
or No fault detected! ->
Eventuell gespeicherte Fehler eines Systems werden
nacheinander angezeigt.
– Press →.
The stored faults are displayed in sequence.
– Note the fault message displayed and refer to the fault

table for the corresponding ABS system BOSCH 5.7
⇒ Chap. 45-6, BOSCH 8.0 ⇒ Chap. 45-7.
If „No fault detected“ appears the program returns to its
initial setting after key → is pressed.
Readout on display:
Select function XX
– End output (Function 06) ⇒ 45-5 page 3.
1) only required for vehicles with ABS/EDL/TCS (BOSCH 5.7), ABS/EDL/TCS/ESP (BOSCH 5.7) or ABS/TCS/ESP (BOSCH 8.0)
45-5 page 2 Performing Self-diagnosis - ABS systems BOSCH 5.7 and

BOSCH 8.0
Edition 07.04
S00.5303.16.20
– Switch off ignition and disconnect the diagnostic plug
connection.
Note
♦ If a fault is detected:
♦ 1. Rectify fault (repair)
♦ 2. Interrogate fault memory (Function 02)
♦ 3. Erase fault memory (Function 05)
♦ 4. End output (function 06)
♦ 5. Road test
♦ 6. Interrogate the fault memory again
Erasing fault memory

Requirements:
• Fault memory interrogated ⇒ 45-5 page 2.

• All faults rectified.
After interrogating the fault memory:
– Press 0 and 5 for the function „Erase fault memory“
and confirm with Q .
Vehicle system test ->
Readout on display: Fault memory erased!
The fault memory is now erased.
– Press →.
Note
♦ If the following message is displayed the test se-
Fault memory was not interrogated
quence is incorrect.
♦ Carefully follow the test sequence step by step: first
interrogate the fault memory, if necessary rectify faults
and then erase the fault memory.
Ending output
– Press 0 and 6 for the function „End output“ and con-
firm with Q .
Readout on display:
Enter address word XX
– Switch off ignition.
– Disconnect plug connections from vehicle system
tester -V.A.G 1552-.
The warning lights -K47-, -K7- and -K86/K155- must go
out after approx. 2 seconds.
Edition 07.04 Performing Self-diagnosis - ABS systems BOSCH 5.7 and 45-5 page 3
S00.5303.16.20 BOSCH 8.0
Automatic test sequence
Note
♦ During testing and installation other control units may
also detect faults, e.g. pulled-out connectors. This is
why you must conclude the self-diagnosis by interro-
gating and erasing the fault memories of all control
units.
♦ With the automatic test sequence all fault memory
contents of the control units are interrogated.
– Press 0 twice for address word „Automatic test se-
quence“ and confirm with Q .
After this all the control unit identifications with possible
entries from the fault memories appear in the display in
the order of the address words.
The „automatic test sequence“ is completed when the fol- Enter address word XX
lowing read-out appears on the display:
45-5 page 4 Performing Self-diagnosis - ABS systems BOSCH 5.7 and

BOSCH 8.0
Edition 07.04
S00.5303.16.20
45-6 Fault table - ABS systems BOSCH 5.7

Note
♦ As the control units are interlinked over two data BUS lines, always start fault finding by activating the function „Au-
tomatic test sequence“ ⇒ Chap. 45-5 on all control units fitted to the vehicle This allows to interrogate all the control
units fitted on the vehicle to determine their possible faults.
♦ All the possible faults which can be detected by the ABS control unit -J104- and which can be displayed on vehicle
system tester -V.A.G 1552- during interrogation of the fault memory content, are listed below.
♦ The fault table is ordered according to the 5-digit fault code on the left.
♦ The fault table may also display the fault type.
♦ The column „Fault elimination“ refers to certain test steps in the electrical test.
♦ Before replacing acomponent fault to be faulty test all corresponding plug connections, lines and earth connection
according to the current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
♦ After carrying out the repair always interrogate and erase the fault memory using vehicle system tester
-V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
♦ After the test drive interrogate the fault memory again.
Read-out on display -V.A.G 1552- Rectifying fault

no fault detected If after repair „No fault detected“ is displayed, the self-diag-
nosis is completed.
If in spite of display read-out „No fault detected“ the ABS
does not operate without fault, proceed as follows:
1. Perform a test drive at a speed above 20 km/h,
2. interrogate the fault memory again, if still no fault is
stored,
3. continue fault finding without self-diagnosis and run
through the Electrical Test completely ⇒ Chapter 45-15.
00257
ABS FL- N101 inlet valve
00259
ABS FR -N99 inlet valve
00265 – Performing a final control diagnosis, function 03
ABS FL- N102 outlet valve ⇒ Chapter 45-12.
00267 – Check wiring and plug connections to the ABS control
ABS FR- N100 outlet unit -J104- according to the current flow diagram
valve ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
00273
ABS RR -N133 inlet valve If none of the above measures results in elimination of the
fault:
00274
ABS RL -N134 inlet valve – Replacing control unit ABS with EDL control unit -J104-
⇒ Chapter 45-17.
00275
ABS RR -N135 outlet
valve
00276
ABS RL -N136 outlet valve
Edition 07.04 Fault table - ABS systems BOSCH 5.7 45-6 page 1
S00.5303.16.20

00283 Open circuit/Short cir- – Read the measured value block ⇒ Chapter 45-10, dis-
Speed sensor vl-G47 cuit to positive play group 001.
Implausible signal – Check wiring and plug connections according to the cur-
rent flow diagram ⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
– Check the front left speed sensor -G47- and sensor ring
for damage.
– Replace the speed sensor -G47- or the sensor ring as re-
quired ⇒ Chapter 45-19.
If the fault occurs again:
– Replacing control unit ABS with EDL control unit -J104-

⇒ Chapter 45-17.
Speed sensor vr-G45 cuit to positive play group 001.
– Check the front right speed sensor -G45- for damage.

⇒ Chapter 45-17.
Speed sensor hr-G44 cuit to positive play group 001.
– Check the rear right speed sensor -G44- for damage.

⇒ Chapter 45-17.
Speed sensor hl-G46 cuit to positive play group 001.
– Check the rear left speed sensor -G46- for damage.

⇒ Chapter 45-17.
45-6 page 2 Fault table - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20

00301 Open circuit – Read the measured value block ⇒ Chapter 45-10, dis-
Return flow pump for ABS play group 002 or 006 .
- V39 – Erasing fault memory (05) ⇒ Chapter 45-5.
– Ending output (06) ⇒ Chapter 45-5.
– Replace hydraulic control unit ⇒ Chapter 45-17.

ABS solenoid valve relay - play group 006.
J106 – Check wiring and plug connections to the ABS control
unit -J104- according to the current flow diagram
⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
If none of the above measures results in elimination of the
fault:

⇒ Chapter 45-17.
Brake light switch -F play group 002.
– Carry out the Electrical Test, test step no. 4 ⇒ Chapter
45-15.
– Check wiring and plug connections according to the cur-
– Replacing brake light switch ⇒ Chapter 45-16.
00532 Signal outside toler- – Carry out the Electrical Test, test step no. 1 ⇒ Chapter
Supply voltage ance 45-15.
Note: Signal too low – Determine and eliminate open circuit in voltage supply
♦ This fault is related to Fitting Locations.
the voltage supply of
the control unit. – Test battery, AC generator and voltage regulator
♦ This fault is only stored Fitting Locations.
if it occurs at a vehicle
speed above 6 km/h. The ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP system is
switched on again as soon as the vehicle voltage exceeds
10 volts and the warning lights go out.
– Test earth connections.

If no fault is found in the voltage supply:
– Replace hydraulic control unit ⇒ Chapter 45-17.

00597 – Test wheels and tyre pressures ⇒ Chapter 00-4.
Different wheel speed – Check the fitting position of the speed sensor and wheel
pulses bearing with sensor ring and replace if necessary
⇒ Chapter 40-3 or ⇒ Chapter 42-3.
S00.5303.16.20

00753 Electrical fault in the cir- – Check wiring and plug connections to the ABS control
Electr. connections wheel cuit unit -J104- according to the current flow diagram
speed pulses ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
00778 defective – Read the measured value block ⇒ Chapter 45-10, dis-
Steering angle sender - play groups 005 and 125.
G85 – Perform null balance of the steering angle sender -G85-
⇒ Chapter 45-13.
– If necessary replace steering angle sender -G85-
⇒ Chap. 45-16.
Balance not performed – Perform null balance of the steering angle sender -G85-
⇒ Chapter 45-13.
Implausible signal – Read the measured value block ⇒ Chapter 45-10, dis-
play groups 005 and 125.
– Check fitting position of the steering angle sender -G85-
⇒ Chapter 45-16.
– Perform null balance of the steering angle sender -G85-
⇒ Chapter 45-13.
01044 – Coding ABS with EDL control unit -J104- ⇒ Chapter 45-
Control unit wrongly coded 8.
01119 – Performing automatic test sequence ⇒ Chapter 45-5.
Signal for gear recognition
Data bus drive: wrong
software version
01200 – Carry out the Electrical Test, test step no. 2 ⇒ Chapter
Power supply for ABS 45-15.
valves – Determine and eliminate open circuit in voltage supply
Note: ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
♦ This fault is related to
the voltage supply to – Test battery, AC generator and voltage regulator
the hydraulic unit -N55- ⇒ Current Flow Diagrams, Electrical Fault Finding and
and the return flow Fitting Locations.
pump motor -V39-. – Test relay for solenoid valves, read measured value block
⇒ Chapter 45-10, display groups 002 or 006.
– Performing a final control diagnosis, function 03

⇒ Chapter 45-12.
S00.5303.16.20

01312 defective 1) – Coding ABS with EDL control unit -J104- ⇒ Chapter 45-
Drive databus 8.
– Test the control unit coding ⇒ Engine - Fuel Injection;
Rep. Gr. 01.
– Testing data BUS ⇒ Electrical system; Rep. Gr. 90
45-15.
defect – Erasing fault memory ⇒ Chapter 45-5.
sporadic 1)
– No further measures required.
– Inform customer.
1) The fault does not result in the ABS warning lamp -K47- or the dual circuit and hand brake system warning lamp -K7 - lighting up. The ABS
function is fully maintained.

01314 No communication – Read the measured value block ⇒ Chapter 45-10, dis-
Engine control unit play group 125.
45-15.
– Perform self-diagnosis of the engine control unit
⇒ Engine - Fuel Injection; Rep. Gr. 01.
please read out fault – Read out fault memory of the engine control unit
memory ⇒ Engine - Fuel Injection; Rep. Gr. 01.
Gearbox control unit play group 125.
45-15.
– Perform self-diagnosis of the gearbox control unit
⇒ automatic gearbox 001; Rep. Gr. 01.
please read out fault – Read out the fault memory of the automatic gearbox con-
memory trol unit ⇒ Automatic Gearbox; Rep. Gr. 01.
01316 No communication – Testing data BUS ⇒ Electrical system; Rep. Gr. 90
Brake control unit
Control unit with display in play group 125.
dash panel insert -J285 – Carry out the Electrical Test, test step no. 6 ⇒ Chapter
45-15.
– Perform self-diagnosis of the dash panel insert
⇒ Electrical System; Rep. Gr. 90.
01321 No communication – Testing data BUS ⇒ Electrical system; Rep. Gr. 90
Airbag control unit -J234 – Read out fault memory of the airbag control unit ⇒ Body
Work; Rep. Gr. 01
S00.5303.16.20

01418
Vehicle stability program
switch valve -1- N225
01419
Vehicle stability program – Check wiring and plug connections to the ABS control
switch valve -2- N226 unit -J104- according to the current flow diagram
01420 ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
high pressure valve -1- – Replacing control unit ABS with EDL control unit -J104-
N227 ⇒ Chapter 45-17.
01421
high pressure valve -2-
N228
S00.5303.16.20

01423 – Check fitting position of the lateral acceleration sender
Lateral acceleration send- -G200- ⇒ Chapter 45-16.
er -G200 – Check wiring and plug connections according to the cur-
– Read measured value block ⇒ Chapter 45-10, display
group 005; replace lateral acceleration sender -G200- if
necessary ⇒ Chapter 45-16.
fault:

⇒ Chapter 45-17.
Electrical fault in the cir- – Check wiring and plug connections according to the cur-
cuit rent flow diagram ⇒ Current Flow Diagrams, Electrical
group 005; replace lateral acceleration sender -G200- if
fault:

⇒ Chapter 45-17.
play group 005.
– Check attachment of the lateral acceleration sender
-G200- ⇒ Chapter 45-16.
– Erase fault memory ⇒ Chapter 45-5, perform test drive
and again interrogate fault memory ⇒ Chapter 45-5.
– Replacing lateral acceleration sender -G200-

⇒ Chap. 45-16.
fault:

⇒ Chapter 45-17.
01424 Electrical fault in the cir- – Check wiring and plug connections according to the cur-
Yaw rate sender -G202, cuit rent flow diagram ⇒ Current Flow Diagrams, Electrical
signal line Fault Finding and Fitting Locations.
01425 Electrical fault in the cir- – Read measured value block ⇒ Chapter 45-10, display
cuit group 005; replace yaw rate sender -G202- if necessary
Yaw rate sender -G202,
⇒ Chapter 45-16.
reference line
fault:

⇒ Chapter 45-17.
S00.5303.16.20

01435 – Read the measured value block ⇒ Chapter 45-10, dis-
Brake pressure sender 1 - play groups 002 and 005.
G201 – Check wiring and plug connections according to the cur-
– Replacing brake pressure sender 1 -G201- ⇒ Chap. 45-
17.
fault:

⇒ Chapter 45-17.
Electrical fault in the cir- – Check wiring and plug connections according to the cur-
cuit rent flow diagram ⇒ Current Flow Diagrams, Electrical
– Read the measured value block ⇒ Chapter 45-10, dis-
play group 005.
– Replacing brake pressure sender 1 -G201- ⇒ Chap. 45-
17.
fault:

⇒ Chapter 45-17.
group 005; replace brake pressure sender 1 -G201- if
fault:

⇒ Chapter 45-17.
S00.5303.16.20

01542 defective – Check wiring and plug connections according to the cur-
Yaw rate sender -G202 rent flow diagram ⇒ Current Flow Diagrams, Electrical
group 005; replace yaw rate sender -G202- if necessary
⇒ Chapter 45-16.
If the fault has still not been corrected:

⇒ Chapter 45-17.
play group 005.
– Check attachment of the yaw rate sender -G202-
⇒ Chapter 45-16.
– Erase fault memory ⇒ Chapter 45-5, perform test drive
and again interrogate fault memory.
– Replacing yaw rate sender -G202- ⇒ Chap. 45-16.

fault:

⇒ Chapter 45-17.
01826 – Test fuse 1.
(Information in the litera- – Test wiring and plug connections to the steering angle
ture) sender -G85- according to the current flow diagram
♦ This fault concerns the
Fitting Locations.
voltage supply of the – Test battery, charge if necessary ⇒ Electrical System;
steering angle sender Rep. Gr. 27.
-G85-.
Inspect coding/variants of 8.
the control units in the – Test the control unit coding ⇒ Engine - Fuel Injection;
drive train Rep. Gr. 01.
– Check coding of the gearbox control unit ⇒ automatic
gearbox 001; Rep. Gr. 01.
18256 – Read out fault memory of the engine control unit
Please read out fault ⇒ Engine - Fuel Injection; Rep. Gr. 01.
memory of the engine CU
18263 Software status moni- – Performing automatic test sequence ⇒ Chapter 45-5.
Data bus drive toring
– Make sure the control units connected to the data BUS
cables have no entry in the fault memory.
– Check whether the correct engine control unit and the
right ABS with EDL control unit -J104- (spare part
number) have been fitted.
S00.5303.16.20

Load signal ⇒ Engine - Fuel Injection; Rep. Gr. 01.
65535 – Replacing control unit ABS with EDL control unit -J104-
Control unit defective ⇒ Chapter 45-17.
S00.5303.16.20
45-7 Fault table - ABS systems BOSCH 8.0

Note
♦ As the control units are interlinked over two data BUS lines, always start fault finding by activating the function „Au-
tomatic test sequence“ ⇒ Chap. 45-5 on all control units fitted to the vehicle This allows to interrogate all the control
units fitted on the vehicle to determine their possible faults.
♦ All the possible faults which can be detected by the ABS control unit -J104- and which can be displayed on vehicle
system tester -V.A.G 1552- during interrogation of the fault memory content, are listed below.
♦ The fault table is ordered according to the 5-digit fault code on the left.
♦ The fault table may also display the fault type.
♦ Before replacing acomponent fault to be faulty test all corresponding plug connections, lines and earth connection
according to the current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
♦ After carrying out the repair always interrogate and erase the fault memory using vehicle system tester
-V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
♦ After the test drive interrogate the fault memory again.

no fault detected If after repair „No fault detected“ is displayed, the self-diag-
nosis is completed.
If in spite of display read-out „No fault detected“ the ABS
does not operate without fault, proceed as follows:
1. Perform a test drive at a speed above 20 km/h,
2. interrogate the fault memory again, if still no fault is
stored,
00003
– Replacing hydraulic control unit ⇒ Chap. 45-18.
Control unit defective
00257
ABS FL- N101 inlet valve
00259
ABS FR -N99 inlet valve
00265
ABS FL- N102 outlet valve
⇒ Chapter 45-12.
00267
– Check wiring and plug connections to the ABS control
ABS FR- N100 outlet unit -J104- according to the current flow diagram
valve ⇒ Current Flow Diagrams, Electrical Fault Finding and
00273 Fitting Locations.
ABS RR -N133 inlet valve If none of the above measures results in elimination of the
00274 fault:
ABS RL -N134 inlet valve – Replacing hydraulic control unit ⇒ Chap. 45-18.
00275
ABS RR -N135 outlet
valve
00276
ABS RL -N136 outlet valve
S00.5303.16.20

00283 Mechanical fault – Read the measured value block ⇒ Chapter 45-11, dis-
Speed sensor vl-G47 play group 001.
Electrical fault in the cir-
cuit
– Check the front left speed sensor -G47- and sensor ring
for damage.

Speed sensor vr-G45 play group 001.
cuit
– Check the front right speed sensor -G45- and sensor ring
for damage.

Speed sensor hr-G44 play group 001.
cuit
– Check the rear right speed sensor -G44- and sensor ring
for damage.

Speed sensor hl-G46 play group 001.
cuit
– Check the rear left speed sensor -G46- and sensor ring
for damage.
S00.5303.16.20

00301 Implausible signal – Read the measured value block ⇒ Chapter 45-11, dis-
Return flow pump for ABS play group 006.
- V39 – Perform actuator diagnosis ⇒ Chapter 45-12.
– Check fuse, wiring and plug connections according to the
current flow diagram ⇒ Current Flow Diagrams, Electri-
cal Fault Finding and Fitting Locations.

00493 no signal/communica- – Read the measured value block ⇒ Chapter 45-11, dis-
tion play groups 005 or 126.
ESP sensor unit -G419 – Check wiring and plug connections to the ABS control
Implausible signal unit -J104- according to the current flow diagram
Fitting Locations.
fault:
– Replacing ESP sensor unit -G419- ⇒ Chapter 45-16.

Brake light switch -F play group 002.
Open circuit – Check wiring and plug connections according to the cur-
– Replacing brake light switch -F- ⇒ Chap. 45-16.
00532 Signal too low – Read the measured value block ⇒ Chapter 45-11, dis-
Supply voltage play group 006.
Note: – Determine and eliminate open circuit in voltage supply
♦ This fault is related to Fitting Locations.
the voltage supply of
the control unit. – Test battery, AC generator and voltage regulator
♦ This fault is only stored Fitting Locations.
if it occurs at a vehicle
speed above 6 km/h. The ABS, ABS/TCS or ABS/TCS/ESP system is switched
on again as soon as the vehicle voltage exceeds 10 volts
and the warning lights go out.
– Test earth connections.


00597 Mechanical fault – Test wheels and tyre pressures ⇒ Chapter 00-4.
Different wheel speed – Check the fitting position of the speed sensor and wheel
pulses bearing with sensor ring and replace if necessary
00753 Short circuit to positive – Check wiring and plug connections to the ABS control
Electr. connections wheel Electrical fault in the cir- unit -J104- according to the current flow diagram
speed pulses cuit ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
S00.5303.16.20

00778 defective – Read the measured value block ⇒ Chapter 45-11, dis-
Steering angle sender - play groups 005 and 125.
G85 – Perform null balance of the steering angle sender -G85-
⇒ Chapter 45-14.
– If necessary replace steering angle sender -G85-
⇒ Chap. 45-16.
No or incorrect basic – Perform null balance of the steering angle sender -G85-
setting/adaption ⇒ Chapter 45-14.
no signal/communica- – Read the measured value block ⇒ Chapter 45-11, dis-
tion play group 125.
play group 005.
– Check fitting position of the steering angle sender -G85-
⇒ Chapter 45-16.
– Perform null balance of the steering angle sender -G85-
⇒ Chapter 45-14.
Control unit wrongly coded 9.
Signal for gear recognition
01130 – Erasing fault memory (05) ⇒ Chapter 45-5.
ABS operation – Ending output (06) ⇒ Chapter 45-5.
– Interrogating fault memory (02) ⇒ Chap. 45-5.

01200 – Test relay for solenoid valves, read measured value block
Power supply for ABS ⇒ Chapter 45-11, display group 006.
valves – Determine and eliminate open circuit in voltage supply
Fitting Locations.
♦ This fault concerns the
voltage supply of the – Test battery, AC generator and voltage regulator
valves of the hydraulic ⇒ Current Flow Diagrams, Electrical Fault Finding and
unit -N55-. Fitting Locations.

⇒ Chapter 45-12.
S00.5303.16.20

01201 – Test relay for return flow pump for ABS -V39-, read
Power supply for ABS measured value block ⇒ Chapter 45-11, display group
pump 006.
Note: – Determine and eliminate open circuit in voltage supply
♦ This fault concerns the Fitting Locations.
voltage supply of the
return flow pump for – Test battery, AC generator and voltage regulator
ABS -V39-. ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.

⇒ Chapter 45-12.
01312 defective 1) – Coding ABS with EDL control unit -J104- ⇒ Chapter 45-
Drive databus 9.
– Test the control unit coding ⇒ Engine - Fuel Injection;
Rep. Gr. 01.
defect – Erasing fault memory ⇒ Chapter 45-5.
sporadic 1)
– No further measures required.
– Inform customer.
1) The fault does not result in the ABS warning lamp -K47- or the dual circuit and hand brake system warning lamp -K7- lighting up. The ABS
function is fully maintained.

Engine control unit tion play group 125.
please read out fault – Read out fault memory of the engine control unit
memory ⇒ Engine - Fuel Injection; Rep. Gr. 01.
Gearbox control unit tion play group 125.
– Perform self-diagnosis of the gearbox control unit
⇒ automatic gearbox 001; Rep. Gr. 01.
please read out fault – Read out the fault memory of the automatic gearbox con-
memory trol unit ⇒ Automatic Gearbox; Rep. Gr. 01.
Control unit with display in tion play group 125.
dash panel insert -J285 – Testing data BUS ⇒ Electrical system; Rep. Gr. 90
– Perform self-diagnosis of the dash panel insert
S00.5303.16.20

Airbag control unit -J234 tion play group 127.
– Perform self-diagnosis for airbag system ⇒ Body Work;
Rep. Gr. 01
01418
switch valve -1- N225
01419
– Check wiring and plug connections to the ABS control
Vehicle stability program unit -J104- according to the current flow diagram
switch valve -2- N226 ⇒ Current Flow Diagrams, Electrical Fault Finding and
01420 Fitting Locations.
Vehicle stability program – Performing a final control diagnosis, function 03
high pressure valve -1- ⇒ Chapter 45-12.
N227
01421
high pressure valve -2-
N228
Brake pressure sender 1 - play group 005.
G201 – Erasing fault memory (05) ⇒ Chapter 45-5.

01486 – Perform or end ESP road and system test ⇒ Chap. 45-
System function test acti- 14
vated
01683 – Test wheels and tyre pressures ⇒ Chapter 00-4.
Wheel speed signals/ – Check the fitting position of the speed sensor and wheel
speed bearing with sensor ring and replace if necessary
– Check wiring and plug connections for the speed sensor
according to the current flow diagram ⇒ Current Flow Di-
agrams, Electrical Fault Finding and Fitting Locations.
01765 – Perform self-diagnosis of the engine control unit
Engine control unit control ⇒ Engine - Fuel Injection; Rep. Gr. 01.
difference
S00.5303.16.20

01766 Implausible signal – Perform ESP road and system test ⇒ Chap. 45-14
Brake control unit control – Erasing fault memory (05) ⇒ Chapter 45-5.
difference

01826 – Test wiring and plug connections to the steering angle
Steering angle sender - sender -G85- according to the current flow diagram
G85, voltage supply KL30 ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
Note:
– Test battery, AC generator and voltage regulator
♦ This fault is stored, if ⇒ Current Flow Diagrams, Electrical Fault Finding and
the steering angle Fitting Locations.
sender -G85- is sepa-
rated from the voltage – Perform test drive or null balance of the steering angle
supply or the onboard sender -G85- ⇒ Chapter 45-14.
voltage is NOK. – Erasing fault memory (05) ⇒ Chapter 45-5.
– Replace steering angle sender -G85- ⇒ Chap. 45-16.

01827 – Perform self-diagnosis of the dash panel insert
Control unit with display in ⇒ Electrical System; Rep. Gr. 90.
dash panel insert -J285,
wheel circumference im-
plausible
16347 – Replacing hydraulic control unit ⇒ Chap. 45-18.
Control unit defective
Inspect coding/variants of 9.
the control units in the – Test the control unit coding ⇒ Engine - Fuel Injection;
drive train Rep. Gr. 01.
– Check coding of the gearbox control unit ⇒ automatic
gearbox 001; Rep. Gr. 01.
Load signal ⇒ Engine - Fuel Injection; Rep. Gr. 01.
S00.5303.16.20
S00.5303.16.20
45-8 Code control unit - ABS

systems BOSCH 5.7
♦ Vehicle system tester -V.A.G 1552- or vehicle diagno-
sis, measurement and information system
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3C-,
-VAS 5051/5A- or -VAS 5051/6A-
The control unit built into the vehicle is coded. New con-
trol units supplied through the spares warehouse are not
coded and must be coded after being installed.
Perform coding with the vehicle diagnosis, measure-
ment and information system -VAS 5051-.
⇒ Chapter 45-4
Perform coding with the vehicle system tester
-V.A.G 1552-
Precondition for coding
Coding is only then possible if the workshop code (WSC)
has been entered into the vehicle system tester
-V.A.G 1552- and when function 11 „Coding 2“ was also
successfully performed on vehicles with ABS/EDL/TCS/
ESP.
Test sequence
– Determine the engine identification characters and the

type of ABS hydraulic control unit fitted on the vehicle.
– Connect up vehicle system tester -V.A.G 1552- and
enter the control unit for brake electronics with the ig-
nition switched on (address word 03) ⇒ Chapter 45-5.
– Select function 0 7 „code the control unit“ and con-
firm with Q .
Coding control unit
Readout on display:
Enter code number XXXXX
– Enter the relevant code number of the vehicle and
confirm with Q.
Table of codes ⇒ 45-8 page 1
Table of codes
Engine Engine identifi- ABS control unit iden- ABS version Code Gearbox
cation charac- tification number number
ters
6Q0614117 ABS 00036
1.0 litre/37 6Q0907379 ABS 00044
AQV, ARV Gearbox
kW 6Q0907379C ABS 00044
6Q0907379G ABS 00044
1.2 ltr./40 kW AWY 6Q0907379G ABS 00044 Gearbox
Edition 07.04 Code control unit - ABS systems BOSCH 5.7 45-8 page 1
S00.5303.16.20
ters
1.2 ltr./47 kW AZQ 6Q0907379G ABS 00044 Gearbox
6Q0907379 ABS 00044
1.4 ltr./44 kW AZF, AZE 6Q0907379C ABS 00044 Gearbox
6Q0907379G ABS 00044
6Q0614117 ABS 00036
6Q0614417 TCS 00052
6Q0907379 ABS 00044
6Q0907379A TCS 00060
1.4 ltr./50 kW AQW, AME, ATZ Gearbox
6Q0907379C ABS 00044
6Q0907379D TCS 00060
6Q0907379G ABS 00044
6Q0907379H TCS 00060
6Q0614117 ABS 00036
6Q0614417 TCS 00116
Gearbox
6Q0907379 ABS 00044
6Q0907379A TCS 00124
6Q0907379C ABS 00044 Gearbox
6Q0907379C ABS 00045 Automatic gearbox
6Q0907379D TCS 00124 Gearbox
1.4 ltr./55 kW AUA, BBY
6Q0907379D TCS 00125 Automatic gearbox
6Q0907379G ABS 00044 Gearbox
6Q0907379G ABS 00045 Automatic gearbox
6Q0907379H TCS 00124 Gearbox
6Q0907379H TCS 00125 Automatic gearbox
6Q0907379Q ESP 03453 Gearbox
6Q0907379Q ESP 03485 Automatic gearbox
6Q0614117 ABS 00036
6Q0614417 TCS 00116
6Q0907379 ABS 00044
6Q0907379A TCS 00124
1.4 ltr./74 kW AUB, BBZ 6Q0907379C ABS 00044 Gearbox
6Q0907379D TCS 00124
6Q0907379G ABS 00044
6Q0907379H TCS 00124
6Q0907379Q ESP 03386
45-8 page 2 Code control unit - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
ters
6Q0907379 ABS 00044
6Q0907379A TCS 00188
6Q0907379C ABS 00044
6Q0907379D TCS 00188
6Q0907379G ABS 00044
2.0 ltr./85 kW AZL Gearbox
6Q0907379H TCS 00188
6Q0907379M ESP 033381)
6Q0907379M ESP 033412)
6Q0907379M ESP 033443)
6Q0907379Q ESP 03338
6Q0907379 ABS 00044
1.9 ltr./47 kW
ASY 6Q0907379C ABS 00044 Gearbox
SDI
6Q0907379G ABS 00044
6Q0614417 TCS 00180
6Q0907379 ABS 00044
6Q0907379A TCS 00188
1.9 ltr./74 kW 6Q0907379C ABS 00044
ATD Gearbox
TDI PD 6Q0907379D TCS 00188
6Q0907379G ABS 00044
6Q0907379H TCS 00188
6Q0907379Q ESP 03411
6Q0907379Q ESP 03479
1.4 ltr./55 kW
AMF 6Q0907379G ABS 00044 Gearbox
TDI PD
6Q0907379H TCS 00188
6Q0907379Q ESP 03357
1.9 ltr./96 kW
ASZ 6Q0907379G ABS 00044 Gearbox
TDI PD
6Q0907379H TCS 00188
1) Fabia
2) Fabia Sedan
3) Fabia estate car
The control unit coding is shown in the display, example 6Q0614117 TCS 5.7 Front X00 ->
00116: Coding 00116 WSC XXXXX
– Press →.
Only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
– Select function 1 1 „Coding 2“ and confirm with Q .

Coding 2
Readout on display:
Enter code number XXXXX
Note
The steering wheel must be in the straight ahead position
before executing the function „Coding 2“.
Edition 07.04 Code control unit - ABS systems BOSCH 5.7 45-8 page 3
S00.5303.16.20
– Enter code number 40168 and confirm with Q.

– Select function 0 4 „initiate basic setting“ and con-
firm entry with Q .
Initiating basic setting
Readout on display: Enter display group number XXX
– Select display group 0 0 1 and confirm with Q.
– Switch off the ignition for about 2 seconds.
Note
The vehicle system tester -V.A.G 1552- must remain
connected up while the ignition is switched off.
– Press 0 6 for the function „End output“ and confirm

with Q .
Note
♦ The ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- will light up and
will remain lit up if the control unit is incorrectly coded.
♦ At the same time, an entry is recorded in the fault
memory ⇒ Chap. 45-5.
45-8 page 4 Code control unit - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
45-9 Code control unit - ABS

BOSCH 8.0
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
The control unit built into the vehicle is coded. New con-
trol units supplied through the spares warehouse are not
coded and must be coded after being installed.
Perform coding of vehicle diagnosis, measurement
and information system -VAS 5051-.
⇒ Chapter 45-4
Perform coding with the vehicle system tester
-V.A.G 1552-
Coding requirements
Coding is only then possible if the workshop code (WSC)
has been entered into the vehicle system tester
-V.A.G 1552- and when function 16 „access authorisa-
tion“ was also successfully performed.
Test sequence
– Determine the engine identification characters and the

type of ABS hydraulic control unit fitted on the vehicle.
– Select function 0 7 „code the control unit“ and con-
firm with Q .
Coding control unit
Readout on display:
Enter code number XXXXXXX
confirm with Q .
Edition 04.05 Code control unit - ABS BOSCH 8.0 45-9 page 1
S00.5303.18.20
Table of codes
Engine Engine ABS control unit ABS Brakes at Brakes at Code Gearbox
identifica- identification ver- the front the rear number
tion char- number sion axle axle
acters
6Q0907379R ABS 13” FS-II Drum brake 0000005
6Q0907379R ABS 14” FS-III Drum brake 0000005
1.2 ltr./40 6Q0907379AA ABS 13” FS-II Drum brake 0000005
AWY, BMD Gearbox
kW 6Q0907379AA ABS 14” FS-III Drum brake 0000005
6Q0907379AF ABS 13” FS-II Drum brake 0002058
6Q0907379AF ABS 14” FS-III Drum brake 0002100
6Q0907379AA ABS 14” FS-III Drum brake 0000005
6Q0907379AF ABS 13” FS-II Drum brake 0002061
1.2 ltr./47 6Q0907379S TCS 14” FS-III Drum brake 0000005
AZQ, BME Gearbox
kW 6Q0907379AB TCS 14” FS-III Drum brake 0000005
6Q0907379AG TCS 13” FS-II Drum brake 0002061
6Q0907379AG TCS 14” FS-III Drum brake 0002103
6Q0907379AH ESP 14” FS-III Drum brake 0000428
6Q0907379T ESP 14” FS-III Drum brake 0000428
6Q0907379S TCS 14” FS-III Drum brake 0000005
Gearbox
6Q0907379AB TCS 14” FS-III Drum brake 0000005
1.4 ltr./55 AUA, BBY, 6Q0907379AH ESP 14” FS-III Drum brake 0000425
kW BKY 6Q0907379R ABS 14” FS-III Drum brake 0000011
6Q0907379S TCS 14” FS-III Drum brake 0000011 Automatic gear-
6Q0907379AB TCS 14” FS-III Drum brake 0000011 box
45-9 page 2 Code control unit - ABS BOSCH 8.0 Edition 04.05
S00.5303.18.20
acters
6Q0907379R ABS 14” FS-III Disc brake 0000005
6Q0907379AA ABS 14” FS-III Disc brake 0000005
6Q0907379AF ABS 14” FS-III Disc brake 0002178
1.4 ltr./74 6Q0907379S TCS 14” FS-III Disc brake 0000005
AUB, BBZ Manual gearbox
kW 6Q0907379AB TCS 14” FS-III Disc brake 0000005
6Q0907379AG TCS 14” FS-III Disc brake 0002178
6Q0907379AH ESP 14” FS-III Disc brake 0000329
6Q0907379T ESP 14” FS-III Disc brake 0000329
6Q0907379AA ABS 15” C54-II Disc brake 0000008
6Q0907379R ABS 15” C54-II Disc brake 0000008
6Q0907379AB TCS 15” C54-II Disc brake 0000008
2.0 ltr./85
AZL 6Q0907379AG TCS 15” C54-II Disc brake 0002226 Gearbox
kW
6Q0907379S TCS 15” C54-II Disc brake 0000008
6Q0907379T ESP 15” C54-II Disc brake 0000275
6Q0907379AH ESP 15” C54-II Disc brake 0000275
6Q0907379S TCS 14” FS-III Drum brake 0000008
1.4 ltr./55
AMF 6Q0907379AB TCS 14” FS-III Drum brake 0000008 Gearbox
kW TDI PD
1.9 ltr./47
ASY 6Q0907379AF ABS 14” FS-III Drum brake 0002142 Gearbox
kW SDI
6Q0907379R ABS 14” FS-III Disc brake 0000008
6Q0907379AA ABS 14” FS-III Disc brake 0000008
6Q0907379AF ABS 14” FS-III Disc brake 0002196
1.9 ltr./74 6Q0907379S TCS 14” FS-III Disc brake 0000008
ATD Gearbox
kW TDI PD 6Q0907379AB TCS 14” FS-III Disc brake 0000008
6Q0907379AG TCS 14” FS-III Disc brake 0002196
6Q0907379T ESP 14” FS-III Disc brake 0000365
6Q0907379AH ESP 14” FS-III Disc brake 0000365
S00.5303.18.20
acters
6Q0907379AF ABS 15” C54-II Disc brake 0002229
6Q0907379AA ABS 15” C54-II Disc brake 0000008
6Q0907379R ABS 15” C54-II Disc brake 0000008
1.9 ltr./96 6Q0907379S TCS 15” C54-II Disc brake 0000008
ASZ Gearbox
kW TDI PD 6Q0907379AB TCS 15” C54-II Disc brake 0000008
6Q0907379AG TCS 15” C54-II Disc brake 0002229
6Q0907379AH ESP 15” C54-II Disc brake 0000296
6Q0907379T ESP 15” C54-II Disc brake 0000296
The read-out on display is the control unit coding, e.g. 6Q0907379T ESP 8.0 front X00 -
0000365): Coding 0000365 WSC XXXXX
– Press →.
only on vehicles with ABS/TCS/ESP BOSCH 8.0
– Function 1 6 select „access authorisation“ and con-

firm with Q .
Access authorisation
Readout on display: Enter code number XXXXX
Note
The steering wheel must be in the straight ahead position
before executing the function „access authorisation“.
– Enter code number 40168 and confirm with Q.

– Select function 0 4 „initiate basic setting“ and con-
firm entry with Q . Readout on display:
Initiating basic setting
– Select display group 0 0 1 and confirm with Q .
Basic setting 1 EIN <8-OFF>
Readout on display:
Bal. steer. angl. send. O.K.
Null balance steering angle sender -G85- is performed
successfully.
– Switch off the ignition for about 2 seconds.

Note
The vehicle system tester -V.A.G 1552- must remain
connected up while the ignition is switched off.
– Check straight-ahead position using function 8 „read

measured value block“ ⇒ Chap. 45-11, display group
number 005.
S00.5303.18.20

with Q .
Note
♦ The ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- will light up and
will remain lit up if the control unit is incorrectly coded.
♦ At the same time, an entry is recorded in the fault
memory ⇒ Chap. 45-5.
S00.5303.18.20
S00.5303.18.20
45-10 Reading measured value

block - BOSCH 5.7
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
The control unit can transmit many measured values.
These measured values provide information about the
operating condition of the system or the connected sen-
sors. In many cases the transmitted measured values are
useful for fault finding and fault elimination.
As all measured values cannot be analysed simultane-
ously they are concentrated in individual display groups,
which can be selected via display group numbers.
Safety measures
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
♦ If the test and measuring devices are operated from
the passenger seat, the passenger could be injured by
the release of the passenger airbag in the event of an
accident.
Test sequence and test tables with

measured values
Perform with the vehicle diagnosis, measurement
⇒ Chapter 45-4
Perform with the vehicle system tester -V.A.G 1552-
– Connect Vehicle system tester -V.A.G 1552- and se-

lect the control unit for brake electronics with the igni-
tion switched on (address word 03) ⇒ Chap. 45-5.
– Press 0 and 8 for the function „Read measured val-
ue block“ and confirm with Q .
Reading measured value block
Readout on display:
Enter display group number XXX
– Enter display group number ⇒ 45-10 page 2.
What now appears in the display is the measured value
block selected in standardised form.
Note
To switch to another display group proceed as follows:
Edition 07.04 Reading measured value block - BOSCH 5.7 45-10 page 1
S00.5303.16.20
Display group -V.A.G 1551- -V.A.G 1552-

number
higher Press 3 Press ↑
lower Press 1 Press ↓
skip Press C Press C
– If the specifications are achieved in all the display

fields, press →.

firm with Q .
Display group number 001:
The current wheel speeds are displayed. They serve to check the speed sensor assignment relatively to the wheel (to
this end raise the vehicle and turn the wheel by hand).
Reading measured value block 1 → Readout on display

0 km/h 0 km/h 0 km/h 0 km/h
Rear right wheel speed (km/h)
Rear left wheel speed (km/h)
Front right wheel speed (km/h)
Front left wheel speed (km/h)

vehicles with ABS, ABS/EDL/TCS BOSCH 5.7

0 0 1
not assigned
Relay for solenoid valves of ABS -J106-
♦ 0 - Not allowed during the function „Read measured value block“. The
relay was not activated with „ignition on“.
♦ 1 - Specified value; with „ignition on“ the relay was activated by the ABS
with EDL control unit -J104-.
Return flow pump for ABS -V39-
♦ 0 - Specified value; no voltage on return flow pump motor.
♦ 1 - Not allowed during the function „Read measured value block“. Voltage present on
return flow pump motor.
Brake light switch -F-
♦ 0 - Brake pedal not actuated
♦ 1 - Brake pedal operated, if deviation carry out electrical test, test step No. 4 ⇒ Chap. 45-15.
45-10 page 2 Reading measured value block - BOSCH 5.7 Edition 07.04
S00.5303.16.20
vehicles with ABS/EDL/TCS/ESP BOSCH 5.7

0 0 activated 0
TCS and ESP push-button -E256-
♦ 0 - Switch not operated
♦ operated - switch operated, if deviation: Carry out electrical
test, test step No. 5 ⇒ Chap. 45-15
Switch for hand-brake control -F9-
♦ 0 - Hand brake not appied
♦ operated - hand brake applied, if deviation: Carry out electrical test, test
step No. 7 ⇒ Chap. 45-15
♦ operated - brake pedal operated, if deviation: Carry out electrical test, test step No. 4
⇒ Chap. 45-15
Brake pedal switch -F47-
♦ operated - brake pedal operated, if deviation: Carry out electrical test, test step No. 4 ⇒ Chap. 45-
15

vehicles with ABS/EDL/TCS BOSCH 5.7
Note
Readout of the display group number must occur while the engine is running.

