Frenos VW Jetta-Bora 2009.

2009 Volkswagen Jetta SEL
2005-2007 BRAKES Brake System - Jetta (A5 Platform)
2005-2007 BRAKES
Brake System - Jetta (A5 Platform)
00 - GENERAL, TECHNICAL DATA

ALLOCATION OF PR NO. TO BRAKES
The following table explains: PR.-No. . These are important for the combination brake caliper/brake disc
and brake pad.
Allocation Electronic parts catalog "ETKA".
Front wheel brakes
Engine version PR No. Front brakes

1.9l -74 kW TDI pump injection 1ZP FN 3 (15)
2.5L - 110 kW
2.0L - 147 kW T-FSI 1ZD FN 3 (16)
Rear wheel brakes
Engine version PR No. Rear brakes

1.9l -74 kW TDI pump injection 1KE CII 41 (15)
2.5L - 110 kW
2.0L - 147 kW T-FSI 1KJ CII 41 (16)
2.0L - 147 kW T-FSI Jetta GLI 1KY CII 38 (16)
only
TECHNICAL DATA, BRAKES
Brake master cylinder and brake booster
Brake master cylinder Diameter in mm 22

Brake booster (left-hand drive) Diameter in inches 11
Front brakes
Front brake FN 3
Hewlett-Packard Company
lunes, 16 de enero de 2012 11:14:16
11:14:06 p.m. Page 1 © 2006 Mitchell Repair Information Company, LLC.
Fig. 1: Exploded View Of Front Brake Calipers (FN 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.
Item Pr.- No. 1ZE/1ZP

1 Brake caliper FN3 (15)
2 Brake pad, thickness mm 14
3 Brake disc Diameter in mm 288
Brake disc, thickness mm 25
4 Brake caliper, piston Diameter in mm 54
Item Pr.- No. 1LL/1ZD

1 Brake caliper FN3 (16)
Rear brake (disc brake)
Rear brake CII 38
lunes, 16 de enero de 2012 11:14:06 p.m. Page 2 © 2006 Mitchell Repair Information Company, LLC.
Fig. 2: Exploded View Of Rear Brake CII

Item Pr.- No. 1KY

1 Brake caliper CII 38 (16)
Rear brake CII 41 (15)

Item Pr.- No. 1KE/1KF

Rear brake CII 41 (16)

Item Pr.- No. 1KJ

45 - ANTI-LOCK BRAKE SYSTEM

GENERAL NOTES ON ANTI-LOCK BRAKING SYSTEM (ABS)
The ABS brake system is divided diagonally (two circuits). The servo-assist is affected pneumatically by the
vacuum brake servo unit.
Vehicles with ABS Mark 60 or ABS Mark 70 do not have a mechanical brake pressure regulator. A
specially matched software program in the control module determines brake pressure regulation at the rear
axle.
Malfunctions of ABS have no influence on the brake system and brake booster. The conventional
brake system remains operational, even without ABS. A change in braking behavior should be
checked. When the ABS Warning Lamp K47 is lit up, the rear wheels may lock prematurely during
braking!
Fig. 5: Identifying Hydraulic Unit And Control Module And Brake Booster
ABS allocation in Left Hand Drive (LHD) vehicles.
1 - Hydraulic unit and control module
2 - Brake booster
Fig. 6: Identifying Control Module, Hydraulic Unit And Hydraulic Pump

Control module - 1 - and hydraulic unit - 2 - form a single unit. Separation can only be performed when
removed from vehicle. The hydraulic pump - 3 - must not be separated from hydraulic unit.
NOTES FOR REPAIR WORK ON ANTI-LOCK BRAKE SYSTEM
Notes for repair work on Anti-lock Brake System
Before performing repairs to the ABS, determine the cause of the malfunction via "Guided Fault
Finding".
"Guided Fault Finding" is performed using Vehicle Diagnosis, Testing and Information System VAS 5051.
Disconnect Ground (GND) cable from the battery with the ignition off.
Before carrying out welding work with an electric welding unit, disconnect the ABS control module.
When working with brake fluid, observe relevant safety precautions and notes --> Brake system,
bleeding.
After work for which the brake system had to be opened, bleed the brake system with brake filler and
bleeder unit VAS 5234 --> Brake system, bleeding.
During the final road test, ensure that a controlled brake test is performed at least once (pulsation must
be felt at the brake pedal).
Absolute cleanliness is required when working on the anti-lock brake system. Do not use any products
which contain mineral oil, such as oils, greases etc.
Thoroughly clean all unions and adjacent areas before loosening, do not use aggressive cleaning
agents such as brake cleaner, gasoline, thinners or similar.
Place removed parts on a clean surface and cover.
After separating control module/hydraulic unit, use transport protection for valve body.
Carefully cover or seal open components if repairs cannot be carried out immediately. (Use plugs 1H0
698 311 A )
Do not use fluffy cloths.
Remove replacement parts from packaging immediately prior to installation.
Only use genuine packed parts.

When the system is open do not work with compressed air and do not move the vehicle.
During painting operations, the electronic control module can be exposed to a max. temperature of 95
° C for only a short period, and to a maximum of 85 ° C for longer periods (approx. 2 hours). Make
sure that no brake fluid enters plug connectors.
VEHICLE DIAGNOSTIC, TESTING AND INFORMATION SYSTEM VAS 5051 , CONNECTING

AND SELECTING FUNCTIONS
Vehicle Diagnostic, Testing and Information System VAS 5051 , connecting and selecting functions
Special tools, testers and auxiliary items required
Fig. 7: VAS 5051 Vehicle Diagnosis, Testing and Information System

Vehicle diagnostic, test and information system VAS 5051
CAUTION: During a test drive, the testing and measuring equipment must
always be secured on the back seat.
These devices may be operated only by a passenger during a test
drive.
Fig. 8: Identifying VAS 5051 And VAS 5051/1

Connect Vehicle Diagnosis, Testing and Information System VAS 5051 - 1 - as follows:
Connect diagnostic cable - 2 - connector to Data Link Connector (DLC).
Fig. 9: Identifying Volkswagen Tester VAS 5051, On Switch

Switch on Vehicle Diagnosis, Testing and Information System VAS 5051 - arrow -.
Diagnostic operation system VAS 5051 is ready for operation when the button fields of the operating modes
are displayed.
Switch on ignition.
Touch Guided Fault Finding on screen.

Select one after another:
Brand
Type
Model year
Version
Engine code
Confirm entered data.
NOTE: Wait until the vehicle diagnosis, test and information system VAS 5051
has checked all the control modules in vehicle.
Press >.
Press the Go to button and select the "Function/component selection" function.
Select "Suspension" on display.
Select "Brake system" on display.
Select "01-On Board Diagnostic (OBD) capable system..." indicated on display.

Select on display "Anti-lock brake system...".
Select "Function" indicated on display.
NOTE: Now, all possible functions of Anti-lock Brake System (ABS) installed in
vehicle are displayed.
Select desired function on display.
ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLATION LOCATIONS
ABS Mark 70 (ABS/ASR)
Fig. 10: Electrical/Electronic Components And Installation Locations -- ABS Mark 70 (ABS/ASR)
1 - ABS control module J104
Location: On hydraulic unit on right side of engine compartment.

Can be checked in "Guided Fault Finding" using VAS 5051
Do not disconnect connector before successfully completing On Board Diagnostic (OBD). Switch
ignition off before separating connector.
Removing and installing
2 - ABS Hydraulic Unit N55
Location: In engine compartment, right side
The hydraulic unit consists of the following components:
ABS hydraulic pump V64

Valve block (contains inlet and outlet valves)

ABS Hydraulic Pump V64 and valve block must not be separated from each other.
3 - Brake Pad Wear Indicator Lamp K32
Location: In the instrument cluster

Function: --> Malfunction displayed by warning lamps for level control system
4 - ABS Warning Lamp K47

5 - Traction Control Indicator Lamp K86

6 - Brake System Warning Lamp K118

7 - Brake Light Switch F up to KW 50/05
Includes Brake Pedal Switch F47

Location: on brake pedal
Removing, installing and adjusting --> Brake Light Switch F up to KW 50/05, removing, installing
and adjusting
8 - Brake Light Switch F from KW 50/05

Location: On brake master cylinder
Removing and installing --> Brake Light Switch F from KW 50/05, removing and installing
9 - ASR/ESP Button E256
Location: in center console
10 - Data Link Connector (DLC)
Location: cover in driver footwell
11 - Right Front ABS Wheel Speed Sensor G45/Left Front ABS Wheel Speed Sensor G47

Removing and installing --> ABS system components on front axle, removing and installing
12 - Wheel bearing housing
13 - Wheel bearing/hub unit
The ABS sensor ring is installed in wheel bearing
14 - Right Rear ABS Wheel Speed Sensor G44/Left Rear ABS Wheel Speed Sensor G46

Removing and installing --> ABS system components on rear axle, removing and installing
15 - Rear axle body with stub axle
16 - Wheel hub with wheel bearing
The ABS sensor ring is installed in wheel bearing
ABS Mark 60 (ABS/EDL/ASR/ESP)
Fig. 11: Electrical/Electronic Components And Installation Locations -- ABS Mark 60

(ABS/EDL/ASR/ESP)
Location: On hydraulic unit on right side of engine compartment.