800 rpm 10 % 1
not assigned
Switch for the Traction Control System -E132-
♦ 0 - Switch not actuated
♦ 1 - Button operated, if deviation: Carry out electrical test, test step No. 5
⇒ Chap. 45-15
current engine torque
♦ Display range 0…100 %
Engine speed
♦ Display range 0…8000 rpm
S00.5303.16.20

770 rpm 33 Nm 33 Nm 0%
Throttle valve angle
Engine loss torque
♦ Display range 0…630 Nm
Engine speed


2:50 h 0 0
not assigned
Disregard display
EDL disconnected because of increased brake temperature
♦ 0 - none
♦ 1 - yes
Stationary time information
♦ too great
♦ ERROR
♦ invalid
S00.5303.16.20

2:50 h on/off
not assigned
not assigned
Stationary time information
♦ too great
♦ ERROR
♦ invalid


0,00° 0.00°/s 1.3 bar 0.00 m/s2
Lateral acceleration sender -G200-
♦ Specified value for vehicle at standstill: -0,7…0.7 m/s2

♦ Specified value at full steering angle and at a speed of 20
km/h: -6,0…6.0 m/s2
Brake pressure sender 1 -G201-
♦ Specified value for not-operated brake: -7,0…7.0 bar
Yaw rate sender -G202-
♦ Specified value for vehicle at standstill: -3,0…3.0 °/s
Steering angle sender -G85-
♦ Specified value when driving straight ahead: -2,5…2,5°1)
1) If a speed of 20 km/h is exceeded self-diagnosis is discontinued by the ABS with EDL control unit -J104-.
S00.5303.16.20


12.7 V on off WSC XXXXX
Workshop code ⇒ operating instructions vehicle system
tester -V.A.G 1552-
♦ off - Specified value; no voltage on return flow pump motor.
♦ on - Not allowed during the function „Read measured value block“. Volt-
age present on return flow pump motor.
♦ on - Specified value; with „ignition on“ the relay was activated by the ABS with EDL
control unit -J104-.
♦ off - Not allowed during the function „Read measured value block“. The relay was not
activated with „ignition on“.
Voltage supply of the ABS with EDL control unit -J104-
♦ Specified value: 11,0…14.5 V


Steering Engine 1 Gearbox 1 Combi 1
angle 1
Data BUS for dash panel insert
♦ 1 - Data BUS connection is present
♦ 0 - Data BUS connection is not present1)
Data BUS for gearbox control unit2)
Data BUS for engine control unit
Data BUS for steering angle sender
1) The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine
control unit or gearbox control unit or dash panel insert defective.
2) Only on vehicles equipped with an automatic gearbox.
S00.5303.16.20
45-11 Reading measured value

block - BOSCH 8.0
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A -
The control unit can transmit many measured values.
These measured values provide information about the
operating condition of the system or the connected sen-
sors. In many cases the transmitted measured values are
useful for fault finding and fault elimination.
As all measured values cannot be analysed simultane-
ously they are concentrated in individual display groups,
which can be selected via display group numbers.
Safety measures
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
♦ If the test and measuring equipment is operated from
the front passenger seat, this can result in injuries to
the persons sitting on that seat in the event of an ac-
cident which involves the front passenger airbag be-
ing deployed.
Test sequence and test tables with

measured values
Perform with the vehicle diagnosis, measurement
⇒ Chapter 45-4
Perform with the vehicle system tester -V.A.G 1552-

– Select function 0 8 „Read measured value block“
and confirm the entry with key Q . Readout on display:
Readout on display:
– Enter display group ⇒ 45-11 page 2.
What now appears in the display is the measured value
block selected in standardised form.
S00.5303.18.20
Note
Proceed according to the following table to switch to an-
other display group:
Display group -V.A.G 1551- -V.A.G 1552-

number
higher Press 3 Press ↑
lower Press 1 Press ↓
skip Press C Press C
– If the nominal values are reached in all display fields,

press the key → .
with Q .
The current wheel speeds are displayed. They serve to check the speed sensor assignment relatively to the wheel (to
this end raise the vehicle and turn the wheel by hand).

0 km/h 0 km/h 0 km/h 0 km/h
Rear right wheel speed (km/h)
Rear left wheel speed (km/h)
Front right wheel speed (km/h)
Front left wheel speed (km/h)
S00.5303.18.20
vehicles with ABS, ABS/TCS BOSCH 8.0

0 0 1
not assigned
♦ 0 - Not allowed during the function „Read measured value block“. The
relay was not activated with „ignition on“.
♦ 1 - Specified value; with „ignition on“ the relay was activated by the ABS
with EDL control unit -J104-.
♦ 0 - Specified value; no voltage on return flow pump motor.
♦ 1 - Not allowed during the function „Read measured value block“. Voltage present on
return flow pump motor.
♦ 1 - Brake pedal actuated
Vehicles with ABS//TCS/ESP BOSCH 8.0

0 0 activated 0
TCS and ESP push-button -E256-
♦ 0 - Switch not operated
♦ operated - switch operated
Switch for hand-brake control -F9-
♦ 0 - Hand brake not appied
♦ operated - hand brake applied
♦ operated - brake pedal operated
S00.5303.18.20

vehicles with ABS/TCS BOSCH 8.0
Note
Readout of the display group number must occur while the engine is running.

800 rpm 10 % 1
not assigned
TCS switch -E132-
♦ 0 - Switch not actuated
♦ 1 - Switch actuated
Engine speed

770 rpm 33 Nm 33 Nm 0%
Throttle valve angle
Engine loss torque
Engine speed
S00.5303.18.20
vehicles with ABS/TCS BOSCH 8.0

2:50 h on/off 0
not assigned
Disregard display
♦ off - no EDL disconnected, EDL system operational
♦ on - EDL disconnected because of increased brake temperature, EDL system not op-
erational
Stationary time information (cooling time for brakes)
♦ Display range 0:0…255:59 - Stationary time of the vehicle after ignition off until the next ignition
on
♦ ERROR - missing message from combiinstrument

2:50 h on/off
not assigned
not assigned
♦ off - no EDL disconnected, EDL system operational
♦ on - EDL disconnected because of increased brake temperature, EDL system not op-
erational
Stationary time information (cooling time for brakes)
♦ Display range 0:0…255:59 - Stationary time of the vehicle after ignition off until the next ignition
on
♦ ERROR - missing message from combiinstrument
S00.5303.18.20


0,00° 0.00°/s 1.3 bar 0.00 m/s2
Lateral acceleration sender -G200-1)
♦ Specified value for vehicle at standstill: -0,7…0.7 m/s2

♦ Specified value at full steering angle and at a speed of 20
km/h: -6,0…6.0 m/s2
Brake pressure sender 1 -G201-2)
Yaw rate sender -G202-1)
♦ Specified value for vehicle at standstill: -3,0…3.0 °/s
Steering angle sender -G85-
♦ Specified value when driving straight ahead: -2,5…2,5°3)
1) The sender is located in the ESP sensor unit -G419-.

2) The sender is located in the hydraulic control unit.
3) If a speed of 20 km/h is exceeded self-diagnosis is discontinued by the ABS with EDL control unit -J104-.


12.7 V on off WSC XXXXX
Workshop code ⇒ operating instructions vehicle system
tester -V.A.G 1552-
♦ off - Specified value; no voltage on return flow pump motor.
♦ on - Not allowed during the function „Read measured value block“. Volt-
age present on return flow pump motor.
♦ on - Specified value; with „ignition on“ the relay was activated by the ABS with EDL
♦ off - Not allowed during the function „Read measured value block“. The relay was not
activated with „ignition on“.
Supply voltage of the ABS control unit -J104-
♦ Specified value: 11,0…14.5 V
S00.5303.18.20
Display group number 007 (not fitted to all vehicles)
The vehicle must be raised and the respective wheel must be turned by hand, in order to check the fitting position of
the speed sensor.

o.k. o.k. o.k. o.k.
Fitting position of speed sensor RR
♦ o.k. - fitting position OK
♦ n.o.k. - fitting position N.O.K.
♦ invalid - wheel does not turn
Fitting position of the speed sensor RL
Fitting position of the speed sensor FR
Fitting position of the speed sensor FL


0 0 1.3 bar
not assigned
Brake pressure sender 1 -G201-1)
1) The sender is located in the hydraulic control unit.
S00.5303.18.20
Display group number 125 (for all vehicles):

Steering Engine 1 Gearbox 1 Combi 1
angle 1 1
Data BUS for dash panel insert
Data BUS for gearbox control unit2)
Data BUS for engine control unit
Data BUS for steering angle sender
2) Only on vehicles fitted with automatic gearbox.


ESP
sensors 1
Data BUS ESP sensor unit -G419-
not assigned
not assigned
not assigned
S00.5303.18.20
Display group number 127 (for all vehicles):

Airbag 1
not assigned
not assigned
Data BUS for airbag control unit
not assigned
S00.5303.18.20
S00.5303.18.20
45-12 Final control diagnosis -

ABS system BOSCH 5.7
and BOSCH 8.0
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
The final control diagnosis is a part of the electrical test.
Final control diagnosis is used to test the pump motor. It
is also used to check the correct operation of the hydrau-
lic circuits (assignment of brake pressure lines to the
wheel brakes, and also the operation of the valves) to en-
sure they are correctly connected and are not leaking.
Note
♦ The vehicle must be raised so that the wheels are
clear of the ground (2nd mechanic required for rotat-
ing the wheels).
♦ It is possible to quit the test procedure at any time by
pressing C
♦ After depressing the brake pedal several times, the
vacuum in the brake servo unit is reduced. Greater ef-
fort is then required to operate the brake pedal in order
to achieve the same fluid pressure in the brake sys-
tem as with vacuum assistance.
♦ Once the vacuum in the brake servo unit has been re-
duced, it is possible that the wheels do not lock ⇒
start engine in order to build up vacuum in the brake
servo unit.
♦ Operate vehicle system tester following the indica-
tions on the display, i.e. carry out all self-diagnosis
working steps in the prescribed sequence.
♦ During actuator diagnosis do not exceed a maximum
wheel speed of 10 km/h. At a higher speed the ABS
with EDL control unit -J104- interrupts the actuator di-
agnosis.
Example (only for vehicle system tester
-V.A.G 1552-):
Final control diagnosis - ->
Read-out on display of V.A.G. 1552 during final control di- IFL: VBAT OFL: 0V Wheel FL locked
agnosis:
IFL = Inlet valve front left
VBAT = V-Battery voltage, voltage present on valve
OFL = Outlet valve front left
OV = O Volt; no voltage on valve
locked/free = Wheel status; must be checked by 2nd me-
EDL valves/Hydr.p:V BAT Wheel FL/FR lock
chanic
Hydr-P = Hydraulic pump (Return flow pump)
Edition 07.04 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 45-12 page 1
S00.5303.16.20
Performing actuator diagnosis

With the vehicle diagnosis, measurement and infor-
mation system -VAS 5051-.
⇒ Chapter 45-4
With the vehicle system tester -V.A.G 1552-

– Press 0 and 3 for the function „actuator diagnosis“
and confirm with Q .
Return flow pump for ABS -V39- must run.
Note
♦ On vehicles with ABS, ABS/EDL/TCS the ABS warn-
ing light -K47- flashes 2x and the dual circuit and hand
brake system warning light -K7- flashes 4x per second
during the next working steps.
♦ On vehicles with ABS/EDL/TCS/ESP the ABS warn-
ing light -K47- flashes 2x per second during the next
working steps .
Readout on display: Hydraulic pump ABS -V64
– Press → within the next 60 seconds.
Readout on display: Operate brake
– Operate brake pedal
– Press →.
Readout on display: IFL: OV OFL: 0V Wheel FL locked
– Instruct the 2nd mechanic to rotate the relevant wheel
by hand.
If the wheel does not lock, it is possible that there is a fault
in the mechanical/hydraulic part of the brake system.
– Press →.
Readout on display: IFL: VBAT OFL: 0V Wheel FL locked
– Press →.

Brake pedal must not yield.
If the brake pedal yields, there is a fault in the hydraulic
unit. In that case replace the hydraulic unit BOSCH 5.7
⇒ Chap. 45-17, BOSCH 8.0 ⇒ Chap. 45-18.
Readout on display:
IFL: VBAT OFL: VBAT Wheel FL free
by hand.
If the wheel locks, it is possible that the brake pressure
lines to the wheel brakes are wrongly connected.
45-12 page 2 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 Edition 07.04
S00.5303.16.20
– Press →.
Return flow pump for ABS -V39- no longer runs.

Readout on display: IFL: VBAT OFL: 0V Wheel FL free
– Press →.
Brake pedal must be felt to yield.

If the brake pedal does not yield, there is a fault in the hy-
draulic unit. In that case replace the hydraulic unit
BOSCH 5.7 ⇒ Chap. 45-17, BOSCH 8.0 ⇒ Chap. 45-
18.
Readout on display: IFL: OV OFL: 0V Wheel FL locked
by hand.
– Press →.
Readout on display: Release brake
– Take your foot off the brake pedal.
– Press →.
– Press →.
Readout on display: IFR: 0V OFR: 0V Wheel FR locked
by hand.
– Press →.
Readout on display: IFR: VBAT OFR: 0V Wheel FR locked
– Press →.

⇒ Chap. 45-17, BOSCH 8.0 ⇒ Chap. 45-18.
Readout on display:
IFR: VBAT OFR: VBAT Wheel FR free
by hand.
– Press →.
S00.5303.16.20
Readout on display:
IFR: VBAT OFR: 0V Wheel FR free
– Press →.

18.
Readout on display: IFR: 0V OFR: 0V Wheel FR locked
by hand.
– Press →.
– Press →.
– Press →.
Readout on display: IRL: 0V ORL: 0V Wheel RL locked
by hand.
– Press →.
Readout on display: IRL: VBAT ORL: 0V Wheel RL locked
– Press →.

⇒ Chap. 45-17, BOSCH 8.0 ⇒ Chap. 45-18.
Readout on display: IRL: VBAT ORL: VBAT Wheel RL free
by hand.
– Press →.

Readout on display:
IRL: VBAT ORL: 0V Wheel RL free
– Press →.
S00.5303.16.20
18.
Readout on display: IRL: 0V ORL: 0V Wheel RL locked
by hand.
– Press →.
– Press →.
– Press →.
Readout on display: IRR: 0V ORR: 0V Wheel RR locked
by hand.
– Press →.
Readout on display: IRR: VBAT ORR: 0V Wheel RR locked
– Press →.

⇒ Chap. 45-17, BOSCH 8.0 ⇒ Chap. 45-18.
Readout on display: IRR: VBAT ORR: VBAT Wheel RR free
by hand.
– Press →.

Readout on display:
IRR: VBAT ORR: 0V Wheel RR free
– Press →.

S00.5303.16.20

18.
Readout on display: IRR: 0V ORR: 0V Wheel RR locked
by hand.
– Press →.
– Press →.
Read-out on display (for vehicles with EDL): EDL valves/Hydr. p: VBAT Wheel FL/FR lock
– Instruct the 2nd mechanic to rotate the relevant
wheels by hand.
– If the wheels do not lock, there is a fault in the hydrau-
lic part of the ABS system. In this case replace the hy-
draulic unit BOSCH 5.7 ⇒ Chap. 45-17, BOSCH 8.0
⇒ Chap. 45-18.
– Press →.
The warning light goes out.

Function unknown or cannot ->
Read-out on display (for vehicles with EDL): be executed at this moment
The final control diagnosis is ended.
– Press →.
Note
♦ If the ABS warning light -K47- does not go out, there
is a fault in the system.
♦ Carefully follow the test sequence step by step: first
interrogate the fault memory then erase.
– End output (function 06) ⇒ Chap. 45-5.
S00.5303.16.20
45-13 Basic setting - ABS sys-

tems BOSCH 5.7
The function „basic setting“ performs the following tasks:
♦ On vehicles with ABS/EDL/TCS and ABS/EDL/TCS/
ESP BOSCH 5.7 the bleeding of the hydraulic unit is
performed via display group 10.
♦ On vehicles with ABS/EDL/TCS/ESP additionally the
null balance of the steering angle sender -G85- is per-
formed via display group 001.
– Bleeding the hydraulic unit (vehicles with ABS/EDL/

TCS/ESP BOSCH 5.7) ⇒ 45-13 page 1.
– Bleeding the hydraulic unit (vehicles with ABS/EDL/
– Null balance of the steering angle sender -G85-
⇒ 45-13 page 4.
– Perform vehicle and system test (vehicles with ABS/
EDL/TCS/ESP BOSCH 5.7) ⇒ 45-13 page 6.
Bleeding the hydraulic unit (vehicles

with ABS/EDL/TCS/ESP BOSCH 5.7)
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
-ROMESS S15-
♦ Brake fluid ⇒ Chapter 00-3
It is only necessary to carry out the basic setting if at least

one chamber of the brake fluid reservoir has run com-
pletely empty, or after completing repairs to the brake
system because of leaks.
Perform basic setting of vehicle diagnosis, measure-
⇒ Chapter 45-4
Perform basic setting of the vehicle system tester
-V.A.G 1552-
Note
Operate the vehicle system tester -V.A.G 1552- by refer-
ring to the read-out on the display:
WARNING!
When replenishing brake fluid with a brake filling
and bleeding appliance, e.g. ROMESS S15, it is im-
portant to ensure a minimum filling pressure of 0.2
MPa (2 bar).
Edition 07.04 Basic setting - ABS systems BOSCH 5.7 45-13 page 1
S00.5303.16.20
If the filling pressure of 0.2 MPa (2 bar) is not reached,

proper bleeding of the hydraulic unit is no longer assured.
– Connect brake filling and bleeding appliance, e. g.

ROMESS S15.
– Press 0 and 4 for the function „basic setting“ and
confirm with Q .
Basic setting
– First actuate the brake pedal 10x and hold brake
down.
– Press 0 , 1 and 0 and confirm with Q .
Note
If you are using V.A.G. 1551 a <3> appears instead of
<↑>.
System in basic setting 10
Readout on display: Rel. pedal;FR+FL bleeder screws OPEN <↑>
– Press ↑.
Readout on display: Actuate pedal 10x; wait
♦ Return flow pump for ABS -V39- runs.
Readout on display: Bleeder screw CLOSED <↑>
– Press ↑.
Readout on display: Rel. pedal;RR+RL bleeder screws OPEN <↑>
– Press ↑.
Readout on display: Bleeder screw CLOSED <↑>
– Press ↑.
Readout on display: Part bleeding ended...
– Press →.
firm the entry with Q .
Readout on display:
45-13 page 2 Basic setting - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
– Separate plug connection to V.A.G. 1552.
– Perform test drive with at least one ABS adjustment.

with ABS/EDL/TCS/ESP BOSCH 5.7)
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
-ROMESS S15-

⇒ Chapter 45-4
Perform basic srtting of the vehicle system tester
-V.A.G 1552-
Note
Operate the vehicle system tester by referring to the
read-out on the display:
WARNING!
and bleeding appliance, e.g. ROMESS S15, it is im-
portant to ensure a minimum filling pressure of 0.2
MPa (2 bar).

– Connect brake filling and bleeding appliance, e. g.

ROMESS S15.
confirm with Q .
Basic setting
Readout on display:
S00.5303.16.20

down.
Readout on display: Rel. pedal;FR+FL bleeder screws OPEN <8>
– Press 8.
Basic setting 10 <8-OFF>
Readout on display: Bleeder screw CLOSED <8>
– Press 8.
Readout on display: Rel. pedal;RR+RL bleeder screws OPEN <8>
– Press 8.
– Press 8.
– Press →.
Readout on display:
Steering angle sender
Null balance of the steering angle sender

-G85-
Null balance of the steering angle sender -G85- is re-
quired if:
♦ The ABS control unit -J104- of the steering angle
sender -G85- or the steering column are replaced.
♦ Settings have been changed on the running gear with-
in the scope of a chassis alignment.
♦ If as a result of a fault entry in the fault memory of the
ABS control unit -J104- the fault table indicates a fault,
perform null balance.
S00.5303.16.20
-V.A.G 1551/3B- or -V.A.G 1551/3C-
Note
For the null balance of the steering angle sender -G85-
first perform function 11 „coding 2“. To do so first enter
the workshop code in the vehicle system tester -V.A.G
1552-.
– Start the engine.

– Turn the steering column one turn to the right and one
turn to the left.
– Perform a short test drive on an even surface. Drive
straight ahead and no faster than 20 km/h, pay specif-
ic attention to the following two points:
♦ If the steering wheel is off straight, correct within the
scope of a chassis alignment. After the alignment
again perform null balance.
♦ If during the test drive the steering wheel is straight,
stop the vehicle in its straight ahead position.
Make sure the steering wheel is not moved. Do not
switch off the ignition!

– Press 1 and 1 for the function „Coding 2“ and con-
firm with Q .
Coding 2
– Enter code number 40168 and confirm entry with Q.
confirm with Q .
Basic setting

Function unknown or cannot - ->
If this appears on the display, function 11 „coding 2“ was be carried out at the moment
not successfully performed.
Basic setting 1 ON <8-OFF> -
Readout on display: Bal. steer. angl. send. O.K.
number 005.
or:
Readout on display:
Bal. steer. angl. send. N.O.K.
or:
S00.5303.16.20
Readout on display:
1. Interrogate fault memory (Function 02) Bal. steer. angl. send. locked
2. Erase fault memory (Function 05)

3. End output (function 06)
4. Switch off the ignition.
5. Switch on the ignition.
6. Again perform null balance.
– Press →.
firm with Q .
Perform ESP road and system test (vehi-

cles with ABS/EDL/TCS/ESP BOSCH 5.7)
The ESP road test is a plausibility test of the signals from
the lateral acceleration sender -G200-, yaw rate sender
-G202- (both senders are integrated in one housing) and
the brake pressure sender 1 -G201-.
The ESP road test should be performed after each re-
placement of the electrical components of the ESP sys-
tem.
If the ESP road test is initiated, it can no longer be inter-
rupted and must be performed.

-V.A.G 1551/3B- or -V.A.G 1551/3C-

confirm with Q .
Basic setting
System in basic setting 3 ->
Readout on display: System test activated O.K.
The ESP road and system test is activated, ESP and TCS
warning light -K155- lights up.
– Press →.
with Q .
S00.5303.16.20
– Disconnect vehicle system tester -V.A.G 1552-.
– Depress the brake pedal forcefully until the ESP and
TCS warning light -K155- goes out, at the same time
the ABS warning light -K47- lights up.
– Now perform the ESP road test.
WARNING!
♦ Observing the rules of the road traffic regula-
tions as well as paying attention to the traffic
conditions must be given top priority.
– Drive a right or a left curve. Subsequently carry out a

change of direction and drive a left or a right curve.
– After cornering, drive straight ahead for a certain peri-
od of time.
Note
♦ A curve with a radius of 10 to 12 meters and a speed
of 15 to 20 km/h must be driven in approx 4 seconds
during cornering.
♦ It must be driven in such a way, that no ABS, EDL,
TCS or ESP control is activated.
♦ If there are other traffic dependent driving manoeu-
vres between cornerings, they will have no influence
on the ESP road test.
If the ABS warning light -K47- goes out, the ESP road and
system test was successfully performed and ended, the
system is OK.
If the ABS warning light -K47- does not go out, the ESP
road and system test was not successfully performed.
– Repeat the ESP road and system test ⇒ 45-13

page 6.
If the ABS warning light -K47- and the ESP and TCS
warning light -K155- light up, there are faults in the sys-
tem.
– Interrogate fault memory ⇒ Chap. 45-5.
S00.5303.16.20
S00.5303.16.20
45-14 Basic setting - ABS sys-

tems BOSCH 8.0
The function „basic setting“ performs the following tasks:
♦ On vehicles with ABS/TCS/ESP BOSCH 8.0 the
bleeding of the hydraulic unit is performed via display
group 10.
♦ On vehicles with ABS/TCS/ESP BOSCH 8.0 the null
balance of the steering angle sender -G85- is per-
formed via display group 001.
♦ On vehicles with ABS/TCS/ESP BOSCH 8.0 the ESP
road and syystem test is performed via display group
003.
– Bleeding the hydraulic unit (vehicles with ABS/TCS/

ESP BOSCH 8.0) ⇒ 45-14 page 1.
– Null balance of the steering angle sender -G85- (vehi-
cles with ABS/TCS/ESP BOSCH 8.0) ⇒ 45-14
page 3.
– Perform road and system test (vehicles with ABS/

with ABS/TCS/ESP BOSCH 8.0)
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
-ROMESS S15-

⇒ Chapter 45-4
Perform basic setting of vehicle system tester
-V.A.G 1552-
Note
Operate the vehicle system tester by referring to the
read-out on the display:
S00.5303.16.20
WARNING!
and bleeding appliance, e.g. -ROMESS S15-, it is
important to ensure a minimum filling pressure of
0.2 MPa (2 bar).
If the filling pressure of 2 MPa (2 bar) is not reached,

– Connect brake filling and bleeding device, e.g.

-ROMESS S15-.
confirm with Q .
Basic setting
down.
Readout on display: Rel. pedal;FR+FL bleeder screws OPEN <8>
– Press 8.
– Press 8.
Readout on display: Rel. pedal;RR+RL bleeder screws OPEN <8>
– Press 8.
– Press 8.
– Press →.
S00.5303.16.20
Readout on display:
– Switch off ignition. Enter address word XX

Null balance of the steering angle sender

-G85- (vehicles with ABS/TCS/ESP
BOSCH 8.0)
Null balance of the steering angle sender -G85- is re-
quired if:
♦ the ABS control unit -J104- or the steering angel send-
er -G85- is replaced and the control unit is coded sub-
sequently.
♦ the steering column is replaced.
♦ Settings have been changed on the running gear with-
in the scope of a chassis alignment.
♦ if as a result of a fault entry in the fault memory of the
ABS control unit -J104- the fault table indicates a fault,
perform null balance.

-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
⇒ Chapter 45-4
Perform basic sitting of the vehicle system tester
-V.A.G 1552-
Note
For the null balance of the steering angle sender -G85-
first perform function 16 „access authorisation“. To do so
first enter the workshop code in the vehicle system tester
-V.A.G 1552-.

– Turn the steering column one turn to the right and one
turn to the left.
– Perform a short test drive on an even surface. Drive
straight ahead and no faster than 20 km/h, pay specif-
ic attention to the following two points:
♦ If the steering wheel is off straight, correct within the
scope of a chassis alignment. After the alignment
again perform null balance.
♦ If during the test drive the steering wheel is straight,
stop the vehicle in its straight ahead position.
S00.5303.16.20
Make sure the steering wheel is not moved. Do not

switch off the ignition!

– Press 1 and 6 for the function „access authorisa-
tion“ and confirm with Q .
Access authorisation
– Enter code number 40168 and confirm entry with Q.
confirm with Q .
Basic setting

Function unknown or cannot - ->
If this appears on the display, function 16 „access author- be carried out at the moment
isation“ was not successfully performed.
Basic setting 1 ON <8-OFF> ->
Readout on display: Bal. steer. angl. send. O.K.
Null balance steering angle sender -G85- is performed
successfully.

number 005.
or:
Basic setting 1 ON <8-OFF> ->
Readout on display: Bal. steer. angl. send. N.O.K.
Null balance steering angle sender -G85- is not per-
formed successfully.
– Switch off ignition then switch on again after 10 sec-

onds.
– Repeat the null balance of the steering angle sender
-G85-.
or:
Readout on display: Bal. steer. angl. send. locked
Null balance of the steering angle sender -G85- was not
performed, because the steering wheel with the steering
angle sender -G85- was not yet moved (steered).
– Switch off ignition then switch on again after 10 sec-

onds.
– Repeat the null balance of the steering angle sender
-G85-.
– Press →.
Readout on display:
firm with Q .
S00.5303.16.20
Perform ESP road and system test (vehi-
cles with ABS/TCS/ESP BOSCH 8.0)
The ESP road test is a plausibility test of the signals from
the lateral acceleration sender -G200-, yaw rate sender
-G202- (both senders in the ESP sensor unit -G419-) and
the brake pressure sender 1 -G201- (in the hydraulic con-
trol unit).
The ESP road test should be performed after each re-
placement of the electrical components of the ESP sys-
tem.
If the ESP road test is initiated, it can no longer be inter-
rupted and must be performed.

-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
⇒ Chapter 45-4
Perform basic setting of vehicle system tester
-V.A.G 1552-

confirm with Q .
Basic setting
System in basic setting 3 ->
Readout on display: System test activated O.K.
The ESP road and system test is activated, ESP and TCS
warning light -K155- lights up.
– Press →.
with Q .
– Disconnect vehicle system tester -V.A.G 1552-.
– Depress the brake pedal forcefully until the ESP and
TCS warning light -K155- goes out, at the same time
the ABS warning light -K47- lights up.
S00.5303.16.20
– Now perform the ESP road test.
WARNING!
♦ Observing the rules of the road traffic regula-
tions as well as paying attention to the traffic
conditions must be given top priority.
– Drive a right or a left curve. Subsequently carry out a

change of direction and drive a left or a right curve.
– After cornering, drive straight ahead for a certain peri-
od of time.
Note
♦ A curve with a radius of 10 to 12 meters and a speed
of 15 to 20 km/h must be driven in approx 4 seconds
during cornering.
♦ It must be driven in such a way, that no ABS, EDL,
TCS or ESP control is activated.
♦ If there are other traffic dependent driving manoeu-
vres between cornerings, they will have no influence
on the ESP road test.
If the ABS warning light -K47- goes out, the ESP road and
system test was successfully performed and ended, the
system is OK.
If the ABS warning light -K47- does not go out, the ESP
road and system test was not successfully performed.
– Repeat the ESP road and system test ⇒ 45-14

page 5.
If the ABS warning light -K47- and the ESP and TCS
warning light -K155- light up, there are faults in the sys-
tem.
– Interrogate fault memory ⇒ Chap. 45-5.
S00.5303.16.20
45-15 Electrical Test - ABS sys-

tems BOSCH 5.7
♦ Test box -V.A.G 1598A-
♦ Adapter -V.A.G 1598/34-
♦ Adapter -V.A.G 1598/34R-
♦ Measuring tool set, e.g. -V.A.G 1594 A-
♦ Hand multimeter, e.g. -V.A.G 1526 A-
The test steps ⇒ 45-15 page 4 apply for:

♦ Vehicles for which the final control diagnosis does not
indicate the fault source. In this case the full electric in-
spection must be carried out.
♦ Vehicles for which the final control diagnosis does
give a direct indication of the fault source. Then only
perform the test steps recommended in the test table
(targeted approach).
Test requirements
2
• Fuses according to current flow diagram O.K.
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
• Before starting the test switch off the ignition and elec-
trical consumers (headlights, lighting, blowers etc.). 1
Connecting test box -V.A.G 1598A-
– Unlatch the multi-pin connector -arrow 1- and discon- S45-0074
nect from the ABS with EDL control unit -J104- by pull-
ing upwards -arrow 2-.
– Connect the test box -V.A.G 1598A- with adapter
-V.A.G 1598/34- -1- to the multi-pin connector on the 3
wiring loom -2-.
Use adapter -V.A.G 1598/34R- for RH drive vehicles. 1
Do not connect the multi-pin connector of the adapter
-V.A.G 1598/34- -3-.
The nominal values are specific to V.A.G 1526A and do
not necessarily apply for other measuring tools.
V.A.G 1598A
After the electrical test:
V.A.G 1598/34 2
– Insert the multi-plug connector on the ABS with EDL
control unit -J104- and lock.
S45-0034
– Performing automatic test sequence ⇒ Chapter 45-5.
Multi-pin connector with contact assign-

ment
Note
All unlisted contacts are not yet assigned and must under
no circumstances be connected to other components!
Edition 07.04 Electrical Test - ABS systems BOSCH 5.7 45-15 page 1
S00.5303.16.20
Contact assignment of 42-pin plug connection -T42-

wiring loom/ABS control unit -J104-
10 1 11
26 42 27 S45-0031
Contact Wiring to component …

1 Earth terminal 31
2 Voltage supply of battery + (terminal 30)
5 Earth terminal 31
6 Voltage supply of battery + (terminal 30)
81) Lateral acceleration sender -G200- (signal line)
91) Lateral acceleration sender -G200- and yaw rate sender -G202-
101) Lateral acceleration sender -G200- and yaw rate sender -G202-
12 Speed sensor front left -G47-
13 Speed sensor rear left -G46-
14 Speed sensor rear left -G46-
15 Speed sensor front right -G45-
16 Speed sensor front right -G45-
192) Rear right speed sensor output
211) Lateral acceleration sender -G200- and yaw rate sender -G202- (earth cable)
23 Voltage supply (terminal 15)
24 Data BUS cable (CAN-R) ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
251) Brake pressure sender 1 -G201- (earth cable)
261) Brake pressure sender 1 -G201- (signal line)
27 Traction control system switch -E132- or TCS and ESP button -E256-
28 Speed sensor front left -G47-
30 Speed sensor rear right -G44-
31 Speed sensor rear right -G44-
32 Brake light switch -F-
342) Rear left speed sensor output
371) Brake pedal switch -F47-
381) Handbrake warning switch -F9-
391) Voltage supply for:
♦ Steering angle sender -G85-
♦ Lateral acceleration sender -G200-
♦ Yaw rate sender -G202-
45-15 page 2 Electrical Test - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20

40 Data BUS cable (CAN-L) ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
411) Yaw rate sender -G202- (signal line)
421) Brake pressure sender 1 -G201- (voltage line)
1) only assigned on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
2) only assigned on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 and navigation system
Overview of test steps
Component to be tested Test steps in test table

⇒ 45-15 page 4
Voltage supply for the ABS return flow pump -V39- to the ABS control unit -J104- – Perform test step 1
Voltage supply of the valves in the hydraulic unit for ABS -N55- to the ABS control – Perform test step 2
unit -J104-
Voltage supply (terminal 15) to the ABS control unit -J104- – Perform test step 3
Function of the brake light switch -F- – Perform test step 4
Function of the traction control system switch -E132- or TCS and ESP button – Perform test step 5
-E256-
Test of the data BUS cables – Perform test step 6
Handbrake warning switch -F9- 1) – Perform test step 7
1) Test can only be performed on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7.
S00.5303.16.20
Test table
Note
♦ The denominations of the bushes of the test box -V.A.G 1598A- with the adapter -V.A.G 1598/34- are identical to
the contact denominations of the ABS with EDL control unit -J104- in the current flow diagram ⇒ Current Flow Di-
agrams, Electrical Fault Finding and Fitting Locations.
♦ If the measured values deviate from the nominal values perform the fault eliminating measures listed in the right
part of the table.
♦ Once these values are reached, additionally check the cable for short-circuit to positive and earth.
♦ If the measured values only differ slightly from the nominal values, clean the bushes and plugs of the test devices
and measuring cables (with contact spray -G 000 700 04-) and repeat the test. Before replacing the relevant com-
ponents test the cables and connectors; more specifically for nominal values below 10 Ω repeat the resistance
measurement on the component.
Switch on measuring range: Voltage measurement (20V=)

Test Test box Test covers • Test condi- Specifica- Measures for devia-
step -V.A.G 1598A- tions tion tions from nominal
with adapter value
-V.A.G 1598/34- ♦ additional
works
1 1+2 Voltage supply for the • Ignition off approx. bat- – Test cable from con-
5+2 ABS return flow pump tery voltage tact 1 or 5 to earth.
-V39- to the ABS con-
trol unit -J104- – Test cable from con-
tact 2 via fuse to bat-
tery + ⇒ Current
Flow Diagrams,
Electrical Fault Find-
ing and Fitting Loca-
tions.
2 1+6 Voltage supply for the • Ignition off approx. bat- – Test cable from con-
5+6 valves in the ABS re- tery voltage tact 1 or 5 to earth.
turn flow pump -V39-
to the ABS control unit – Test cable from con-
-J104- tact 6 via fuse to bat-
tery + ⇒ Current
Flow Diagrams,
Electrical Fault Find-
ing and Fitting Loca-
tions.
3 23 + 1 Voltage supply (termi- • Ignition on approx. bat- – Test cable from con-
23 + 5 nal 15) to the ABS tery voltage tact 1 or 5 to earth.
control unit -J104-
– Test cable from con-
tact 23 to the con-
nector of terminal 15
⇒ Current Flow Dia-
grams, Electrical
Fault Finding and
Fitting Locations.
S00.5303.16.20

Test Test box Test covers • Test condi- Specifica- Measures for devia-
step -V.A.G 1598A- tions tion tions from nominal
with adapter value
-V.A.G 1598/34- ♦ additional
works
4 5 + 32 Function of the brake • Ignition off < 1.0 V – Test brake light
light switch -F- switch -F- and read
• Brake pedal
measured value
not actuated
block ⇒ Chap. 45-
10, display group
number 003.
tact 5 to earth.
– Test cable from
contact 32 to the
brake light switch -F-
grams, Electrical
Fault Finding and
Fitting Locations.
– Actuate brake approx. bat- – Test brake light
pedal tery voltage switch -F- ⇒ Chap.
45-16.
– Test fuse.
5 5 + 27 Function of the trac- • Ignition on
tion control system
switch -E132- or TCS • Traction control approx. bat- – Test cable from con-
and ESP button system switch tery voltage tact 5 to earth.
-E256- or TCS and
– Test cable fom
ESP button
contact 27 to traction
pressed.
control system
• Traction control < 1.0 V switch -E132- or
system switch TCS and ESP button
or TCS and -E256-.
ESP button not – Check traction con-
pressed.
trol system switch
-E132- or TCS and
ESP button -E256-
S00.5303.16.20
Switch on measuring range: Resistance measurement (200 Ω/20 MΩ)

Test Test box Test covers • Test conditions Specifica- Measures for devia-
step -V.A.G 1598A- tion tions from nominal val-
with adapter ♦ additional works ue
-V.A.G 1598/34-
6 24 + 40 Data BUS ca- • Ignition off
bles
• Measuring range
200 Ω set
– Disconnect control
units on the data
BUS drive
⇒ Electrical Sys-
tem; Rep. Gr. 90
– Connect Test box
-V.A.G 1598A- with
adapter -V.A.G 1598/
34-
– Check the data BUS max. 1.5 Ω – Check data BUS
cable for open cir- ⇒ Chapter 48-27.
cuit.
– Check wiring accord-
• Ignition off ∞Ω ing to current flow di-
agram ⇒ Current
• Measuring range 20 Flow Diagrams, Elec-
MΩ set trical Fault Finding
– Check cables for and Fitting Locations.
short-circuit be-
tween the cables or
for short-circuit to
positive term. or
earth.