Do not disconnect connector before successfully completing On Board Diagnostic (OBD). Switch
ignition off before separating connector.
Location: In engine compartment, right
The hydraulic unit consists of the following components:
ABS Hydraulic Pump V64

Brake Pressure Sensor 1 G201

Valve block (contains inlet and outlet valves)
ABS Hydraulic Pump V64 and valve block must not be separated from each other.
3 - Brake Pad Wear Indicator Lamp K32

4 - ABS Warning Lamp K47

5 - ASR/ESP Control Lamp K155
Only on vehicles with ABS/EDL/ASR/ESP

Location: In instrument cluster
6 - Brake System Warning Lamp K118
Location: In instrument cluster

7 - Brake light switch F up to KW 50/05

Location: on brake pedal
Removing, installing and adjusting --> Brake Light Switch F up to KW 50/05, removing, installing
and adjusting
8 - Brake Light Switch F from KW 50/05

Location: On brake master cylinder
9 - ASR/ESP Button E256

Location: in center console
10 - ESP-Sensor Unit G419


Location: Under front passenger seat
Combined Transverse Acceleration Sensor G200 and Rotation Rate Sensor G202
Combined in one housing

Removing and installing --> ESP-sensor unit G419 , removing and installing
11 - Data Link Connector (DLC)
Location: Cover in driver footwell
12 - Steering Angle Sensor G85
Location: On steering column between steering wheel and steering column switch
Removing and installing --> Steering angle sensor G85 , removing and installing
13 - Right Front ABS Wheel Speed Sensor G45/Left Front ABS Wheel Speed Sensor G47

Removing and installing --> ABS system components on front axle, removing and installing
The ABS sensor ring is installed in wheel hub
16 - Right Rear ABS Wheel Speed Sensor G44/Left Rear ABS Wheel Speed Sensor G46

Removing and installing (Front Wheel Drive (FWD)) --> ABS system components on rear axle,
removing and installing
The ABS sensor ring is installed in wheel hub
MALFUNCTION DISPLAYED BY WARNING LAMPS FOR LEVEL CONTROL SYSTEM
ABS/ASR
Fig. 12: Instrument Cluster Warning Lamps (ABS/EDL/ASR/ESP)

Warning lamps
Item Designation
1 Traction Control Indicator Lamp K86
2 Brake Pad Wear Indicator Lamp K32
3 ABS Warning Lamp K47
4 Brake System Warning Lamp K118
Brake Pad Wear Indicator Lamp K32
If Brake Pad Wear Indicator Lamp K32 - 2 - does not switch off 3 seconds after the ignition is
switched on, or if it lights up when vehicle is driven, the malfunction may be:
- a - Brake pads may be worn.
Check front and rear axle brake pads/linings. Replace worn brake pads/linings.
- b - There is a malfunction in the wire routing --> Electrical Wiring Diagrams, Troubleshooting and
Component Locations
ABS Warning Lamp K47
If ABS Warning Lamp K47 - 3 - does not go out after the ignition is switched on and the test
sequence is complete, the malfunction may be:
- a - Voltage supply is below 10 volts.
- b - There is an ABS malfunction.
CAUTION: The ABS system remains switched off during an ABS malfunction - b - ,
but the traditional brake system remains fully functional.
- c - There was a temporary wheel speed sensor malfunction since the last vehicle start.
If this is the case, the ABS warning lamp will go out automatically after vehicle is started again and a speed
of 20 km/h has been exceeded.
- d - Connection from instrument cluster to ABS Control Module J104 has an open circuit --> Electrical
Wiring Diagrams, Troubleshooting and Component Locations
- e - The instrument cluster is faulty.
ABS Warning Lamp K47 and Brake System Warning Lamp K118
If ABS Warning Lamp K47 - 3 - goes out, but Brake System Warning Lamp K118 - 4 - lights up, the
malfunctions may be:
- a - Parking brake is applied.
- b - Brake fluid level is too low (warning lamp blinks).
Three warning tones are audible after switching on ignition.
- c - A malfunction in wiring to Brake System Warning Lamp K118 --> Electrical Wiring Diagrams,
Troubleshooting and Component Locations.
If ABS Warning Lamp K47 - 3 - and Brake System Warning Lamp K118 - 4 - lights up, ABS system
is malfunctioning. A change in braking behavior should be checked.
CAUTION: After ABS Warning Lamp K47 and Brake System Warning Lamp K118
light up, rear wheels may lock prematurely when braking.
Traction Control Indicator Lamp K86
If Traction Control Indicator Lamp K86 - 1 - does not go out after the ignition is switched on and the
test sequence is complete, malfunction may be:
There is a malfunction present which only affects the ASR. The ABS and EBD safety systems are still
completely functional check DTC memory.
- a - Short circuit to B+ in ASR/ESP Button E256.
- b - A malfunction in activation of Traction Control Indicator Lamp K86 --> Electrical Wiring Diagrams,
- c - ASR system was switched off by ASR/ESP Button E256
If Traction Control Indicator Lamp K86 flashes while driving, ASR system is regulating the system.
If Traction Control Indicator Lamp K86 - 1 - did not light up during self-test, the following
malfunction may be:
- a - The Traction Control Indicator Lamp K86 is malfunctioning perform electrical test.
ABS/EDL/ASR/ESP
Fig. 13: Instrument Cluster Warning Lamps (ABS/EDL/ASR/ESP)

Warning lamps
Item Designation
1 ASR/ESP Control Lamp K155
2 Brake Pad Wear Indicator Lamp K32
3 ABS Warning Lamp K47
4 Brake System Warning Lamp K118
Brake Pad Wear Indicator Lamp K32
If Brake Pad Wear Indicator Lamp K32 - 2 - does not switch off 3 seconds after the ignition is
switched on, or if it lights up when vehicle is driven, the malfunction may be:
- a - Brake pads may be worn.
Check front and rear axle brake pads/linings. Replace worn brake pads/linings.
- b - There is a malfunction in the wire routing --> Electrical Wiring Diagrams, Troubleshooting and
Component Locations.
ABS Warning Lamp K47
If ABS Warning Lamp K47 - 3 - does not go out after the ignition is switched on and the test
sequence is complete, the malfunction may be:
- a - Voltage supply is below 10 volts.
- b - There is an ABS malfunction.
CAUTION: The ABS system remains switched off during an ABS malfunction - b - ,
but the traditional brake system remains fully functional.
- c - There was a temporary wheel speed sensor malfunction since the last vehicle start.
If this is the case, the ABS warning lamp will go out automatically after vehicle is started again and a speed
of 20 km/h has been exceeded.
- d - Connection from instrument cluster to ABS Control Module J104 has an open circuit --> Electrical
Wiring Diagrams, Troubleshooting and Component Locations.
- e - The instrument cluster is faulty.
ABS Warning Lamp K47 and Brake System Warning Lamp K118
If ABS Warning Lamp K47 - 3 - goes out but Brake System Warning Lamp K118 - 4 - lights up, the
malfunctions may be:
- a - Parking brake is engaged.
- b - Brake fluid level is too low (warning lamp blinks).
Three warning tones are audible after switching on the ignition.
- c - A malfunction in wiring to Brake System Warning Lamp K118 --> Electrical Wiring Diagrams,
If ABS Warning Lamp K47 - 3 - and Brake System Warning Lamp K118 - 4 - lights up, ABS system
is malfunctioning. A change in braking behavior should be checked.
CAUTION: After ABS Warning Lamp K47 and Brake System Warning Lamp K118
light up, rear wheels may lock prematurely when braking.
ASR/ESP Control Lamp K155
If ASR/ESP Control Lamp K155 - 1 - does not go out after ignition is switched on and the test
sequence is complete, malfunction causes may be:
There is a malfunction present which only affects the ASR/ESP. The ABS/EDL and EBD safety systems are
still completely functional check DTC memory.
- a - Short circuit to B+ in ASR/ESP Button E256.
- b - A malfunction in activation of ASR/ESP Control Lamp K155 --> Electrical Wiring Diagrams,
- c - ASR/ESP system was switched off by ASR/ESP Button E256
If ASR/ESP Control Lamp K155 flashes while driving, the ASR or ESP system is regulating the
system.
If ASR/ESP Control Lamp K155 - 1 - did not light up during self-test, the following malfunction may
be:
- a - The ASR/ESP Control Lamp K155 is malfunctioning Perform electrical test.
HYDRAULIC UNIT, BRAKE BOOSTER/MASTER BRAKE CYLINDER
ABS Mark 70 (ABS/ASR)
Fig. 14: Exploded View ABS Mark 70 (ABS/ASR) Components

3 - Brake line
Brake master cylinder/primary piston circuit to hydraulic unit

Identification: Tube fitting with threads M10 x 1
4 - Brake line
Brake master cylinder/secondary piston circuit to hydraulic unit

5 - Brake line
To left front brake caliper

6 - Brake line
to right front brake caliper

7 - Brake line
To left rear brake caliper

8 - Brake line
To right rear brake caliper

9 - Torx bolt, 5.5 Nm
Use new bolts.
10 - Bracket
11 - Hex head bolt, 8 Nm
12 - Gasket
For brake booster
13 - Brake booster
On gasoline engines the vacuum required is taken from intake manifold.

On Diesel engines, a vacuum pump is installed to create vacuum --> Vacuum pump for brake
booster (Diesel vehicles), overview.
Functional check:
Forcefully press brake pedal several times with engine switched off. This dissipates any vacuum
present in the unit.
Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working
properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
If faulty, replace completely.

Removing and installing --> Brake booster, removing and installing
14 - Sealing ring
15 - Tandem brake master cylinder
Application Electronic Parts Catalog (ETKA)

Cannot be repaired. If faulty, replace completely.
Removing and installing --> Brake master cylinder, removing and installing
16 - Hex nut, 25 Nm
Replace each time
17 - Sealing plug
Moisten with brake fluid and press into brake fluid reservoir
18 - Brake fluid reservoir
19 - Cap
20 - Sealing plug
Connection for vacuum hose
21 - Vacuum hose
Insert into brake booster
Connecting brake lines from tandem brake master cylinder to hydraulic unit
Fig. 15: Connection Of Brake Lines From Dual Master Brake Cylinder To Hydraulic Unit -- On
Tandem Main Brake Cylinder
On tandem main brake cylinder:
A - Master cylinder primary piston circuit to hydraulic unit
- Identification: Tube fitting with threads M10 x 1
B - Master cylinder secondary piston circuit to hydraulic unit
1 - Hydraulic unit to left front brake caliper
3 - Hydraulic unit to right rear brake caliper
4 - Hydraulic unit to left rear brake caliper
Fig. 16: Connection Of Brake Lines From Dual Brake Master Cylinder To Hydraulic Unit -- On
Hydraulic Unit
On hydraulic unit:
A - Hydraulic unit to master cylinder primary piston circuit
B - Hydraulic unit to master cylinder secondary piston circuit
2 - Hydraulic unit to right front brake caliper
Control module and hydraulic unit, removing
Fig. 17: Identifying Special Tools - Brakes, Servicing