Test Test box Test covers • Test conditions Specifica- Measures for devia-
step -V.A.G 1598A- tion tions from nominal val-
with adapter ♦ additional works ue
-V.A.G 1598/34-
71) 38 + 2 Switch for hand- • Ignition off < 1.0 V – Reading measured
brake control -F9- value block ⇒ Chap.
• Handbrake not ap-
45-10, display group
plied
number 002.
– Apply handbrake. approx. bat-
tery voltage
tact 2 via fuse to bat-
tery +.
– Test cable from
contact 38 to the
handbrake warning
switch -F9-
grams, Electrical
Fault Finding and Fit-
ting Locations.
1) This test sequence can only be performed on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7.
S00.5303.16.20
45-16 Electrical/electronic components and fitting locations - ABS/

ESP systems BOSCH 5.7 and BOSCH 8.0
Summary of components - Electrical/electronic components and fitting locations -

ABS/ESP systems BOSCH 5.7
All components marked with 1) can be tested using the vehicle system tester -V.A.G 1552- or the fault read-out scan
tool -V.A.G 1551- with the self-diagnosis or using the vehicle diagnosis, measurement and information system
-VAS 5051-.
1 - Hydraulic control unit BOSCH

5.71) 1 2 3 4 5 6 7 8 9
T fitted until CW 21/2004
T different versions:
♦ for ABS and ABS/EDL/TCS
BOSCH 5.7 without brake
pressure sender 1 -G201-
♦ for ABS/EDL/TCS/ESP
BOSCH 5.7 with brake pres-
sure sender 1 -G201-
♦ Distinguishing features
⇒ Chapter 45-2
T Fitting location: in right of en-
gine compartment
⇒ Chapter 45-17
T disassembling and assem-
bling ⇒ Chapter 45-17
ABS/EDL/TCS/ESP BOSCH 5.7
must not be disassembled and
repaired 10
2 - Brake pressure sender 1
-G201- 1) 11
T only on vehicles with ABS/
EDL/TCS/ESP BOSCH 5.7 12
T Fitting location: screwed into
the hydraulic control unit 13
⇒ Chapter 45-17
T must only be replaced, but 17 15 14
not repaired
3 - Brake servo unit with master 16 S45-0186
brake cylinder and brake fluid
reservoir
4 - Traction control system switch -E132 - or TCS and ESP button -E256-
T Fitting location: Centre part of dash panel above radio
T Operation: Switching off the TCS or ESP function
T can be inspected in the measured value block ⇒ Chapter 45-10 and during the Electrical Test ⇒ Chapter
45-15
T removing and installing ⇒ Electrical System; Rep. Gr. 96; Switches in the dash panel and in the doors, re-
moving and installing switches in the centre console
5 - Traction control system warning light -K86- or ESP and TCS warning light -K155-
T Fitting location: in the dash panel insert
Operation:
T the warning light lights up:
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 1
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
♦ for about 2 seconds after ignition is switched on

♦ if fault is detected in TCS or ESP operation
♦ after switching the traction control system switch or TCS and ESP button to „OFF“
⇒ 45-16 page 6
T the warning light flashes:
♦ during TCS/ESP control
6 - ABS warning light -K47-
Operation:
T the ABS warning light lights up:
♦ for about 2 seconds after the ignition is switched on or the engine is started
♦ if a fault is detected, e.g. open circuit to wheel speed sensor
⇒ 45-16 page 6
7 - Dual circuit and hand brake system warning light -K7-
Operation:
T Dual circuit and hand brake system warning light:
♦ lights up if hand-brake is applied
♦ flashes if low brake fluid level
♦ lights up for about 2 seconds after ignition is switched on
♦ lights up if the electronic brake pressure distribution fails, i.e. when the ABS warning light -K47- comes on
⇒ 45-16 page 6
8 - Dash panel insert
T fitted up to model year 2004
9 - Steering angle sender -G85-1)
T only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
T Fitting location: on steering column between the steering wheel and the steering column switch
T can be tested in the measured value block ⇒ Chapter 45-10
10 - Diagnostic connection
T Fitting location: in the storage area on the driver's side
T Sensor ring for ABS is built into the wheel hub
♦ removing and installing: can only be replaced together with wheel hub and wheel bearing ⇒ Chapter 42-5
12 - Rear right and rear left wheel speed sensors -G44/G46-1)
T removing and installing (disc brake or drum brake) ⇒ Chapter 45-19
T Rear wheel speed sensor cables
♦ removing and installing (disc brake or drum brake) ⇒ Chapter 45-19
13 - Switch for hand-brake control -F9-
T Fitting location: on handbrake lever
T can be inspected in the measured value block ⇒ Chapter 45-10 and during the Electrical Test ⇒ Chapter
45-15.
14 - Lateral acceleration sender -G200- and yaw rate sender -G202-1)
T only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
T Fitting location: under left front seat
T both senders are integrated in one housing
T can be tested in the measured value block ⇒ Chapter 45-10
15 - Brake light switch -F-1)
T is open in the off position
♦ adjust ⇒ 45-16 page 8
♦ removing and installing ⇒ 45-16 page 8
45-16 page 2 Electrical/electronic components and fitting locations - ABS/ESP

systems BOSCH 5.7 and BOSCH 8.0
Edition 11.04
S00.5303.17.20
♦ replace after each removal
T can be inspected in the measured value block ⇒ Chapter 45-10 and during the Electrical Test ⇒ Chapter 45-
15
17 - Front right and front left wheel speed sensors -G45/G47-1)
T Front wheel speed sensor cables
♦ removing and installing ⇒ Chapter 45-19
Summary of components - Electrical/electronic components and fitting locations -

ABS/ESP systems BOSCH 8.0
All components marked with 1) can be tested using the vehicle system tester -V.A.G 1552- or the fault read-out scan
tool -V.A.G 1551- with the self-diagnosis or using the vehicle diagnosis, measurement and information system
-VAS 5051-.
1 - Hydraulic control unit BOSCH

8.01) 1 2 3 4 5 6 7 8 9 10
T fitted as of CW 22/2004
T different versions:
♦ ABS
♦ ABS/TCS
♦ assignment ⇒ Spare part
catalogue
♦ Distinguishing features 11
⇒ Chapter 45-2
T Fitting location: in right of en-
gine compartment
⇒ Chapter 45-18
2 - Traction control system 21
switch -E132- or TCS and ESP
button -E256-1)
T Fitting location: Centre part
of dash panel above radio
T Operation: Switching off the
TCS or ESP function
⇒ Electrical System; 12
Rep. Gr. 96; Switches in the
dash panel and in the doors, 13
removing and installing 20
switches in the centre con- 14
sole
3 - Traction control system warn-
ing light -K86- or ESP and TCS
warning light -K155-
17 16 15
T Fitting location: in the dash 19 18 S45-0185
panel insert ⇒ item 6
Operation:
⇒ 45-16 page 6
4- ABS warning light -K47-
T Fitting location: in the dash panel insert ⇒ item 6
Operation:
⇒ 45-16 page 6
5- Dual circuit and hand brake system warning light -K7-
Operation:
⇒ 45-16 page 6
6- Dash panel insert
T fitted up to model year 2004
7- Traction control system warning light -K86- or ESP and TCS warning light -K155-
Operation:
⇒ 45-16 page 6
8- ABS warning light -K47-
Operation:
⇒ 45-16 page 6
9- Dual circuit and hand brake system warning light -K7-
Operation:
⇒ 45-16 page 6
10 - Dash panel insert
T fitted as of model year 2005
11 - Steering angle sender -G85-1)
T only on vehicles with ABS/TCS/ESP BOSCH 8.0
T Fitting location: on steering column between the steering wheel and the steering column switch

Edition 11.04
S00.5303.17.20
T Fitting location: in the storage area on the driver's side
13 - Rear right and rear left wheel speed sensors -G44/G46-1)
T removing and installing (disc brake or drum brake) ⇒ Chapter 45-19
T Rear wheel speed sensor cables
♦ removing and installing (disc brake or drum brake) ⇒ Chapter 45-19
15 - Handbrake warning switch -F9-1)
T Fitting location: on handbrake lever
16 - ESP sensor unit -G419-1)
T only on vehicles with ABS/TCS/ESP BOSCH 8.0
T Fitting location: under left front seat
T Lateral acceleration sender -G200- and yaw rate sender -G202- are combined in a common housing with the
ESP sensor unit -G419-
♦ there are no separate fault codes
17 - Brake light switch -F-1)
T is open in the off position
♦ adjust ⇒ 45-16 page 8
♦ removing and installing ⇒ 45-16 page 8
♦ replace after each removal
19 - Brake servo unit with master brake cylinder and brake fluid reservoir
20 - Front right and front left wheel speed sensors -G45/G47-1)
T Front wheel speed sensor cables
♦ removing and installing ⇒ Chapter 45-19
21 - Hydraulic control unit BOSCH 8.01)
T ABS/TCS/ESP
T Distinguishing features ⇒ Chapter 45-2
T Fitting location: in right of engine compartment
T ABS/TCS/ESP BOSCH 8.0 must not be disassembled and repaired
Indication of faults by means of warning

lights
♦ Vehicle system tester -V.A.G 1552- or fault read-out
scan tool -V.A.G 1551- or vehicle diagnosis, measure-
-V.A.G 1551/3B-, -V.A.G 1551/3C- or Diagnostic ca-
ble -VAS 5051/5A- or -VAS 5051/6A -
Note
♦ When using the fault reader -V.A.G 1551- a minor de-
viation in the display is possible.
♦ When using the vehicle diagnosis, measurement and
information system -VAS 5051- the electrical test is in- 4
tegrated in the „Targeted fault finding“.
S45-0184
Dash panel insert up to model year 2004
1 2 3
Dash panel insert as of model year 2005
Warning lights
Pos. Denomination
1 Brake pad warning light -K32-
2 Traction control system warning light -K86-
ESP and TCS warning light -K155-
3 ABS warning light -K47-
4 Dual circuit and hand brake system warning
light -K7-
0
Brake pad warning light -K32- (-1-) 4

S45-0187
♦ If the brake pad warning light -K32- (-1-) does not go 1 2 3
out after switching the ignition on or glows during the
driving operation, the following can be the causes of
the fault:
a - The brake pads could be worn down.
Check the brake pads on the front and rear axles.
Replace the brake pads if they are worn down ⇒ Chapter
46-1 and ⇒ Chapter 46-2.
b - There is a fault in the wiring ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
ABS warning light -K47- (-3-)
♦ If the ABS warning light -K47- (-3-) does not go out af-
ter the ignition is switched on and after completion of
the test sequence, the causes of the fault may be:
a - Voltage supply is less than 11 volts.
b - An ABS fault is present. If an ABS fault is present,
the anti-lock brake system remains switched off
while the conventional brake system remains fully
operational.

Edition 11.04
S00.5303.17.20
WARNING!
If an ABS fault -b- is present, the anti-lock brake
system remains switched off while the convention-
al brake system remains fully operational.
c - A fault existed on a wheel speed sensor after the

last vehicle start (sporadic fault). If there is a fault on
a vehicle speed sensor, the ABS warning light -K47-
goes out automatically after restarting the vehicle
and after a speed above 20 km/h is reached.
d - The connection form the dash panel insert to the
ABS control unit -J104- (databus) is interrupted
e - The dash panel insert is defective.
ABS warning light -K47- (-3-) and dual circuit and
hand brake system warning light -K7- (-4-)
♦ If the ABS warning light -K47- (-3-) goes out or the
dual circuit and hand brake system warning light -K7-
(-4-) lights up or flashes, the causes of the fault may
be:
a - The hand-brake is still applied (warning light lights
up).
b - The brake fluid level is too low (warning light flash-
es).
c - There is a fault in the wiring between dash panel in-
sert and brake fluid level warning contact -F34-
♦ If the ABS warning light -K47- (-3-) and the dual circuit
and hand brake system warning light -K7- (-4-) do not
go out, then the ABS and EBD (Electronic Brake pres-
sure Distribution) have failed.
One must reckon with a somewhat changed braking
characteristic.
WARNING!
Once the ABS warning light -K47- and the dual cir-
cuit and hand brake system warning light -K7-
have lit up then one can expect the rear wheels to
lock quite early on when braking.
ABS warning light -K47- (-3-), dual circuit and hand

brake system warning light -K7- (-4-), traction control
system warning light -K86- (-2-) and ESP and TCS
warning light -K155- (-2-)
♦ If the ABS warning light -K47- (-3-) and the dual circuit
and hand brake system warning light -K7- (-4-) goes
out, but the traction control system warning light -K86-
(-2-) or the ESP and TCS warning light -K155- (-2-) re-
main lit, the causes of the fault may be:
a - Fault relates only to TCS or ESP.
b - ASR is switched off with traction control system

switch -E132- or ESP with TCS and ESP button
-E256-.
c - TCS or ESP is in regulating mode (flashing rhythm
3x per second).
d - Short-circuit to positive in traction control system
switch -E132- or in TCS and ESP switch -E256-
(warning light goes out after approx. 5 minutes).
1
Display overview of the warning lights -K7-,
-K47-, -K86- or -K 155-
Warning lights
2
1 - Dual circuit and hand brake system warning light
-K7-
2 - ABS warning light -K47-
3 - Traction control system warning light -K86- or ESP
3
and TCS warning light -K155-
For the warning lights of the pos. 3 there are two dif- S45-0203
ferent symbols, ⇒ Dash panel insert as of model year
2004 and dash panel insert as of model year 2005.
Display overview
System condition Dual circuit and ABS warning light Traction control Traction control
hand brake sys- -K47- system warning system switch
tem warning light light -K86- or ESP -E132- or TCS and
-K7- and TCS warning ESP button -E256-
light -K155-
Ignition on lights up lights up lights up not actuated
test of the lights(-K7-
is only indicated for
the test in the dash
panel insert)
System o.k. does not light up does not light up does not light up not actuated
ESP/TCS or ABS/ does not light up does not light up flashes (3x/seconds) not actuated
TCS -in recess
ESP/TCS or ABS/ does not light up does not light up lights up activated
TCS are switched off
ESP/TCS or ABS/ does not light up does not light up does not light up activated
TCS are switched on
again via TCS and
ESP button -E256- or
traction control sys-
tem switch
-E132-(were
switched off)
Setting, removing and installing the

brake light switch -F-

Edition 11.04
S00.5303.17.20
Note
The brake light switch must be removed for setting.
– Remove the storage area on the driver's side ⇒ Body

Work; Rep. Gr. 70.
– Unplug connector from brake light switch.
For vehicles up to 07.01
– Turn brake light switch -1- 90° to the left and remove
from its bracket -2-.
Note 1
♦ Carry out installation of the brake light switch only af-
ter attaching the ball head of the pushrod fron the
brake servo unit to the brake pedal ⇒ Chapter 46-4.
♦ The contact surface which the tappet is to touch on
the brake pedal should be greased using polycar-
bamide grease - G 052 142 A2- before installing the
2
brake light switch.
– To adjust, pull out the plunger of the brake light switch

fully. S45-0062
– Press down brake pedal as far as possible by hand.
– Guide the brake light switch through the assembly
opening and install again by turning 90° to the right.
– Release brake pedal.
For vehicles from 08.01
– Turn brake light switch -1- 45° to the left and remove
from its bracket -2-.
Note 1
♦ The brake light switch may only be installed once to
ensure that it has an adequately tight fit.
♦ Carry out installation of the brake light switch only af-
ter attaching the ball head of the pushrod fron the
brake servo unit to the brake pedal ⇒ Chapter 46-4. 2
♦ The contact surface which the tappet is to touch on
the brake pedal should be greased using polycar-
bamide grease -G 052 142 A2- before installing the
brake light switch.
S45-0101
– Guide the brake light switch through in the assembly
opening and install by turning it 45° to the right.
Pull the brake light switch tappet out completely up to its
stop before assembly since it will be automatically adjust-
ed and set during assembly.
Brake pedal always remains in the off position in this case
(not actuated).
– After installing the brake light switch, check whether

brake pedal is in the end position (release position).
– Insert plug into brake light switch.
– Inspecting operation of the brake light switch BOSCH

5.7 ⇒ Chap. 45-10 BOSCH 8.0 ⇒ Chap. 45-11.
Actuate brake pedal ⇒ all brake lights must light up.
Release brake pedal ⇒ all brake lights must go out.
– Install the storage area on the driver's side ⇒ Body

Work; Rep. Gr. 70.
Removing and installing steering angle

sender -G85- - vehicles with ABS/EDL/
TCS/ESP BOSCH 5.7 or ABS/TCS/ESP
BOSCH 8.0
The description of the structure and function of the steer-
ing angle sender -G85- can be found in self-study pro-
gramme No. 42.

-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
Removing
WARNING!
Disconnect earth strap from the battery before
commencing work on the electrical system.
If the battery earth strap is disconnected and con-
nected, carry out additional operations
– Disconnect battery ⇒ Electrical System; Rep. Gr. 27.

– Check whether the front wheels are in the straight-
ahead position.
– Remove steering wheel ⇒ Body Work; Rep. Gr. 69.
– Removing steering column trim ⇒ Body Work;
Rep. Gr. 70.
The steering angle sender -G85- is fitted together with the
coil spring -2- in housing -1-.
They must not be separated or disassembled.
When removing pay attention to the steering angle send-
er -G85- to obtain correct re-installation:
2 1 S48-0188

Edition 11.04
S00.5303.17.20
♦ Position the steering angle sender -G85- in the middle
position as shown:
1
A yellow dot must be visible in the window -1-.
The markings -arrows- must be flush.
Make sure this correct position is maintained.
S48-0189
♦ Secure the coil spring -2- against unintentional turning

by covering it with adhesive tape -1-.
1
-3- Housing for steering angle sender -G85-
2 3 S48-0190
– Disconnect plugs -1- and -2-.
2 S45-0199
– Carefully release catch hooks -arrows-, remove hous-

ing -1- with steering angle sender -G85- and coil
spring.
Installing
– Slide housing -1- with steering angle sender -G85-

and coil spring onto the steering column and lock into
position with steering column switch -arrows-.
– Connect both plug connections.
Note
After removing the transport protection or the adhesive
tape do not turn the coil spring, only the positioning of the
steering angle sender -G85- in centre position is allowed. 1 S48-0191
– Removing transport protection or adhesive tape.

– Position the steering angle sender in the centre posi-
tion: 1
A yellow dot must be visible in the window -1-.
The markings -arrows- must be flush.
Make sure this correct position is maintained.
– Fitting steering column trim ⇒ Body Work;

Rep. Gr. 70.
– Install steering wheel ⇒ Body Work; Rep. Gr. 69.
– Connect battery ⇒ Electrical System; Rep. Gr. 27.
– Perform null balance of the steering angle sender
-G85-. S48-0189
♦ using the vehicle diagnosis, measurement and infor-
mation system -VAS 5051- ⇒ Chapter 45-4.
or
♦ using the vehicle system tester -V.A.G 1552-
⇒ Chapter 45-13.

If a fault is stored in the fault memory:
– Eliminating fault ⇒ Chapter 45-6.

– Erasing fault memory ⇒ Chapter 45-5.
♦ using the vehicle diagnosis, measurement and infor-
mation system -VAS 5051- ⇒ Chapter 45-4.
or
♦ using the vehicle system tester -V.A.G 1552-
⇒ Chapter 45-14.


Edition 11.04
S00.5303.17.20
Removing and installing lateral accelera-

tion sender -G200- and yaw rate sender
-G202- or ESP sensor unit -G419- - vehi-
cles with ABS/EDL/TCS/ESP BOSCH 5.7
or ABS/TCS/ESP BOSCH 8.0
Note
♦ The lateral acceleration sender -G200- and the yaw
rate sender -G202- are combined in one housing for
the ABS/EDS/ASR/ESP BOSCH 5.7.
♦ Only the ESP sensor unit -G419- for the ABS/ASR/
ESP BOSCH 8.0 exists. The lateral acceleration
sender -G200- and the yaw rate sender -G202- are in-
tegrated in it.
♦ The removed unit is sensitive to strong vibrations.
♦ If the unit was exposed to strong vibrations or blows,
its function cannot be guaranteed.

-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
Removing
WARNING!
♦ Disconnect earth strap from the battery before
commencing work on the electrical system.
♦ If the battery earth strap is disconnected and
connected, carry out additional operations

– Remove the driver's seat ⇒ Body Work; Rep. Gr. 72.
Note 3
2
♦ The unit is located under the base of the left front seat
before the cross member.
♦ -Arrow- in Fig. S45-0113 points in the travel direction. 1
– Unplug plug -1- from the unit -3-.
– Unscrew hexagon nuts -2- and remove unit -3-.
Installing
Installation is performed in the reverse order. Pay atten-
tion to the following points:
– Connect battery ⇒ Electrical System; Rep. Gr. 27. S45-0113
– Perform automatic test sequence ⇒ Chapter 45-5 ei-

ther using the vehicle system tester -V.A.G 1552- or
the vehicle system test ⇒ Chapter 45-4 using the ve-
-VAS 5051-.


Tightening torques:
Sender -G200/G202 - on body (ABS/EDL/ 6 Nm

TCS/ESP BOSCH 5.7)
ESP sensor unit -G419- on body (ABS/TCS/ 6 Nm
ESP BOSCH 8.0)

Edition 11.04
S00.5303.17.20
45-17 Hydraulic control unit (ABS systems BOSCH 5.7), Brake ser-
vo unit/Master brake cylinder
Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake

Cylinder
Note
♦ Removing and installing the hydraulic control unit completely ⇒ 45-17 page 2.
♦ Repairing the hydraulic control unit ⇒ 45-17 page 6.
♦ Mount bracket before assembling the brake lines.
♦ Do not bend brake lines when assembling or when connecting.
♦ Install brake hoses without transposition.
♦ Brake hoses must not come into contact with other components during operating condition.
♦ Do not remove the plugs on the connection threads and the holes in the parts carrying brake fluid until just before
assembling.
♦ Tighten all the brake line pipe screws to a tightening torque of 14 Nm.
1 - Hydraulic control unit

T ABS BOSCH 5.7 3 4
T ABS/EDL/TCS BOSCH 5.7 5
3 2
catalogue 2 4 8 6
T fitted until CW 21/2004
2 - Brake line 1
T identification marking of the 5
hydraulic unit „VL“ 9
T to front left brake caliper
3 - Brake line
T identification marking of the
6
hydraulic unit „VR“
7 10 7
T to front right brake caliper 11
4 - Brake line 21 12
hydraulic unit „HZ2“ 20
T Master brake cylinder/float-
ing piston circuit to hydraulic
control unit 19
5 - Brake line
19 13
hydraulic unit „HZ1“
T Master brake cylinder/pres- 18
sure rod piston circuit to hy-
draulic control unit 17
6 - Brake line 13
hydraulic unit „HL“
T to wheel brake cylinder/rear
left brake caliper
16 15 14 S45-0107
7 - Brake line
T identification marking of the hydraulic unit „HR“
T to wheel brake cylinder/rear right brake caliper
8 - Brake pressure sender 1 -G201-
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 1
S00.5303.16.20 unit/Master brake cylinder
T must only be replaced, but not repaired

9- Line
T ABS/EDL/TCS/ESP BOSCH 5.7
T to ABS control unit
T ABS/EDL/TCS/ESP BOSCH 5.7
T must not be repaired, replace completely in the event of faults
T Brake pressure sender 1 -G201- must be replaced, but not repaired
T fitted until KW 21/2004
11 - Line holder
T for brake line
12 - Bracket
T for brake line
T 2 units
13 - Bracket
T for brake line
T 3 units
14 - Brake servo unit
15 - Master brake cylinder
T cannot be repaired, replace completely in the event of faults
T Tightness test ⇒ Chapter 47-2
16 - Brake fluid reservoir
17 - Self-locking nuts, 20 Nm
18 - Bracket
T for ABS, ABS/ABS/EDL or ABS/EDL/TCS/ESP BOSCH 5.7
19 - Screw, 8 Nm
20 - Bracket
T for ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7
21 - Hexagon collar nut, self-locking, 20 Nm
Removing and installing the hydraulic

control unit
The removal and installation of the relevant hydraulic
control unit is described according to the example of
the ABS system BOSCH 5.7. Removal and installa-
tion is similar for the ABS/EDL/TCS or ABS/EDL/TCS/
ESP system BOSCH 5.7.
45-17 page 2 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
WARNING!
♦ Make absolutely sure that no brake fluid gets
into the plug connector housing of the hydrau-
lic control unit. This may result in the corrosion
of the contacts and to system failure.
♦ Carefully clean out the plug connector housing
with compressed air if it gets dirty.
♦ Do not bend the brake lines around the hydrau-
lic control unit.

pedal load -V.A.G 1869/2-
-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
-ROMESS S15-
♦ Repair kit SP-No. 1H0 698 311 A
Removing
Note
2
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding. 1
– Remove engine cover ⇒ Engine, Mechanics;
Rep. Gr. 10.
Vehicles with TDI PD Turbocharger engines
S45-0193
– Remove top charge-air pipe -1- with connecting hose
-2- ⇒ TDI Engine, Mechanics; Rep. Gr. 21.
– Actuate brake pedal and arrest with brake pedal ar-

rester.
– Attach the bleeder hose of the bleeding bottle onto the
vent valve of the front left brake caliper and open
bleeder valve.
– Shut the vent valve once the brake fluid has flown out.
– Disconnect the bleeder hose from the vent valve.
– Place sufficient non-fluffing cloths under and around
S45-0016
– Unlatch the multi-pin connector -arrow 1- and pull off

upwards from the control unit -arrow 2-.
– Close the plug connector housing of the control unit
with a cap.
– If necessary remove the brake lines from the line hold- 2
er.
– Mark brake lines.
– Unscrew brake lines from hydraulic control unit.
– Close off immediately brake lines.
1
– Shut off immediately threaded bores (brake line con-
nections) on the hydraulic control unit with plugs from
repair kit SP No. 1 H0 698 311 A.
S45-0065
Note
To avoid overvoltage and static discharge do not touch
the plug contacts of the brake pressure sender 1 -G201-.
– Unplug connector from brake pressure sender 1

-G201-.
– Remove right drive shaft from the flange shaft and tie
up. Avoid damaging the paintwork on the drive shaft
during this operation.
♦ Drive shaft with constant velocity joint ⇒ Chapter 40-4
♦ Drive shaft with tripod joint ⇒ Chapter 40-5
– Remove shield from the assembly carrier ⇒ Chap.

40-1.
– Unscrew the nuts of the two hydraulic control unit
brackets.
– Remove hydraulic control unit with brackets from the 2
threaded bores at the body.
– Remove the hydraulic control unit downwards from 1
the vehicle.
– Separate bracket -1- from the fixing bolt of the bracket S45-0067
-2-.
– Release the screws -arrows- and remove hydraulic
control unit from bracket -2-.
Installing
Note
♦ New hydraulic control units are filled with hydraulic oil
and bleed.
♦ Only then remove plugs from the hydraulic unit when
the relevant brake line is installed. 2
♦ If the plugs were already removed from the hydraulic
unit before the brake line is installed, then brake fluid
may escape and adequate filling and bleeding can no
1
longer be guaranteed.
S45-0067
– Screw bracket -2- onto the hydraulic control unit.
Edition 07.04
S00.5303.16.20
– Tighten up the screws -arrows- fully to the specified
tightening torque.
– Insert bracket -1- onto the fixing bolt of the bracket -2-.
Note
Do not immediately tighten the nuts for securing the hy-
draulic control unit to the body. This facilitates the screw-
ing of the individual brake lines onto the hydraulic control
unit.
– Install the hydraulic control unit and screw on nuts as

well as collar nut.
– Mount plug on brake pressure sender 1 -G201-.

– Remove plugs from the brake lines to be installed.
WARNING!
Pay attention to the correct channel assignment of
the brake lines. Interchanging the brake lines will
result in dangerous brake control actions.
– Connect the brake line to the hydraulic control unit

and tighten ⇒ 45-17 page 1.
– Tighten the collar nut and nuts for securing the hy-
draulic control unit to the specified tightening torque.
– Fit drive shaft to flange shaft.
♦ Drive shaft with constant velocity joint ⇒ Chapter 40-4
♦ Drive shaft with tripod joint ⇒ Chapter 40-5
– If necessary install shield on the assembly carrier

⇒ Chap. 40-1.
– Insert the multi-plug connector on the control unit and
lock.
– Install top charge-air pipe -1- with connecting hose -2-

⇒ TDI Engine, Mechanics; Rep. Gr. 21.
– Installing engine cover ⇒ Engine, Mechanics;

Rep. Gr. 10. 2
1
– Coding control unit ⇒ Chap. 45-8
– Perform null balance of the steering angle sender
-G85- (only for vehicles with ABS/EDL/TCS/ESP)
⇒ Chap. 45-13.
S45-0193

-VAS 5051-.

Note
For vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP
BOSCH 5.7 perform a test drive after bleeding with at
least one ABS control!
Tightening torques:
Hydraulic control unit to bracket 8 Nm

Bracket to hydraulic control unit and 20 Nm
to body
♦ Use new nuts and new hexagon
collar nut!
Brake line to hydraulic control unit 14 Nm
Drive shaft to flange shaft - gearbox M8 = 40 Nm
M10 = 70 Nm
♦ Use new screws!
Shield to assembly carrier 35 Nm
Repairing the hydraulic control unit ABS

or ABS/EDL/TCS BOSCH 5.7
The hydraulic control units ABS and ABS/EDL/TCS
BOSCH 5.7 must be repaired, while the hydraulic
control units ABS/EDL/TCS/ESP BOSCH 5.7 must not
be disassembled. It must be replaced in case of re-
pairs. For ABS/EDL/TCS/ESP only the brake pressure
sender 1 -G201- must be replaced ⇒ 45-17 page 10.
Note
♦ Inspecting and repairs of the hydraulic control unit
must only be performed by skilled personnel in ap-
proved automobile workshops (Bosch service centres
or contract dealers of the vehicle manufacturer).
♦ Observe the notes in the manufacturer's instructions
for the replacement of hydraulic control units.

♦ Caliper gauge (commercially available)
Edition 07.04
S00.5303.16.20
Note
♦ The sealing surface on the hydraulic control unit must
be clean and undamaged. It must never be reworked,
e.g. with files, scrapers etc. If necessary replace the
hydraulic unit.
♦ The gasket on the control unit must not be removed, it
cannot be replaced.
♦ The screws (inner Torx T20) of the hydraulic unit/con-
trol unit must be replaced after each disassembling.
Use the screws included in the parts kit. Tightening
must occur in the prescribed sequence and in steps.
♦ If the control unit is being replaced tentatively tighten
the fixing screws only slightly Tighten the screws to
the specified torque once the control unit is correctly
positioned on the hydraulic control unit.
♦ Maximum 5 tightening procedures (hydraulic unit)
may be carried out throughout the entire life of the hy-
draulic control unit. Pay attention to the colour mark-
ings (approx. 3 mm wide red lines) on the hydraulic
control unit. Replace the complete hydraulic control
unit if more than 5 tightening procedures have been
performed (-arrow- area for colour markings).
♦ The threads in the hydraulic unit for securing the con-
trol unit must not be rethreaded. If the thread is dam-
aged (screws are hard to tighten by hand or they
cannot be tightened to the prescribed torque) replace
♦ Blowing out of the control unit or the hydraulic unit with
compressed air to secure an oily or aqueous film on
and between the valve domes or the solenoid coils is S45-0111
not permissible. Only use moisture-free and oil-free
compressed air, e.g. from a spray. Cleaning with hy-
drocarbon solvents is not allowed.
♦ If the hydraulic control unit is open protect the valve
domes, solenoid coils, contact springs against dam-
age and soiling.
♦ If the hydraulic control unit is open it is not permissible
to apply a voltage to the contact springs of the hydrau-
lic pump. Risk of contact arcing.
♦ Repair is only possible with the hydraulic control unit
removed.
♦ Disassembly and assembly of the hydraulic control
unit is described on an ABS unit BOSCH 5.7. The pro-
cedure for the ABS/EDL/TCS unit BOSCH 5.7 is iden-
tical. The ABS/EDL/TCS/ESP unit BOSCH 5.7 must
not be disassembled. It must be replaced in case of
repairs. Only the brake pressure sender 1 -G201-
must be replaced ⇒ 45-17 page 10.
a
– Remove hydraulic control unit with bracket ⇒ 45-17
page 2
Disassembling the hydraulic control unit
Hydraulic unit for ABS -N55- with return flow pump
for ABS -V39- (-a-):
b
S45-0068
♦ Hydraulic unit: The valve block includes the control

valve and the contact springs of the hydraulic pump.
♦ Do not separate the return flow pump for ABS -V39-
from the hydraulic unit for ABS -N55-.
5 2 4 1 6
ABS control unit -J104- (-b-):
♦ Contact assignment ⇒ Chap. 45-15
Note
The hydraulic control unit ABS/EDL/TCS/ESP BOSCH
5.7 must not be disassembled. It must be replaced as a
complete unit in the case of repairs. Only the brake pres-
sure sender 1 -G201- must be replaced ⇒ 45-17
page 10.
– Release inner Torx screws T20 -Postions 1 through to

6-.
S45-0071
When tightening the control unit -b- of the hydraulic unit

-a- make sure the valve domes -1- are not tilted along
with the solenoid coils -4-. 4 b a
3 - Silicone seal
– Cover the solenoid coils of the control unit.

– Protect the valve domes and contact springs -2- of the
return flow pump for ABS -V39- against damage and
soiling. Do not use fluffing cloths or a transport protec-
tion of an already installed spare part hydraulic pump.
This is a requirement for possible guarantee claims.
Assembling the hydraulic control unit 3 2 1
S45-0070
If new or removed control units -1- are installed again, in-

spect the heat conduction posts -3-.
– Inspect the end faces of the heat conduction posts for

good heat conduction properties. The faces must not
exhibit any deposit, e.g. oxidation.
3 3
– Check projection of the posts using a gauge.
Dimension must be of 0.8…1.0 mm between the top
side of the heat conduction posts and the seal -2-. 2
– Press the end face of the heat conduction posts with
your thumb, they must give.
If faults are found during one of the 3 test steps, the con-
1
trol unit must be replaced.
S45-0110
Edition 07.04
S00.5303.16.20
– Inspect the sealing surface on the hydraulic unit for
soiling, if necessary clean with white spirits and a non-
fluffing paper or linen cloth.
– If an oily or aqueous film appears on the surface of the
hydraulic unit, clean with white spirits and a non-fluff-
ing paper or linen cloth.
– If there is a considerable oily and aqueous film be-
tween the valves use moisture-free and oil-free com-
pressed air to blow it out.
– If damage is noticed on the hydraulic unit, e.g. scoring
or scratching etc., near the seal, replace the hydraulic
unit.
– Inspect the contact springs of the hydraulic pump for
burning points and oxidation. Reworking or cleaning is
not possible, replace the hydraulic unit.
Note
♦ Before fitting the control unit to the hydraulic unit make
sure the seal protrudes by min. 0.1 mm from the con-
trol unit housing.
♦ When assembling the control unit and the hydraulic
unit make sure the valve domes of the hydraulic unit
do not tilt along with the solenoid coils of the control
unit.
– Place the control unit on the hydraulic unit and guide

the solenoid coils over the valves by exerting a slight
pressure. While doing so center the control unit rela-
tively to the hydraulic unit. The edge of the control unit
must engage in the groove of the hydraulic unit.
– Press by hand on the control unit until it fixes in place
with the two centre screws.
Note
♦ Screw on the hydraulic unit and the control unit in the
prescribed sequence and in steps. Tightness will not
be guaranteed if this is not observed. 5 2 4 1 6
♦ Only use new inner Torx screws from the parts kit.
♦ When screwing together make sure the left and right
gap between the control unit and the hydraulic unit is
always the same.
– First screw in the inner Torx screws and tighten them

by hand in the alternating sequence 1 - 2, 3 - 4, 5 - 6.
– Tighten all inner Torx screws in the alternating se-
quence 1 - 2, 3 - 4, 5 - 6 to the prescribed torque.
S45-0071
– Indicate each fitting of the hydraulic unit with the con-

trol unit in the area -arrow- with a permanent mark ap-
prox. 3 mm wide. Colour: red
For this use e.g. lead seal enamel.
– Install hydraulic control unit with bracket ⇒ 45-17

page 2.
Tightening torque:
Control unit to hydraulic unit 3 Nm

♦ Use new screws!
S45-0111
Removing and installing brake pressure
sender 1 -G201- - vehicles with ABS/EDL/
TCS/ESP BOSCH 5.7
A description of the structure and function of the brake
pressure sender 1 -G201- can be found in self-study pro-
gramme no. 42.

-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
♦ Hexagon socket wrench insert, e. g. -900S Lg 24-
Note
♦ Repair of the brake pressure sender 1 -G201- is not
allowed. Only the brake pressure sender 1 -G201-
must be replaced.
♦ No additional seals or lubricants may be used when
sealing the sender/hydraulic unit. A thread moistened
with brake fluid is allowed.
♦ The sealing surfaces of the conical seat on the sender
and on the hydraulic unit must not be damaged,e.g.
small surfaces, grooves.
♦ The threads on the sender and on the hydraulic unit
must not be damaged. Re-cutting the thread is not al-
lowed. Replace the complete hydraulic unit if the
thread is damaged (sender difficult to screw in).
♦ Replacement of the brake pressure sender 1 -G201-
is limited to a maximum of 4 repeat screwing proce-
dures (torque connections). Pay attention to the col-
our markings (approx. 3 mm wide green lines) on the
hydraulic control unit (-arrow- for colour markings). If
more than 4 tightening procedures are performed the
complete hydraulic unit must be replaced
Removing
– Remove the hydraulic control unit ⇒ 45-17 page 2.

S45-0112
– Unscrew brake pressure sender 1 -G201-
Edition 07.04
S00.5303.16.20
– Check the ball sealing surface of the hydraulic unit for
damage.
Teplace the hydraulic unit if they are damaged (e.g.
small surfaces, grooves). Reworking of the sealing
surface is not allowed.
Installing
– Screw in the brake pressure sender 1 -G201- by hand

up to the stop and tighten to the prescribed torque.
– Indicate each fitting of the sender brake pressure
sender -G201- with the control unit in the area -arrow-
with a permanent mark approx. 3 mm wide (green).
– Installing the hydraulic control unit ⇒ 45-17 page 2.
– Inspect the tightness on the connection of the brake
pressure sender 1 -G201- under pressure (brake ped-
al pressed).
If brake fluid escapes:
– Tighten up the sender fully to the specified tightening

torque.
If brake fluid still escapes:
S45-0112
– Replace the brake pressure sender 1 -G201- or hy-
draulic unit and check tightness.
-VAS 5051-.
If faults are stored in the fault memory:

Note
For vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP
BOSCH 5.7 perform a test drive after bleeding with at
least one ABS control!
Tightening torque:
Brake pressure sender 1 -G201- on hy- 20 Nm

draulic unit
Edition 07.04
S00.5303.16.20
45-18 Hydraulic control unit (ABS systems BOSCH 8.0), Brake ser-
vo unit/Master brake cylinder
Summary of Components of Hydraulic Control Unit Brake Servo Unit/Master Brake

Cylinder
Note
♦ Removing and installing the hydraulic control unit completely ⇒ 45-18 page 3.
♦ Mount bracket before assembling the brake lines.
♦ Do not bend brake lines when assembling or when connecting.
♦ Brake hoses must not come into contact with other components during operating condition.
♦ Do not remove the plugs on the connection threads and the holes in the parts carrying brake fluid until just before
assembling.
♦ Tighten all the brake line pipe screws to a tightening torque of 14 Nm.
♦ The repair of the hydraulic control unit ABS/ASR/ESP BOSCH 8.0 is not permissible.

5
T ABS BOSCH 8.0
4
⇒ 45-18 page 3 5 3
T ABS/TCS BOSCH 8.0 4 2
catalogue
6 7
2
hydraulic unit „ABS“ 1
2 - Brake line
hydraulic unit „VR“ 8
7 12 9 8
T to front right brake caliper
T Connect ⇒ 45-18 page 7 10
hydraulic unit „HL“
10
left brake caliper
hydraulic unit „HR“ 18
right brake caliper
17
5 - Brake line 12
hydraulic unit „VL“
T to front left brake caliper 16 15 14 S45-0168
T Connect ⇒ 45-18 page 7
T ABS/TCS/ESP BOSCH 8.0
T identification marking of the hydraulic unit „ESP“

7- Brake line
T identification marking of the hydraulic unit „HZ2“
T Master brake cylinder/floating piston circuit to hydraulic control unit
8- Brake line
T identification marking of the hydraulic unit „HZ1“
T Master brake cylinder/pressure rod piston circuit to hydraulic control unit
9- Bracket
T for hydraulic control unit ABS/TCS/ESP BOSCH 8.0
10 - Screws, 8 Nm
T for holder to hydraulic control unit
11 - Line holder
T for brake line
12 - Bracket
T for brake line
T 2 units
13 - Bracket
T for brake line
T 3 units
15 - Master brake cylinder
T Tightness test ⇒ Chapter 47-2
17 - Self-locking nuts, 20 Nm
T for bracket to body
18 - Bracket
T for ABS, ABS/TCS, ABS/TCS/ESP BOSCH 8.0
19 - Hexagon collar nut, 20 Nm
T for bracket to body
20 - Bracket
T for hydraulic control unit ABS, ABS/TCS BOSCH 8.0
21 - Bracket
T for brake line
T 2 units
Edition 07.04
S00.5303.16.20
Removing and installing the hydraulic
control unit
WARNING!
♦ Make absolutely sure that no brake fluid gets
into the plug connector housing of the hydrau-
lic control unit. This may result in the corrosion
of the contacts and to system failure.
♦ Carefully clean out the plug connector housing
with compressed air if it gets dirty.
♦ Do not bend the brake lines around the hydrau-
lic control unit.

-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-,
-VAS 5051/5A- or -VAS 5051/6A-
-ROMESS S15-
♦ Repair kit SP-No. 1H0 698 311 A
Removing
Note
radio sets fitted with anti-theft coding.

Rep. Gr. 10.

2
1
S45-0193
– Actuate brake pedal and arrest with brake pedal ar-

rester.
– Attach the bleeder hose of the bleeding bottle onto the
vent valve of the front left brake caliper and open
bleeder valve.
– Shut the vent valve once the brake fluid has flown out.
– Place sufficient non-fluffing cloths under and around
Unlatch the multi-pin connector
The unlatching of the multi-pin connector is described ac-
cording to the example of the ABS system BOSCH 8.0.
On the ABS/TCS and ABS/TCS/ESP systems BOSCH S45-0016
8.0 the unlatching is identical.
– Release multi-pin connector -1-.

– Insert red fuse -2- up to the stop in -direction of the ar-
row-.
1 2 S45-0169
– Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
– Pull out multi-pin connector -2- from ABS control unit
-J104-.
– Close the plug connector of the ABS control unit
-J104- with a cap.
Unscrew brake lines from hydraulic control unit.
1
2 S45-0170
Edition 07.04
S00.5303.16.20
2 3 4
er.
– Mark brake lines -1…6-. 5
– Unscrew brake lines -1…6- from hydraulic control
unit.
6
S45-0171

2 3 4
er.
– Mark brake lines -1…6-.
5
– Unscrew brake lines -1…6- from hydraulic control
unit.
Remove the hydraulic control unit 6
The removal of the hydraulic control unit is described on S45-0172
an ABS/TCS/ESP unit. The removal of an ABS or an
ABS/TCS unit occurs in the same way as for the ABS/
TCS/ESP unit.
– Unscrew nuts -4- from bracker -3-.