Torque wrench V.A.G 1331

Brake pedal actuator V.A.G 1869/2
Fig. 18: Sealing Plug Repair Set, Part No. 1H0 698 311 A
Plug 1H0 698 311 A
After separating the control module from the hydraulic unit, the transport protection for valve body must be
placed on the hydraulic unit.
There is no guarantee for hydraulic units without transportation protection.
1 - Transport protection for valve body (foam material)
2 - Sealing plugs M10
Removing
Location:
The control module is bolted to the hydraulic unit and is located at right side in engine compartment.
CAUTION: Do not bend the brake lines in the area of the hydraulic unit!
Read out and note the control module coding.

Disconnect battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .
Remove engine cover.
1.9 L diesel engine:
Disconnect connection hose to intake connection --> 21 - TURBOCHARGER, G-CHARGER .

Remove Intake Flap Motor V157 --> 23 - DIESEL FUEL INJECTION .
Fig. 19: Releasing Control Module Connector And Pull Off

Release connector from control module in direction of - arrow 1 - and disconnect in direction of -
arrow 2 -.
Install brake pedal loading device V.A.G 1869/2.
Connect bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and
open bleeder valves.
Operate brake pedal using brake pedal depressor V.A.G 1869/2 at least 60 mm.
Close left front and left rear bleeder valves.
Do not remove brake pedal loading device V.A.G 1869/2.
Place sufficient lint-free cloths under control module and hydraulic unit.
Make sure that brake fluid does not come in contact with terminals.
Fig. 20: Connection Of Brake Lines From Dual Brake Master Cylinder To Hydraulic Unit -- On
Hydraulic Unit
Mark both brake lines of main brake cylinder - A - and - B - and remove from hydraulic unit.
Seal brake lines and threaded holes immediately with sealing plugs 1H0 698 311 A .
Mark brake lines (brake caliper) - 1 - to - 4 - , remove and seal.
Fig. 21: Pulling Hydraulic Unit With Control Module Upward

Pull hydraulic unit with control module upward out of dampers in direction of - arrow -.
Unfastening control module from hydraulic unit
Set hydraulic unit with control module upward on to a clean, level surface.
Fig. 22: Location Of Torx Bolts

Remove Torx bolts - arrows -.
Fig. 23: Removing Control Module From Hydraulic Unit

Pull off control module from hydraulic unit in direction of - arrow - without canting.
Carefully pull off all seals from valve body of hydraulic unit.
CAUTION: If a control module is removed, the circuit board is exposed.

No moisture or particles of dirt must penetrate in interior of
control module.
The hydraulic pump must not be separated from the hydraulic
unit.
Cover solenoid coils of control module with a lint-free cloth.
After separating the control module and hydraulic unit, use transport protection for valve body.
Installing new control module
CAUTION: Excessive shaking (e.g. dropping, impact) can destroy the control
module. Control module must no longer be used.
Surface must be cleaned before installing.
Fig. 24: Identifying Sealing Rings Slid Over Valve Dome

Push all seals - A - slightly over valve body.

Place control module without canting it on to hydraulic unit.
Sealing rings are then brought into their end position.
Bolt hydraulic unit and control module with new Torx bolts supplied.
NOTE: A new control module may be installed on an already used hydraulic

unit twice at maximum, in order to guarantee the seal of the elastic
gasket.
A used control module may not be installed a second time.
Control module and hydraulic unit, installing
NOTE: Remove sealing plugs on new hydraulic unit when the corresponding
brake line is going to be installed.
If the sealing plugs are removed too early, brake fluid can escape, and
can no longer be guaranteed that the unit is sufficiently filled or
adequately bled.
When installing, make sure the damper rubber is not pushed out of the
console.
Installation is in reverse order of removal.

Remove brake pedal loading device V.A.G 1869/2.
Bleed brake system --> Brake system, bleeding.
Connect battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .
Code ABS Control Module J104 using in "Guided Fault Finding".
Torque specifications:
Control module to hydraulic unit
5.5 Nm
Use new bolts!