– Unscrew hexagon collar nut -6-. 1
– Remove the hydraulic control unit ABS, ABS/TCS or
ABS/TCS/ESP BOSCH 8.0 -1- with bracket -2- and
-3- upwards out of the vehicle.
7
5 - Threaded bores welded to the body 2
7 - Threaded bores welded to the body
3
Installing
6
Note
5 4
♦ New hydraulic control units are filled with hydraulic oil
S45-0178
and bleed. 4
♦ Only then remove plugs from the hydraulic unit when
the relevant brake line is installed.
♦ If the plugs were already removed from the hydraulic
unit before the brake line is installed, then brake fluid
may escape and adequate filling and bleeding can no
longer be guaranteed.
Installation is performed in the reverse order. Pay atten-
tion to the following points:
WARNING!
– Connecting the brake lines ⇒ 45-18 page 7

– Make sure that the multi-pin connector latches cor-
rectly with the ABS control unit -J104-.
– Remove brake pedal arrester, e.g. -V.A.G 1238 B- or
brake pedal load -V.A.G 1869/2-
– Code ABS control unit -J104-:
♦ using vehicle system tester -V.A.G 1552- ⇒ Chapter
45-9.
♦ using vehicle diagnosis, measurement and informa-
tion system -VAS 5051- ⇒ Chapter 45-4.
– Perform test drive after the bleeding of air with at least

one ABS adjustment.
Tightening torques:
Brake line to hydraulic control unit 14 Nm

Bracket with hexagon collar nut to 20 Nm
body
♦ Use new nut!
Bracket with nuts to body 20 Nm
♦ Use new nuts!
Removing and installing bracket for the

hydraulic control unit 1
Removing and installing bracket for ABS or ABS/TCS
BOSCH 8.0
Removing
– Removing the hydraulic control unit ABS or ABS/TCS

BOSCH 8.0 ⇒ 45-18 page 3.
– Separate bracket -4- from the fixing bolt of the bracket 2
-2-.
– Release screws -3- (2x).
– Remove bracket -2- from hydraulic control unit -1-. 3
Installing
3
Installation is carried out in the reverse order.
Tightening torque:
Bracket to hydraulic control unit 8 Nm 4

S45-0179
Edition 07.04
S00.5303.16.20
Removing and installing bracket for ABS/TCS/ESP
BOSCH 8.0
1
Removing
– Removing the hydraulic control unit ABS/TCS/ESP

BOSCH 8.0 ⇒ 45-18 page 3.
– Separate bracket -4- from the fixing bolt of the bracket
-2-.
– Release screws -3- (3x).
– Remove bracket -2- from hydraulic control unit -1-.
2
Installing
Tightening torque:
Bracket to hydraulic control unit 8 Nm 3 3
4
Connecting the brake lines
Note S45-0180
♦ Mount braket before assembling the brake lines.
♦ Do not bend brake lines when assembling or when
connecting.
♦ Brake hoses must not come into contact with other
components during operating condition.
♦ Do not remove the plugs on the connection threads
and the holes in the parts carrying brake fluid until just
before assembling.
♦ Tightening torque of pipe screws for brake lines of 14
Nm.
WARNING!
vehicles with ABS or ABS/TCS BOSCH 8.0

Connecting the brake lines to the master brake cylin-
der
Pos. Denomina- Connecting points

tion
1 HZ1 Master brake cylinder/push rod
piston circuit
2 HZ2 Master brake cylinder/floating 1
piston circuit
2
S45-0173
Connecting the brake lines to the hydraulic control

unit 2 3 4
1
tion 5
1 FR Front right brake caliper
2 RL Wheel brake cylinder/rear left
brake caliper
3 RR Wheel brake cylinder/rear right
brake caliper
4 FL Front left brake caliper
5 HZ2 Master brake cylinder/floating 6
piston circuit
6 HZ1 Master brake cylinder/push rod S45-0171
piston circuit

Connecting the brake lines to the master brake cylin-
der
B
tion
piston circuit
2 HZ2 Master brake cylinder/floating A
piston circuit 1
2
Note
♦ When tightening the pipe screw to the brake line in the
S45-0174
area of the crimping -arrow A- counterhold by hand.
♦ When tightening the pipe screw to the brake line in the
area of the crimp -arrow B- counterhold by hand.
Connecting the brake lines to the hydraulic control 2 3 4
unit 1
Pos. Denomina- Connecting points 5
tion
1 FR Front right brake caliper
2 RL Wheel brake cylinder/rear left
brake caliper
3 RR Wheel brake cylinder/rear right
brake caliper
4 FL Front left brake caliper
6
5 HZ2 Master brake cylinder/floating
piston circuit S45-0172
piston circuit
Edition 07.04
S00.5303.16.20
45-19 Removing and Installing

Parts of the ABS System
on the Front and Rear
Axle
Removing and installing wheel speed

sensor on the front axle - Vehicles with
ABS systems BOSCH 5.7 or BOSCH 8.0
Removing
– Raise vehicle.
– Separate plug connection -1- wheel speed sensor ca-
ble/wheel speed sensor. 3
– Release Allan screw -3-. 1
– Remove wheel speed sensor -2- from the wheel-bear-
2
ing housing.
Installing
– Insert the wheel speed sensor in the bore of the

wheel-bearing housing and tighten the Allan screw -3-
to 8 Nm.
– Connect plug connection -1- wheel speed sensor ca-
ble/wheel speed sensor.
S45-0125
Removing and installing front wheel

speed sensors - Vehicles with ABS sys-
tems BOSCH 5.7
♦ Wiring loom repair kit, e.g. Skoda Car Tool Kit Škoda,
Order No.: S 504 500 V
-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
Removing
Note
♦ It is prohibited to repair shielded leads of the ABS sys-
tem.
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.

Rep. Gr. 10.
Edition 07.04 Removing and Installing Parts of the ABS System on the Front 45-19 page 1
S00.5303.16.20 and Rear Axle

2
1
S45-0193
– Unlatch the multi-pin connector -arrow 1- and discon-

nect from the control unit -arrow 2-.
S45-0074
– Lever off the cap of the multi-pin connector on both

sides with a screwdriver and remove cap.
– Open cable strap.
S45-0075
45-19 page 2 Removing and Installing Parts of the ABS System on the Front
and Rear Axle
Edition 07.04
S00.5303.16.20
– Release secondary lock (purple) with a small screw-
driver in the direction of the arrow.
S45-0076
Contact assignment for multipin plug connector

T42a wiring loom/ABS control unit -J104-

10 1 11
15 + 16 Speed sensor front right -G45-
12 + 28 Speed sensor front left -G47-
30 + 31 Speed sensor rear right -G44-
13 + 14 Speed sensor rear left -G46-
– Open wiring loom.

– Using a suitable ejection tool from the wiring loom re-
pair kit press out the relevant contacts.
– Raise vehicle. 26 42 27 S45-0031
– Remove wheel.
– Release plug connection on speed sensor and sepa-
rate plug connector.
– Remove defective speed sensor cable.
Installing
1
– Draw in new speed sensor cable.
– Connect speed sensor cable to speed sensor.
– Clip on speed sensor cable -arrows- and mount in
bracket -1-.
– Actuate steering from left to right up to the stop and
check for free movement of the speed sensor cable.
Note
When assembling the speed sensor cable make sure it is
not twisted when installed in the wheelhouse.
S45-0078
– Mount wheel.
– Lower the vehicle.
– Insert contact in the plug housing and insert the single
cable seal with a suitable plug-in tool from the wiring
loom repair kit up to the stop.
– Secure contacts with the secondary lock.
– Mount new cable strap for wiring loom on multi-pin
connector.
– Position the cap on the multi-pin connector and lock
into position. L
VW AG 6Q0 973 042 R
1 928 403 931
– Insert the multi-plug connector on the control unit and B00 1928 404 293
lock.
S45-0079


Rep. Gr. 10.
2
– Perform automatic test sequence ⇒ Chapter 45-5 ei- 1
-VAS 5051-.
S45-0193
Removing and installing front wheel

speed sensors - Vehicles with ABS sys-
tems BOSCH 8.0
-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
Removing
Note
♦ It is prohibited to repair shielded leads of the ABS sys-
tem.
and Rear Axle
Edition 07.04
S00.5303.16.20
Rep. Gr. 10.
– Remove top charge-air pipe -1- with connecting hose 2

S45-0193
– Release multi-pin connector -1-.

– Insert red fuse -2- up to the stop in -direction of the ar-
row-.
1 2 S45-0169
– Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
– Pull out multi-pin connector -2- from hydraulic control
unit.
1
2 S45-0170
– Open cable straps -2-.

– Lever off the cap -1- of the multi-pin connector on both
sides from the catches -arrow- with a screwdriver. 1 2
– Remove cap -1- from the bottom part of the multi-pin
connector.
I
D E L PH
S45-0194
– Slide secondary lock (purple) -1- with a small screw-

driver in the -direction of the arrow-.
1
At the same time the contacts are released.
S45-0195
Contact assignment for multipin plug connector wir-

ing loom/ABS control unit -J104-
13 12 2 1
Contact Wiring to component
6 + 18 Speed sensor front right -G45-
22 +34 Speed sensor front left -G47-
19 + 31 Speed sensor rear right -G44-
20 + 33 Speed sensor rear left -G46-
– Open wiring loom.

– Using a suitable ejection tool from the wiring loom re-
pair kit press out the relevant contacts. 38 37 24 14 26 25
– Raise vehicle. S45-0196
– Remove wheel.
– Remove defective speed sensor cable.
Installing
– Draw in new speed sensor cable.

– Connect speed sensor cable to speed sensor.
and Rear Axle
Edition 07.04
S00.5303.16.20
– Clip on speed sensor cable -arrows- and mount in
bracket -1-.
– Actuate steering from left to right up to the stop and
check for free movement of the speed sensor cable.
1
Note
When assembling the speed sensor cable make sure it is
not twisted when installed in the wheelhouse.
– Mount wheel. S45-0078

– Insert contact in the plug housing and insert the single
cable seal with a suitable plug-in tool from the wiring
loom repair kit up to the stop.
– Secure contacts by sliding the secondary lock (pur-
ple).
DELPHI
S45-0197
– Insert catch -arrow A- of the cap -1- into the recess

1
-arrow B- of the bottom part -2- of the multi-pin con-
nector.
1
– Swivel cover -1- in -direction of the arrow- and lock B
into position with the bottom part -2- of the multi-pin
connector.
2
– Mount new cable strap for wiring loom on multi-pin
connector.
– Insert the multi-plug connector on the ABS with EDL A
control unit -J104- and lock.
DELPHI
S45-0198
2


Rep. Gr. 10.
2
– Perform automatic test sequence ⇒ Chapter 45-5 ei- 1
-VAS 5051-.
S45-0193
I
Sensor ring for ABS on the front and rear
axle 1
The sensor ring -1- is fitted in the wheel hub with wheel
bearing -2- and cannot be replaced individually.
In the event of damage or defect of the sensor ring, re-
place wheel hub with wheel bearing.
I - Removing and installing wheel hub and wheel bear-
2
ing for front axle ⇒ Chap. 40-3
II - Removing and installing wheel hub and wheel bear-
ing for rear axle ⇒ Chap. 42-5
II
Removing and installing wheel speed 1
sensor on the rear axle
Vehicles with disc brakes
Removing
2
S45-0073
– Raise vehicle.
– Separate plug connection -1- wheel speed sensor ca-
ble - wheel speed sensor.
– Release Allan screw -2-.
– Pull the wheel speed sensor from the axle stud and 2 1
brake carrier.
Installing
– Insert the wheel speed sensor in the bore of the axle

stud and tighten the Allan screw -2- to 8 Nm.
– Connect plug connection -1- wheel speed sensor ca-
ble - wheel speed sensor.
Vehicles with drum brakes
S45-0200
and Rear Axle
Edition 07.04
S00.5303.16.20
Removing and installing the wheel speed sensor occurs
in the same way as for the disc brake version ⇒ 45-19
page 8.
1 - Plug connection wheel speed sensor cable/wheel
speed sensor
2
2 - Allan screw for fixing the wheel speed sensor 1
Repairing rear wheel speed sensor ca-

bles - Vehicles with ABS systems
BOSCH 5.7 and BOSCH 8.0
-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
Removing S45-0201
Note

– Unclip wheel speed sensor cable on rear axle and
body.
– Removing the seat bench ⇒ Body Work; Rep. Gr. 72.
– Removing trim panel at bottom of pillar C ⇒ Body
Work; Rep. Gr. 70.
– Removing the entrance plate ⇒ Body Work;
Rep. Gr. 68.
– Fold back the floor covering around the seat bench.
– Release the rubber grommet -1- and pull the wheel
speed sensor cable -2- into the vehicle interior.
– Separate the wheel speed sensor cable between
crimp connection -arrow A- and sheathing -arrow B-.
1
Installing
– Draw in the new wheel speed sensor cable and attach 2

the rubber grommet.
A B
– Insulate the two cable extremities with a 6…7 mm wire
stripper.
– Twist the two cable extremities.
S45-0080
Note
♦ The insulation of the cable extremities must not be
pinched together.
♦ Make sure the correct red crimp connector for 0.5
mm2 is selectd.
– Slide the crimp connector on the cable extremities and

crimp it together at both sides with the stop pliers.
Note
♦ The crimp connector must be heated from the centre
towards the outside until it is fully sealed and the ad-
hesive flows out.
♦ Set the hot-air blower to the relevant temperature ac-
cording to the operating instructions.
♦ During shrinking make sure the hot nozzle does not S45-0081
damage any other cables, plastic parts or insulating
materials.
– After crimping shrink the crimp connector with the hot-

air blower.
To do so use the hot-air blower from the wiring loom
repair kit.
– If the repair cable was initially wrapped, you must re-

wrap this point with yellow insulating tape, or if neces-
sary again attach the cable with a cable strap.
– Installing the entrance plate ⇒ Body Work;

Rep. Gr. 68.
– Installing trim panel at bottom of pillar C ⇒ Body
Work; Rep. Gr. 70. S45-0202
– Installing the seat bench ⇒ Body Work; Rep. Gr. 72.

-VAS 5051-.
ABS systems BOSCH 5.7

ABS systems BOSCH 8.0

– Erase fault memory.
and Rear Axle
Edition 07.04
S00.5303.16.20
46 – Brakes, Brake mechanics
46-1 Repairing the front wheel

brake
Repairing front brake, the floating cali-

per disc brake FS-III
♦ Piston jig -MP 9-403-
♦ Brake pedal load, e.g. -V.A.G 1869/2 -
♦ Torque wrench
-ROMESS S15-
Note
♦ After replacing the brake pads forcefully apply the
brake pedal repeatedly to ensure the brake pads go
into their normal operating position.
♦ Use brake pedal load, e.g. -V.A.G 1869/2 - or
-V.A.G 1238 B-, before removing a brake caliper or
separating a brake hose from the brake caliper
♦ Use a bleeding bottle, that only comes into contact
with the brake fluid, to drain brake fluid from the brake
fluid reservoir. Brake fluid is toxic and must never be
sucked up by mouth!
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws: 120 Nm.
Edition 02.03 Repairing the front wheel brake 46-1 page 1

S00.5303.13.20
1 - Brake disc
T Thickness: 22 mm 14
T Wear limit: 19 mm
13
T always replace axle-wise
T Unscrew the brake caliper
before removing
T Do not use force to separate 12
the brake discs from the
wheel hub, if necessary use 11
rust solvent; as you could
otherwise damage the brake 10
discs.
2 - Screw, 4 Nm 1
3 - Brake pads
T with wear indicator
– with a corresponding wear
(limit 2 to 3 mm) the warning
lamp in the dash panel insert
lights up 9
T Thickness: 19.6 mm (includ- 6
ing the support plate) 5
T Wear limit: 2.0 mm without
supporting plate 8 2
T Check thickness
⇒ Inspection and Mainte- 7
nance
T always replace axle-wise 6
T do not unscrew the brake
hose when replacing the 5
brake pad
⇒ 46-1 page 3 3 S46-0087
T do not interchange the inside
and outside brake pads ⇒ 46-1 page 3
4 - Brake caliper
T removing:
– Remove the brake pads ⇒ 46-1 page 3
– Use brake pedal load
– Unscrew brake hose from brake caliper
T Installing:
– Installing brake pads ⇒ 46-1 page 3
– Screw the brake hose onto the brake caliper
– Remove brake pedal load
– Bleed the brake system ⇒ Chapter 47-4
6 - Cap
T removing
7 - Tensioning sleeve
8 - Brake hose with supports, hollow screw and gasket rings
T must be replaced completely, do not dismantle
T Tightening torque: 35 Nm
46-1 page 2 Repairing the front wheel brake Edition 02.03

S00.5303.13.20
10 - Screw, 10 Nm
11 - Cover plate
Removing and installing brake pads -

Floating caliper disc brake FS-III
♦ Torque wrench
-ROMESS S15-
1
Removing
– Remove wheel.
Note
1
♦ When removing mark the brake pads you intend to
keep using. Install in the same location, as otherwise
this may cause uneven braking!
♦ Do not unscrew the brake hose when replacing the
brake pad.
– Disconnect the plug connection for the brake pad

wear indicator (where the vehcile is fitted with this). S46-0088
– Remove caps -1-.
– Unscrew and remove the two guide bolts -arrow- from
the brake caliper.
S46-0089

S00.5303.13.20
– Remove the brake caliper -1- and secure with wire in

such a way that the weight of the brake caliper does
not burden or damage the brake hose. 1
– Remove brake pads -2- and -3- from the brake caliper. 3
Installing
Note
2
Drain brake fluid from the brake fluid reservoir using a
ventilation bottle before pushing the piston back in.
Caution!
Brake fluid is toxic and must never be sucked off by S46-0090
mouth.
Note MP 9-403
Use alcohol only to clean the brake caliper housing.
– Clean the brake caliper.

– Push piston back with piston jig -MP 9-403-.
Note
Do not interchange the inside and outside brake pads.
Pay attention to identification.
S46-0074
– Insert the brake pads with the white marking on the

rear side „piston side“ in the piston.
– Insert the brake pads with the black three-finger clip in
the brake caliper housing.
Kolbenseite
M46-0001

S00.5303.13.20
– First position the brake caliper at the bottom.
– Mount the brake caliper with brake pads onto the
wheel bearing housing.
The brake caliper pin -arrow- must be located behind the
guide of the wheel bearing housing!
FS -
S46-0101
– Screw the brake caliper with both guide bolts -arrows-

onto the wheel bearing housing.
– Connect up the plug connection for the brake pad

wear indicator (where the vehcile is fitted with this).
– Insert the caps of the guide bolts.
– Attach the wheel.
Note
♦ After each brake pad replacement forcefully apply the
S46-0089
♦ Check brake fluid level after replacing the brake pads,
if necessary top up with brake fluid.

S00.5303.13.20
Repairing front brake, the floating caliper disc brake FS-III

Special tools, test and measuring equipment and aids required
♦ ⇒ 46-1 page 1
Note
⇒ 46-1 page 1
1 - Brake disc
T Thickness: 18 mm
T Wear limit: 15 mm
22
T Unscrew the brake caliper 21
before removing
T Do not use force to separate
wheel hub, if necessary use 20
rust solvent; as you could
otherwise damage the brake 19
discs.
2 - Screw, 4 Nm 18
3 - Brake pads 17 1
– with a corresponding wear
(limit:2 to 3 mm) the warning
lamp in the dash panel insert 16
lights up
T with riveted retaining spring 10 11 15
12
T Install brake pad with a 13 14
smaller pad surface on the 2
piston side
T Thickness: 17.6 mm (includ-
ing the support plate)
T Wear limit: 2.0 mm without 9 3
supporting plate
T Check thickness 8
⇒ Inspection and Mainte- 7 4
6 5
nance
T do not unscrew the brake S46-0091
hose when replacing the
brake pad
T do not interchange the inside and outside brake pads ⇒ 46-1 page 7
4 - Brake caliper
T removing:
– Remove the brake pads ⇒ 46-1 page 7
T Installing:
– Installing brake pads ⇒ 46-1 page 7

S00.5303.13.20
5 - The rubber bush below
T before screwing in coat thread with lithium grease -G 052 150 A2-
6 - Bottom bushing
T with slits on one side
7 - Bottom distance sleeve
8 - Fillister head screw with internal serrations bottom, 25 Nm
T M8 x 48
9 - Air deflector
10 - Screw, 10 Nm
T for air deflector
11 - Fillister head screw with internal serrations top, 25 Nm
T M8 x 59
12 - Top distance sleeve
13 - Top bushing
T with slits on one side
14 - The rubber bush above
18 - Screw, 10 Nm
19 - Cover plate

Floating caliper disc brake FS-II
♦ ⇒ 46-1 page 3
Removing
– Remove wheel.

S00.5303.13.20
Note 1
brake pad.

– Release fillister head screw with internal serrations -1- 2
and -2-.
Note
S46-0102
Figure shows floating caliper disc brake FS-II with re-
moved air deflector.
– Remove the brake caliper -1- and secure with wire in

such a way that the weight of the brake caliper does 1
not burden or damage the brake hose.
3
– Remove brake pads -2- and -3- from the brake caliper.
Installing
Note 2
Caution!
S46-0090
Brake fluid is toxic and must never be sucked off by
mouth.
Note
Only use alcohol to clean the brake caliper housing.

– Push piston back with piston jig -MP 9-403-. MP 9-403
– Install brake pad with a smaller pad surface on the pis-
ton side.
– Install brake pads with a greater pad surface in the
brake caliper housing.
S46-0074

S00.5303.13.20
– First position the brake caliper at the bottom.
– Mount the brake caliper with brake pads onto the
wheel bearing housing.
The brake caliper pin -arrow- must be located behind the
guide of the wheel bearing housing!
S46-0103
– Screw the brake caliper to the wheel bearing housing

with fillister head screws with internal serrations -1- 1
and -2-

Note
2
♦ Check brake fluid level after replacing the brake pads, S46-0102

S00.5303.13.20
Repairing the front brake - the floating caliper disc brake C54-II
♦ ⇒ 46-1 page 1
Note
⇒ 46-1 page 1
1 - Brake disc
T the max. wheel run-out is not
marked
T released combination of a
brake disc without marking
and a wheel hub with mark-
ing
T with a fixing hole for the
wheel hub
T Thickness: 25 mm
T Wear limit: 22 mm
T for removing, first of all un-
bolt brake caliper complete
from wheel bearing housing
T Do not use force to separate
wheel hub, if necessary use
rust solvent, as you could
otherwise damage the brake
discs.
2 - Screw, 4 Nm
3 - Brake disc
T with a roughly 5 mm marking
for marking the maximum
wheel run-out
T released combination of a
brake disc with marking and
a wheel hub without marking
T with 5 fixing holes for the
wheel hub
T Thickness: 25 mm
T Wear limit: 22 mm
T for removing, first of all unbolt brake caliper complete from wheel bearing housing
T Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent, as you could
otherwise damage the brake discs.
4 - Pad retaining plate
T fit on before installing brake pads
5 - Brake pads
– with a corresponding wear (limit 2 to 3 mm) the warning lamp in the dash panel insert lights up
T Thickness: 18.6 mm (including the support plate)
T Wear limit: 2.0 mm without supporting plate
T Check thickness ⇒ Inspection and Maintenance

S00.5303.13.20
T do not unscrew the brake hose when replacing the brake pad
6- Brake carrier
T is supplied as replacement part assembled with guide pin and protective caps as well as adequate quantity
of grease on guide pins
T if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed grease packing
to lubricate the guide bolts)
T also use grease packing for greasing the slot on the guide pin and brake caliper for attaching the protective
cap
7- Protective cap
T contained in repair kit
T insert into the slot of the brake carrier and of the guide pin; grease the slot first using grease packing from the
repair kit
8- Guide bolts
9- Heat shield
T insert into piston
Fitting position: insert plate at heat shield into opening (slot) of the brake caliper
10 - Brake caliper
T removing:
– Unbolt brake caliper from brake carrier
T Installing:
– Bolt brake caliper onto brake carrier
11 - Screw, 30 Nm
14 - Screw, 125 Nm
T clean ribbing on underside each time removed
18 - Cover plate
19 - Screw, 10 Nm
T with and without marking of the maximum wheel run-out
T one can combine a wheel hub without marking of the maximum wheel run-out with a brake disc with marking
of the maximum wheel run-out; the total wheel run-out of the floating caliper disc brake C54-II will not be re-
duced

S00.5303.13.20

Removing and installing brake pads - the

floating caliper disc brake C54-II
♦ ⇒ 46-1 page 3
Removing
– Remove wheel.
Note
♦ When removing mark the brake pads you intend to 2
keep using. Install in the same location, as otherwise 1
brake pad.
♦ If brake pads are changed, replace heat shield in the
caliper and pad retaining plates.

– Detach brake line from fixture at wheel bearing hous- 1
ing.
– Screw out bolt -1-.
S46-0122
– Remove brake caliper -2- and secure with wire in such
a way that the weight of the brake caliper does not pull
on or damage the brake hose.
– Remove heat shield -2-. 2
– Take out brake pad -1-.
– Swivel brake pad -4- out to the side in -direction of
arrow A- and at the same time take out to the front in
-direction of arrow B-.
– Remove pad retaining plates -3- and -5-.
Installing
3
Note 1
ventilation bottle before pushing the piston back in. A
B
Caution!
Brake fluid is toxic and must never be sucked off by 4
mouth.
5 S46-0123

S00.5303.13.20
Note
Only use white spirits to clean the brake caliper housing
and brake carrier.

– Clean contact surfaces for pad retaining plates at the
brake carrier, remove any corrosion present.
– Push piston back with piston setting and timing device
-MP 9-403 -.
MP 9-403
– Install the heat shield.
Fitting position: insert plate at heat shield into opening
(slot) of the brake caliper.
– Install the pad retaining plate.

– Insert brake pads.
– Fit brake caliper to the brake carrier.
Do this while using new collar screws from the repair
set.
– Attach brake line to fixture and secure with new clip. S46-0124

Note
Tightening torques:
Brake caliper to brake carrier 30 Nm

♦ Use new screws!
Wheel bolts 120 Nm

S00.5303.13.20

S00.5303.13.20
46-2 Repairing a rear brake
Removing and installing rear brake -

Drum brake
♦ Torque wrench
♦ Torque wrench with angle indicator
♦ Brake pedal load, e.g. -V.A.G 1869/2-
-ROMESS S15-
Note
♦ After replacing the wheel-brake cylinder, brake carrier
and the rear brake shoes, forcefully apply the brake
pedal once to ensure the brake shoes go into their
normal operating position.
♦ Generally tighten the brake line pipe screws to a tight-
ening torque of 14 Nm.
♦ Use a bleeding bottle, that only comes into contact
with the brake fluid, to drain brake fluid from the brake
fluid reservoir. Brake fluid is toxic and must never be
sucked up by mouth!
♦ Use brake pedal loader, e. g. -V.A.G 1869/2- before
removing a brake cylinder, a brake carrier or before
separating a brake line from the brake cylinder.
Edition 04.05 Repairing a rear brake 46-2 page 1

S00.5303.18.20
1 - 4 Nm
2 - Brake drum
T Brake drum diameter 200 15
mm
T Wear limit: 201 mm
T clean carefully, and check for 14 13
wear, damage, dimensional
accuracy and perfect brake 12 10
surface
3 - Cap
11 9
⇒ Chapter 42-5
30° 8
T for vehicles with ABS the 6
sensor ring is built into the
wheel hub
⇒ Chapter 42-5
7
catalogue
6 - turn 30 Nm and 90°
7 - Brake carrier with brake shoe 5 4 3 2
T removing:
– Reset brake ⇒ 46-2 page 3 S46-0092
– Remove the brake drum
– Unscrew the brake line
– Remove the brake carrier
– unhook the hand brake cable if necessary
T Installing:
– Install the brake carrier
– hook on the hand brake cable if necessary
– Screw on the brake line
– Install the brake drum
T repairing ⇒ 46-2 page 4
8- Hand-brake cable
T Setting the hand-brake ⇒ 46-2 page 8
9- Axle stud
10 - Brake line
12 - Plug
46-2 page 2 Repairing a rear brake Edition 04.05

S00.5303.18.20
T to plug the hole for the speed sensor in the axle stud
14 - Axle body
15 - Axle body
Resetting brake
– Use a screwdriver to push the wedge up through a
hole for the wheel screws in the brake drum.
S42-0031

S00.5303.18.20
Repairing rear brake - drum brake

♦ Torque wrench
♦ Brake pedal load, e.g. -V.A.G 1869/2-.
♦ Plastic wedge -3409-
♦ Brake filling and bleeding device, e. g. -ROMESS S15-
♦ Hook (commercially available)
♦ Solid lubricant paste -G 000 650-
Note
♦ Use brake pedal loader, e. g. -V.A.G 1869/2- before removing a brake cylinder, a brake carrier or before separating
a brake line from the brake cylinder.
♦ After working on the rear axle brake: Release hand-brake; forcefully activate the brake pedal repeatedly.
1 - Spring cap
T to remove push against pres- 6 7 8
sure spring and turn 90°
2 - Pressure spring
3 - Locating spring
4 - Pressure rod
T Grease the contact points 3 4 5
with solid lubricant paste
-G 000 650- 9
5 - Wedge
T when removing and installing
8
the brake drum push up
through a hole for wheel 2
screws (reset brake) ⇒ 46-2
page 3
6 - Wheel-brake cylinder
T check the system for tight-
ness ⇒ 46-2 page 5 10
T Repairs not allowed
T removing:
– Remove the brake shoe 11
⇒ 46-2 page 6
– Use brake pedal load 12
– Unscrew the brake line
– Remove the wheel-brake 1 16 15 13
cylinder
T Installing:
– Install the wheel-brake cylin- 1 2 14
der
– Screw on the brake line
S46-0093
– Install the brake shoe ⇒ 46-2 page 6
7 - Allen screw, 8 Nm
8 - Tensioning pin
9 - Brake carrier

S00.5303.18.20
10 - Cap
T remove to check brake pad thickness
11 - Sliding block
T Cover the whole contact surface of the brake shoe with solid lubricant paste -G 000 650-
12 - Brake shoe
T Minimum pad thickness without supporting shoe: 1.5 mm
T Check the brake pad thickness ⇒ Inspection and Maintenance
T Visual checking of the brake pad thickness through the inspection hole in the brake carrier ⇒ 46-2 page 5.
T always use equivalent pad quality per axle
T Brake pads can also be supplied without supporting shoe
13 - Tension spring
14 - Bottom retractor spring
T Grease the contact points with solid lubricant paste -G 000 650-
15 - Top retractor spring
16 - Brake shoe with lever for hand-brake
T Setting the hand-brake ⇒ 46-2 page 8
Checking the wheel-brake cylinder for tightness

3409
– Lift off dust cup.
To this end use demounting key -3409-.
– If there is any brake fluid in the dust cup, replace

wheel-brake cylinder.
Make sure the dust cup is not damaged when lifting it off.
S46-0079
Checking the brake pad thickness through the

inspection hole in the brake carrier.
2
– Unclip cap -1- from the brake carrier-2-.
– Checking the brake pad thickness through the inspec-
tion hole in the brake carrier.
Minimum pad thickness without supporting shoe
(wear dimension) 1.5 mm.
Note
The brake pads must not be soiled with brake fluid or
grease.
1 S46-0094

S00.5303.18.20
Removing and installing brake shoe -

Drum brake
♦ Torque wrench
♦ Hook (commercially available)
♦ Solid lubricant paste -G 000 650-
Removing
– Remove wheel.
– Remove the brake drum.
– Remove spring cap with pressure springs. S46-0070
– Use a screwdriver to lever off the brake shoes from
the bottom support in the direction of the arrow.
– Unhook the retractor spring at the bottom.
2 3
– Unhook the hand-brake cable.
– Carefully guide the brake shoes out between the
wheel hub and the brake carrier.
– Tighten the brake shoe in the vice.
– Remove the tension spring -1- for wedge -2-. 1
– Unhook the retractor spring at the top -3- with hook A
-A-.
S46-0071
– Unhook the locating spring -1- with hook -A-.

– Remove the pressure rod -2- and the wedge -3- from
the brake shoe. 3 1
2
A
S46-0072

S00.5303.18.20
Installing
– Grease the contact point of the pressure rod using sol- 2
id lubricant paste -G 000 650-.
– Insert the locating spring -1- in the brake shoe -2- and
1
position the brake shoe on the pressure rod -3-
S46-0095
– Hook locating spring -1- with hook -A- in the pressure

rod -2-.
– Insert wedge -3-. 3 1
Note
Pay attention to the fitting position of the wedge. The
raised part of the wedge -arrow- must remain visible dur-
ing installation. 2
A
S46-0073
– Grease the contact point of the pressure rod using sol-

id lubricant paste -G 000 650-.
2 3
– Insert the brake shoe with brake lever in the pressure
rod.
– Hook on the retractor spring at the top -3- with hook
-A-.
– Hook on the tension spring -1- for wedge -2-.
1
– Carefully guide the brake shoes in between the wheel
hub and the brake carrier. A
– Position the brake shoe on the brake cylinder piston.
– Hook the hand-brake cable onto the brake lever.
– Grease the contact points of the bottom retractor
S46-0071
spring on the brake shoe with solid lubricant paste
-G 000 650-.
– Insert the bottom retractor spring and lift the brake
shoe onto the bottom bracket.
– Insert the pressure spring with spring cap.
– Install the brake drum.
– Activate the foot pedal forcefully once; this causes the
rear wheel-brake to be adjusted.
– Setting the hand-brake ⇒ 46-2 page 8.

S00.5303.18.20
Setting the hand-brake - drum brake
Note
♦ Resetting of the hand-brake is not required after reset-
ting of the rear brake due to automatic resetting of the
rear wheel-brake.
♦ Resetting is only required after replacing the hand-
brake cable, the brake carrier or the brake pads/brake
shoes.
– Remove the centre console ⇒ Body Work;

Rep. Gr. 68.
– Release the hand-brake.
– Forcefully apply the foot brake repeatedly.
– Pull the handbrake on and release it three times.
This sets the components into position.
– Put the hand-brake lever into the 1st catch position

(after being in the release position).
– Tighten adjusting nut -arrow- until both wheels are
hard to turn by hand.
Note
The adjusting nut must be screwed over the end of the
tension rod (self-locking effect).
– Release hand-brake and check whether both wheels

rotate freely, if necessary release adjusting nut slight-
ly.
– Put the hand-brake lever into the 4th catch position
(after being in the release position).
No wheel should be rotatable; tighten the adjusting S46-0096
nut if necessary.
– Release hand-brake and check whether both wheels

rotate freely, if necessary release adjusting nut slight-
ly.
and release the hand-brake.
The hand-brake must automatically return into the re-
lease position below the 1st catch.
– Install the centre console ⇒ Body Work; Rep. Gr. 68.

S00.5303.18.20
Removing and installing rear brake - Disc brake
♦ Torque wrench
♦ Torque wrench with angle indicator
♦ Brake pedal load, e.g. -V.A.G 1869/2 -
♦ Brake filling and bleeding device, e. g. -ROMESS S15-
Note
♦ After replacing the brake pads forcefully apply the brake pedal repeatedly to ensure the brake pads go into their
normal operating position.
♦ Use the brake pedal load, e.g. -V.A.G 1869/2- before removing a brake caliper or separating a brake hose from the
brake caliper.
1 - 4 Nm
2 - Brake disc
T Thickness: 9 mm 14
T Wear limit: 7 mm 13
15 16
T if worn replace axle-wise
3 - Cap
⇒ Chapter 42-5
70 Nm and tighten a further 12
30°
11
T removing and installing 10 17
⇒ Chapter 42-5
9
catalogue
18
6 - turn 30 Nm and 90°
19
7 - Cover plate 8
8 - Axle stud
9 - ABS speed sensor
10 - Allen screw, 8 Nm
T for speed sensor ABS 1
11 - Axle body
12 - Hand-brake cable 7 6 5 4 3 2
T Setting the hand-brake
⇒ 46-2 page 13 S46-0097
13 - Allan screw, tighten to 30 Nm
and then turn by a further 30°
14 - Brake line with supports, hollow screw and seal

S00.5303.18.20
T Tightening torque of the hollow screws: 35 Nm

15 - Self-locking hexagon screw, 35 Nm
16 - Brake caliper
T removing:
– Unscrew brake line from brake caliper
T Installing:
– Screw the brake line onto the brake caliper
– repair ⇒ Chapter 47-1
– One must first adjust the hand-brake cable after undertaking repair or replacement work
– Setting the hand-brake ⇒ 46-2 page 13
17 - Brake pads
T Thickness: 16.9 mm (including the support plate)
T Wear limit: 2.0 mm without supporting plate
T Check thickness ⇒ Inspection and Maintenance
18 - Pad retaining spring
T always replace when changing the pads
19 - Brake carrier with guide bolts and protective caps
T must be assembled with sufficient grease on the guide bolt, supplied as a spare part
T fit a repair set if there is any damage to the protective caps or guide bolts; (use the enclosed grease packing
to lubricate the guide bolts)

Disc brake
♦ Resetting and turning out tool -MP 9-401-
♦ Torque wrench
Note
♦ Do not unscrew the brake line on the brake caliper
when replacing the brake pad.
Removing
– Remove wheel.

S00.5303.18.20
wear indicator (where the vehcile is fitted with this -
only right vehicle side).
– Lift off the clip -1- with a screwdriver and pull down to
remove.
– Push the brake lever -2- in the direction of the arrow
and unhook the hand-brake cable -3-.
– Unscrew the fixing screws of the brake carrier while

counterholding the guide bolts.
– Remove the brake caliper and secure with wire in
such a way that the weight of the brake caliper does
not burden or damage the brake hose.
S46-0098
– Remove the brake pads and pad retaining springs -ar-

rows-.
Note
♦ Only use alcohol to clean the brake caliper housing.
♦ The adherend for the brake pads must be free from
glue residues and grease.
Installing
Note
S46-0104
Caution!
Brake fluid is toxic and must never be sucked off by
mouth.

S00.5303.18.20
Note B
♦ Only use the resetting and turning out tool to reset the
piston.
A
♦ When resetting the piston with a piston resetting de-
vice the automatic reset in the brake caliper is de-
stroyed.
– Insert theresetting and turning out tool -MP 9-401-,

the tool collar -arrow B- must be located on the brake
caliper.
– Place an open-jawed spanner SW 13 on a suitable MP 9-401
spanner surface -arrow A- if the piston is difficult to
move.
– Screw in the piston by turning the knurled wheel clock- S47-0039
wise on the resetting and turning out tool -MP 9-401-.
– Insert the new pad retaining springs -arrows- and
brake pads in the brake carrier.
– Remove the protective foil from the supporting plate of
the brake pad.
Note
There are four self-locking hexagon screws in the repair
set, which must be fitted.
S46-0104
– Secure the brake caliper to the brake carrier using

new self-locking screws.
Hold the guide bolts while tightening the screws.
S46-0098

S00.5303.18.20
and hook on the hand-brake cable -3-.
– Fit clip -1-.
– Setting the hand-brake ⇒ 46-2 page 13
wear indicator (where the vehcile is fitted with this -
only right vehicle side).
Note
Setting the hand-brake - disc brake
Note
♦ Resetting of the hand-brake is not required after reset-
ting of the rear brake due to automatic resetting of the
rear wheel-brake.
♦ Resetting is only required after replacing the hand-
brake cable, the brake caliper or after replacing the
brake pads or the brake disc.
♦ The brake pedal must be ventilated and fully function-
al.
– Remove the centre console ⇒ Body Work;

Rep. Gr. 68.
– Forcefully apply the foot brake repeatedly.
– Tighten adjusting nut -arrow A- so far that the levers
-arrow B- rise from the stops on the brake calipers.
A
Note
The adjusting nut must be screwed over the end of the
tension rod (self-locking effect).
S46-0099

S00.5303.18.20
– Check distance -a- between the lever and stop on the

left and right brake caliper using a feeler gauge.
With the hand-brake released the total distance -a-
(between the lever and the stop) on the left and right
brake caliper must not be less than or exceed a mini-
mum of 1 mm and a maximum of 4mm; the maximum
distance of 3 mm on a brake must not be exceeded.
– Pull the handbrake on and release it three times. This

sets the components into position.
– With the hand-brake released check whether the two
wheels turn freely, release the adjusting nut slightly
and check distance -a- again if necessary.
and release the hand-brake.
The hand-brake must automatically return into the re-
lease position below the 1st catch.
– Install the centre console ⇒ Body Work; Rep. Gr. 68.

S00.5303.18.20
46-3 Handbrake
Summary of components of hand brake

1 - Hand-brake lever
T removing and installing: 3 4
– Removing the centre con-
sole ⇒ Body Work;
Rep. Gr. 68 2
catalogue
2 - Cover
T removing:
11
– Press down the catch pegs
at the bottom of the trim pan-
el with a small screwdriver
and pull off the trim towards 1 11
the front.
T Installing: 5
– Slide the trim panel until the 10
catch peg catches onto the 6
hand-brake lever. Check
trim panel catch. 7
catalogue
3 - Compensating clamp
4 - Adjusting nut
T Setting the hand-brake
⇒ Chap. 46-2 8
5 - Grommet
T removing:
9
– Pull hand-brake cable from
guide tube.
– Release grommet. 5
– Pull grommet from guide S46-0106
tube.
T Installing:
The installation occurs in reverse order. After installing make sure the grommet fits correctly in the body re-
cess.
6- Right guide tube
T for hand-brake cable
7- Left guide tube
T for hand-brake cable
8- Hand-brake cable
T Check fitting position:
The positioning ring of the hand-brake cable must be located in the recess of the retaining clip.
9- Hand-brake lever support
T welded to the body tunnel
10 - Switch for hand-brake control -F9-
T clipped onto hand-brake lever
T replace if defective
11 - Tighten self-locking hexagon nut 20 Nm and 90°
Edition 08.00 Handbrake 46-3 page 1

S00.5303.04.20
Removing and installing the hand-brake

cable
Removing
– Removing the centre console ⇒ Body Work;
Rep. Gr. 68.
– Raise vehicle.
– Remove wheel.
– Release adjusting nut -arrow- and unhook hand-brake
cable from compensating clamp.
Note
The retaining clip for the hand-brake cable must be re-
placed each time it is removed.
– Remove the retaining clip of the rear axle.

– Unhook hand-brake cable from brackets.
Vehicles with drum brakes

– Removing brake drum ⇒ Chap. 46-2. S46-0096
– Unhook the hand-brake cable from the brake lever.
– Pull hand-brake cable out of brake carrier.
Vehicles with disc brakes

– Lift off the clip -1- with a screwdriver and pull down to
remove.
and unhook the hand-brake cable -3-.