Hydraulic unit hex bolt to bracket 8 Nm
Brake lines to ABS module:
Thread M10 x 1 14 Nm
Thread M12 x 1 14 Nm
ABS Mark 60 (ABS/EDL/ASR/ESP)
Fig. 25: Exploded View Of ABS Mark 60 (ABS/EDL/ASR/ESP) Components

3 - Brake line

Identification: Diameter 6.5 mm and tube fitting with longer threads M12 x 1
4 - Brake line

Identification: Diameter 6.5 mm and tube fitting with longer threads M12 x 1
5 - Brake line
To left front brake caliper

Identification: 5.25 mm and pipe bolt with short thread M12 x 1
6 - Brake line
To right front brake caliper

Identification: Diameter 5.25 mm and tube fitting with threads M10 x 1
7 - Brake line
To left rear brake caliper

Identification: Diameter 5.25 mm and lube fitting with shorter thread M12 x 1
8 - Brake line
to right rear brake caliper

Identification: Diameter 5.25 mm and tube fitting with thread M10 x 1
9 - Torx bolt, 5.5 Nm
Use new bolts.
10 - Bracket
12 - Gasket
For brake booster
13 - Brake booster
On gasoline engines the vacuum required is taken from the intake manifold.
Some vehicles with gasoline engine and automatic transmission are equipped with a Brake System
Vacuum Pump V192 --> Brake system vacuum pump V192.
A vacuum sensor is installed in vehicles with OHB-V --> Brake Booster Vacuum Sensor G483 ,
removing and installing.

On Diesel engines, a vacuum pump is installed to create vacuum --> Vacuum pump for brake
booster (Diesel vehicles), overview.
Functional check:
Forcefully press brake pedal several times with engine switched off. This dissipates any vacuum
present in the unit.

14 - Sealing ring
15 - Brake Booster Vacuum Sensor G483
Only for vehicles with OHB-V

Removing and installing --> Brake Booster Vacuum Sensor G483 , removing and installing
16 - Tandem brake master cylinder

17 - Heat shield
18 - Hex nut, 25 Nm
Replace each time it is removed
19 - Sealing plug
Moisten with brake fluid and press into brake fluid reservoir
21 - Cap
22 - Sealing plug
23 - Vacuum hose
Connecting brake lines from dual brake master cylinder to hydraulic unit
Tandem Main Brake Cylinder
On tandem brake master cylinder:
A - Master cylinder primary piston circuit to hydraulic unit
- Identification: Diameter 6.5 mm and tube fitting with thread M12 x 1
B - Master cylinder secondary piston circuit to hydraulic unit
Hydraulic Unit
On hydraulic unit:
A - Hydraulic unit to master cylinder primary piston circuit
- Identification: Diameter 6.5 mm and tube fitting with long thread M12 x 1
B - Hydraulic unit to master cylinder secondary piston circuit
- Identification: Diameter 6.5 mm and tube fitting with long thread M12 x 1
- Identification: Diameter 5.25 mm and tube fitting with short thread M12 x 1
2 - Hydraulic unit to right front brake caliper
- Identification: Diameter 5.25 mm and pipe bolt with short thread M12 x 1
Control module and hydraulic unit, removing
Fig. 28: Identifying Special Tools - Brakes, Servicing


Fig. 29: Sealing Plug Repair Set, Part No. 1H0 698 311 A
Plug 1H0 698 311 A
After separating control module from hydraulic unit, the transport protection for valve body must be placed
on hydraulic unit.
There is no guarantee for hydraulic units without transportation protection.
1 - Transport protection for valve body (foam material)
Removing
Location:
The control module is bolted to the hydraulic unit and is located at right side in engine compartment.
CAUTION: Do not bend the brake lines in the area of the hydraulic unit!
Read out and note present control module coding.

1.9 L diesel engine:
Disconnect connection hose to intake connection --> 21 - TURBOCHARGER, G-CHARGER .

Remove Intake Flap Motor V157 --> 23 - DIESEL FUEL INJECTION .
Fig. 30: Control Module Connector Released And Pulled Off

Release connector from control module in direction of - arrow 1 - and disconnect in direction of -
arrow 2 -.
Install brake pedal loading device V.A.G 1869/2.
Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open
bleeder valves.
Depress brake pedal using brake pedal depressor V.A.G 1869/2 at least 60 mm.
Close left front and left rear bleeder valves.
Do not remove brake pedal loading device V.A.G 1869/2.
Place sufficient lint-free cloths under control module and hydraulic unit.
Make sure that brake fluid does not come in contact with terminals.
Hydraulic Unit
Mark both brake lines of brake master cylinder - A - and - B - and remove from hydraulic unit.
Seal brake lines and threaded holes immediately with sealing plugs from repair kit 1H0 698 311 A .
Mark brake lines (brake caliper) - 1 - to - 4 - , remove and seal.
Lift hydraulic unit with control module upward out of dampers.
Unfastening control module from hydraulic unit
Set hydraulic unit with control module downward on to a clean, level surface.
Fig. 32: Identifying Hydraulic Pump E 5 Hex Socket Head Bolt

Remove Torx bolts E 5 - arrows - from hydraulic pump.
CAUTION: The hydraulic pump must not be separated from the hydraulic unit.
Fig. 33: Identifying Red Bracket From The Repair Kit And Two Sealing Plugs On Hydraulic Unit
For this reason, secure hydraulic pump to hydraulic unit using red retainer - 1 - from replacement part
set and two sealing plugs - 2 -.
Fig. 34: Identifying Hydraulic Unit With Hydraulic Pump Joint

Carefully separate hydraulic unit with hydraulic pump upward at interface - 1 - from control module.
Fig. 35: Removing Control Module & Identifying Contact Pin