– Pull hand-brake cable out of guide tube.
2
Installing
– Insert new retaining clip on the hand-brake cable. 1 N46-0176
The positioning ring must be located in the recess of

the retaining clip.
– Setting the hand-brake:

Vehicles with drum brakes ⇒ Chap. 46-2
Vehicles with disc brakes ⇒ Chap. 46-2
46-3 page 2 Handbrake Edition 08.00

S00.5303.04.20
46-4 Foot Controls, Brake Pedal
Summary of Components of Foot Controls, Brake Pedal
Caution!
The travel of the brake pedal must not be shortened by additional floor coverings.
Note
♦ Replace self-locking nuts each time they are removed.
♦ Grease all bearing points and contact surface of the brake light switch tappet before assembly with polycarbamide
grease -G 052 142 A2-.
1 - Bracket
T for foot controls
T Crash strut cannot be re- 11 12 13
moved, as it is welded to
bracket
⇒ 46-4 page 3
2 - Hexagonal screw
15
3 - Self-locking hexagon nut, 28
Nm
T 4 pieces for securing the
brake servo unit to the brack- 1
et
T 2 pieces for securing the 2
bracket to the assembly plate
4 - Brake light switch 3
catalogue
10
T before assembling the brake
light switch clip brake pedal
to the pressure rod of the
brake servo unit
9
T Setting, removing and install-
3
ing the brake light switch
⇒ Chap. 45-16 7 7
T Inspecting function of the
4
brake light ⇒ Chap. 45-16 6
5 - Accelerator pedal with sender 8 5
-G79- and -G185-
⇒ Engine, Mechanics; S46-0113
Rep. Gr. 20
6 - Brake pedal
7 - Bushing
8 - Cap
9 - Bearing bolt
10 - Self-locking hexagon nut, 25 Nm
Edition 07.04 Foot Controls, Brake Pedal 46-4 page 1

S00.5303.16.20
12 - Front wall
13 - Module carrier
14 - Bracket
T for crash strut
15 - Self-locking hexagon screw, 10 Nm
Separating the brake pedal from the

brake servo unit and clipping onto brake
servo unit
♦ Release tool -T30021- or -T10006 A-
Separating the brake pedal from the brake servo unit
– Remove the cover with storage area ⇒ Body Work;

Rep. Gr. 70.
– Removing the brake light switch ⇒ Chap. 45-16.
Note
Fig. shows the separation of the brake pedal from the
brake servo unit with the foot controls removed for clarity.
– Press brake pedal -1- towards the brake servo unit T30021
and hold in position.
– Insert release tool -T30021- or -T10006 A- and pull to-
wards the driver's seat while counterholding the brake 2
pedal. (At this moment the pedal must not move back-
wards.)
This causes the retaining lugs -3- of the support to be
pressed off the spherical head of the push rod -2-.
– Pull the release tool and brake pedal jointly towards 1

the driver's seat. (This causes the brake pedal to be
drawn off the ball knob of the pressure rod). 3 S46-0114
Clipping the brake pedal onto the brake servo unit
– Hold the ball knob of the pressure rod -2- before the
support and press the brake pedal -1- towards the
brake servo unit so that the ball knob is heard to catch.
3 - Bracket
– Setting and installing the brake light switch ⇒ Chap. 3

45-16.
– Install the cover with storage area ⇒ Body Work;
Rep. Gr. 70.
– Check operation of the brake lights.
2 1
S46-0115
46-4 page 2 Foot Controls, Brake Pedal Edition 07.04

S00.5303.16.20
Removing and installing the foot con-
trols
-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
Removing
Note

Rep. Gr. 70.
Vehicles without air conditioning
– Removing the left footwell vent ⇒ Heating, Air Condi-

tioning; Rep. Gr. 80.
Vehicles with air conditioning

Vehicles with Convenience system central control
unit -J393-
– Remove the convenience system central control unit

-J393- ⇒ Body Work; Rep. Gr. 70.
– Unscrew plastic nuts -1-.

– Remove cover -2-. 1 1
– Removing brake light switch ⇒ Chap. 45-16.
– Pull out plug of accelerator pedal position sender
-G79-.
– Separating the brake pedal from the brake servo unit
⇒ 46-4 page 2.
2
S48-0106

S00.5303.16.20
– Unscrew the hexagon nuts for securing the foot con-

trols -arrows-.
The top hexagon nut for securing the foot controls is
not visible in the figure. It is located at the bulkhead
behind the crash strut.
– Remove foot controls.

Installing
– Setting and installing the brake light switch ⇒ Chap.

45-16.
-VAS 5051-.
Tightening torque:
Foot controls on brake servo unit and on as- 28 Nm

sembly plate S46-0116
♦ Use new nuts!
Removing and installing brake pedal

-VAS 5051-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or
-VAS 5051/6A-
♦ Internal extractor (10.0…14.0 mm) -Kukko 21/02-
♦ Polycarbamide grease -G 052142 A2-
Removing
Note

Rep. Gr. 70.


S00.5303.16.20
unit -J393-

-J393- ⇒ Body Work; Rep. Gr. 70.

– Pull out plug of accelerator pedal position sender
-G79-.
– Separating the brake pedal from the brake servo unit
⇒ 46-4 page 2. 1
– Unscrew hexagon nut -1-.
2
Note
In the Fig. hexagon screw for bearing bolt is covered by
the bracket.
S46-0117
– Remove hexagon screw for bearing bolt -arrow-.
– Remove brake pedal -2-.
– Pull bearing bolt -1- out of the casing tube -3- of the
brake pedal.
1
Note 2
Replace all removed bushings. 2 3
– Insert and tension interior extractor -Kukko 21/2- on
the bushing -2-. KUKKO 21/02
– Pull out bushing by hand from the casing tube.
Installing
S46-0118
Note
Do not tilt bushings when installing.
– Insert new bushings in the brake pedal if they were re-

moved.
Press in bushings up to stop.
– Grease bearing points of the brake pedal (bearing

bolts and bushings) with polycarbamide grease
-G 052 142 A2-.
45-16.
-VAS 5051-.

S00.5303.16.20
Tightening torque:
Brake pedal to bracket 25 Nm

♦ Use new nut!

S00.5303.16.20
47 – Brake, Brake Hydraulics
47-1 Repairing the brake caliper
Summary of Components of Brake Caliper FS-III
Note
♦ When repairing install complete repair set.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease -G 052 150 A2-.
1 - Dust cap
2 - Vent valve, 10 Nm
T before screwing in thinly coat
thread with lithium grease 4 5
-G 052 150 A2-
3 - Bushing 1 2
T insert in brake caliper hous-
ing 3
5 - Caps
T insert in bushing
6 - Brake caliper housing
7 - Seal
⇒ 47-1 page 2
8 - Piston
⇒ 47-1 page 2
9 - Protective cap
⇒ 47-1 page 2
T when inserting piston do not
damage
9 8 7 6 4 5
S47-0068
Edition 03.01 Repairing the brake caliper 47-1 page 1

S00.5303.08.20
Removing and installing piston of brake

caliper FS-III
♦ Disassembly wedge -3409-
♦ Lithium grease -G 052 150 A2-
Removing
– Insert wooden plate in the channel to avoid damaging
the piston when it is ejected.
– Press out piston from the brake caliper housing with S47-0051
compressed air -arrow-.
Note
3409
When removing the gasket ring make sure the cylinder
surface is not damaged.
– Remove gasket ring with disassembly wedge -3409-.
Installing
– Clean the piston and gasket ring surfaces with alcohol
and subsequently dry.
– Before installing the piston and gasket ring in the
brake caliper housing thinly coat with lithium grease
-G 052 150 A2-.
S47-0031
– Insert new gasket ring in the groove of the brake cali-
per housing.
– Position the new protective cap with the outer sealing
lip on the piston.
S47-0032
47-1 page 2 Repairing the brake caliper Edition 03.01

S00.5303.08.20
– Insert inner sealing lip of the protective cap with disas-
sembly wedge -3409- in the groove of the cylinder. 3409
To do so hold the piston in front of the brake caliper
housing.
S47-0033
– Press the piston in the brake caliper housing with the

piston jig -MP 9-403-.
MP 9-403
Note
The outer sealing lip of the protective cap will fall in the
piston groove.
S47-0050

S00.5303.08.20
Summary of Components of Brake Caliper FS-II
Note

2 - Dust cap
3 - Vent valve, 10 Nm 4 5
thread with lithium grease
-G 052 150 A2-
2 3
4 - Top distance sleeve
T insert with Lithium grease
-G 052 150 A2-
5 - Top bushing 1
T slotted
-G 052 150 A2-
6 - Top bush
6
-G 052 150 A2- 7
7 - Bottom bush
-G 052 150 A2-
8 - Bottom bushing
T slotted
-G 052 150 A2-
9 - Bottom distance sleeve
-G 052 150 A2-
10 - Seal
T removing and installing 12 11 10 9 8
⇒ 47-1 page 2
11 - Piston
T removing and installing S47-0069
⇒ 47-1 page 2
12 - Protective cap
T when inserting piston do not damage

caliper FS-II
Removing and installing the piston occurs in the same
way as for the piston of the brake caliper of the FS-III
brake ⇒ 47-1 page 2.

S00.5303.08.20
Summary of components of brake caliper C54-II
Note
1 - Dust cap
2 - Vent valve, 10 Nm
T before screwing in thinly coat 1 2 3
-G 052 150 A2-
3 - Hexagon collar bolt, 30 Nm
4 - Guide bolts
5 - Protective cap
T insert into slot of the brake 4
carrier and of guide pin;
grease slot first of all, use 5
grease packing of repair kit
6 - Brake carrier with guide bolt
6
and protective cap
T is supplied as replacement
part assembled with guide
pin and protective caps as
well as adequate quantity of
grease on guide pins 3
T if there is any damage to the
protective caps or guide bolts
fit a repair set; use the en- 10
closed grease packing to lu-
bricate the guide bolts 9
7 - Protective cap 8
⇒ 47-1 page 2
7
damage
8 - Piston
⇒ 47-1 page 2
9 - Seal

caliper C54-II
Removing and installing the piston occurs in the same
way as for the piston of the brake caliper of the FS-III
brake ⇒ 47-1 page 2.

S00.5303.08.20
Summary of components of rear brake caliper
Note
♦ When repairing always install complete repair set.
♦ In the event of repair it is absolutely necessary to pre-bleed the brake calipers before installing them in the vehicle
(without brake pads) ⇒ 47-1 page 8.
1 - Self-locking hexagon screw,

35 Nm
T counterhold at guide bolt
when releasing and tigtening 1 2
2 - Dust cap
3 - Vent valve, 10 Nm 3
-G 052 150 A2-
4 - Guide bolts
T grease before fitting protec-
tive cap ⇒ item 5 4
T to grease use the grease
supplied with the repair set 5
5 - Protective cap 6
T pull onto brake carrier and
guide bolt
6 - Brake carrier with guide bolt 1
and protective cap
T must be assembled with suf-
ficient grease on the guide
bolts, supplied as a spare
part
T if there is any damage to the
protective caps or guide bolts
fit a repair set; use the en-
closed grease packing to lu-
10 9 8 7
bricate the guide bolts
7 - Protective cap
⇒ 47-1 page 7 S47-0070
damage
8 - Piston with automatic adjusting device
9 - Seal
10 - Brake caliper housing with lever for hand-brake cable
T replace brake caliper housing if the lever for the hand-brake cable is not tight
T after repair pre-bleed brake caliper housing ⇒ 47-1 page 8

S00.5303.08.20
Removing and installing the rear brake
caliper piston
♦ Resetting and turning out tool -MP 9-401-
♦ Disassembly wedge -3409-
♦ Brake fluid ⇒ Chap. 00-3 A
Removing
– Insert resetting and turning out tool -MP 9-401 -.
Collar -arrow B- must be located before the piston.
B
Note MP 9-401
If there is a resistance in the piston position open-end
wrench waf 13 on the provided wrench surfaces -arrow
A-. S47-0035
– Release the piston from the brake caliper housing by

turning the knurled wheel to the left.
3409
Note
When removing the gasket ring make sure the cylinder
surface is not damaged.
– Remove gasket ring with disassembly wedge -3409-.
Installing
– Clean the piston and gasket ring surfaces with alcohol
and subsequently dry.
– Before installing the piston and gasket ring in the
brake caliper housing thinly coat with lithium grease S47-0036
-G 052 150 A2-.
– Insert new gasket ring in the brake caliper housing.
– Position the new protective cap with the outer sealing
lip on the piston.
S47-0037

S00.5303.08.20
– Insert inner sealing lip with disassembly wedge

-3409 - in the groove of the cylinder.
To do so hold the piston in front of the brake caliper
housing.
3409
S47-0038
– Insert resetting and turning out tool -MP 9-401 -.

B
The collar -arrow B- must rest on the brake caliper.
A
Note
♦ If there is a resistance in the piston position open-end
wrench waf 13 on the provided wrench surfaces -ar-
row A-.
♦ When adjusting the piston with a piston jig or by actu-
ating the foot brake the automatic adjustment in the
brake caliper is destroyed.
MP 9-401
– Screw in piston by turning the knurled wheel to the
right.
– Insert brake pads. S47-0039
Pre-bleeding the brake caliper
Note
Set up brake caliper for pre-bleeding.
– Open vent valve -arrow A-.

– Using a commercially available ventilation reservoir fill
brake fluid until bubble-free brake fluid drips out of the
threaded bore (brake hose connection) -arrow B-.
– Close vent valve.
A
S47-0049
B

S00.5303.08.20
47-2 Brake Servo Unit, Master Brake Cylinder
Summary of Components of Brake Servo Unit, Master Brake Cylinder
Note
The complete master brake cylinder and brake servo unit can be replaced independently of one another.

⇒ 47-2 page 5
catalogue 3
T on petrol engines the re-
quired negative pressure is 1 2
drawn from the induction
pipe 14
T Diesel engines are fitted with
MA
a vacuum pump or tandem X
pump for fuel and negative MI

N
pressure supply
Functional test:
– With the engine off press 4
down brake pedal repeatedly
with force (this reduces the 5 5
pressure already present in 13 12
the device). 6
– Now hold the brake pedal in
brake position using a medi- 7
um foot pressure and start
the engine. If the brake servo
unit operates perfectly the
brake pedal must yield no-
ticeably under your foot (ser-
vo boost takes effect).
T if there are faults replace 10 9 6 8
completely
T disconnect from brake pedal 11
or clip onto brake pedal
⇒ Chap. 46-4
T Non-return valve in vacuum S47-0071
hose of the vacuum pump
⇒ 47-2 page 7
T Non-return valve in the vacuum hose of the tandem pump for fuel and vacuum supply ⇒ 47-2 page 8
Functional test:
– It must be possible to blow through the valve in the direction of the arrow.
– Against the direction of the arrow the valve must be closed.
2 - Brake fluid level warning contact -F34-
T cannot be removed or repaired
3 - Cap
T removing:
– Drain brake fluid.
– Press out retaining pin from the lateral catches of the brake fluid reservoir and master brake cylinder.
– Pull brake fluid reservoir upwards out of the sealing plugs.
T Installing:
Edition 07.04 Brake Servo Unit, Master Brake Cylinder 47-2 page 1
S00.5303.16.20
– Fill up with new brake fluid.

– On vehicles without ABS or with ABS BOSCH 5.7 or ABS, ABS/TCS BOSCH 8.0 bleed brake system
⇒ Chapter 47-4.
– On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 perform basic setting:
♦ using vehicle system tester -V.A.G 1552- ⇒ Chapter 45-13
♦ using vehicle diagnosis, measurement and information system -VAS 5051- ⇒ Chapter 45-4.
– On vehicles with ABS//TCS/ESP BOSCH 8.0 perform basic setting:
♦ using vehicle system tester -V.A.G 1552- ⇒ Chapter 45-14.
♦ using vehicle diagnosis, measurement and information system -VAS 5051- ⇒ Chapter 45-4.
5- Sealing plugs
T moisten with brake fluid and press in brake fluid reservoir
6- Self-locking nut, 20 Nm
T replace after each installation
7- Master brake cylinder
T Tightness test ⇒ 47-2 page 2
8- Retaining pin
T to secure brake fluid reservoir at brake master cylinder
9- Gasket ring
T replace after disassembling the master brake cylinder
10 - Sealing plugs
11 - Vacuum hose
T insert with brake servo unit
12 - Cap
T check for firm seating
14 - Gasket
T for brake servo unit
Checking the master brake cylinder for

tightness
♦ Brake-power regulator or brake system tester, e.g.
-V.A.G 1310- or -V.A.G 1310 A-
Inspection requirement
• Function and tightness of the brake system (hydraulic

control unit or load-dependent brake-power regulator,
brake lines, brake hoses, brake calipers and wheel-
brake cylinder) O.K.
Test
– Release the vent valve on one of the front brake cali-

pers.
47-2 page 2 Brake Servo Unit, Master Brake Cylinder Edition 07.04
S00.5303.16.20
– Connect the pressure gauge of the tester -V.A.G
1310 - or -V.A.G 1310 A- and bleed.
– Push down brake pedal until the pressure gauge on
the tester indicates 5 MPa (50 bar).
– Throughout the test which lasts 45 seconds the pres-
sure loss must not exceed 0.4 MPa (4 bar).
– If the pressure loss exceeds 0.4 MPa (4 bar) replace
the master brake cylinder.
Tightening torque: V.A.G 1310
Vent valve in brake caliper 10 Nm
Removing and installing the master

brake cylinder
♦ Hose clamp -MP 7-602-
♦ Removal and installation pliers, e.g. -VAS 5024-
♦ Vehicle system tester -V.A.G 1552- or vehicle diagno- S47-0107
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
♦ Brake filling and bleeding device, e.g. -ROMESS S15-
♦ Extraction bottle (commercially available)
♦ Repair kit SP.-No. 1H0 698 311 A
Note
♦ The master brake cylinder must not be repaired. 6 7
♦ assignment ⇒ Spare part catalogue 1
Removing

Rep. Gr. 10.
– Remove air filter ⇒ Engine, Fuel Injection;
Rep. Gr. 24 (fuel engines) or ⇒ Rep. Gr. 23 (diesel
engines).
Note
2
radio sets fitted with anti-theft coding. MAX
– Remove battery and battery tray ⇒ Electrical System; MIN 3

Rep. Gr. 27.
– Lay sufficient non-fluffing cloths around the engine
and gearbox. 4
5
– Disconnect plug -1- from the brake fluid level warning
contact -F34-.
– Unclip vacuum hose -6- from the brake fluid reservoir. S47-0073
S00.5303.16.20
– After opening the breather screws on the front axle

brake calipers pump off brake fluid by repeatedly
pressing the brake pedal.
– Clamp off the running-on line of the clutch master cyl-
inder -2- with hose clamp -MP 7-602-.
– Open spring strap clamps of the running-on line of the
clutch master cylinder using assembly pliers or
-VAS 5024-.
– Disconnect the running-on line of the clutch master
cylinder -2- from the brake fluid reservoir -3- and tie
up.
– Unclip the brake lines from the holder -7-.
– Unscrew the brake lines from the tandem master
brake cylinder -5- and shut off.
– Shut-off the connections of the brake lines on the
master brake cylinder with screw plugs from the repair
kit SP No. 1 H0 698 311 A.
– Release the nuts of the master brake cylinder.
– Carefully pull off the master brake cylinder -5- from the
brake servo unit -4-.
Installing
Note
♦ Install new gasket ring between the master brake cyl-
inder and the brake servo unit.
♦ When installing the master brake cylinder with the
brake servo unit pay attention to the correct position-
ing of the pressure rod in the master brake cylinder.
♦ Only fill up with new brake fluid.

– Install battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
Vehicles without or with ABS BOSCH 5.7 or ABS,
ABS/TCS BOSCH 8.0

Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP
BOSCH 5.7
– Perform basic setting:

45-13.
S00.5303.16.20
45-14.
– Bleed clutch ⇒ gearbox; Rep. Gr. 30.

– Install air filter ⇒ Engine, Fuel Injection; Rep. Gr. 24
(fuel engines) or ⇒ Rep. Gr. 23 (diesel engines).
Rep. Gr. 10.
hicle diagnosis system, measurement and information
system -VAS 5051-.
Tightening torques:
Master brake cylinder to brake servo 20 Nm

unit
♦ Use new nuts!
Brake line to master brake cylinder 14 Nm
Removing and installing brake servo

unit
♦ Hose clamp -MP 7-602-
-VAS 5051-
-VAS 5051/5A- or -VAS 5051/6A-
Removing

Rep. Gr. 10.
– Remove air filter ⇒ Engine, Fuel Injection;
Rep. Gr. 24 (fuel engines) or ⇒ Rep. Gr. 23 (diesel
engines).
Note
S00.5303.16.20
– Remove battery and battery tray ⇒ Electrical System;

Rep. Gr. 27.
– Lay sufficient non-fluffing cloths around the engine
and gearbox.
– Disconnect plug -1- from the brake fluid level warning
contact -F34-. 6 7
– Unclip vacuum hose -6- from the brake fluid reservoir.
1
– Clamp off the running-on line of the clutch master cyl-
inder -2- with hose clamp -MP 7-602-.
– Open spring strap clamps of the running-on line of the
clutch master cylinder using assembly pliers or
-VAS 5024-.
– Disconnect the running-on line of the clutch master 2
cylinder -2- from the brake fluid reservoir -3- and tie MAX
up.
– Unclip the brake lines from the holder -7-. MIN 3
– Unscrew the brake lines from the tandem master
brake cylinder -5- and shut off. 4
– Shut-off the connections of the brake lines on the 5
master brake cylinder with screw plugs from the repair
kit SP No. 1 H0 698 311 A.
S47-0073


unit -J393-

- J393- ⇒ Body Work; Rep. Gr. 70.

– Removing brake pedal from brake servo unit
⇒ Chapter 46-4.
– Unscrew the nuts for brake servo unit -arrows-.
– Guide the brake servo unit with master brake cylinder
towards the front and remove.
Installing
– Clipping the brake pedal onto the brake servo unit

⇒ Chap. 46-4.
45-16. S47-0074
S00.5303.16.20
– Install battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Removing brake pedal from brake servo unit
⇒ Chapter 46-4.
– Unscrew the nuts for brake servo unit -arrows-.
– Guide the brake servo unit with master brake cylinder
towards the front and remove.
Vehicles without or with ABS BOSCH 5.7 or ABS,
ABS/TCS BOSCH 8.0

BOSCH 5.7

45-13. S47-0074

45-14.
– Bleed clutch ⇒ gearbox; Rep. Gr. 30.

Rep. Gr. 10.
hicle diagnosis system, measurement and information
system -VAS 5051-.
Tightening torques:
Brake servo unit to foot controls 20 Nm

♦ Use new nuts!
Brake line to master brake cylinder 14 Nm
Removing and installing the vacuum

pump for the brake servo unit
Vehicles with 1.9 ltr./47 kW SDI engine
S00.5303.16.20
The vacuum supply of the brake servo unit occurs via a

vacuum pump on vehicles with a suction diesel engine
⇒ 1.9/47 SDI Engine, Mechanics; Rep. Gr. 15.
Removing and installing tandem pump

for fuel and vacuum supply
For vehicles with TDI PD Turbocharger engines
The vacuum supply of the brake servo unit occurs via a
tandem pump on vehicles with a turbo-diesel engine
S00.5303.16.20
47-3 Brake-power regulator, brake-pressure reducer
Summary of Components of Brake-Power Regulator
Note
♦ After removing the brake lines close connection bores on the brake-power regulator with screw plugs.
♦ Only remove the screw plugs from the connection bores when the brake lines are installed.
WARNING!
Pay attention to the correct channel assignment of the brake lines. Interchanging the brake lines will result
in dangerous brake control actions.
1 - Brake-power regulator
T load dependent
catalogue 1 2 3 4
T testing and adjusting
⇒ 47-3 page 2
T Adjusting values ⇒ Chap. 14 15
00-3 5
2 - Bracket
T for brake-power regulator
3 - Hexagon screw, 20 Nm
4 - Brake line with pipe screw
T Brake-power regulator - rear
right brake hose
T Tightening torque of the pipe
screws: 14 Nm
T Brake-power regulator - rear 13
left brake hose 7 6
screws: 14 Nm
T Master brake cylinder -
brake-power regulator
screws: 14 Nm 8
12 11
T Master brake cylinder -
brake-power regulator
T Tightening torque of the pipe 10 9
screws: 14 Nm S47-0075
8 - Bracket
T for rear axle
9 - Oval-head countersunk screw, 20 Nm
10 - Hexagonal screw
11 - Hexagonal nut, 20 Nm
12 - Tension spring
13 - Rear left brake hose
14 - Rear axle
Edition 07.04 Brake-power regulator, brake-pressure reducer 47-3 page 1

S00.5303.16.20
Inspecting and adjusting the brake-pow-

er regulator
♦ Brake-power regulator or brake system tester, e. g.
-V.A.G 1310- or -V.A.G 1310 A-
Fitting location of the brake-power regulator

The brake-power regulator is secured to a bracket as-
signed to the mount for rear axle and is controlled by the
rear axle movement via a spring.
Check for proper operation
– Forcefully apply the brake pedal and release quickly

(vehicle is standing on its wheels). While doing so the
lever of the brake-power regulator must move.
Pressure test and adjustment
Note
♦ The brake-power regulator is adjusted on a vehicle
ready for driving.
♦ Vehicle ready for driving: Weight of the vehicle with
full fuel tank and full water reservoir for windscreen
wiper/washer and headlamp cleaning system, spare
wheel, tool kit, jack and driver (75 kg). The spare
wheel, tool kit, jack and driver must be located in the
position prescribed by the vehicle manufacturer.
– Raise vehicle and connect pressure gauge of the test-

er to the brake caliper (front left wheel) and connect to
the wheel-brake cylinder (rear right wheel).
– Bleed both pressure gauges.
– Lower vehicle and repeatedly depress vehicle and al-
low to settle on the rear axle.
– Press brake pedal and measure pressures.
– Compare measured pressure values to the specified V.A.G 1310
adjusting values ⇒ Chap. 00-3.
– If necessary adjust brake-power regulator ⇒ 47-3
page 2.
Adjusting brake-power regulator
Test pressure on rear axle too high:
– Release tension spring on brake-power regulator.

Test pressure on rear axle too low:
– Tighten tension spring on brake-power regulator.
Note S47-0107
Adjust without load on the brake pedal, observe the fol-

lowing sequence:
47-3 page 2 Brake-power regulator, brake-pressure reducer Edition 07.04

S00.5303.16.20
– Read off values.
– Relieve brake pedal.
– Adjust tension spring on brake-power regulator.
– Again load brake pedal.
– Read-off values and if necessary correct adjustment.
– Remove pressure gauge.
Removing and installing brake-power

regulator
-V.A.G 1310- or -V.A.G 1310 A-
pedal load device, e.g. -V.A.G 1869/2-
♦ Oil catch pan
Removing
– Press brake pedal and arrest with brake pedal arrest-

er.
– Position the oil catch pan under the brake-power reg-
ulator to collect escaping brake fluid.
– Mark brake lines.
– Unscrew brake lines -1-, -2-, -3- and -4- on the brake- 1
power regulator.
7 2
– Shut-off brake lines to prevent brake fluid from run-
ning out and soiling.
– Shut-off the connections of the brake lines on the
brake-power regulator with screw plugs from repair kit
SP No. 1 H0 698 311 A.
– Unscrew hexagon nut -5- and remove hexagon screw
-6-.
– Release oval-head countersunk screw -7-.
– Remove brake-power regulator. 3
6 4
Installing S47-0077
5
WARNING!

– Adjusting brake-power regulator ⇒ 47-3 page 2.

S00.5303.16.20
Tightening torques:
Brake-power regulator to bracket 20 Nm

Brake-power regulator to tension spring 20 Nm
Brake line to brake-power regulator 14 Nm
Inspecting the brake-pressure reducer

Brake-pressure reducers are fitted on vehicles without
ABS and without load-dependent brake-power regulator,
Assignment ⇒ Spare part catalogue.
Fitting location
A brake-pressure reducer is fitted on each brake circuit. 6 7
The brake-pressure reducer -3- is screwed directly into
the master brake cylinder -1-, the other brake pressure
reducer -4- is connected to the master brake cylinder by
means of a short brake line.
1 2
2- Brake servo unit
5- Front left disc brake
6- Front right disc brake
7- Rear right drum brake
8- Rear left drum brake
3
Pressure test 4 8
S47-0079
Special tools, test and measuring equipment and 5
-V.A.G 1310- or -V.A.G 1310 A-
– Raise vehicle and connect pressure gauge of the test-

er to the front left brake caliper and connect to the rear
right wheel-brake cylinder. Because of the diagonal
brake circuits after the pressure test proceed in the
same way for the 2nd brake circuit (front right brake
caliper and rear left wheel brake cylinder).
– Bleed both pressure gauges.
– Press brake pedal and measure pressures.
– Compare measured pressure values to the specified V.A.G 1310
values ⇒ Chap. 00-3.
At a given pressure of 10 MPa (100 bar) the pressure
reducer must be closed.
A drop in pressure of maximum 1MPa (10 bar) 3 min-
utes is allowed.
If the test pressures are not reached, inspect the brake
system for leaks.
If the brake system is tight and the test pressures are ex-
ceeded, replace the brake pressure reducer. The brake
pressure reducer must not be repaired.
– Remove pressure gauge. S47-0107

S00.5303.16.20
Removing and installing the brake-pres-

sure reducer
-V.A.G 1310- or -V.A.G 1310 A-
-ROMESS S15-
♦ Brake fluid ⇒ Chap. 00-3
Removing
– Insert the bleeder hose of the bleeding bottle on the

vent valve of the left and right brake caliper.
– Shut the vent valve once the brake fluid flowed out.
– Removing the brake-pressure reducer.
1 - Brake-pressure reducer for front left wheel/rear right
wheel brake circuit.
2 - Brake line from the brake-pressure reducer to the
rear right wheel-brake cylinder
3 - Brake line from the brake-pressure reducer to the
rear left wheel-brake cylinder
5
4 - Brake-pressure reducer for front right wheel/rear left
wheel brake circuit.
4 6
5 - Brake line from the master brake cylinder to the front
right brake caliper 3 7
6 - Brake line from the master brake cylinder to the front 1
left brake caliper S47-0080
7 - Brake line from the master brake cylinder to the 2
brake pressure reducer
Installing

– Perform pressure test ⇒ 47-3 page 4.
Tightening torques
Brake-pressure reducer to master brake 14 Nm

cylinder
Brake line to brake-pressure reducer 14 Nm
(tube or hose connection)
Brake lines to master brake cylinder 14 Nm

S00.5303.16.20

S00.5303.16.20
47-4 Bleeding Brake System
Bleeding Brake System - vehicles with-

out and with ABS, ABS/EDL/TCS or ABS/
EDL/TCS/ESP BOSCH 5.7 or ABS, ABS/
TCS or ABS/ASR/ESP BOSCH 8.0
Note
♦ On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/
ESP the EDL function is integrated in the TCS func-
tion.
♦ The procedure for bleeding air from the brake system
is described with the brake filling and bleeding appli-
ance -ROMESS S15-.
BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0
If one chamber of the brake fluid reservoir has run com-
pletely dry, e.g. leakage in the brake system, the hydrau-
lic unit must be bled via the function „basic setting“ either
using the vehicle system tester -V.A.G 1552- or using the
vehicle diagnosis, measurement and information system
-VAS 5051-.
Continued for vehicles with ABS systems BOSCH 5.7
or BOSCH 8.0
WARNING!
On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/
ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0 a
filling pressure of at least 0.2 MPa (2 bar) must be
maintained when filling with brake fluid using
brake filling and bleeding device -ROMESS S15-.

Distinction between ABS, ABS/EDL/TCS and ABS/
EDL/TCS/ESP BOSCH 5.7 as well as ABS, ABS/TCS
and ABS/TCS/ESP BOSCH 8.0
⇒ Chapter 45-2
Note
♦ Perform basic setting on vehicles with ABS/EDL/TCS
or ABS/EDL/TCS/ESP BOSCH 5.7 either using the
vehicle system tester -V.A.G 1552- ⇒ Chapter 45-13
or using the vehicle diagnosis, measurement and in-
formation system -VAS 5051- ⇒ Chapter 45-4.
♦ Perform basic setting on vehicles with ABS/TCS/ESP
BOSCH 8.0 either using the vehicle system tester
-V.A.G 1552- ⇒ Chapter 45-14 or using the vehicle
diagnosis, measurement and information system
-VAS 5051- ⇒ Chapter 45-4.
♦ Bleeding brake system on vehicles with ABS BOSCH
5.7 or ABS, ABS/TCS BOSCH 8.0, as for vehicles
without ABS.
Edition 07.04 Bleeding Brake System 47-4 page 1

S00.5303.16.20
♦ Bleeding brake system on vehicles without ABS

BOSCH 5.7 or ABS, ABS/TCS BOSCH 8.0, as for ve-
hicles without ABS. DUring bleeding move the rear
wheel-brake lever of the brake-power regulator.
♦ Only use new brake fluid ⇒ Chap. 00-3.
WARNING!
♦ Brake fluid is hygroscopic, i.e. it retains humidi-
ty from the ambient air, and must therefore al-
ways be stored in airtight containers.
♦ Brake fluid must never come into contact with
fluids containing mineral oils (oil, petrol, clean-
ing agent). Mineral oils damage the plugs and
boots of the brake system.
♦ Drained (used) brake fluid must never be used
again.
♦ Observe the disposal instructions!
♦ Brake fluid is toxic, avoid skin contact.
♦ Because of its caustic effect brake fluid must
not come into contact with paint.
♦ Rinse any brake fluid spills with a lot of water.
♦ Dispose of brake fluid in compliance with the
applicable environmental regulations.
Bleeding the brake system of air using

the brake filling and bleeding device,
e. g. -ROMESS S15-
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3A-, -V.A.G 1551/3B-,
-V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A -
Note
♦ Bleeding of the brake system on vehicles with ABS is
undertaken as for vehicles without ABS.
♦ For vehicles without ABS and with brake-power regu-
lator move the rear wheel-brake lever of the regulator
during bleeding.
– Connect up the brake filling and bleeding device but

do not switch it on.
– Press brake pedal and arrest with brake pedal arrest-
er.
S45-0016
47-4 page 2 Bleeding Brake System Edition 07.04

S00.5303.16.20
– Remove dust caps from the vent valves of the brake
calipers/wheel-brake cylinder.
– Open the bleed valves in the prescribed sequence
with the hose of the bleeding bottle fitted, switch on
the brake filling and bleeding device and bleed both
the wheel-brake cylinder and the brake calipers
Bleeding sequence
1. Rear right wheel-brake cylinder/brake caliper
2. Rear left wheel-brake cylinder/brake caliper
3. Front right brake caliper
4. Front left brake caliper
– After bleeding close the relevant vent valve and fit
dust cap.
– Disconnect the brake filling and bleeding device.
– Separate connection from brake fluid reservoir and re-
move brake pedal arrester.
Note
♦ After bleeding perform a test drive. While doing so
perform at least one ABS adjustment!
♦ After bleeding or replacing the ABS, EDL/TCS control
unit BOSCH 5.7 or the ABS, ABS/TCS control unit
BOSCH 8.0 perform a final control diagnosis:
either using vehicle system tester -V.A.G 1552-
⇒ Chapter 45-12
using vehicle diagnosis, measurement and informa-
– Perform test drive with ABS adjustment.

BOSCH 5.7
Note
The bleeding of the brake system on vehicles with ABS/
EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 occurs via
the basic setting.

45-13.

Note
TCS/ESP BOSCH 8.0 occurs via the basic setting.

S00.5303.16.20

45-14.
Bleeding the brake system of air without

using the brake filling and bleeding de-
vice
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3A-, -V.A.G 1551/3B-,
-V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A -
Note
♦ Bleeding of the brake system on vehicles with ABS is
undertaken as for vehicles without ABS.
♦ For vehicles without ABS and with brake-power regu-
lator move the rear wheel-brake lever of the regulator
during bleeding.
♦ Always check the brake fluid level in the brake fluid
reservoir while bleeding the sustem of air and top up
the brake fluid to the „MAX“ marking if necessary.
– Build up pressure in the brake system by pumping the

brake pedal.
– Open the vent valve with the hose of the bleeding bot-
tle fitted.
– Close the vent valve while the pedal is pressed down.
– Repeat this procedure until no more air escapes.
Bleeding sequence
1. Rear right wheel-brake cylinder/brake caliper
2. Rear left wheel-brake cylinder/brake caliper
3. Front right brake caliper
4. Front left brake caliper
– After bleeding close the relevant vent valve and fit
dust cap.
Note
After bleeding perform a test drive. While doing so per-
form at least one ABS adjustment!
– Perform test drive with ABS adjustment.

S00.5303.16.20
BOSCH 5.7
Note
EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 occurs via
the basic setting.

45-13.

Note
TCS/ESP BOSCH 8.0 occurs via the basic setting.

45-14.
Changing the brake fluid

⇒ Inspection and Maintenance

S00.5303.16.20

S00.5303.16.20
48 – Steering
48-1 Steering column
Summary of components
Note
♦ Do not carry out repair work on the steering column.
♦ Replace the self-locking nuts and screws.
♦ Welding and straightening of the steering components is not allowed.
♦ Steering columns are supplied as a spare part with ignition lock housing but without lock cylinder and ignition starter
switch. The lock cylinder and ignition starter switch must be removed from the removed steering column or be ob-
tained as a spare part.
♦ After an accident and if the steering column is damaged replace steering components ⇒ item 1 in 48-1 page 1 i.e.
2, 6 and 7.
1 - Steering column 15 14
T adjustable 12
T Assignment ⇒ Spare part 11
catalogue
T inspecting for damage
⇒ Chap. 48-2
10
⇒ Chap. 48-3 13
2 - Steering column
T rigid
catalogue
T inspecting for damage
⇒ Chap. 48-2 9
⇒ Chap. 48-3
3 - Hexagon screw, 23 Nm 7
4 - Hexagon bolt, 20 Nm + torque
a further 90° (1/4 turn) 8 1
5 - Steering gear
6 - Bushing
2
T replace if damaged 6
⇒ Chap. 48-3
T Observe the mounting se-
4 3
quence ⇒ Chap. 48-5
9 - Bracket
5
⇒ Chap. 48-5
Edition 08.01 Steering column 48-1 page 1

S00.5303.09.20
12 - Frequency link
13 - Module carrier
14 - Front wall
15 - Combination screw, 25 Nm
48-1 page 2 Steering column Edition 08.01

S00.5303.09.20
48-2 Inspecting steering col-

umn
Optical inspection
– Inspecting parts of the steering column for damage.
– If any damage is visible, replace steering column com-
pletely.
Functional test
Inspection requirement:
• Universal joint of steering column pulled off steering
gear.
– Check whether the steering column turns freely with-

out jerking.
Vehicles with an adjustable steering column

a
– Check whether the length and height of the steering
column can be adjusted.

In the event of an accident so-called deformation ele-
ments may shift on the steering column.
They are located on the two top bolted connections of the
steering column.
If there is any damage remove the steering column until
dimension -a- can be checked.
S48-0206
– Inspect dimension -a- with a sliding caliper.
Dimension -a-: minimum 37 mm
If a fault is found during one of these inspections or if di-
mension -a- is not reached, the steering column must be
replaced.
– If this is the case replace the steering column com-

pletely.
Edition 08.01 Inspecting steering column 48-2 page 1

S00.5303.09.20
48-2 page 2 Inspecting steering column Edition 08.01

S00.5303.09.20
48-3 Removing and installing

steering column
♦ Diagnostic cable -V.A.G 1551/3-, - V.A.G 1551/3A-,
-V.A.G 1551/3B- or - V.A.G 1551/3C-
♦ Adhesive tape (commercially available)
Note
♦ New steering columns supplied as spare parts are se-
cured for transport. This transport security must be re-
moved once the steering column has been installed.
♦ Steering columns are supplied as a spare part with ig-
nition lock housing but without lock cylinder and igni-
tion starter switch. The lock cylinder and ignition
starter switch must be removed from the removed
steering column or be obtained and installed as a
spare part.
♦ Do not carry out repair work on the steering column.
♦ Welding and straightening on axle body and axle
studs not allowed.
♦ Connect battery ⇒ Electrical System; Rep. Gr. 27.
Removing the steering column

– Remove the storage area on the driver's side ⇒ Body
Work; Rep. Gr. 70.
– Removing steering-column control ⇒ Electrical Sys-
tem; Rep. Gr. 94. 1
– Unplug connector for the ignition starter switch -1- and 2 S48-0159
the connector for the immobilizer -2- reading coil.
– Unbolt earth strap -arrow-.
S48-0106
Edition 07.03 Removing and installing steering column 48-3 page 1

S00.5303.14.20
– Unscrew bolt -1-.

– Remove universal joint in the direction of the arrow
from the input shaft of the steering gear.
S48-0107
– Unclip cable guide -2- on the steering column and re-

move wiring loom -1-.
– Remove cable strap -3- from the steering column in
2
1
S48-0161
– Open the cover -2- of the cable guide -1- and remove
wiring loom -3-.
– Remove cable strap -4- from the steering column in 4
Note
♦ For reasons of clarity the work steps in the following
figures are shown on a removed steering column, i.e.
without background. 3
♦ Before removing the steering column mark the posi-
tion of the top and bottom part relatively to each other
and secure the steering column against separation.
♦ On vehicles fitted with a rigid steering column there is
2
no colour coding and safe positioning of the top and 1 S48-0162
bottom part of the steering column.
If the top and bottom part of the steering column are sep-
arated the pairing of the clover-leaf profile is no longer
guaranteed. Moreover, this could result in the greased
area becoming soiled.
48-3 page 2 Removing and installing steering column Edition 07.03

S00.5303.14.20
– Mark the top and bottom part of the steering column
relatively to each other on the bottom side with a col-
our marker.
Arrow A - Marking on bottom part of the steering col-
umn
Arrow B - Marking on top part of the steering column
B
S48-0173
– Secure the bottom part -1- and top part -2- of the
steering column against separation.
To do so use the transport security -3- of a replace- 1 2
ment steering column or attach the top and bottom
part of the steering column with wire.
3
S48-0160

3
1 - Steering column
2
2 - Bracket
3 - Frequency link
4
1
1 S48-0163

S00.5303.14.20
– Unscrew bolts -2-.

– Remove steering column -1-.
3 - Bracket 1
4 - Module carrier
4
3 2
2 S48-0164
Note
♦ If the old steering column -3- is installed again do not
remove the bushing -1-. 2
♦ Only remove the bushing -1- in the event of damage
3
or if a spare part steering column is used.

– Remove the bushing -1- from the steering column fork 1
-3-.
Note
♦ Steering columns are supplied as a spare part with ig-
nition lock housing but without lock cylinder and igni-
tion starter switch.
♦ If the lock cylinder and ignition starter switch of the re- S48-0165
moved steering column are O.K., they must be fitted
in the new steering column.
♦ Removing lock cylinder and ignition starter switch
Installing the steering column
Note
♦ The installation of the steering column is described for
an adjustable steering column. When installing a rigid
steering column one does not need to remove the se-
curing mechanism of the top and bottom part of the
2
steering column. 3
♦ When installing the old steering column again do not
replace the bushing.
♦ Only replace the bushing if damaged.
♦ If a spare part steering column is fitted, a new bushing 1
and a new screw must first be fitted in the steering col-
umn fork before installing the steering column.
– Insert the new bushing -1- in the steering column fork

-3-.
– Insert and tighten new new screw -2-.
S48-0165

S00.5303.14.20
– Installing the lock cylinder and ignition starter switch in
the ignition lock housing ⇒ Electrical System;
3
Rep. Gr. 94. 2
– Insert the steering column with bushing -1- in the
bracket -2-.
– Screw in screw -4- from the right and initially tighten to
5 Nm (do not fully tighten the screw yet).
3 - Frequency link
4
1
1 S48-0163
– Swivel the steering column -1- on the bracket -3- and

align and match the fixing holes of the steering column
and bracket.
1
Note
Carefully screw the screws in the bracket without tilting.

4 - Module carrier
4
3 2
2 S48-0164
– Tighten the screw -4- to the specified tightening

torque.
3
1 - Steering column
2
2 - Bracket
3 - Frequency link
4
1
1 S48-0163

S00.5303.14.20
– Remove transport security -3- or wire security.

1 - Bottom part of the steering column
2 - Top part of the steering column
1 2


Tightening torques: 3
S48-0160
Bushing on the steering column fork 7 Nm
Bushing on bracket 20 Nm
Steering column on bracket 23 Nm
Universal joint on input shaft 20 Nm + 90°
♦ Use new screw!

S00.5303.14.20

ignition lock housing
♦ Diagnostic cable -V.A.G 1551/3-
Note
♦ When the battery is reconnected perform the following
operations depending on the vehicle equipment: En-
code the radio, re-set the clock, initialise the power
windows ⇒ Inspection and Maintenance.
Removing ignition lock housing

– Removing trim panel ⇒ Body Work; Rep. Gr. 70.
– Removing steering-column control ⇒ Electrical Sys-
tem; Rep. Gr. 94.
– Removing lock cylinder and ignition starter switch
⇒ Electrical System; Rep. Gr. 94. S48-0176
– Remove pull-off screws -arrows-.
– Remove the ignition lock housing.
Installing ignition lock housing

– Insert the ignition lock housing and tighten new pull-off
screws.
– Tighten pull-off screws until the head shears off.
– Installing lock cylinder and ignition starter switch
– Performing automatic test sequence ⇒ Chap. 45-4.

If entries from the fault memory are shown:
– Eliminating fault ⇒ Chap. 48-25.

– Erasing fault memory ⇒ Chap. 48-25.
Edition 07.00 Removing and installing ignition lock housing 48-4 page 1
S00.5303.03.20
48-4 page 2 Removing and installing ignition lock housing Edition 07.00
S00.5303.03.20
48-5 Frequency link, bracket
Removing and installing frequency link

1
2
Removing
– Removing scuttle ⇒ Body Work; Rep. Gr. 66.
Note
The wiper arms must be in end position.
– Release hexagon screw -1-.

– Press wiper system towards the bulkhead.
– Unscrew combination screws -2-. S48-0139
Rep. Gr. 70.
– Unscrew hexagon screw -4-.
3
1 - Steering column 2
2 - Bracket
3 - Frequency link
– Remove frequency link.
Installing
4
1
Tightening torques:
Frequency link on bulkhead 25 Nm

1 S48-0167
Frequency link on bracket 23 Nm

Wiper linkage on body 5 Nm
Removing and installing bracket

Removing
– Removing the dash panel ⇒ Body Work; Rep. Gr. 70.
– Removing steering column ⇒ Chap. 48-3.
Edition 07.00 Frequency link, bracket 48-5 page 1

S00.5303.03.20
Note
For reasons of clarity the surrounding components are 1
not shown in the following figures.
– Remove frequency link -1- from the bracket -3-.

2
3
S48-0179

– Unscrew hexagon screw -2- and remove bracket -1-.
3
4 - Module carrier 3
4
2 1
Installing 2
S48-0178
Note
♦ Hexagon screws -2- and -3- are identical and are
tightened to the same torque. 3
♦ When installing the bracket -1- observe the mounting
sequence of the hexagon screws -2- and -3-. 3
– Position the bracket -1- on the module carrier -4-. 4
– Screw in hexagon screws -2- and initially tighten to 5
Nm (do not fully tighten the screws yet).
– Insert and tighten hexagon screws -3-.
– Tighten the hexagon screws -2- to the specified tight-
ening torque. 2 1
Further installation occurs in reverse order. 2
S48-0178
Tightening torques:
Bracket on module carrier 23 Nm

Frequency link on bracket 23 Nm
48-5 page 2 Frequency link, bracket Edition 07.00

S00.5303.03.20
48-6 Steering without servo unit (mechanical steering)
Summary of components
Note
♦ If the front axle is damaged as a result of an accident certain steering components must be replaced ⇒ Chapter
48-9.
♦ Repairs to the steering gear are not provided for, if there is a complaint about the steering gear it must be replaced.
♦ Only use steering gear grease to grease the gear rack ⇒ Chapter 00-2.
1 - Universal joint
T of steering column 2
1
2 - Tighten hexagon screw
20 Nm + 90°
3 - Tighten self-locking hexagon
nut 20 Nm + 90°
4 - Steering-knuckle arm of the 3
wheel-bearing housing
5 - Steering gear
6 - Assembly carrier 5 4
T with impression as shown in
the figure, only if the front ex-
haust pipe is fitted below the
engine-gearbox assembly 6
carrier
T without impression, not
shown in the figure, only if
the front exhaust pipe is fitted
above the engine-gearbox
assembly carrier
7 - Hinged bracket
T The shape of the hinged 7
bracket depends on the
gearbox
50 Nm + 90° 8
8 S48-0268
Edition 11.04 Steering without servo unit (mechanical steering) 48-6 page 1
S00.5303.17.20
48-6 page 2 Steering without servo unit (mechanical steering) Edition 11.04
S00.5303.17.20

mechanical steering gear
♦ Gearbox jack with adapter, e.g. -V.A.G 1383 A- with
-V.A.G 1359/2-
-V.A.G 1359/2-
Note
Apart from replacing the bellows, track rod ends and track
rods no other repairs may be carried out on the steering
gear.
Removing steering gear
Caution!
Bring the steering wheel in centre position (wheels
straight ahead) and make sure they do not turn dur-
ing repairs as this could damage the coil spring of
the airbag unit.
– Secure the steering wheel with the wheels in straight S48-0196

ahead position with adhesive tape -arrow- against un-
intended turning.
S48-0106
Edition 07.00 Removing and installing mechanical steering gear 48-7 page 1
S00.5303.03.20
– Remove hexagon screw -1-.

from the input shaft of the steering gear.
– Raise vehicle.
S48-0107
– Remove noise insulation panel -arrows-.
Note
The figure shows the noise insulation panel on models
with 1.4 ltr./74 kW engines. Other engine variants may
have noise insulation panel versions that differ slightly
from the figure.
– Remove front wheels.
Vehicles with exhaust pipe under the assembly

carrier
– Removing front exhaust pipe with catalyst ⇒ Engine -
Mechanics; Rep. Gr. 26. S48-0111

– Unscrew hexagon screw -1- and -2- from the pendu-
lum support.
2
1
S48-0112
48-7 page 2 Removing and installing mechanical steering gear Edition 07.00
S00.5303.03.20
– Screw up hexagon nut of the track rod end -1- suffi-
ciently so that the extractor -Matra V176- is supported Matra V176
on the hexagon nut.
1
– Use extractor -Matra V176- to press track rod/track
rod end -2- on both sides off the steering arm.
– Unscrew hexagon nut on both sides from the track rod
end.
– Pull track rod end on both sides out of steering arm.
2
S48-0114
– Insert wooden insert (490 x 270 x 50 mm) -2- in the

adapter.
– Position gearbox jack with adapter and support as-
sembly carrier.
2
– Release hexagon screws -1- for steering gear. 1
1
Note
♦ Observe the recommended sequence for the follow-
ing steps.
maximum 20 Nm as otherwise the fixing bolt thread V.A.G 1359/2 1
becomes damaged.
V.A.G 1383A S48-0116
– Unscrew left screw -4- for assembly carrier -3- and

screw in a fixing bolt of -T10096- to 20 Nm.
shown in figure) and screw in a fixing bolt of -T10096-
to 20 Nm.
– Release hexagon screws -1- on both sides.
4
2
3
S48-0117
S00.5303.03.20

screws (Pos. -2- and -4-) are consecutively replaced with
the fixing bolts.
5
Note
When pulling off the steering gear make sure the serra-
tion of the input shaft of the steering gear is not tilted or 4
stuck relatively to the drive shaft of the steering column. 1
– Slowly lower assembly carrier with gearbox jack and 2
adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-.
– Remove steering gear towards the rear.
Installing steering gear 3

S48-0117
Caution!
After installing the steering gear check the position
of the steering wheel after performing a test drive. If
the steering wheel is not straight peform a chassis
alignment.
Note
♦ Coat the seal on the steering gear with lubricant be-
fore installing the steering gear, e.g. lubricating soap.
♦ Make sure all sealing surfaces are clean.
♦ After positioning the steering gear on the drive shaft of
the steering column make sure the seal on the steer-
ing gear is not bent on the assembly plate and correct-
ly seals the footwell opening. Otherwise this could
cause water penetration and/or noise.
♦ Before fitting the steering gear check the centre posi-
tion of the gear rack ⇒ Chap. 48-8.
♦ Before positioning the universal joint of the steering
column on the input shaft of the steering gear, first
make sure the vehicle is on the ground and all wheels
are pointing straight ahead.
– Check the centre position of the gear rack of the steer-

ing gear, if necessary adjust ⇒ Chap. 48-8.
– Place the steering gear from the rear onto the lowered
assembly carrier and tighten new hexagon screws -1-
by hand.
– Check correct fit of the seal on the steering gear valve 2
housing. 1
– Slowly raise the assembly carrier with gearbox jack 1
and adapter, and while doing so insert the input shaft
of the steering gear in the opening in the vehicle floor.
2 - Wooden insert (490 x 270 x 50 mm)
V.A.G 1359/2 1
V.A.G 1383A S48-0201
S00.5303.03.20
Note
ing steps.
♦ Unscrew the fixing bolts of -T10096- one at a time.
Subsequently, replace it with a new bolt tightened to
the recommended torque and further rotation.

torque.
3 - Engine-gearbox assembly carrier

– Tighten new bolts for the rear left support by hand.
– Tighten new bolts for left console and support to the 3
recommended tightening torque. S48-0197

figure).
– Tighten new bolts for the rear right support by hand.
– Tighten new bolts for right console and support to the
– Tighten the rear right support bolts to the recommend-
– Tighten hexagon screws for fixing the steering gear to
the assembly carrier to the recommended tightening
torque.
– Insert track rod end/track rod into steering arm and
tighten new hexagon nut ⇒ Chap. 48-16.
If the joint stub rotates when tightening, counterhold
with hexagon socket wrench (SW6).

new hexagon screws -1- and -2-.
Vehicles with exhaust pipe under the assembly

carrier
– Installing front exhaust pipe with catalyst ⇒ Engine -
2
1
– Fit front wheels.
– Install noise insulation panel. S48-0112
S00.5303.03.20
– Lower vehicle.
– Slide the universal joint of the steering column in the
direction of the arrow onto the input shaft of the steer-
ing and tighten with a new hexagon screw -1-.
– Fit cover for universal joint.
Caution!
perform a chassis alignment. 1
– Carrying out chassis alignment ⇒ Chap. 44-2.
S48-0170
Tightening torques:
Steering gear to assembly carrier 50 Nm + 90°

♦ Use new screws!
Assembly carrier to body 70 Nm + 90°
♦ Use new screws!
♦ Use new screws!
♦ Use new screws!
♦ Use new nuts!
Universal joint to steering gear 20 Nm + 90°
♦ Use new screw!
Wheel bolts 120 Nm
S00.5303.03.20
48-8 Inspecting and adjusting

mechanical steering gear
Check the centre position of the gear

rack of the steering gear, if necessary
adjust
Note
♦ Before installing the steering gear place the gear rack
in centre position.
♦ The gear rack of spare part steering gears is already
in centre position.
♦ Dimension -a- must be equal on both the right and left
side if the steering gear. If the dimension on the two
sides is not the same, distance -a- must be corrected.
– Check dimension -a-, if necessary adjust. S48-0181
-a- = 68.5 mm
– Adjusting dimension -a- by turning the input shaft -1-

of the steering gear. 1
2 - Gear rack
Adjusting the steering gear (adjusting

the pressure plate clearance)
Note
2
2 mechanics are required for this adjustment.
S48-0182
• Put the wheels in straight ahead position.
– Raise vehicle.
– Move the steering wheel alternately approx. 30°. on
the centre axle.
If the steering clearance is too great rattling noises will
be audible inside the vehicle.
– While moving the steering wheel have the 2nd me-

chanic carefully screw in the ajusting screw -1- until no
more rattling noises can be heard inside the vehicle.
Caution!
The steering must automatically return to straight
ahead position after a manoeuvre or cornering with- 1
out sticking, correct if necessary. S48-0183
Edition 07.00 Inspecting and adjusting mechanical steering gear 48-8 page 1
S00.5303.03.20
– Secure adjusting screw -1- against turning.

To this end apply 3 centre punch marks -arrows- uni-
formly distributed on the collar of the steering gear
housing.
1
S48-0184
48-8 page 2 Inspecting and adjusting mechanical steering gear Edition 07.00
S00.5303.03.20
48-9 Disassembling and as-

sembling the steering
gear
♦ Hose strap pliers, e.g. -V.A.G 1275-
♦ Steering gear grease ⇒ Chapter 00-2
Note
♦ Always replace all steering components (except pos. 6) after an accident or in the event of damage to the front axle.
♦ Do not carry out repair work on the steering gear ⇒ item 10 in 48-9 page 2. If there are any complaints about the
steering gear ⇒ item 10 in 48-9 page 2 replace it.
♦ Always use original clamping collars and circlips.
1 - Right track rod end

T inspect ⇒ Chapter 48-10 1 2
⇒ Chapter 48-10 4
T before installing, remove
grease on tapered stud 5
2 - Lock nut, 50 Nm
3 - Spring strap clip
T use assembly pliers, e.g.
-VAS 5024- for removing
and installing
4 - Boot 6
T can only be replaced with the 7
steering gear removed
T before removing boot detach
the track-rod end ⇒ Chapter 8 9
48-10
T must not be twisted after set- 10
ting the wheel toe
T inspect for wear and damage
(cuts, splits)
5 - Warm-type clamp
T removing: open with cutting
pliers
6 - Gasket 12
T pay attention to installation
instructions for installing
5 2 11
⇒ Chapter 48-7
4
7 - Clamp 3 S48-0269
T replace if thread of stamp nut
damaged
8 - Right track rod
T tightening torque on steering rack: 80 Nm
Edition 11.04 Disassembling and assembling the steering gear 48-9 page 1
S00.5303.17.20
T track rod and track rod end are supplied as replacement part pre-set
T lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing re-
placement track rod/track rod end tighten lock nut fully to 50 Nm
T Setting wheel toe ⇒ Chap. 44-2.
9- Rubber insert
Fitting position:
♦ larger bore must point outwards
♦ replace if damaged or worn
10 - Steering gear
T do not repair
T setting ⇒ Chapter 48-8
T inspecting centre position ⇒ Chapter 48-8
11 - Left track rod end
T before installing, remove grease on tapered stud
12 - Left track rod
T lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing re-
placement track rod/track rod end tighten lock nut fully to 50 Nm
48-9 page 2 Disassembling and assembling the steering gear Edition 11.04
S00.5303.17.20
48-10 Track rod ends, track rods
Play, correct attachment and joint boots

⇒ Chap. 48-16
Removing and installing track rod ends

⇒ Chap. 48-16
Removing and installing track rods

⇒ Chap. 48-16
Edition 07.00 Track rod ends, track rods 48-10 page 1

S00.5303.03.20
48-10 page 2 Track rod ends, track rods Edition 07.00

S00.5303.03.20
48-11 Power-assisted steering
Structure and function

The EPHS (Electrically Powered Hydraulic Steering) is a 6 7
power-assisted steering system which uses its own elec- 5 8
tric motor to drive the pump.
1- Power-steering gear 4
2- Sensor for power steering -G250-
9
3- Steering column
4- Control unit in dash panel insert -J285- 3 10
5- Sender for speedometer -G22- 11 12 13
6- Engine control unit
1 2
7- Servotronic warning light -K92- in dash panel insert
8- Signal for servotronic warning light -K92- through
databus
9- Signal for engine speed via data BUS a 20 14
10 - Signal for driving speed via data BUS b
11 - Hollow screw with non-return valve
12 - Pressure line
c d
13 - Signal for steering angle speed
19
14 - Return-flow line
18
17
M
15 - Airbag control unit -J234-

16 - Crash signal over the databus
17 - Terminal +30 f e 16 15 S48-0200
18 - Terminal + 15
19 - Earth
20 - Engine pump aggregate - consisting of:
a- Screwed lid
b- Reservoir for hydraulic oil
c- Pressure limiting valve
d- Gear pump
e- Electric motor
f- Power-assisted steering control unit -J500-
The steering hydraulics pump -V119- includes the gear
pump -d- and the electric motor -e-.
This steering uses a gear pump integrated in the engine
pump aggregate instead of the servo pump (vane pump)
traditionally used in power-assisted steering systems.
This gear pump -d- is not driven directly via the vehicle's
combustion engine but by an electric motor -e- integrated
in the engine pump aggregate.
Signals for steering angle speed -13-, for vehicle speed
-10- and engine speed -9- are sent to the control unit -f-.
This control unit controls the speed of the electric motor
-e- on the gear pump and thus also the supplied quantity
or volume of hydraulic oil.
Re-engaging protection
The electrohydraulic power-assisted steering has a re-
engaging protection after faults, failure or crash.
Edition 11.04 Power-assisted steering 48-11 page 1

S00.5303.17.20
After a crash or after the display of the crash signal on the

vehicle system tester -V.A.G 1552- or at the vehicle diag-
nostic, measuring and information system -VAS 5051-
the vehicle memory must be erased to de-activate the re-
engaging protection.
The re-engaging protection can be neutralised by switch-
ing off the ignition and switching it on again. If necessary
wait 15 minutes to allow the engine pump aggregate to
cool down after overheating. If after this waiting period
the re-engaging protection cannot be neutralised by
switching the engine on again, the fault must be found in
the vehicle electric system or e.g. in the engine pump ag-
gregate. In these instances perform the self-diagnosis
and if necessary replace the engine pump aggregate.
48-11 page 2 Power-assisted steering Edition 11.04

S00.5303.17.20
Summary of components of power-assisted steering (TRW)
Note
♦ If the front axle is damaged as a result of an accident certain steering components must be replaced ⇒ Chapter
48-15.
♦ Repairs on the power-steering gear are not foreseen. In the event of failure determine the cause with the pressure
and tightness test as well as by performing self-diagnosis.
♦ If there is a fault on the power-steering gear, replace the steering gear, unless the fault is in the power-steering
sensor.
♦ Oil types: Hydraulic oil ⇒ Chapter 00-2.
♦ Oil volume in the system ⇒ Chapter 00-2
1 - Self-tapping screw, 6 Nm 1 2 1 3 4 5
2 - Heat shield 6
catalogue 9
3 - Steering column universal 10 8
joint
7
4 - Screw, 20 Nm + torque a fur- 11
ther 90° (1/4 turn) 11
12
5 - Gasket
T for power-assisted steering
sensor -G250- with adapter
cable ⇒ item 6 19 13
17
catalogue
20 17 15
6 - Sensor for power steering
-G250- 18 16
T with adapter cable ⇒ item 8 14
⇒ Chapter 48-13
catalogue
7 - Screw, 6 Nm 22
T for power-assisted steering
sensor -G250- with adapter
cable ⇒ item 6
catalogue
8 - Adapter cable
T assignment ⇒ Spare part 21 S48-0266
catalogue
9 - Gasket
T for power-assisted steering sensor -G250- with fixed connecting line ⇒ item 10
10 - Sensor for power steering -G250-
T with fixed connecting line

S00.5303.17.20
11 - Screw, 6 Nm
T for power-assisted steering sensor -G250- with fixed connecting line ⇒ item 10
12 - Nut, self-locking, 20 Nm and torque a further 90° (1/4 turn)
13 - Steering-knuckle arm (of the wheel-bearing housing)
T Pipe screw M16x1.5
T power-assisted steering gear - engine pump aggregate
T Torque for pipe screw on the power-assisted steering gear: 30 Nm
15 - O-ring
16 - Hollow screw, 35 Nm
T with non-return valve
T M14x1.5
17 - Gasket ring
18 - Pressure line
T Pay attention to installation position relative to subframe ⇒ 48-11 page 6
T Torque for pipe screw on the engine pump aggregate: 30 Nm
19 - Power-steering gear
T with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assem-
bly carrier
T with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
22 - Hinged bracket
T The shape of the hinged bracket depends on the gearbox

S00.5303.17.20
Summary of components of power-assisted steering (KOYO)
1 - Self-tapping screw, 6 Nm
1 2 1 4
2 - Heat shield
catalogue
3 - Steering column universal
joint 5 6 7
8
5 - Gasket
T for power-steering sensor
-G250- ⇒ item 6
15 9
catalogue
6 - Sensor for power steering 16 13
-G250- 13 11
⇒ Chapter 48-13 14 12 10
catalogue
7 - Screw, 7,5 Nm
T for power-steering sensor
-G250-
⇒ item 6 18
catalogue
8 - Nut, self-locking, 20 Nm and 17
1
torque a further 90° ( /4 turn)
9 - Steering-knuckle arm (of the 17 S48-0267
wheel-bearing housing)
T Pipe screw M16x1.5
T Torque for pipe screw on the power-assisted steering gear: 30 Nm
11 - O-ring
12 - Hollow screw, 40 Nm
T with non-return valve
T M14x1.5
13 - Gasket ring
14 - Pressure line
T Pay attention to installation position relative to subframe ⇒ 48-11 page 6
T Torque for pipe screw on the engine pump aggregate: 30 Nm
T with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assem-
bly carrier
T with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier

S00.5303.17.20

18 - Hinged bracket
T The shape of the hinged bracket depends on the gearbox
Summary of components of pressure line (hose) - power steering TRW or KOYO

In the figure, the hose is illustrated at an engine pump aggregate of the TRW. The hose is analogous for the engine
pump aggregate of KOYO
1 - Engine pump aggregate

T with encapsulation, assign-
ment ⇒ Spare part cata-
logue
T with half encapsulation, as- 4
signment ⇒ Spare part cata-
logue
T without encapsulation, as-
signment ⇒ Spare part cata-
logue
2 - Return line (return hose)
3
catalogue
T must not be pinched off dur-
2
ing disassembling work 5
T No less than minimum bend-
ing radius of 100 mm 1 6
⇒ Chapter 48-13
3 - Line holder
5 - Pressure line (expansion
hose)
catalogue
T must not be pinched off dur-
ing disassembling work
T No less than minimum bend-
ing radius of 100 mm
T Pay attention to installation
position relative to subframe
⇒ 48-11 page 6 S48-0198
⇒ Chapter 48-13
6 - Spacer holder
T clipped onto body
7 - Cable of power-assisted steering sensor -G250-
Fitting location of pressure line (flexible hose)

Maintain a clearance of about 10 mm between pressure
line (flexible hose) and subframe.

S00.5303.17.20
– Insert a suitable spacer between subframe and pres-
sure line.
Use new hollow screw for power-assisted steering gear
of TRW.
– Tighten banjo bolt of pressure line by hand with new

seals at the power-assisted steering gear.
– Remove spacer.
– Inspect clearance between subframe and pressure
line, adjust if necessary.
– Tighten banjo bolt fully to the specified tightening
torque.
Tightening torque:
Pressure line to the power-assisted steer- 35 Nm

ing gear (TRW)
♦ Use new hollow screw!
Pressure line to the power-assisted steer- 40 Nm
ing gear (KOYO)

S00.5303.17.20

S00.5303.17.20

power-steering gear (TRW
or KOYO)
-V.A.G 1359/2-
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3A -, - V.A.G 1551/3B-,
- V.A.G 1551/3C- or -VAS 5051/6A-
♦ Jumper cable (commercially available)
♦ Oil catch pan (commercially available)
-V.A.G 1359/2-
♦ Plastic screw plugs for line connections on the power-
assisted steering gear (commercially available)
♦ Hydraulic oil ⇒ Chap. 00-2
Note
♦ Apart from replacing the bellows, track rod ends and
track rods no other repairs may be carried out on the
power-steering gear.
♦ Absolute cleanliness is required when working on the
power steering.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover if
the repair cannot be carried out immediately.
before fitting.
♦ Use only genuine - wrapped parts.
♦ Do not use drained hydraulic oil again.
♦ Replace gaskets on hydraulic lines after each disas-
sembly.
♦ For vehicles with KOYO steering manufactured as of
43/04 a component modification was performed as an
enhancement for which the steering gear pinion has
been offset by 1 tooth. For these reasons the steering
gear is modified as of this date. For vehicles manufac-
tured before this date the steering wheel is turned by
approx. 1/8 turn when replacing the steering gear. Do
not set the steering wheel with track rods, rather offset
the steering wheel in the grooves of the steering col-
umn ⇒ Body Work; Rep. Gr. 69.
♦ Disposing of the power-steering gear ⇒ Chap. 48-17.
Edition 04.05 Removing and installing power-steering gear (TRW or KOYO) 48-12 page 1
S00.5303.18.20
Removing the power-assisted steering

drive
Caution!
Bring the steering wheel in its central position (with
the wheels straight ahead) and make sure that it
does not turn during repairs as this could damage
the coil spring of the airbag unit.
– Secure the steering wheel with the wheels in straight

ahead position with adhesive tape -arrow- against un-
intended turning.
S48-0196

– Remove cover -2-.
1 1
S48-0106
– Release screw -1-.

from the input shaft of the power-steering gear.
– Before disconnecting the battery determine the code
Note
Because of the different dimensions of the battery the
screw cap of the hydraulic oil reservoir on certain vehicle
versions is concealed by the battery tray and battery. If
this is the case remove the battery tray and battery. 1
S48-0107
48-12 page 2 Removing and installing power-steering gear (TRW or KOYO) Edition 04.05
S00.5303.18.20
– Remove air filter, if necessary ⇒ Engine, Fuel Injec-
tion System; Rep. Gr. 24 (petrol engines) or
⇒ Rep. Gr. 23 (diesel engines).
– If necessary remove the battery and battery tray
– Unhook cable of power-steering sensor -G250- from
line holder -arrows-.
– Raise vehicle.
S48-0109
Note
from the figure.

er
– Removing front exhaust pipe with catalyst ⇒ Engine -

S48-0111
– Unscrew screws -1- and -2- from the pendulum sup-

port.
2
1
S48-0112
S00.5303.18.20

-2-.
S48-0113
– Screw up nut of the track rod end -1- sufficiently so

that the extractor -Matra V176- is supported on the Matra V176
nut. 1
– Use puller - Matra V176- to press track rod/track rod
– Screw off the nut on both sides from the track rod end.
– Pull track rod end on both sides out of steering arm.
S48-0114
– Unscrew the screwed lid -1- of the hydraulic oil reser-

voir -2- of the engine pump aggregate. 2
– Extract the hydraulic oil with an extraction bottle via
the filler neck. 1
Note
♦ After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the return
hose and expansion hose.
♦ Do not pinch off the expansion hose and the return
hose with hose clamps -MP 7-602- or any other tools.
Pinching off may result in damage to the expansion
hose and return hose. S48-0147
♦ To avoid damage make sure the bending radius of at
least 100 mm is respected when bending or tying up
the expansion hose or return hose.
S00.5303.18.20
– Place the oil catch pan to catch drained off hydraulic
oil under the steering gear.
– Insert wooden insert (490 x 270 x 50 mm) -2- in the
adapter, e.g. -V.A.G 1359/2-.
2
– Position gearbox jack with adapter and support as- 1
sembly carrier.
1
– Release screws -1- for power-steering gear.
Note
ing steps. V.A.G 1359/2 1
maximum 20 Nm as otherwise the fixing bolt thread V.A.G 1383A S48-0116
becomes damaged.
– Unscrew left screw -4- for assembly carrier -3- and

screw in a fixing bolt of -T10096- to 20 Nm.
shown in figure) and screw in a fixing bolt of - T10096-
to 20 Nm.
– Release screws -1- on both sides.
4
2

screws (Pos. -2- and -4-) are consecutively replaced with 3
S48-0117
the fixing bolts.
Caution!
When lowering the assembly carrier make sure the
pressure line (expansion hose), return hose and the
line of the power-steering sensor -G250- are not ex-
posed to traction.
– Lower subframe -4- about 4 cm.

5 - Fixing bolt of -T10096-
3
– Unscrew pressure line (expansion hose) -1- and re- 2
turn line (return hose) -2- on the power-steering gear.
– Shut off the pressure line and return line with a plastic
bag and adhesive tape. 4
– Tie up the pressure line and return line.
– Shut off the threaded bores (connections for pressure 1
and return lines) on the power-steering gear with plas-
tig screw plugs.
5 S48-0115
S00.5303.18.20
Vehicles with power steering (TRW)
– Release Allen screws -1-.

– Remove the power-assisted steering sensor -G250-
(-2-) with seal -3- out of the power-steering gear valve
housing.
2 3
The new removal of the power-assisted steering sensor
-G250- with adapter cable is illustrated in the figure. The
removal of the power-assisted steering sensor -G250-
with fixed connection line occurs in the same way.
4
1
S48-0259
Vehicles with power steering (KOYO)
– Release Allen screw -1-.

– Remove the power-assisted steering sensor -G250- 3
(-2-) with seal -3- out of the power-steering gear valve
housing. 2
Note
When lowering the assembly carrier make sure there is
sufficient clearance between the drive shafts and the sta-
bilizer.
1
– Slowly lower assembly carrier with gearbox jack and S48-0260
adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-.
– Remove power-steering gear towards the rear.
Installing the power-assisted steering

drive
♦ Pay attention to fitting position when attaching pres-
sure line (flexible hose) to the power steering gear
⇒ Chap. 48-11.
♦ When tensioning and while driving the pressure line
(expansion hose) and the return line (return hose)
must not touch or chafe.
♦ To connect the pressure line use new gasket rings.
♦ Use new hollow screw for the connection of the pres-
sure line to the power steering gear (TRW).
♦ To connect the return line use new O-rings.
♦ Coat the seal on the power-steering gear with lubri-
cant before installing the power-steering gear, e.g. lu-
bricating soap.
♦ Make sure all sealing surfaces are clean.
♦ After positioning the power-steering gear on the drive
shaft of the steering column make sure the seal on the
power-steering gear is not bent on the assembly plate
and correctly seals the footwell opening. Otherwise
this could cause water penetration and/or noise.
S00.5303.18.20
♦ Before fitting the power-steering gear check the cen-
tre position of the gear rack ⇒ Chap. 48-14.
♦ Before positioning the universal joint of the steering
column on the input shaft of the steering gear, first
make sure the vehicle is on the ground and all wheels
are pointing straight ahead.
♦ For vehicles with KOYO steering manufactured as of
43/04 a component modification was performed as an
enhancement for which the steering gear pinion has
been offset by 1 tooth. For these reasons the steering
gear is modified as of this date. For vehicles manufac-
tured before this date the steering wheel is turned by
approx. 1/8 turn when replacing the steering gear. Do
not set the steering wheel with track rods, rather offset
the steering wheel in the grooves of the steering col-
umn ⇒ Body Work; Rep. Gr. 69.
2
1
– Check the centre position of the gear rack of the pow- 1
er-steering gear, if necessary adjust ⇒ Chap. 48-14.
– Place the power-steering gear from the rear onto the
lowered assembly carrier and tighten new screws -1-
by hand.
– Check correct fit of the seal on the power-steering V.A.G 1359/2 1
gear valve housing.
– Align the assembly carrier with the fixing bolts of V.A.G 1383A S48-0201
-T10096- screwed into the body.
Note
Raise the assembly carrier until a distance of approx. 4
cm is between the console and body.
– Slowly raise the assembly carrier with gearbox jack 2 3

and adapter, and while doing so insert the input shaft
of the power-steering gear in the opening in the vehi-
cle floor.
2 - Wooden insert (490 x 270 x 50 mm)
4
Vehicles with power steering (TRW)
– Insert the power-assisted steering sensor -G250- (-2-) 1

with new seal -3- into the power-steering gear valve
housing. S48-0259
The installation of the power-assisted steering sensor
-G250- with adapter cable is illustrated in the ilustration.
The installation of the power-assisted steering sensor
-G250- with fixed connection line occurs in the same way. 3
Vehicles with power steering (KOYO) 2
– Insert the power-assisted steering sensor -G250- (-2-)
with new seal -3- into the power-steering gear valve
housing.
– Insert and tighten screw -1-.
S48-0260
S00.5303.18.20
– Mount the pressure line (expansion hose) -1- and re-

turn line (return hose) -2- on the power-steering gear
with new gasket rings.
– A new hollow screw must be used to connect the pres- 3
sure line (expansion hose) -1- to the power-steering
gear (TRW).
2
3 - for power-assisted steering sensor -G250- with
fixed connecting line 4
5 - Fixing bolt of -T10096- 1
Pay attention to fitting location of pressure line
⇒ Chap. 48-11.
– Raise assembly carrier until the console touches the 5 S48-0115

body.
Note
ing steps.
♦ Unscrew the fixing bolts of -T10096- one at a time. It
should be subsequently replaced by a new bolt tight-
ened to the recommended torque.

torque.

– Tighten new bolts for the rear left support by hand.
– Tighten new bolts for left console and support to the 3
recommended tightening torque. S48-0197

figure).
– Tighten new bolts for the rear right support by hand.
– Tighten new bolts for left console and support to the
– Tighten up the rear right support bolts to the recom-
– Tighten screws for fixing the steering gear to the as-
sembly carrier to the recommended tightening torque.
tighten new nut ⇒ Chap. 48-16.
S00.5303.18.20
If the joint stub rotates when tightening, counterhold
with hexagon socket wrench (SW 6).
– Hook the coupling rod joint stub in the stabilizer and

tighten nut.
new screws -1- and -2-.
er
2
– Installing front exhaust pipe with catalyst ⇒ Engine - 1
– Fit front wheels. S48-0112
– Install noise insulation panel.

– Attach line of power-steering sensor -G250- with the
line holders -arrows-.
S48-0109
– Slide the universal joint of the steering column in the

-direction of the arrow- onto the input shaft of the pow-
er steering and tighten with a new screw -1-.
– Fit cover for universal joint.
Caution!
Observe the applicable safety instructions for dis-
connecting the battery with the jumper cable!
– Connect the removed battery with jumper cable.

– Filling and bleeding the power-steering system 1
⇒ Chap. 48-23.
– Disconnect the Jumper cable. S48-0170
– If necessary install the battery and battery tray
– Install air filter, if removed ⇒ Engine, Fuel Injection
System; Rep. Gr. 24 (petrol engines) or
– Perform self-diagnosis ⇒ Chap. 48-25.
If faults are displayed in the fault memory:
S00.5303.18.20

Caution!
Note
For vehicles with KOYO steering manufactured as of 43/
04 a component modification was performed as an en-
hancement for which the steering gear pinion has been
offset by 1 tooth. For these reasons the steering gear is
modified as of this date. For vehicles manufactured be-
fore this date the steering wheel is turned by approx. 1/8
turn when replacing the steering gear. Do not set the
steering wheel with track rods, rather offset the steering
wheel in the grooves of the steering column ⇒ Body
Work; Rep. Gr. 69.
Tightening torques:
Power-steering gear to assembly carrier 50 Nm + 90°

♦ Use new screws!
Assembly carrier to body 70 Nm + 90°
♦ Use new screws!
♦ Use new screws!
♦ Use new screws!
♦ Use new nuts!
power-assisted steering sensor -G250- 6 Nm
to power-assisted steering gear (TRW)
power-assisted steering sensor -G250- 7.5 Nm
to power-assisted steering gear (KOYO)
Hollow screw for pressure line to power 35 Nm
steering gear (M14x1.5) - TRW
steering gear (M14x1.5) - KOYO
Pipe screw for return line to power 30 Nm
steering gear (M16x1.5)
Universal joint to power-steering gear 20 Nm + 90°
♦ Use new screw!
Wheel bolts 120 Nm
S00.5303.18.20
48-13 Power-assisted steering

sensor -G250- and the hy-
draulic line for power
steering
Check power-assisted steering sensor

-G250- (TRW or KOYO)
Check power-assisted steering sensor -G250- (TRW)
⇒ Chapter 48-25
Check power-assisted steering sensor -G250- (KOYO)
⇒ Chapter 48-25
Remving and installing power-assisted

steering sensor -G250- (TRW or KOYO)
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3A-, - V.A.G 1551/3B-
or -V.A.G 1551/3C- Diagnostic cable -VAS 5051/5A-
or -VAS 5051/6A-
Removing
– Before disconnecting the battery determine the code
– Remove air filter, if necessary ⇒ Engine - Fuel Injec-
– Raise vehicle.
– Remove front left wheel.
– Remove soundproofing panel.
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66.
Note
The followings steps for removing the line do not need to
be carried out on vehicles with a power steering of TRW
and a power-assisted steering sensor -G250- (-2-) with 2 3
an adapter cable -4-.
4
1
S48-0259
Edition 11.04 Power-assisted steering sensor -G250- and the hydraulic line for 48-13 page 1
S00.5303.17.20 power steering
– Unhook line of the power-assisted steering sensor

-G250- from the line holders -arrows-.
The line of the power-assisted steering sensor -G250- is
attached with 3 line holders and a spacer holder.
S48-0109
– Open spacer holder -arrow-.

– Remove line -1- power-assisted steering sensor/en-
gine pump aggregate.
1
S48-0125
– Disconnect plug -1- from the engine pump aggregate

with noise encapsulation -2-.
1
The engine pump aggregate of TRW is illustrated in the
figure. The plug assignment for the engine pump aggre-
gate of KOYO is analogous to the version of TRW.
2
S48-0126
48-13 page 2 Power-assisted steering sensor -G250- and the hydraulic line for
power steering
Edition 11.04
S00.5303.17.20
Inspecting the power-assisted steering sensor
-G250- (TRW)
for power-assisted steering sensor -G250- with fixed con-
necting line (TRW):
– Unscrew bolts -1- completely.

2 3
– Pull the power-assisted steering sensor -G250- (-2-)
with the seal -3- out of the power-steering gear.
4
1
S48-0270
for power-assisted steering sensor -G250- with adapter

cable (TRW):
– Detach the adapter cable -4-from the power-assisted

steering sensor -G250- (-2-).
– Unscrew bolts -1- completely.
2 3
– Pull the power-assisted steering sensor -G250- (-2-)
4
1
S48-0259
The power-steering sensor -G250- (KOYO)

– Pull the power-assisted steering sensor -G250- (-2-) 3
2
Installing
Installation is performed in a similar way in the reverse or-
der. Pay attention to the following points:
– Use new seal for power-assisted steering sensor

-G250-! 1
System; Rep. Gr. 24 (petrol engines) or S48-0260
– Perform automatic test sequence ⇒ Chapter 48-25
either using the vehicle system tester -V.A.G 1552- or
using the vehicle system test ⇒ Chapter 48-25 using
the vehicle diagnosis, measurement and information
system -VAS 5051-.

Tightening torques:
power-assisted steering sensor -G250 - to 6 Nm

power-assisted steering gear (TRW)
power-assisted steering sensor -G250 - to 7.5 Nm
power-assisted steering gear (KOYO)
Wheel bolts 120 Nm
Removing and installing hydraulic lines

(TRW or KOYO)
-V.A.G 1359/2-
♦ Catch pan (commercially available)
-V.A.G 1359/2-
♦ Plastic screw plugs for line connections on the power-
assisted steering gear (commercially available)
Notes for working on hydraulic lines

the engine pump aggregate as well as in the return
line and pressure line (expansion hose).
♦ Do not pinch off the pressure line (expansion hose)
and the return line with hose clamps -MP 7-602- or
with any other tools. Pinching off may cause damage
to the hydraulic lines.
♦ Use new hollow screw for the connection of the pres-
sure line to the power steering gear (TRW).
♦ Pay attention to fitting location of pressure line (flexi-
ble hose) ⇒ Chapter 48-11.
2
least 100 mm is respected when bending the pressure
line (expansion hose) or return line.
1
♦ Replace O-rings as well as gasket rings on the hy-
draulic lines after each disassembly.
Removing
– Use catch pan to collect the drained off hydraulic oil.
voir -2- of the engine pump aggregate.
– Extract the hydraulic oil with an extraction bottle via S48-0147
the filler neck.
power steering
Edition 11.04
S00.5303.17.20
Rep. Gr. 66.
– Unclip return line -4- from the line holders -5-.
5
– Open spacer holder -7-. 2
4
– Take return-flow line -4- or pressure line -6- out of the 6
spacer -7-.
– Open spring strap clamp -2- with assembly pliers and 7
carefully pull off return line from the support of the en-
gine pump aggregate -1-.
– Unscrew pipe screw -3- from the engine pump aggra- 3
gate and pull out the pressure line.
1
8 - Lines of power-assisted steering sensor -G250-
8
– Close the threaded bores and supports on the engine
pump aggregate. S48-0199
– Remove the screws attaching the assembly carrier to

the body in the prescribed sequence and replace
them with the fixing bolts from -T10096- ⇒ Chapter
48-12.
Caution!
When lowering the assembly carrier make sure the
line of the power-assisted steering sensor -G250- is
not exposed to traction, if necessary pull out the
plug on the engine pump aggregate.
– Lowering assembly carrier with power-assisted steer-

ing gear.
– Disconnect pressure line -1- or return-flow line -2-
from steering gear.
3 - for power-assisted steering sensor -G250- with 3
fixed connecting line (TRW): 2
5 - Fixing bolt from -T10096-
4
– Seal threaded holes on the steering gear (e.g. with
plastic screw plugs).
1
– Remove pressure or return line.
Installing
5 S48-0115
– When installing the pressure line it is essential to pay
attention to the fitting location ⇒ Chapter 48-11.
– Mount return line with new O-ring on the power steer-
ing gear.
– Attach a pressure line tightly with new seals to the
power steering gear ⇒ Chapter 48-11.
– Screw return line with new O-ring onto the engine
pump aggregate.
– Installing assembly carrier ⇒ Chapter 48-12.