When removing control module, make sure that the valve body of the hydraulic unit does not jam or get bent
in the magnetic coils of the control module.
Adapter - 2 - for pump motor.
Cover control module solenoid coils with a lint-free cloth.
After separating control module and hydraulic unit, use transport protection for valve body.
Installing new control module
CAUTION: Excessive shaking (e.g. dropping, impact) may destroy the control
module. Control module must no longer be used.
Before new control module can be installed, pump motor adapter must first be inserted until it stops
and engages. Adapter guide must not be damaged.
The adapter supplied as replacement part for control module can be engage only once and then must
not be separated again.
The white grouting compound on base of control module serves as a seal and must not be removed.
All contact surfaces on adapter, pressure sensor and control module as well as silicon gel and sealing
elements must not be touched by hand or objects, soiled or damaged.
Press adapter into adapter guide until it stops, it must then be engaged.
Place control module without canting it on to hydraulic unit.
Bolt hydraulic unit and control module with new Torx bolts supplied.
NOTE: A new control module may be installed on an already used hydraulic

unit twice at maximum, in order to guarantee the seal of the elastic
gasket.
A used control module may not be installed a second time.
Control module and hydraulic unit, installing
NOTE: Remove sealing plugs on new hydraulic unit when the corresponding
brake line is going to be installed.
If the sealing plugs are removed too early, brake fluid can escape, and
can no longer be guaranteed that the unit is sufficiently filled or
adequately bled.

Code ABS Control Module J104.
When doing this, a basic setting of Steering Angle Sensor G85 , of Transverse Acceleration Sensor G200
and of Brake Pressure Sensor 1 G201 must be performed.
Control unit to hydraulic unit 5.5 Nm
Use new bolts!

Hydraulic unit hex bolt to bracket 8 Nm
Brake lines to ABS module:
Thread M 10 x 1 14 Nm
Thread M 12 x 1 14 Nm
ABS SYSTEM COMPONENTS ON FRONT AND REAR AXLES, REMOVING AND INSTALLING
ABS system components on front axle, removing and installing
Fig. 36: ABS System Components On Front Axle, Removing And Installing
1 - ABS wheel speed sensor
Before inserting sensor, clean inner surface of mounting hole and coat with hot bolt paste G 052 112
A3
2 - Hex socket head bolt, 8 Nm
The ABS sensor ring is installed in the wheel hub
4 - Drive axle
Speed sensor on front axle, removing and installing
Removing
Raise vehicle.
Fig. 37: ABS Speed Sensor On Front Axle, Removing And Installing
Separate speed sensor and speed sensor wiring connector - 1 -.

Remove bolt - 2 - from wheel bearing housing.
Remove ABS speed sensor from wheel bearing housing.
Installing
Before inserting wheel speed sensor, clean inner surface of bore hole and coat sensor completely with
hot bolt paste G 052 112 A3 .
Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm.
Connect speed sensor to speed sensor wiring.
ABS system components on rear axle, removing and installing
Fig. 38: ABS System Components On Rear Axle, Removing And Installing
Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
2 - Hex socket head screw, 8 Nm
Speed sensor on rear axle, removing and installing
Removing
Raise vehicle.
Fig. 39: ABS Speed Sensor On Rear Axle, Removing And Installing
Separate speed sensor and speed sensor wiring connector - 1 -.

Remove bolt - 2 - from wheel bearing housing.
Remove ABS speed sensor from wheel bearing housing.
Installing
Before inserting wheel speed sensor, clean inner surface of hole and coat sensor completely with hot
bolt paste G 052 112 A3 .
Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm.
Connect speed sensor to speed sensor wiring.
COMPONENTS OF ESP SYSTEM, REMOVING AND INSTALLING
ESP-sensor unit G419 , removing and installing
ESP Sensor Unit G419 consists of Transverse Acceleration Sensor G200 and Rotation Rate Sensor G202.
They are installed in one housing under front passengers seat.
After replacing ESP Sensor Unit G419 , a basic setting must be performed for Transverse Acceleration
Sensor G200.
CAUTION: Excessive shaking (e.g. dropping, impact) may destroy the ESP Sensor
Unit G419. ESP Sensor Unit G419 must no longer be used.
ESP Sensor Unit G419 , removing
Remove front passengers seat --> 72 - SEAT - FRAMES .

Remove sill panel trim --> 68 - INTERIOR EQUIPMENT and lift carpet.
Remove connector station and insert through opening in felt mat.
Lift felt mat.
Fig. 40: ESP Sensor Unit G419 Connector

Disconnect connector - 1 - from ESP Sensor Unit G419.

Remove two mounting nuts - arrows -.
Remove ESP Sensor Unit G419.
ESP Sensor Unit G419 , installing
Installation is in reverse order of removal, with special attention to the following:
When installing ESP Sensor Unit G419 , make sure it is properly seated on the bracket and is free of tension.
NOTE: Never force ESP Sensor Unit G419 into position using the mounting
nuts.
Tighten securing nuts to 9 Nm.