– Filling with hydraulic oil and bleeding the steering sys-
tem ⇒ Chapter 48-23.
Caution!

Tightening torques:
Hollow screw for pressure line to power- 35 Nm

assisted steering gear (M14 x 1.5),
TRW
Hollow screw for pressure line to power- 40 Nm
assisted steering gear (M14 x 1.5),
KOYO
Pipe screw for return line to power-as- 30 Nm
sisted steering gear (M16 x 1.5)
Pipe screw for pressure line to engine 30 Nm
pump aggregate (TRW)
pump aggregate (KOYO)
Wheel bolts 120 Nm
power steering
Edition 11.04
S00.5303.17.20
48-14 Inspecting and adjusting

the power-steering gear
The checking and adjusting is illustrated on a power-
steering gear of TRW. For the power-steering gear of
KOYO the checking and adjusting is performed analo-
gously to the power-steering gear of TRW.
Check the centre position of the gear

rack of the power-steering gear, if neces-
sary adjust
– Before installing the power-steering gear place the

gear rack in centre position.
Note
♦ The gear rack of spare part steering gears is already
in centre position.
♦ Dimension -a- must be equal on both the right and left
side if the steering gear. If the dimension on the two
sides is not the same, distance -a- must be corrected.
– Check dimension -a-, if necessary adjust. S48-0131
-a- = 72.5 mm
– Adjusting dimension -a- by turning the input shaft -1-

of the power-steering gear.
1
2 - Gear rack
Adjusting the power-steering gear (ad-

justing the pressure plate clearance)
Note
2 mechanics are required for this adjustment.
2
• Put the wheels in straight-ahead position. S48-0132
– Raise vehicle.
– Move the steering wheel alternately approx. 30°. on
the centre axle.
If the steering clearance is too great rattling noises will
be audible inside the vehicle.
Edition 11.04 Inspecting and adjusting the power-steering gear 48-14 page 1
S00.5303.17.20
– While moving the steering wheel have the 2nd me-

chanic carefully screw in the ajusting screw -1- until no
more rattling noises can be heard inside the vehicle.
Caution!
The steering must automatically return to straight
ahead position after a manoeuvre or cornering with-
out sticking, correct if necessary.
1
S48-0183
– Secure adjusting screw -1- against turning.

– Apply 3 centre punch marks -arrows- uniformly distrib-
uted on the collar of the power-steering gear housing.
S48-0184
48-14 page 2 Inspecting and adjusting the power-steering gear Edition 11.04
S00.5303.17.20
48-15 Disassembling and as-

sembling the power-as-
sisted steering gear
Disassembling and assembling the pow-

er-assisted steering gear (TRW)
Note
♦ If the front axle is damaged as a result of an accident
these steering components must be replaced: Posi-
tion 1 to 5 and position 9 to 20.
♦ No provision is made for repairing the power-steering
gear ⇒ item 12 in 48-15 page 3. In the event of fail-
ure determine the cause with the pressure and tight-
ness test as well as by performing self-diagnosis or
vehicle system test. If there is a complaint about the
power -assisted steering gear ⇒ item 12 in 48-15
page 3 then it must be replaced.
♦ Welding and straightening of the steering components
is not allowed.
♦ Only use steering gear grease to grease the gear rack
⇒ Chapter 00-2.
♦ A mixed lining of TRW and KOYO components is not
permissible, assignment ⇒ Spare part catalogue.
Edition 11.04 Disassembling and assembling the power-assisted steering gear 48-15 page 1
S00.5303.17.20

1 2
3
⇒ Chapter 48-16
4
T before installing, remove 5
grease on tapered stud
2 - Lock nut, 50 Nm
T use assembly pliers, e.g. 7
-VAS 5024- for removing 8
and installing 7
4 - Boot 6 14
T can only be replaced with the
power steering gear re- 15
moved 9 16
the track-rod end ⇒ Chapter
48-16 10 11 17
T must not be twisted 12 16
(cuts, splits)
18
5 - Warm-type clamp
13
T removing: open with cutting 16
pliers 16
6 - Gasket 20
instructions for installing 5 2 19
⇒ Chapter 48-12 4
T with and without recess for
anti-twist lock
3 S48-0264
catalogue
T Change to the steering gear housing in the area of the sealing surface
With series start the steering gear housing is fitted with an anti-twist lock -arrow- for the seal.
In the course of the series production the anti-twist lock is no longer applicable.
T for attaching heat shield
8 - Heat shield
9 - Clamp
Fitting position:
♦ inscription must point in direction of travel
♦ Replace the clamp if the thread of the nut is damaged
10 - Right track rod
T lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm.
After installing the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm.
11 - Rubber bearing
Fitting position:
♦ the larger internal diameter points towards the outer side of the vehicle
48-15 page 2 Disassembling and assembling the power-assisted steering gear Edition 11.04
S00.5303.17.20
T no provision made for repairs
T Change to the steering gear housing in the area of the sealing surface
With series start the steering gear housing is fitted with an anti-twist lock -arrow- for the seal.
In the course of the series production the anti-twist lock is no longer applicable.
13 - Gasket
14 - Gasket
15 - for power-assisted steering sensor -G250- with adapter cable
16 - Screw, 6 Nm
17 - Adapter cable
18 - for power-assisted steering sensor -G250- with fixed connecting line
20 - Left track rod
Disassembling and assembling the pow-

er-assisted steering gear (KOYO)
S00.5303.17.20
Note
♦ If the front axle is damaged as a result of an accident these steering components must be replaced: Position 1 to
5 and position 9 to 17.
♦ No provision is made for repairing the power-steering gear ⇒ item 12 in 48-15 page 5. In the event of failure de-
termine the cause with the pressure and tightness test as well as by performing self-diagnosis or vehicle system
test. If there is a complaint about the power -assisted steering gear ⇒ item 12 in 48-15 page 5 then it must be
replaced.
♦ A mixed lining of TRW and KOYO components is not permissible, assignment ⇒ Spare part catalogue.

1 2
3
⇒ Chapter 48-16
4
T before installing, remove 5
grease on tapered stud
2 - Lock nut, 50 Nm
T use assembly pliers, e.g. 7
-VAS 5024- for removing 8
and installing 7
4 - Boot
T can only be replaced with the
6
power steering gear re-
moved
9
the track-rod end ⇒ Chapter
48-16 10 11
T must not be twisted 12 13
(cuts, splits) 14
5 - Warm-type clamp 15
T removing: open with cutting
pliers
6 - Gasket 17
instructions for installing 5 2 16
⇒ Chapter 48-12 4
catalogue
3 S48-0265
T for attaching heat shield
8 - Heat shield
9 - Clamp
Fitting position:
♦ inscription must point in direction of travel
♦ Replace the clamp if the thread of the nut is damaged
10 - Right track rod
S00.5303.17.20
T setting the wheel toe ⇒ Chapter 44-2.
11 - Rubber bearing
Fitting position:
♦ the larger internal diameter points towards the outer side of the vehicle
T no provision made for repairs
13 - Gasket
14 - Sensor for power steering -G250-
15 - Screw, 6 Nm
17 - Left track rod
S00.5303.17.20
S00.5303.17.20
48-16 Track rod ends, track rods

for power steering and
mechanical steering
The checking as well as removing and installing the
track rod ends are identical on the power steering of
TRW or KOYO of the mechanical steering.
Inspecting play, correct attachment and

boots of track rod ends
– Raise vehicle (wheel clear of the ground) and inspect
play by moving the track rods and wheels.
Nominal value play: no play
– Inspect attachment.
– Check boots for damaged (e.g. tears) and for correct
position.
– If necessary replace track rod ends.
Removing and installing track rod ends

♦ Extractor -Matra V176- Matra V176
1
Removing
The track rod ends can be replaced with the track rods
and the power steering gear installed.
– Raise vehicle.
– Screw up hexagon nut -1- sufficiently so that the puller 2
-Matra V176- is supported on the hexagon nut.
– Use puller -Matra V176- to press track rod/track rod
S48-0114
– Unscrew hexagon nut from the track rod end.
– Pull track rod end out of steering arm.
– Release hexagon nut (lock nut) -2-.
– Unscrew track rod end -3- from track rod -1-.
The surrounding components are not shown to simplify

the illustration. 2
1 3
S48-0120
Edition 11.04 Track rod ends, track rods for power steering and mechanical 48-16 page 1
S00.5303.17.20 steering
Installing
Note
When installing pay attention to marking on the shank of I
the track rod end -arrow-.
I - Left track rod end - marking „D“
II - Right track rod end - marking „C“
– Remove grease on tapered shank of track rod end.

– Screw track rod end fully onto the track rod.
– Tighten hexagon nut (lock nut).
– Align track rod in such a way that the stud of the track
rod end is in the installation position.
tighten hexagon nut. If the joint stub rotates when II
tightening, counterhold with hexagon socket wrench
(SW6).
Tightening torques:
Lock nut of track rod/track-rod end 50 Nm S48-0121
Hexagon nut of track rod end/track rod 20 Nm + 90°

to steering arm
♦ Use new nut!
Wheel bolts 120 Nm
Removing and installing track rods

♦ Torque wrench, e. g. -V.A.G 1332-
6-
8-
♦ Grease EN-0042, Material No. N 052 721 00 con-
forming to TL 721
Note
The track rods can only be removed and installed if the
mechanical steering gear or power-steering gear is re-
moved.
48-16 page 2 Track rod ends, track rods for power steering and mechanical
steering
Edition 11.04
S00.5303.17.20
Removing
– Removing mechanical steering gear ⇒ Chap. 48-7, or
power-steering gear ⇒ Chap. 48-12.
– Clean outside of steering gear in the area of the boot.
– Open warm-type clamp as well as spring strap clip
and push back boot.
Mechanical steering gear
– Grip the steering gear in a vice with protective jaws on

the gear rack.
Make sure the gear rack serration is not gripped.
– When removing counterhold the track rods on the

gear rack of the steering gear.
– Unscrew track rod -1- from the gear rack -2-. V.A.G 1332
Power-steering gear
2
Note
When removing and installing the right-hand track rod, 1
open the warm-type clamp and wring strap clip of the left-
hand boot additionally and push back the boot. The rea-
son for this is that it is always necessary to counterhold at V.A.G 1332/8 S48-0185
the left-hand side of the steering rack when slackening
and tightening the track rods.
– Unscrew the front track rod -1- of the steering rack -2-.
To do so use torque wrench with open-jawed wrench
insert SW 32, e. g. -V.A.G 1332/6-. Counterhold
open-end wrench SW 19 -3- on the left side of the
V.A.G 1332
steering rack.
3
Installing
Mechanical steering gear
– Grip the steering gear in a vice on the gear rack. Use 1

protective jaws.
– Screw track rod into the gear rack of the steering gear. 2
– When installing counterhold the track rods on the gear
rack of the steering gear.
V.A.G 1332/6 S48-0122
– Tighten track rod.

Power-steering gear
– Screw track rod into the gear rack of the steering gear.
– Counterhold on flattened part of left gear rack with
open-end wrench.
– Tighten track rod.
– Unscrew track rod end from the track rod ⇒ 48-16

page 1.
– Inspect boot for wear (cuts, splits) and inspect sealing
surfaces for boot cleanliness. If there is any damage,
replace boot.
Edition 11.04 Track rod ends, track rods for power steering and mechanical 48-16 page 3
S00.5303.17.20 steering
Note
Always use original clamping collars and circlips.
– Push boot, warm-type clamp and spring strap clips

onto track rod.
– Screw track rod end onto the track rod ⇒ 48-16
page 1.
– Turn track rod in such a way that the stud of the track
rod end is in the installation position.
– Grease contact surface of boot on track rod (recess)
with grease EN-0042, Material No. N 052 721 00 con-
forming to TL 721 (grease quantity: 0.8g).
– Fit on boot.
The boot must on no account be installed twisted (distort-
ed).
– Tighten the warm-type clamp using the hose binding V.A.G 1275
claw, e.g. -V.A.G 1275-.
– Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
– Installing mechanical steering gear ⇒ Chap. 48-7, or
installing power-steering gear ⇒ Chap. 48-12.
– Check overall track and adjust if necessary, vehicle
alignment ⇒ Chapter 44-2.
Tightening torques:
Track rod in gear rack of the mechani- 80 Nm

cal steering gear
S48-0059
Track rod in steering rack of power 80 Nm
steering gear
48-16 page 4 Track rod ends, track rods for power steering and mechanical
steering
Edition 11.04
S00.5303.17.20
48-17 Disposing of the power-

steering gear
♦ Catch pan for hydraulic oil (commercially available)
Note
♦ The disposal of the power-steering gear of TRW or
KOYO is identical.
♦ The oils used in the power-steering gears do not con-
tain any harmful substances. These oils may be dis-
posed of together with the drained engine and
gearbox oil.
♦ Dispose of used oils in compliance with the applicable
environmental regulations.
♦ Used oils (this concept refers to used engine and gear
oils including ATF as well as mineral hydraulic oils),
suitable for preparation must never be mixed with
brake fluid, antifreeze agent, artificial resin or thinners,
chemicals etc.
1 1
♦ After »draining« the used parts must be allowed to 2
drip.
♦ When disposing of used parts comply with the appli-
cable regulations as there are minor residual amounts
of hydraulic oil in the power-steering gear.
1
♦ The ambient temperature must be of at least 20°C to 3
drain the steering gear.
S48-0128
– Unscrew pipe screws -1-.
– Pull off coolant hoses -2- and -3-.
Note
Do not shut off the threaded bores -arrows-.
– Hold the power-steering gear over a catch pan and re-

peatedly turn the steering pinion from stop to stop until
no more hydraulic oil runs out of the threaded bores.
– Disposing of the power-steering gear.
Edition 11.04 Disposing of the power-steering gear 48-17 page 1

S00.5303.17.20
48-17 page 2 Disposing of the power-steering gear Edition 11.04

S00.5303.17.20
48-18 Engine pump aggregate
Summary of components of engine pump aggregate (TRW)

The engine pump aggregate
♦ is a complete component consisting of steering hydraulics pump -V119- (electric motor and gear rack pump), the
power-steering control unit -J500- and the hydraulic oil reservoir.
♦ has a re-engaging protection after faults, failure or crash ⇒ Chap. 48-11.
Note
♦ No provision is made for repairing the engine pump aggregate.
♦ The cause of any problems which may be arising is determined by the pressure and tightness test.
♦ If there is insufficient hydraulic oil in the reservoir always check the steering system for leaks.
♦ If there is a leak in the area of the line connections first check the lines/line connections for tightness, if necessary
tighten and wipe dry.
♦ Always replace gasket rings.
1 - Encapsulation
T bottom open version
T not fitted to all vehicles
3
catalogue
2 - Encapsulation
4
T bottom closed version
6 1
T not fitted to all vehicles
5 2
T Disassembling is only possi- 7
ble after removing the engine
pump aggregate and the 8 9
holder 10
catalogue
3 - Screwed lid
T with oil dipstick
9
4 - Gasket ring
5 - Reservoir
T replacing ⇒ Chapter 48-21
9 8
6 - Clamp 8 11
T different versions 12
catalogue
T Tightening torque: 3 Nm 14 13
7 - Gasket ring
T different versions
11
catalogue
8 - Hexagonal nut, 7 Nm 16 15 11 S48-0261
T when tightening counterhold
on rubber bearing ⇒ item 9
9 - Rubber bearing
Edition 11.04 Engine pump aggregate 48-18 page 1

S00.5303.17.20
T check for damage (tears in rubber, rubber torn away from metal plate), if necessary replace
T with power-assisted steering control unit -J500-
T No provision is made for repair
T Replacing reservoir ⇒ Chap. 48-21
T Self-diagnosis ⇒ Chap. 48-25
T Electrical test ⇒ Chap. 48-26
11 - Tighten hexagon screw 20 Nm + 90°
12 - Bracket
T for engine pump aggregate
T install with assembly pliers, e. g. -VAS 5024-
15 - O-ring
T replace after disassembling the pressure line
16 - Pressure line (expansion hose)
T Engine pump aggregate - Power-steering gear
48-18 page 2 Engine pump aggregate Edition 11.04

S00.5303.17.20
Summary of components of engine pump aggregate (KOYO)
The engine pump aggregate
♦ is a complete component consisting of steering hydraulics pump -V119- (electric motor and gear rack pump), the
power-steering control unit -J500- and the hydraulic oil reservoir.
♦ has a re-engaging protection after faults, failure or crash ⇒ Chap. 48-11.
Note
♦ No provision is made for repairing the engine pump aggregate.
♦ The cause of any problems which may be arising is determined by the pressure and tightness test.
♦ If there is insufficient hydraulic oil in the reservoir always check the steering system for leaks.
♦ If there is a leak in the area of the line connection first check the lines/line connections for tightness, if necessary
♦ Always replace gasket rings.
1 - Rear bracket
T for engine pump aggregate 4 6
T the bearings in the bracket
are not used as replacement
part, in case of bearing dam- 1 7
age replace bracket
20 Nm + 90°
2
8
T replace after each removal 2 5
3 - Fillister head screw, 7 Nm
4 - Screwed lid 9
3 9
T with flat gasket ring
T as replacement part only 14
screwed lid with oil dipstick is 19 10 14
available together
20
catalogue 10
5 - Flat gasket ring 9 9 11
11
6 - Screwed lid
T with O-ring 18 17 12
catalogue 13
7 - O-ring
8 - Encapsulation 16
T bottom open version
T not fitted to all vehicles 2
catalogue
9 - Self-locking fillister head 15
screw, 7 Nm
T replace after each removal S48-0262
catalogue
10 - Cap nuts, 7 Nm
11 - Reservoir
T replacing ⇒ Chapter 48-21
Edition 11.04 Engine pump aggregate 48-18 page 3

S00.5303.17.20

12 - Gasket ring
T with screwed in threaded bores
T power-assisted steering control unit -J500- and electric motor must not be separated
14 - Fillister head screw, 7 Nm
T without threaded bores
T Screw insert -arrow- only with fillister head screws ⇒ item 9
T power-assisted steering control unit -J500- and electric motor must not be separated
16 - Front bracket
T for engine pump aggregate
T the bearings in the bracket are not used as replacement part, in case of bearing damage replace bracket
17 - O-ring
T replace after disassembling the pressure line
18 - Pressure line (expansion hose)
T Engine pump aggregate - Power-steering gear
T install with assembly pliers, e. g. -VAS 5024-
48-18 page 4 Engine pump aggregate Edition 11.04

S00.5303.17.20
48-19 Inspecting engine pump

aggregate
The engine pump aggregates TRW or KOYO can also be
checked apart from the inspections described in this
chapter in the framework of the self-diagnosis of the pow-
er-steering ⇒ Chapter 48-25, of the electrical test
⇒ Chapter 48-26 or the self-diagnosis with the vehicle di-
agnosis, measurement and information system
-VAS 5051- ⇒ Chapter 48-25.
Testing function of the engine pump ag-

gregate
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3- or -VAS 5051/6A-
The checking of the function is identical for the engine

pump aggregates of TRW or KOYO.
Check for proper operation
– Raise vehicle.
Rep. Gr. 66.
– Start engine.
– If necessary turn steering up to stop.
– Listen to and/or touch the engine pump aggregate to
check whether it is running.
If the engine pump aggregate is not working:

– Carry out electrical test ⇒ Chap. 48-26.
– Remove fault.
– Install the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66.
– Install left front wheel.
If the engine pump aggregate is working and if there are
other faults:

If entries from the fault memory are displayed:

Edition 11.04 Inspecting engine pump aggregate 48-19 page 1

S00.5303.17.20
If no faults are displayed in the fault memory:
– Check the feed pressure of the engine pump aggre-

gate ⇒ 48-19 page 2.
Tightening torque:
Wheel bolts 120 Nm
Check the feed pressure of the engine

pump aggregate
The checking of the feed pressure is identical for the en-
gine pump aggregates of TRW or KOYO. The description
of the test is performed on an engine pump aggregate of
TRW.

-VAS 5051-
♦ Power-assisted steering testing device, e. g.
-V.A.G 1402-
♦ Adapter, e.g. -V.A.G 1402/1A-
♦ Adapter, e.g. -V.A.G 1402/2-
♦ Adapter, e.g. -V.A.G 1402/3-
♦ Hose from adapter set, e. g. -V.A.G 1402/6-
Note
♦ If there is insufficient hydraulic oil in the reservoir of
the engine pump aggregate always check the power-
steering system for leaks ⇒ Chap. 48-23.
♦ If there is a leak on the power-steering gear first check
the lines/line connections for tightness, if necessary
♦ Inspecting the gasket ring on the input shaft of the
power-steering gear and on the gear rack seal
⇒ Chap. 48-23. If there are leaks on the gasket ring
or on the gear rack seal replace the power-steering
gear.
♦ Disposing of the power-steering gear ⇒ Chap. 48-17.
the engine pump aggregate as well as in the pressure
line (expansion hose).
♦ After the feed pressure test replace the O-ring on the
pipe screw of the pressure line.
48-19 page 2 Inspecting engine pump aggregate Edition 11.04

S00.5303.17.20
♦ Do not pinch off the pressure hose and the return
hose with hose clamps -MP 7-602- or any other tools.
Pinching off may result in damage to the pressure and
return line.
the pressure line.
Test requirements
• Tightness of the system

• Pressure and return line not buckled or tied up.
Note
♦ Because of the different battery dimensions, on cer-
tain models the screwed lid of the hydraulic oil filler
and inspection hole is covered by the battery tray and
battery. If this is the case remove the air filter, the bat- 2
tery tray and battery.
♦ Before disconnecting the battery determine the code 1

voir of the engine pump aggregate -2-.
the filler neck.
– Raise vehicle.
Note
from the figure.
S48-0111

S00.5303.17.20

Rep. Gr. 66
– Open spacer holder -1- and remove pressure line (ex-
pansion hose) -2-.
Note
After removing the pressure line from the engine pump
aggregate hydraulic oil will escape from the connection
opening.
1
2
– Place the catch pan under the engine pump aggre- S48-0135
gate to collect escaping hydraulic oil.
– Release pipe screws -3- from the engine pump aggre-
gate -1-.
– Pull out the pressure line (expansion hose) -2- from 2
the engine pump aggregate.
3
Note
♦ The pressure line must not be exposed to traction.
♦ Make sure the bending radius of the pressure line is
no less than 100 mm.
– Tie up the pressure line on the stabilizer.

1
S48-0136
Connect tester
C
– Connect Power-steering tester -1-, e. g. -V.A.G 1402-.
– Suspend the power-steering tester on front axle. Hos-
es must not be exposed to tension. B 5
2- Adapter, e.g. -V.A.G 1402/3-
3- Hose from adapter set, e. g. -V.A.G 1402/6-
4- Adapter, e.g. -V.A.G 1402/2-
5- Adapter, e.g. -V.A.G 1402/1A-
A- Pressure line (expansion hose) 4
B- Engine pump aggregate with encapsulation
C- Return line (return hose)
A 1
2
S48-0138

S00.5303.17.20
Test preparations
– Open the shut-off valve on the power-steering tester

pressure gauge -1-. Lever -2- points perpendicularly
down.
1
Caution!
– If necessary connect battery to jumper cable.

– Filling with hydraulic oil and bleeding the steering sys- 2
tem ⇒ Chapter 48-23. S48-0195
Test
Note
♦ A 2nd mechanic is required to check the feed pres-
sure of the engine pump aggregate or the system
pressure.
♦ To avoid damaging the engine pump aggregate or the
power-steering system, the test of the feed or system
pressure must not last longer that approx. 5…10 sec-
onds.
♦ Do not close the shut-off valve of the tester pressure
gauge during this test. If the shut-off valve is closed
the indicated nominal pressure will drop to 0 MPa
(bar) once a pressure valve in the engine pump aggre-
gate responds.
– Start engine.
– Given a maximum left and right steering angle hold
the steering wheel in position with a force of approx.
10…20 Nm during approx. 5…10 seconds.
– Read off pressure at maximum steering angle (left/
.right) and with the engine at idling speed.
– Compare the measured value to the nominal value ac-
cording to the following table.
Nominal value overpressure1)

Engine
MPa bar
Fuel engines 9,6…10,4 96…104 2
Diesel engines 9,6…10,4 96…104
1) maximum system pressure or feed pressure of the engine pump
1
aggregate
Note
If the nominal value is exceeded or if it is not reached re-
place the engine pump aggregate.
– Switch off engine.

voir of the engine pump aggregate -2-. S48-0147

S00.5303.17.20

the filler neck.
– Removing Power-steering tester, e. g. -V.A.G 1402-.
– If necessary replace defective engine pump aggre-
gate ⇒ Chap. 48-20.
Disposing of the engine pump aggregate ⇒ Chap. 48-
20
– Position pressure line (expansion hose) -2- in spacer

holder -1- and close spacer holder.
– Mount pressure line on the engine pump aggregate.
– Disconnect the jumper cable.
Rep. Gr. 66.
– Install noise insulation panel. 1
2
⇒ Electrical System; Rep. Gr. 27. S48-0135
– If necessary connect battery ⇒ Electrical System;

Rep. Gr. 27.
– Perform self-diagnosis ⇒ Chap. 48-25

Tightening torques:
Pressure line to engine pump aggregate 30 Nm

TRW
KOYO
Wheel bolts 120 Nm

S00.5303.17.20

as well as disposing of en-
gine pump aggregate
Removing and installing engine pump

aggregate (TRW)
-VAS 5051-
In the event of failure determine the cause with the func-

tional, pressure and tightness test as well as by perform-
ing self-diagnosis.
Note
the engine pump aggregate as well as in the hydraulic
lines.
♦ Do not pinch off the hydraulic lines with hose clamps
-MP 7-602- or any other tools. Pinching off may result
in damage to the pressure and return line.
the pressure line.
Removing engine pump aggregate
Note
and inspection hole is covered by the battery tray and 2
battery. If this is the case remove the air filter, the bat-
tery tray and battery. 1

S48-0147
Edition 11.04 Removing and installing as well as disposing of engine pump 48-20 page 1
S00.5303.17.20 aggregate

the filler neck.
– Raise vehicle.
Note
from the figure.

Rep. Gr. 66 S48-0111
Vehicles with radiator fan control unit -J293-
– Disconnect plugs -1- and -2- from the radiator fan con-
trol unit -J293- -4-.
3
– Unscrew nuts -3-.
– Remove radiator fan control unit -4-.
2
1
S48-0140

pansion hose) -3-, return line -2- and the line of the
power-steering sensor -G250-.
– Position the oil catch pan under the engine pump ag-
gregate. 2 3
S48-0141
48-20 page 2 Removing and installing as well as disposing of engine pump

aggregate
Edition 11.04
S00.5303.17.20
– Disconnect plugs -1-, -2- and -3- from the engine
pump aggregate with encapsulation -4-. 1 2 3
1 - Data BUS plug and terminal 15
2 - Earth plug and terminal 30
3 - Power-steering sensor -G250- plug
Note
♦ Residual hydraulic oil remains in the engine pump ag-
gregate. When removing the pressure line some of
this residual amount will flow out.
♦ When tying up the hydraulic line make sure the bend-
ing radius of 100 mm is reached. 4
S48-0143
– Unscrew the pressure line (expansion hose) -1- from

the engine pump aggregate and tie up.
– Shut off the pressure line with a plastic bag and adhe-
sive tape to protect it against dirt.
– Open the spring strap clamp -3- on the return line (re- 2 3
turn hose) -2-.
– Carefully pull off the return line -2- from the reservoir
support of the engine pump aggregate -4- and shut off 1
with a plastic bag and adhesive tape to protect it
against dirt.
4
S48-0142

2
– Remove engine pump aggregate with encapsulation
-1- and with holder -2- downwards.
1
S48-0144
Removing the holder and rubber bearing.
– Unscrew the hexagon nuts -arrows-.

3
– Remove holder -2-. 2
– Open encapsulation -3-.
– Remove engine pump aggregate -1-. 1
Note
To replace the rubber bearing do not remove the encap-
sulation.
S48-0145
– Unscrew rubber bearing -arrow-.
Installing engine pump aggregate
Note
♦ Only use original spring band clamps.
♦ Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
♦ After installing the engine pump aggregate fill with hy-
draulic oil ⇒ 48-23.
♦ When installing the pressure line on the engine pump
aggregate use new O-ring. S48-0146

– It is absolutely necessary to counterhold the rubber

bearing when tightening the hexagon nuts to secure
the holder on the engine pump aggregate.
Caution!
– If necessary connect removed battery to jumper ca-

ble.
– If necessary install air filter.
– If necessary disconnect the jumper cable.
– If necessary re-install the air filter.

aggregate
Edition 11.04
S00.5303.17.20

Tightening torques:
Rubber bearing to engine pump aggre- 7 Nm

gate TRW
Holder to engine pump aggregate TRW 7 Nm
Holder with engine pump aggregate 20 Nm +
TRW to body 90°
♦ Use new screws!
TRW
Radiator fan control unit -J293- to body 6 Nm
Wheel bolts 120 Nm
Removing and installing engine pump

aggregate (KOYO)
-VAS 5051-
In the event of failure determine the cause with the func-

tional, pressure and tightness test as well as by perform-
ing self-diagnosis.
Note
the engine pump aggregate as well as in the hydraulic
lines.
♦ Do not pinch off the hydraulic lines with hose clamps
-MP 7-602- or any other tools. Pinching off may result
in damage to the pressure and return line.
the pressure line.
Removing engine pump aggregate
Note
and inspection hole is covered by the battery tray and
battery. If this is the case remove the air filter, the bat- 2

the filler neck.
– Raise vehicle.
Note
from the figure.

Rep. Gr. 66
S48-0111

aggregate
Edition 11.04
S00.5303.17.20
Vehicles with radiator fan control unit -J293-
– Disconnect plugs -1- and -2- from the radiator fan con-
trol unit -J293- -4-.
3
– Unscrew nuts -3-.
– Remove radiator fan control unit -4-.
2
1
S48-0140

pansion hose) -3-, return line -2- and the line of the
power-steering sensor -G250-.
– Position the oil catch pan under the engine pump ag-
gregate. 2 3
S48-0141
– Disconnect plugs -1-, -2- and -3- from the engine

pump aggregate.
1 - Data BUS plug and terminal 15
2 - Earth plug and terminal 30
3 - Power-steering sensor -G250- plug
Note 3
♦ Residual hydraulic oil remains in the engine pump ag-
gregate. When removing the pressure line some of
this residual amount will flow out.
2
♦ When tying up the hydraulic line make sure the bend- 1
ing radius of 100 mm is reached.
S48-0271
– Unscrew the pressure line (expansion hose) -3- at the

engine pump aggregate -4- and tie up.
– Shut off the pressure line with a plastic bag and adhe-
sive tape to protect it against dirt. 1 2
– Open the spring strap clamp -1- on the return line (re-
turn hose) -2-.
– Carefully pull off the return line -2- from the reservoir
support of the engine pump aggregate -4- and shut off
with a plastic bag and adhesive tape to protect it
against dirt.
3
4
S48-0272
– Unscrew hexagon screw -arrow-.

1 - Front bracket
S48-0273

1
– Remove engine pump aggregate -2- with the brackets
-1- and -3- downwards.
2
S48-0274

aggregate
Edition 11.04
S00.5303.17.20
Remove bracket
– Unscrew fillister head screws -5-. 1 2 3

– Remove bracket -1- and -3- from the engine pump ag-
gregate -2-.
The bearings -4- and -6- are not used as replacement 4
part. In case of bearing damage the corresponding brack-
et must be replaced.
6
Caution! 5
The power steering control unit -J500- (-A-) and the
electric motor -B- must not be separated.
A
5
5 B S48-0275
Installing engine pump aggregate
Note
♦ Only use original spring band clamps.
♦ Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
♦ After installing the engine pump aggregate fill with hy-
draulic oil ⇒ 48-23.
♦ When installing the pressure line on the engine pump
aggregate use new O-ring.
Caution!
– If necessary connect removed battery to jumper ca-

ble.
– If necessary install air filter.
– If necessary disconnect the jumper cable.

Tightening torques:
Front bracket on engine pump aggregate 7 Nm

KOYO
Rear bracket on engine pump aggregate 7 Nm
KOYO
Holder with engine pump aggregate 20 Nm +
KOYO to body 90°
♦ Use new screws!
KOYO
Radiator fan control unit -J293- to body 6 Nm
Wheel bolts 120 Nm
Disposing of the engine pump aggregate

♦ Catch pan for hydraulic oil (commercially available)
Note
♦ The oils used in the engine pump aggregate do not
contain any harmful substances. These oils can be
disposed of together with drained engine and gearbox
oil.
♦ Dispose of used oils in compliance with the applicable
environmental regulations.
♦ Used oils (this concept refers to used engine and gear
oils including ATF as well as mineral hydraulic oils),
suitable for preparation must never be mixed with
brake fluid, antifreeze agent, artificial resin or thinners,
chemicals etc.
♦ After »draining« the used parts must be allowed to
drip.
♦ When disposing of used parts comply with the appli-
cable regulations as there are minor residual amounts
of hydraulic oil in the engine pump aggregate.
♦ To drain the engine pump aggregate the ambient tem-
perature must be of at least 20 °C.
– Removing the engine pump aggregate ⇒ Chap. 48-

20.
– Removing the holder, encapsulation and rubber bear- C
ing.
Do not shut off the line connections -arrows A and B- or
the filling opening of the reservoir -arrow C-.
– Unscrew the screwed lid of the engine pump aggre-

gate reservoir.
– Hold the engine pump aggregate over a catch pan A
and fully drain the hydraulic oil by turning it repeatedly.
– Dispose of the engine pump aggregate in compliance
with the applicable regulations.
B
S48-0154

aggregate
Edition 11.04
S00.5303.17.20
48-21 Replace reservoir of en-

gine pump aggregate
Note
♦ Absolute cleanliness is required when replacing the
reservoir.
♦ Clean thoroughly the area between the connection fit-
ting for return flow at the reservoir and connection for
pressure line at the engine pump aggregate before
separating via the entire circumference, but do not
use any aggressive cleaning agents, such as brake
cleaner, petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover opened components if the repair is not
completed immediately.
before fitting.
♦ Use only genuine wrapped parts.
♦ The contact surface of the reservoir/engine pump ag-
gregate must not come in contact with sealants.
♦ Noise insulation not fitted on all vehicles, assignment
⇒ Spare part catalogue.
Replace reservoir of engine pump aggre-

gate (TRW)
♦ Hot-air blower e.g. -V.A.G 1416-
♦ Protective gloves (commercially available)
♦ Rubber hammer (commercially available)
Note
♦ When replacing the reservoir make sure that the
housing -1- of the engine pump aggregate is not ex-
posed to traction, pressure or knock.
♦ A damage of the housing can lead to damage at the
pump or at the seal power-assisted steering control
unit -J500-/housing.
Disassemble reservoir
20.
After extraction of the hydraulic oil there will be residues 1
in the engine pump aggregate.
S48-0290
– Close screw connection for the pressure line at the
engine pump aggregate.
Edition 11.04 Replace reservoir of engine pump aggregate 48-21 page 1

S00.5303.17.20
– Remove holder -1- from the engine pump aggregate

-3-.
– If fitted, remove encapsulation -2- from engine pump 2
aggregate. 1
S48-0276
– Clamp the engine pump aggregate in a vice with pro-

tective jaws.
Note
♦ The engine pump aggregate must only be clamped at
the power steering control unit -J500- (-1-), on no ac-
count at the housing -2-.
♦ The housing -2- must not rest against the vice or
against the work bench. 1
♦ A non-observance of the mentioned safety measures
leads to a non-repairable damage at the engine pump 2
aggregate.
S48-0289
– Open clamp -1- and remove upwards.
WARNING!
Wear gloves when heating and pulling off the res-
2
ervoir.
1
– Heat the reservoir -2- in the lower area evenly all
around with a hot-air blower e.g. -V.A.G 1416-
Caution!
The reservoir must be heated up to maximum 80 °C. 3
– Detach reservoir -2- from engine pump aggregate -3-. S48-0277
48-21 page 2 Replace reservoir of engine pump aggregate Edition 11.04

S00.5303.17.20
Assembling reservoir
Note
♦ Ensure a clean, grease- and oil-free contact surface
for gasket ring and reservoir at the engine pump ag-
gregate.
♦ No lubricant must be used for assembling the reser-
voir on the engine pump aggregate.
♦ The contact surface of the reservoir/engine pump ag-
gregate must not come in contact with sealants.
– Clamp the engine pump aggregate in a vice with pro-

tective jaws.
Note
♦ The engine pump aggregate must only be clamped at
the power steering control unit -J500- (-1-), on no ac-
count at the housing -2-.
♦ The housing -2- must not rest against the vice or 1
against the work bench.
♦ A non-observance of the mentioned safety measures 2
leads to a non-repairable damage at the engine pump
aggregate.
– Insert a new gasket ring ⇒ Spare part catalogue in S48-0289

the sealing surface of the engine pump aggregate.
– Ensure that the gasket ring is sitting correctly.
WARNING!
Wear gloves when heating and positioning the res-
ervoir.
– Heat the new reservoir in the lower area evenly all

around with a hot-air blower e.g. -V.A.G 1416-
Caution!
The reservoir must be heated up to maximum 80 °C.
– Position the reservoir -1- on the engine pump aggre- 1

gate -2-. A
– Position the reservoir in such a way that the connec-
tion fitting for the return-flow line -arrow A- is located
vertically above the screw connection for the pressure
line -arrow B-.
– Pull the reservoir -1- up to the stop onto the engine
pump aggregate -2-.
– For this step knock with a rubber hammer evenly all
around on the reservoir -1-, but on no account on the
filler tube.
2 B
– Make sure that the reservoir does not tilt.
– Attach reservoir with new clamp at engine pump ag- S48-0278
gregate.
– Tighten the screw of the clamp to the specified tight-
ening torque.

S00.5303.17.20
– Close connection fitting for the return-flow line at res-

ervoir.
– Fill reservoir up to approx. 1/4 with hydraulic oil and 1 2
check for tightness at joint of reservoir/engine pump
aggregate.
– In case of leakage eliminate the fault.
3
– Empty the reservoir.
For reasons of guarantee, mark the replacement of
the reservoir.
– Make an approx. 15x30 mm large permanent colour

marking -2- e.g with seal paint on the location marked
in the figure. 4
S48-0279
The marking must cover the reservoir -1-, the clamp -3-
and the engine pump aggregate -4-.
– If fitted, mount encapsulation -2- at engine pump ag-

gregate -3-, assignment of encapsulation ⇒ Spare 2
part catalogue.
1
– Install holder -1- at the engine pump aggregate -3-.
– Open connection fitting for the return-flow line at the 3
reservoir and screw connection for the pressure line at
the engine pump aggregate.
– Installing the engine pump aggregate ⇒ Chap. 48-20.
Tightening torque:
Clamp at reservoir of engine pump ag- 3 Nm

gregate
S48-0276
♦ Use new clamp!
Replace reservoir of engine pump aggre-

gate (KOYO)
There are two versions for attaching the reservoir -1- at

the engine pump aggregate -6-: 1 2 3 4
♦ Attachment with fillister head screws -2-, as well as
with cap nuts -3- and threaded bores -5- 3
♦ Attachment with fillister head screws -2- and -4- 4
Disassemble reservoir
5
20. 2
5
After extraction of the hydraulic oil there will be residues
in the engine pump aggregate. 6
S48-0284
– Close screw connection for the pressure line at the
engine pump aggregate.

S00.5303.17.20
– If fitted, remove encapsulation from engine pump ag-
gregate.
Reservoir attached with cap nuts and fillister head
screws
A B
– Unscrew cap nuts -arrows A-.
– Unscrew fillister head screws -arrows B-.
When detaching the reservoir, the engine pump aggre-
gate must not be counterheld. B A
– Detach reservoir from the engine pump aggregate.
S48-0280
Reservoir attached with fillister head screws
– Unscrew fillister head screws -arrows A-.

– Unscrew fillister head screws -arrows B-.
A B
B A
S48-0280
Note
When detaching the reservoir -1-, one must absolutely
counterhold at pump aggregate -2-
Caution!
The pump aggregate -2- must on no account be 1
pulled out from the housing with power-assisted
steering control unit -J500- -3-. A separation leads to
damage at the engine pump aggregate, which can- 2
not be eliminated with workshop possibilities.
– Carefully detach reservoir -1- from pump aggregate 3

-2-.
S48-0281

S00.5303.17.20
Assembling reservoir
Note
♦ Ensure a clean, grease- and oil-free contact surface
for gasket ring and reservoir at the engine pump ag-
gregate.
♦ Do not use any sealant for sealing the contact surfac-
es of the reservoir/engine pump aggregate.
♦ When inserting a new gasket ring -1- and when as-
sembling the reservoir, one must absolutely counter-
hold at the pump aggregate -2-.
Caution! 1
The pump aggregate -2- must on no account be
pulled out from the housing with power-assisted 2
steering control unit -J500- -3-. A separation leads to
damage at the engine pump aggregate, which can-
not be eliminated with workshop possibilities. 3
– Insert a new gasket ring -1- ⇒ Spare part catalogue in
the sealing surface of the pump aggregate -2-. At the
same time absolutely counterhold at pump aggregate. S48-0282
– Ensure that the gasket ring is sitting correctly.
– Position new reservoir on the engine pump aggregate.
– Screw in new fillister head screws -arrows B- and
pretighten hand-tight.
– Screw on or in cap nuts or fillister head screws -arrows
A- and pretighten hand-tight. A B
Note
Begin with the tightening of the screws with fillister head
screws -arrows B-. B A
– Tighten up fillister head screws -arrows B- and cap
nuts or fillister head screws -arrows A- crosswise to
the specified tightening torque.
– Close connection fitting for the return-flow line at res- S48-0280
ervoir.
– Fill reservoir up to approx. 1/4 with hydraulic oil and
check for tightness at joint of reservoir/engine pump
aggregate.
– In case of leakage eliminate the fault. 3
– Empty the reservoir. 1
For reasons of guarantee, mark the replacement of
the reservoir. 2
– Make a large permanent colour marking -2- e.g with
seal paint on the location marked in the figure.
The marking must cover the reservoir -3- and the fillister
head screw -1-.
– If fitted, mount encapsulation at engine pump aggre-

gate, assignment of encapsulation ⇒ Spare part cat-
alogue. S48-0283

S00.5303.17.20
– Open connection fitting for the return-flow line and
screw connection for the pressure line.
– Installing the engine pump aggregate ⇒ Chap. 48-20.
Tightening torques:
Reservoir to engine pump aggregate - fil- 7 Nm

lister head screws -arrows B- A B
♦ Use new fillister head screws!
Reservoir to engine pump aggregate - 7 Nm
cap nuts -arrows A-
Reservoir to engine pump aggregate - fil- 7 Nm B A
lister head screws -arrows A-
S48-0280

S00.5303.17.20

S00.5303.17.20
48-22 Checking hydraulic oil

level
Inspecting hydraulic oil level, if neces-

sary topping up
-VAS 5051-
♦ Diagnostic cable -V.A.G 1551/3A-, -V.A.G 1551/3B-
or -VAS 5051/6A -
Note
♦ Preferably check the hydraulic oil level in cold condi-
tion.
♦ Hydraulic oil amount in the system: approx. 0.80 ltr.
♦ The screwed lid -1- for the reservoir -2- is located in an
opening on the frame side rail in the front left section
2
of the engine compartment.
1
♦ On certain models the screwed lid -1- of the reservoir
is covered by the battery tray because of the different
battery dimensions. If this is the case remove the bat-
♦ Check the hydraulic oil level with the dipstick of the
screwed lid -1-.
♦ Do not refer to the „MAX“ and „MIN“ markings on the
reservoir to check the hydraulic oil level.
of radio sets fitted with anti-theft coding. S48-0147

– Unscrew the screwed lid from the engine pump aggre-
gate reservoir.
– Wipe the oil dipstick with a clean non-fluffing cloth.
– Screw the lid by hand onto the engine pump aggre-
gate reservoir and unscrew again.
Note
The correct oil level can only be determined for a fully
screwed in screwed lid.
– Checking the oil level.
Edition 11.04 Checking hydraulic oil level 48-22 page 1

S00.5303.17.20
Hydraulic oil in a cold condition (for an engine

temperature up to approx. 50 °C)
The oil level must be located:
between the bottom marking -arrow A- and the top mark-
ing -arrow B- of the oil dipstick TRW.
In the area between the markings „Min“ and „Max“ on the
oil dipstick KOYO.
♦ If the oil level is above the upper marking -arrow B- or
„Max“, drain off some oil.
♦ If the oil level is below the lower marking -arrow A- or
„Min“, first check the hydraulic system for leaks (In-
specting power-assisted steering system for tightness
⇒ Chapter 48-23), and then one can begin to top up
the system with hydraulic oil. It is not enough to simply
top up the oil.

gate reservoir.
Hydraulic oil at a normal operating temperature

(for an engine temperature above 50 °C)
The oil level must be located:
between the bottom marking -arrow A- and the top mark-
ing -arrow B- of the oil dipstick TRW.
In the area between the markings „Min“ and „Max“ on the
oil dipstick KOYO.
♦ An oil level above the upper marking -arrow B- or
„Max“ is permissible in warm condition, no oil is
drained off.
♦ If the oil level is above the upper marking -arrow B- or
„Max“, no oil is drained off.
♦ If the oil level is below the lower marking -arrow A- or
„Min“, first check the hydraulic system for leaks (In-
specting power-assisted steering system for tightness
⇒ Chapter 48-23), and then one can begin to top up
the system with hydraulic oil. It is not enough to simply
top up the oil.

gate reservoir.
If the battery was removed:


48-22 page 2 Checking hydraulic oil level Edition 11.04

S00.5303.17.20
48-23 Filling and bleeding the

power steering system,
and checking tightness
Filling and bleeding the power steering

system
-VAS 5051-
or -VAS 5051/6A-
Note
♦ The screwed lid for filling the power steering system
with hydraulic oil is located in a recess on the frame
side rail in the front left section of the engine compart-
ment.
tain models the screwed lid covered by the battery
tray and battery. If this is the case remove the air filter,
the battery tray and battery.
♦ Only fill an empty hydraulic system when the engine is
cold.
♦ Use new hydraulic oil only.
♦ Topping up hydraulic oil ⇒ Chap. 48-22
♦ Check the hydraulic oil level with the dipstick of the
screwed lid of the engine pump aggregate reservoir.
♦ Do not refer to the „MAX“ and „MIN“ markings on the 2
reservoir to check the hydraulic oil level.

– Fill the engine pump aggregate reservoir -2- with hy-
draulic oil and check the hydraulic oil level with the
screwed lid dipstick -1-.
S48-0147
Edition 11.04 Filling and bleeding the power steering system, and checking 48-23 page 1
S00.5303.17.20 tightness
For checking the hydraulic oil level, screw the screwed lid
hand-tight to the reservoir.
Note
♦ Only the oil level of the fully screwed in lid applies.
♦ Pay attention to the different appearances of „Min“
and „Max“ markings at oil dipstick of the screwed lid
for the reservoir of TRW or KOYO.
– For an empty power steering system fill with enough

hydraulic oil to reach the top marking -arrow B- or
„Max“ on the oil dipstick.
Arrow A - bottom marking on screwed lid of TRW
„MIN“ - bottom marking on screwed lid of KOYO
Caution!
– If necessary connect the battery with jumper cable.

– Raise the vehicle until the front wheels are fully off the
ground.
– Put the front wheels in straight ahead position.
– Open the screwed lid of the hydraulic oil reservoir.
– With the engine off turn the steering wheel 10 x from
stop to stop.
– Inspecting the hydraulic oil level and if necessary top
up ⇒ Chap. 48-22.
– Loosely screw on the screwed lid of the hydraulic oil
reservoir, do not tighten.
– Start engine and run for approx. 10 seconds.
– Switch off engine.
up ⇒ Chap. 48-22.
– Loosely screw on the screwed lid of the hydraulic oil
reservoir, do not tighten.
– Repeat the following steps until the hydraulic oil level
no longer drops. The hydraulic oil level must reach the
top marking.
♦ Start the engine.
♦ Turn steering wheel 10 x from stop to stop.
♦ Switch off engine.
♦ Inspecting the hydraulic oil level and if necessary top
up ⇒ Chap. 48-22.

gate reservoir.
48-23 page 2 Filling and bleeding the power steering system, and checking
tightness
Edition 11.04
S00.5303.17.20
Note
Possible residual air in the steering system will automati-
cally escape during driving after approx. 10…20 km.
– Disconnect the jumper cable.

Only run through the following steps if the battery has
been disconnected and the battery, battery tray and air fil-
ter have been removed.
– Install the battery and battery tray ⇒ Electrical Sys-

tem; Rep. Gr. 27.

Tightening torques:

TRW
KOYO
Screwed lid on hydraulic oil reservoir tightened
by hand
Wheel bolts 120 Nm
Checking the power steering system for

leaks
Check the power steering system for tightness after
assembly work and in the event of hydraulic oil loss
in the reservoir.

-VAS 5051-
or -VAS 5051/6A-
Note
tain models the screwed lid with oil dipstick for check-
ing and topping up the hydraulic oil is covered by the
battery tray and battery. If this is the case remove the
air filter, the battery tray and battery.

– Raise vehicle.
Note
from the figure.

Rep. Gr. 66.
Caution! S48-0111

– If necessary connect battery to jumper cable.

– Start engine, idling speed.
Note
A 2nd mechanic is required to check the tightness of the
pressure line, return line and the connections.
– Turn the steering wheel in both directions up to the

stop and hold for maximum 5…10 seconds.
This will build up the highest possible pressure.
– Check the pressure line (expansion hose) and return

line (return hose) for tightness.
If there are leaks replace the relevant line or hose.
– Check all line and hose connections for correct posi-

tion and tightness.
In the event of leaks tighten the line or hose connec-
tions to the allowed tightening torques or replace the
seal or line.
– Checking the engine pump aggregate for tightness.

If there are leaks replace the engine pump aggregate.
– Check the hydraulic oil reservoir for tightness.

If there are leaks replace the engine pump aggregate.

up ⇒ Chap. 48-22.
tightness
Edition 11.04
S00.5303.17.20
Note
♦ If there is a repeated loss of hydraulic oil from the en-
gine pump aggregate reservoir, and if the line or hose 2 1
and its connections as well as the engine pump aggre-
gate and its reservoir have been repeatedly thorough-
ly inspected, remove and inspect the power steering
gear.
♦ The checking of the power-steering gear is identical to 2
the steering gears of TRW and KOYO. The figure
shows the power-steering gear of TRW.
– Removing power steering gear ⇒ Chap. 48-12.

3
– Remove gasket -1-.
– Open warm-type clamps -3-. 3 S48-0285
– Push back boots -2-.

– Check the input shaft gasket ring on the valve housing
of the power steering gear -arrow A- for tightness.
A
– Check gear rack gasket rings -arrow B- for leaks. B
If hydraulic oil is visible in the steering gear housing and/
or in the boot, replace the power steering gear.
S48-0152
– If there is no hydraulic oil in the steering gear housing

and/or in the boot, secure the boot -2- with new warm-
type clamp -3- ⇒ Chap. 48-16.
2 1
– Mount gasket -1- on the valve housing of the power
steering gear ⇒ Chapter 48-12.
– Installing power steering gear ⇒ Chap. 48-12.
Note 2
If there is no more hydraulic oil in the engine pump aggre-
gate reservoir the engine pump aggregate may have »run
dry« and may have been damaged.
3
– Replace engine pump aggregate ⇒ Chap. 48-20.
– If necessary disconnect the jumper cable. 3 S48-0285

Rep. Gr. 66.
– Install noise insulation panel.

If the battery was removed:


tightness
Edition 11.04
S00.5303.17.20
48-24 Power steering noises
Notes for eliminating the noises

A closed hydraulic system will always produce running
noise.
Noise is always produced when the steering is turned up
to the end stops (this must only occur briefly).
The increased pumping noise in the steering end stops
(during parking manoeuvers) is system related and tech-
nically unavoidable.
For noises that differ from the usual technically unavoid-
able operating noises take the following measures:
– Checking the hydraulic oil level in the reservoir of the

engine pump aggregate ⇒ Chap. 48-22.
– Checking the feed pressure of the engine pump ag-
gregate ⇒ Chap. 48-19.
– Check the connections of the pressure line (expan-
sion hose) and return line (return hose) on the power
steering gear as well as the engine pump aggregate
(air in steering system).
– Check routing of the pressure line (expansion hose)
and return line (return hose) (lines pinched or in con-
tact with other vehicle parts)
– Check attachment of the power steering gear to the
assembly carrier -arrows-.
– If necessary tighten hexagon screws.
S48-0153
Check attachment of engine pump aggregate
(TRW)
– Check attachment of holder -2- with engine pump ag- 2
gregate -1- to body -arrows-.
– If necessary tighten hexagon screws.
For reasons of clarity the surrounding components are
1
S48-0205
Edition 11.04 Power steering noises 48-24 page 1

S00.5303.17.20
– Check attachment of holder -2- to engine pump aggre-

gate -1- -arrows-.
3 - Encapsulation
3
2
– If necessary tighten hexagon nuts to the specified
tightening torques, while doing so counterhold rubber
bearings.
1
Note
To test the rubber bearing for damage remove the engine
pump aggregate with encapsulation and disassemble the
holder.
– Removing the engine pump aggregate ⇒ Chap. 48- S48-0145

20.
– Check rubber bearing (3) -arrow- for damage (e.g.
tears, separation of the metal plates with threaded
bores from the rubber bearing).
– In case of damage replace rubber bearing ⇒ Chap.
48-20.
Check attachment of engine pump aggregate

(KOYO)
For reasons of clarity the surrounding components are
S48-0146
– Check attachment of front holder -1- with engine

pump aggregate to body.
– If necessary tighten the hexagon screw -arrow- to the
specified tightening torque. 1
S48-0273
48-24 page 2 Power steering noises Edition 11.04

S00.5303.17.20
– Check attachment of rear holder -1- with engine pump
aggregate -2- to body. 1
– If necessary tighten the hexagon screws -arrows- to
the specified tightening torque.
3 - Front bracket
2
S48-0274
– Check attachment of bracket -1- and -3- at the engine

pump aggregate -2-. 1 2 3
– If necessary tighten the fillister head screws -4- and
-5- to the specified tightening torque.
5 S48-0286
Note
To test the rubber bearing for damage remove the engine
pump aggregate -2- and disassemble the holder -1-. 1 2 3
20.
– Remove holder -1- from the engine pump aggregate
-2-.
4
The rubber bearing -3- can be checked on an installed
holder -4-.
6
– Check rubber bearing -3- and -6- for damage (e.g.
tears).
– In case of rubber bearing, replace holder -1- or holder
-4- ⇒ Chapter 48-20.
5 S48-0287
5 - Fillister head screws
Edition 11.04 Power steering noises 48-24 page 3

S00.5303.17.20
Tightening torques:
Pipe screw for return-flow line to power- 30 Nm

steering gear (TRW/KOYO)
steering gear (TRW)
steering gear (KOYO)
pump aggregate (TRW)
pump aggregate (KOYO)
Holder with engine pump aggregate to 20 Nm + 90°
body (TRW/KOYO)
♦ Use new screws!
Holder to engine pump aggregate 7 Nm
(TRW/KOYO)
Rubber bearing to engine pump aggre- 7 Nm
gate (TRW)
Power-steering gear to assembly carrier 50 Nm + 90°
(TRW/KOYO)
♦ Use new screws!
48-24 page 4 Power steering noises Edition 11.04

S00.5303.17.20
48-25 Self-diagnosis on the

power-assisted steering
system
The power steering of TRW or KOYO can be checked
with the self-diagnosis. Performing the self-diagnosis is
identical on both steering systems.
The self-diagnosis can be carried out:
♦ using the vehicle system tester -V.A.G 1552-, or the
fault read-out scan tool -V.A.G 1551- ⇒ 48-25
page 1
♦ or the vehicle diagnosis, measurement and informa-
tion system -VAS 5051- ⇒ 48-25 page 11.
The control unit and the hydraulic unit (eletric motor and
gear pump) as well as the hydraulic oil reservoir form a
single unit, the so-called engine pump aggregate, which
cannot be disassembled. Only the reservoir for hydraulic
oil is replaceable.
The engine pump aggregate is located in the front left of
the engine compartment between the bumper and the
wheelhouse.
Self-diagnosis is related to the electrical and electronic
parts of the power-assisted steering. The control unit de-
tects faults during the operation of the vehicle and stores
them in a permanent memory, whose information is re-
tained even if the battery voltage is disconnected.
After the ignition is switched on servotronic warning light
-K92- lights up. As soon as this starts an internal check
cycle is completed ⇒ 48-25 page 1.
Before starting fault finding, always initiate self-diagnosis.
If faults are stored, these can be displayed or be printed
out with vehicle system tester -V.A.G 1552- or fault read-
out scan tool -V.A.G 1551- or the vehicle diagnosis,
measurement and information system -VAS 5051-.
I
Indication of faults by means of warning

light for Servotronic -K92-
If the servotronic warning light -K92- -arrow- does not go
out after the ignition is switched on faults may be stored.
I - Dash panel insert up to model year 2004
II - Dash panel insert as of model year 2005
Connect vehicle system tester II

-V.A.G 1552- or fault read-out scan tool
-V.A.G 1551- and select functions.
♦ vehicle system tester -V.A.G 1552- or fault read-out
scan tool -V.A.G 1551-
♦ Diagnostic cable -V.A.G 1551/3A, 3B oder 3C-
0
S48-0288
Edition 11.04 Self-diagnosis on the power-assisted steering system 48-25 page 1

S00.5303.17.20
Note
♦ The description of the self-diagnosis only relates to
vehicle system tester -V.A.G 1552- using the current
program card.
♦ The use of fault reader -V.A.G 1551- with integrated
printer is similar. A minor deviation on the display
read-out is possible.
Test conditions
• Fuses must be OK in compliance with the current flow

diagram.
• Battery voltage at least 11.5 volts
• All electrical components must be switched off
The diagnostic connection is located on the left next to V.A.G 1552
the storage compartment on the driver's side.
– Unclip cover and remove downward. V.A.G 1551/3

– Connect vehicle system tester -V.A.G 1552- or fault
read-out scan tool -V.A.G 1551- with appropriate ca-
S01-0087
ble.
Note
If there is no readout on the display: ⇒ Operating instruc-
tions of the vehicle system tester
– Enter address word 4 4 for „power-assisted steer-

ing“ and confirm the entry with Q .
6Q0423156 Power steering 0001 ->
Readout on display: Coding 00110 WSC XXXXX
♦ 6Q0423156 : Version number of the control unit
♦ Power-assisted steering: System denomination
♦ 0001: Software version number
♦ Coding 00110: Coding of the control unit
♦ WSC XXXXX : Workshop code
– Press →.
If one of the following messages appears in the display, The control unit does not respond
carry out fault finding as stated in the fault finding pro-
gramme in the diagnostic cable ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations. Vehicle system test HELP
Fault in communication build-up
or
or Vehicle system test HELP
K cable does not connect to earth
or Vehicle system test HELP

K cable does not connect to pos. term.
Overview of the selectable functions on
the Vehicle system tester -V.A.G 1552-
01 - Interrogating control unit version ⇒ 48-25 page 1
48-25 page 2 Self-diagnosis on the power-assisted steering system Edition 11.04

S00.5303.17.20
02 - Interrogating fault memory ⇒ 48-25 page 3
05 - Erasing fault memory ⇒ 48-25 page 3
06 - Ending output
07 - Coding control unit ⇒ 48-25 page 8
08 - Reading measured value block ⇒ 48-25 page 9
Interrogating and erasing fault memory
Interrogating fault memory

– Enter function 0 2 „Interrogate fault memory“ and
confirm entry with Q .
X faults detected!
The number of faults stored appears on the display.
The stored faults are displayed in sequence.
– Find the fault displayed in the fault table ⇒ 48-25

page 5 and rectify fault.
No fault detected ->
If „No fault detected“ is shown in the display and if the key
→ is pressed, the programme returns to the initial posi-
tion.
Erasing fault memory
Note
The contents of the fault memory are output automatically
after the fault memory is erased. If it is not possible to
erase the fault memory, interrogate the fault memory
once again and rectify any faults.
Requirements
• Fault memory was interrogated ⇒ 48-25 page 3.

• All faults were rectified.
– Select function 0 5 „Erase fault memory“ and con-
firm with Q .
Readout on display: Fault memory erased!
The fault memory is now erased.
– Press →.
Readout on display:
Select function XX
– Select function 0 6 „End output“ and confirm with
Q.
Automatic test sequence

During testing and installation other control units may
also detect faults, e.g. pulled-out connectors or CAN da-
tabus faults. This is why, when the work is concluded,

S00.5303.17.20
that it is necessary to interrogate and erase the fault

memory on all control units.
– Select function 0 0 „Automatic test sequence“ and

confirm with Q . The vehicle system tester
-V.A.G 1552- sends all known address words in se-
quence.
When a control unit answers with its identification, the
fault memory of the relevant system is also read out.
Any faults stored for one of the systems are displayed in
sequence. The -V.A.G 1552- then transmits the next ad-
dress word.
The automatic test sequence has ended when the follow- Enter address word XX
ing read-out appears on the display:
– Erase the fault memory and then carry out a test drive.
– Once again interrogate the fault memory of all the
control units using the „automatic test sequence“.
If no fault is stored:
– Press →.
Readout on display:
Select function XX
Q.

S00.5303.17.20
Fault table
Note
♦ All the possible faults which can be detected by the dash panel insert and can be displayed by -V.A.G 1552- are
listed below according to the 5-digit fault code.
♦ Do not take any notice of the SAE code to the right of the fault code or the fault index (e.g. 136).
♦ Before replacing components found to be defective first check the wiring and plug connections to these compo-
nents as well as the earth cables according to the current flow diagram.
♦ After repair always interrogate the fault memory using vehicle system tester -V.A.G 1552- and erase the memory.
♦ All static and sporadic faults are stored in the fault memory. A fault is detected as static if it exists for at least 2
seconds. If the fault is then no longer present, it is stored as a sporadic (temporary) fault. „/SP“ appears on the right
of the display.
♦ After switching on the ignition, all the faults which exist are set to sporadic and are not stored as static faults unless
they continue to exist after completing the check.
♦ If a sporadic fault no longer occurs during 50 driving cycles (ignition on for at least 5 minutes, road speed > 30 km/
h), it is erased.
Readout on -V.A.G 1552- Possible cause of Possible effects Rectifying fault

fault
00566 ♦ The motor pump ♦ Power steering discon- – Analyse measured
Power steering Implausible sig- assembly is defect nects value block 001 dis-
operation nal ♦ Fault terminal 30 play field 1 ⇒ 48-25
page 9
– Replace the motor
pump assembly
– Electrical test
⇒ Chapter 48-26.
00816 ♦ Short circuit to ♦ The power-assisted – Analysing measured
Power steering Short circuit to earth in the line steering is operating in value block 002
sensor -G250 earth connection from emergency mode ⇒ 48-25 page 9
the power steer- ♦ Steering requires
ing sensor to the – Test wiring ⇒ Current
greater effort Flow Diagrams, Elec-
control unit
♦ The control lamp on trical Fault Finding
♦ Sensor for power the servotronic -K92- is and Fitting Locations
steering defective lit up
– Replace sensor
Power steering Open circuit/ pos. in the line steering is operating in value block 002
sensor -G250 Short circuit to connection from emergency mode ⇒ 48-25 page 9
positive
control unit
♦ The control lamp on trical Fault Finding
♦ Line interruption the servotronic -K92- is and Fitting Locations
♦ Sensor for power lit up
– Replace sensor
steering defective
00816 ♦ Sensor for power ♦ The power-assisted – Analysing measured
Power steering defective steering defective steering is operating in value block 002
sensor -G250 emergency mode ⇒ 48-25 page 9
♦ Steering requires – Replace sensor
greater effort
♦ The control lamp on
the servotronic -K92- is
lit up

S00.5303.17.20

fault
00817 ♦ Temperature in hy- ♦ Steering requires – Allow temperature to
Power steering draulic system too greater effort drop
temperature high ♦ Power steering discon- – Analysing measured
protection nects value block 001
⇒ 48-25 page 9
01288 ♦ Alternator not reg- ♦ Steering requires – Analysing measured
Terminal 30 Signal too high ulating voltage greater effort value block 001
power steering ♦ Battery dis- ♦ Power steering discon- ⇒ 48-25 page 9
Signal too low
charged/exces- nects – Check battery
sively charged ♦ The control lamp on ⇒ Electrical System;
the servotronic -K92- is Rep. Gr. 27.
lit up
– Test alternator
⇒ Electrical System;
Rep. Gr. 27.
– Check wiring and plug
connections accord-
ing to the current flow
diagram ⇒ Current
Flow Diagrams, Elec-
trical Fault Finding
and Fitting Locations
01289 ♦ Loose contact ♦ Steering requires – Analysing measured
Terminal 15 Signal too low greater effort value block 004
power steering ♦ Power steering discon- ⇒ 48-25 page 9
nects – Test wiring ⇒ Current
Flow Diagrams, Elec-
and Fitting Locations
Power steering Short circuit to pos. in the line steering is operating in value block 004
reference volt- positive connection from emergency mode ⇒ 48-25 page 9
age
control unit
♦ Sensor defective and Fitting Locations
– Replace sensor
Power steering Short circuit to earth in the line steering is operating in value block 004
reference volt- earth connection from emergency mode ⇒ 48-25 page 9
age
control unit
♦ Sensor defective and Fitting Locations
– Replace sensor
01309 ♦ Power steering ♦ Steering requires – Replace the motor
Power steering defective control unit defec- greater effort pump assembly
control unit - tive ♦ Power steering discon-
J500 nects

S00.5303.17.20

fault
01312 ♦ Data bus cables ♦ Power steering discon- – Check data bus
Data bus drive defective defect nects ⇒ Chapter 48-27
♦ a connected con- ♦ Steering requires
trol unit is faulty greater effort
01314 ♦ Data bus cables ♦ The power-assisted – Check data bus
Engine control No communica- defect steering is operating in ⇒ Chapter 48-27
unit tion ♦ Engine control unit emergency mode or
does not operate at all – Interrogate fault mem-
defective ory of engine control
♦ Steering requires unit ⇒ Engine, Fuel
greater effort Injection; Rep. Gr. 01.
Engine control please read out defect steering is operating in ⇒ Chapter 48-27
unit fault memory ♦ Engine control unit emergency mode or
does not operate at all – Interrogate fault mem-
defective ory of engine control
♦ Steering requires unit ⇒ Engine, Fuel
greater effort Injection; Rep. Gr. 01.
Control unit with No communica- defect steering is operating in ⇒ Chapter 48-27
display in dash tion ♦ Dash panel insert emergency mode
– Interrogate fault mem-
panel insert - defective ♦ Steering requires ory of dash panel in-
J285 greater effort sert ⇒ Electrical
♦ The control lamp on System; Rep. Gr. 90
the servotronic -K92- is
lit up
Control unit with please read out defect steering is operating in ⇒ Chapter 48-27
display in dash fault memory ♦ Dash panel insert emergency mode
– Interrogate fault mem-
panel insert - defective ♦ Steering requires ory of dash panel in-
J285 greater effort sert ⇒ Electrical
System; Rep. Gr. 90
01321 ♦ Data bus cables – Check data bus
Airbag control No communica- defect ⇒ Chapter 48-27
unit -J234 tion ♦ Airbag control unit – Interrogate the fault
defective memory of the airbag
control unit ⇒ Body
Work; Rep. Gr. 01
01321 ♦ Data bus cables – Check data bus
Airbag control please read out defect ⇒ Chapter 48-27
unit -J234 fault memory ♦ Airbag control unit – Interrogate the fault
defective memory of the airbag
control unit ⇒ Body
Work; Rep. Gr. 01
01656 ♦ Airbag control unit ♦ Power steering discon- – Erasing fault memory
Crash signal -J234- has trig- nects ⇒ 48-25 page 3
gered airbags
♦ Final control diag-
nosis Airbag con-
trol unit -J234-
completed

S00.5303.17.20

fault
01656 ♦ Crash signal of ♦ Power steering discon- – Erasing fault memory
Crash signal Implausible sig- airbag control unit nects ⇒ 48-25 page 3
nal -J234- N.O.K.
– Check data bus
♦ Data bus cables ⇒ Chapter 48-27
defect
– Test crash signal
♦ Control units on
⇒ Body Work;
the data bus are
Rep. Gr. 01; Self-di-
incorrectly coded
agnosis airbag sys-
tem
Coding control unit

– Connect up the vehicle system tester -V.A.G 1552-
and select „power-assisted steering“ (address word
44) ⇒ 48-25 page 1.
– Enter function 0 7 „code the control unit“ and con-
firm with Q .
Code control unit HELP
Readout on display:
Enter code number XXXXX (0-32000)
confirm with Q.
Table of codes Power steering control unit

-J500-
Caution!
Recoding of the control unit for the power-assisted
steering at the customer's request can only be un-
dertaken in compliance with the table of codes. Oth-
er assignments are not allowed.
Note
The weight PR numbers for the front axle/engine can be
found on the vehicle data sticker. The vehicle data sticker
is located on the luggage compartment floor and in the
Service Schedule.
Table of codes (up to 04/2001)
Shock absorber PR number Selectable cod-

ing1)
J06, J07, J08, J13, J14, J15, J20, J21, J22 00110
00130
00160
J01, J02, J03, J04, J05, J09, J10, J11, J12, J16, J17, J18, J19, J23, J24, J25, J26 00140
00150
00160
1) Coding at customer's request

S00.5303.17.20
Table of codes (up to 05/2001)
Shock absorber + power steering + airbags PR. number Selectable coding

without airbag with airbag
L05 (L06, L07, L08, L19, L20, L21, L32, L33) + 1N2 + 4UC (4UE, 4UF) 10110
L09 (L11, L12, L13, L14, L26, L35) + 1N2 + 4UC (4UE, 4UF) 10120
L01 (L02, L03, L04, L15, L16, L17, L18) + 1N2 + 4UC (4UE, 4UF) 10140
1N5 + 4UC (4UE, 4UF) 10160
L05 (L06, L07, L08, L19, L20, L21, L32, L33) + 1N2 + 4UA 00110
L09 (L11, L12, L13, L14, L26, L35) + 1N2 + 4UA 00120
L01 (L02, L03, L04, L15, L16, L17, L18) + 1N2 + 4UA 00140
1N5 + 4UA 00160
The meaning of the code numbers
Code Meaning
number:
00110 Normal power steering for »heavy vehicles«
101101) Normal power steering for »heavy vehicles«
00120 Sport steering RS
101201) Sport steering RS
00130 Convenience - greater power steering at low driving speeds (e.g. when parking) for »heavy vehicles«
(has not been used before)
101301) Convenience - greater power steering at low driving speeds (e.g. when parking) for »heavy vehicles«
00140 Normal power steering for »light vehicles«
101401) Normal power steering for »light vehicles«
00150 Convenience - greater power steering at low driving speeds (e.g. when parking) for »light vehicles«
101501) Convenience - greater power steering at low driving speeds (e.g. when parking) for »light vehicles«
00160 Handicap - greater power steering for vehicles for the handicapped
101601) Handicap - greater power steering for vehicles for the handicapped
1) These code numbers cannot be entered in old software versions of the control unit.
The control unit coding appears in the display, (e.g. 6Q0423156 Power steering 0001 ->
00110) Coding 00110 WSC XXXXX
– Press →.
Readout on display:
Select function XX
Q.

– Connect up the vehicle system tester-V.A.G 1552-
and select „power-assisted steering“ (address word
44) ⇒ 48-25 page 1.

S00.5303.17.20
Readout on display:
Select function XX
– Enter function 0 8 „Read measured value block“
and confirm the entry with key Q .
Read measured value block HELP
Readout on display:
– Enter display group ⇒ 48-25 page 10.
List of display groups

Measured value block 001
Reading measured value block 1 → Readout on display:

12.3 V 0.0 A 27 °C off
Pump motor
♦ off
♦ on
Temperature on the control unit for the power-assisted steer-
ing
Pump motor current
Voltage terminal 30

0.0 °/s 0 rpm 0 rpm 0.0 A
Pump motor current
Actual speed pump motor
Nominal speed pump motor
Angular speed on power steering sensor

S00.5303.17.20

0 km/h 0 rpm off yes
Power steering sensor G250
♦ yes
♦ no
Pump motor
♦ off
♦ on
Vehicle engine speed
Vehicle speed

0h 2 correct 12.1 V
Voltage terminal 15
Sensor for power steering reference voltage
♦ too small
♦ correct
♦ too great
Engaging counter of power steering
Engaging duration of the power steering in hours
Connect vehicle diagnosis, measure-

and select functions
♦ Vehicle diagnosis, measurement and information sys-
tem -VAS 5051-
♦ Diagnostic cable -VAS 5051/5A- or Diagnostic cable
-VAS 5051/6A-
WARNING!
♦ For test drives, test and measuring equipment
must always be fastened to the rear seat.
♦ The equipment must be operated by an assist-
ant during test drives.
– Mount the plug of the diagnostic cable - VAS 5051/

5A- or the diagnostic cable -VAS 5051/6A - on the di-

S00.5303.17.20
agnostic connection in the storage compartment on

the driver's side.
– Switch on the vehicle diagnosis, measurement and in-
formation system -VAS 5051-.
The vehicle diagnosis, measurement and information
system -VAS 5051- is operational, if it shows the key-
boards of its operating modes.
– On the screen, select the Geführte Fehlersuche .
– Select the following one after the other:
♦ Brand
♦ Type
♦ Model year
♦ Variant
♦ Engine identification characters
– Confirm the data entered.

Wait until the vehicle diagnosis, measurement and infor-
mation system -VAS 5051- has communicated with all
the control units in the vehicle (vehicle system test).
– Press the Sprung and choose the „Selected Func-

tions/Components“ option.
– Select on the display „chassis“.
– Select on the display „steering“.
– Select on the display the indicated „01-self-diagnosa-
ble system…“.
– Select on the display the indicated „electrical power
steering…“.
Now all possible components and functions of the steer-
ing system in the vehicle are indicated.
– Select on the display the desired component or the

desired function.

S00.5303.17.20
48-26 Electrical Test of Power

Steering
2
1
♦ Hand multimeter, e.g. -V.A.G 1526B-
♦ Measuring tool set, e.g. -V.A.G 1594C-
Test conditions
• Fuses according to current flow diagram O.K.

• Battery voltage at least 11.5 volts
Procedure

Rep. Gr. 66
S48-0291
Engine pump aggregate TRW
– Unplug connectors -1- and -2-.

Engine pump aggregate KOYO
– Unplug connectors -1- and -2-.

3 - Plug of power-assisted steering sensor -G250-, re-
mains in position
2
1
S48-0271
Contact assignment (TRW or KOYO)

Connector -1-:
4 1
1- Data BUS Low 1
2- Data BUS High
3- not yet assigned
4- Terminal 15 1 2
Connector -2-:
1 - Terminal 30
2 - Earth
– Switch on the ignition.

2
– Test with a hand-held multimeter and suitable test S48-0151
prods from the measuring tool set:
Contact assignment (TRW or KOYO)
Connector -1-
between contact: Specified value:
4 and earth approx. battery voltage
Edition 11.04 Electrical Test of Power Steering 48-26 page 1

S00.5303.17.20
Connector -2-
1 and 2 approx. battery voltage
1 and earth approx. battery voltage
– Switch off the ignition.
Resistance measurement (TRW or KOYO)
Connector -1-
4 and earth ∞Ω
Connector -2-
1 and earth ∞Ω
2 and earth approx. 0 Ω
1 and 2 approx. 60 Ω
If the specified values are not reached:
– Test the wiring according to the current flow diagram

48-26 page 2 Electrical Test of Power Steering Edition 11.04

S00.5303.17.20
48-27 Checking the data BUS
Operation
The control units that are compatible with the data bus
are connected via two twisted data BUS cables
(CAN_High and CAN_Low) and exchange information
(messages). Both the power steering control unit -J500-
and the other data bus compatible control units detect
missing information on the data BUS as faults.
Other information: ⇒ Self-study Programme No. 24; The
CAN data bus
Note
The central terminating resistor of the data BUS cables is
located in the engine control unit. The test will thus focus
on the engine control unit.

♦ Hand multimeter, e.g. -V.A.G 1526 A-
♦ Measuring tool set, e.g. -V.A.G 1594 A-
♦ Test box -V.A.G 1598/31-
♦ Current flow diagram
Test condition
• A data BUS fault was detected by the power steering
Test sequence
– Switch off the ignition.
– Unlock the connector from the engine control unit and
unplug.
– Connect the test box -V.A.G 1598/31- to the engine
control unit.The control unit wiring loom is not con-
nected.
– Connect the earth clip of the test box -arrow- to the
negative battery terminal.
– Test the central terminating resistor in the engine con-
trol unit.
– To this end perform a resistance measurement be-
tween the test box bushes ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
V.A.G 1598/31
Nominal value: 60…72 Ω
If the resistance is not within the nominal value
S24-0380
range:
– Replace the engine control unit⇒ Chap. 24-8.

If the resistance is within the nominal value range:
– Unplug the test box -V.A.G 1598/31- from the engine

control unit.
Edition 12.99 Checking the data BUS 48-27 page 1

S00.5303.01.20
– Connect the test box -V.A.G 1598/31- to the wiring

loom control unit.
Connect the earth clip of the test box -arrow- to the
negative battery terminal.
– Test the data BUS cables for short-circuits.

– To this end perform a resistance measurement be-
tween the test box bushes ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
Nominal value: ∞ Ω
If the nominal value is reached (there is no short-circuit V.A.G 1598/31
between the cables):
– Test the data BUS cables for a short-circuit to the pos- S24-0380
itive battery terminal or earth or for interruption
48-27 page 2 Checking the data BUS Edition 12.99

S00.5303.01.20
48-28 Electric/Electronic components and fitting locations

1 - Servotronic warning light
-K92-
T Fitting location: in the dash 3 4
panel insert
T Operation: 1
The servotronic warning light
♦ lights up until the engine
starts
♦ if it does not go out, faults
may have been stored 2
1
T Perform self-diagnosis
⇒ Chap. 48-25
2 - Dash panel insert up to model
0
year 2004
3 - Dash panel insert as of model 12
year 2005
T Fitting location: in the stor-
age area on the driver's side
5 - The power-steering sensor 5
-G250- (KOYO)
T Fitting location: in the valve
dome of the power-steering 11
gear 10
T Operation:
♦ Determining the steering-
wheel angle and calculating
the steering angle speed
6
♦ if the sensor fails the power
7
steering switches to pro- 9
grammed emergency opera- 8
tion, the steering function is S48-0263
guaranteed, but the steering
effort becomes greater
♦ Malfunctions of the sensor are stored in the power steering control unit -J500-
T Perform self-diagnosis ⇒ Chap. 48-25
6 - Inspecting the power-assisted steering sensor -G250- (TRW)
T with fixed connecting line
T Fitting location: in the valve dome of the power-steering gear
T Operation:
♦ Determining the steering-wheel angle and calculating the steering angle speed
♦ if the sensor fails the power steering switches to programmed emergency operation, the steering function is
guaranteed, but the steering effort becomes greater
7 - Inspecting the power-assisted steering sensor -G250- (TRW)
T with adapter cable
T Fitting location: in the valve dome of the power-steering gear
T Operation:
Edition 11.04 Electric/Electronic components and fitting locations 48-28 page 1

S00.5303.17.20
♦ Determining the steering-wheel angle and calculating the steering angle speed
♦ if the sensor fails the power steering switches to programmed emergency operation, the steering function is
guaranteed, but the steering effort becomes greater
8- Adapter cable
T for power-steering sensor -G250- ⇒ item 7
9- Power-assisted steering control unit -J500-
T Fitting location: integrated in the engine pump aggregate ⇒ item 10
T Operation:
♦ To convert the signals for driving the gear pump in function of the steering angle speed and the vehicle speed.
♦ Re-engaging protection after faults
♦ Temperature protection for power steering
♦ detects faults during operation and stores them in a permanent memory
T Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate
⇒ Chap. 48-20
10 - Engine pump aggregate (TRW)
11 - Power-assisted steering control unit -J500-
T Fitting location: integrated in the engine pump aggregate ⇒ item 12
T Operation:
♦ To convert the signals for driving the gear pump in function of the steering angle speed and the vehicle speed.
♦ Re-engaging protection after faults
♦ Temperature protection for power steering
♦ detects faults during operation and stores them in a permanent memory
T Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate
⇒ Chap. 48-20
12 - Engine pump aggregate (KOYO)
48-28 page 2 Electric/Electronic components and fitting locations Edition 11.04

S00.5303.17.20

Mecanica Skoda Fabia

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 04.05 List of Supplements

List of Supplements Edition 04.05

40 – Front wheel suspension

Edition 04.05 Table of Contents I

42 – Rear wheel suspension

44 – Wheels, Tyres, Chassis Alignment

Table of Contents Edition 04.05

45 – Anti-Lock Brake System

Edition 04.05 Table of Contents III

Table of Contents Edition 04.05

46 – Brakes, Brake mechanics

47 – Brake, Brake Hydraulics

Edition 04.05 Table of Contents V

- Summary of Components of Brake-Power Regulator ........................................... 47-3 page 1

Table of Contents Edition 04.05

- Removing the power-assisted steering drive ...................................................... 48-12 page 2

Edition 04.05 Table of Contents VII

Table of Contents Edition 04.05

Nominal values front axle

Spring strut type axle

Edition 04.05 Chassis 00-1 page 1

Nominal values rear axle

Twist-beam rear axle

Vehicle data sticker and PR number

00-1 page 2 Chassis Edition 04.05

Edition 04.04 Steering 00-2 page 1

00-2 page 2 Steering Edition 04.04

Brake variants and their assignment

Engine litre/ 1,0/37 1,2/40 1,2/47

Edition 04.05 Brakes 00-3 page 1

Engine litre/ 1,2/47 1,4/44 1,4/50

00-3 page 2 Brakes Edition 04.05

Engine litre/ 1,4/55 1,4/74 2,0/85 1.9/47 SDI

Edition 04.05 Brakes 00-3 page 3

Engine litre/ 1.9/74 TDI PD 1.9/96 TDI PD 1.4/55 TDI PD

00-3 page 4 Brakes Edition 04.05

Model/Version bar MPa bar MPa

Pressure value of the distributor valve

Part no.of the distributor valve: 6Y0°612°151 2

The colour marking on the main brake cylinder is not vis- 1

Classification N 052 766 X0 (USA standard FMVSS 571.116 DOT4)

Edition 04.05 Brakes 00-3 page 5

00-3 page 6 Brakes Edition 04.05

00-4 Wheels, Tyres

Possible wheel-tyre combinations

Edition 07.03 Wheels, Tyres 00-4 page 1

ent tyre temporarily in the event of breakdown. Take

Manufacturing date Meaning

00-4 page 2 Wheels, Tyres Edition 07.03

40 – Front wheel suspension

40-1 Repairing front axle

An overview of the front axle

Edition 04.05 Repairing front axle 40-1 page 1

40-1 page 2 Repairing front axle Edition 04.05

Edition 04.05 Repairing front axle 40-1 page 3

Inspecting the steering joint

Inspecting radial play

– Forcefully push the wheel at the bottom towards the

– Remove the drive shaft from wheel-bearing housing

40-1 page 4 Repairing front axle Edition 04.05

– Insert steering joint in the wheel-house bearing.