Perform basic setting of Transverse Acceleration Sensor G200.
Steering angle sensor G85 , removing and installing
Steering angle sensor is installed between steering wheel and steering column switches --> 94 - LIGHTS,
SWITCHES - EXTERIOR .
Then a basic setting of Steering Angle Sensor G85 must be performed.
VAS 5051 , connecting and selecting functions --> Vehicle Diagnostic, Testing and Information System
VAS 5051 , connecting and selecting functions.
Brake Booster Vacuum Sensor G483 , removing and installing
Removing
Remove battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .
Fig. 41: Identifying Cover Of E-Box, Wire & Bolts

Open cover - 1 - and remove wire - 2 - from fuse holder.

Remove bolts - arrows - and remove battery holder.
Fig. 42: Brake Booster Vacuum Sensor G483 And Harness Connector
Disconnect harness connector - 1 - from Brake Booster Vacuum Sensor G483 - 2 -.

Insert a screwdriver between stop and one end of securing ring into groove of sealing ring.
Fig. 43: Brake Booster Vacuum Sensor G483 And Securing Ring
Press securing ring - 1 - as far out of groove until Brake Booster Vacuum Sensor G483 - 2 - can be
pulled out of brake booster.
Installing
46 - BRAKES - MECHANICAL COMPONENTS

FRONT BRAKES, SERVICING
Front brakes, FN 3 calipers, servicing
NOTE: After replacing brake pads, depress brake pedal firmly several times
with vehicle stationary so that the brake pads are properly seated in
their normal operating position.
Use brake filler/bleeder unit VAS 5234 to extract brake fluid from brake
fluid reservoir.
Before removing brake caliper or disconnecting brake hose, brake
pedal depressor V.A.G 1869/2 must be inserted (this relieves pressure).
Fig. 44: Exploded View Of Front Brake Components

1 - Bolt, 4 Nm
2 - Brake disc
Internally vented, diameter 288 mm

Thickness 25 mm
Wear limit: 22 mm
Always replace both sides
Remove brake caliper prior to removing
3 - Brake pads
Thickness 14 mm without backing plate

With wear indicator
When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster
Wear limit: 2 mm without backing plate
Checking thickness 20.1

Removing and installing --> Brake pads, removing and installing,
4 - Retaining spring
Insert in both holes of brake caliper
5 - Brake carrier
Bolt to wheel bearing housing
6 - Brake caliper
Do not disconnect brake hose when changing brake pads

Removing and installing --> Brake caliper, removing and installing, brake caliper FN3
Servicing --> Front brake caliper, servicing
7 - Guide pins, 30 Nm
8 - Cap
Remove
9 - Brake hose with banjo fitting and union bolt, 35 Nm
10 - Ribbed bolt, 190 Nm
Clean if re-using
11 - Bolt
12 - Bracket
With fastened brake carrier
15 - Hex socket head screw, 8 Nm
16 - Shield plate

Brake pads, removing and installing,
Fig. 45: Torque Wrench V.A.G 1331

Fig. 46: Piston Resetting Tool T10145

Piston resetting tool T10145
Removing
If reusing brake pads, mark location. Install in same position when installing otherwise uneven
braking will occur!
Remove wheels.
Fig. 47: Prying Brake Pad Retaining Spring Out From Brake Caliper Housing With A Screwdriver
Using screwdriver, pry off brake pad retaining spring from brake caliper - arrow - and remove.
Fig. 48: Location Of Brake Pad Wear Indicator Connector

Disconnect connector - 1 - for brake pad wear indicator.
Fig. 49: Protective Caps

Remove caps - arrows -.
Fig. 50: Removing/Installing Brake Caliper Guide Pins

Loosen both guide pins - arrows - and remove from brake caliper.
Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or
damage the brake hose.
Remove brake pad from brake caliper or from brake carrier.
Clean brake caliper, especially the adhesion surface for the brake pad, it must be free of residual
adhesive and grease.
Use only appropriate solvents for cleaning brake caliper.
Installing
Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from
brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and
cause damage.
Fig. 51: Pressing Piston Back

Press piston back into caliper housing.

Remove protective foil from backing plate of outer brake pad.
Set outer brake pad onto carrier.
Insert inner brake pad with retaining spring in brake caliper (piston).
When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct
installation position has been reached.
Do not damage adhesion surface.
Fig. 52: Removing/Installing Brake Caliper Guide Pins

Tighten brake caliper to brake carrier using both guide pins.

Install both caps.
Install retaining spring in brake caliper.
Connect harness connector of brake pad wear indicator.
Install wheels.
Tightening torques of wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT
After changing brake pads check brake fluid level.
Torque specification:
Guide pin to brake carrier 30 Nm
Brake caliper, removing and installing, brake caliper FN3

Fig. 54: Brake Pedal Depressor V.A.G 1869/2

Removing
Work procedure applies only for replacing or when performing subsequent service work on brake
caliper.
Remove wheels.
Using screwdriver, pry off brake pad retaining spring from brake caliper and remove.
Disconnect connector for brake pad wear indicator.
Press bleeder bottle hose onto brake caliper bleeder valve and then open bleeder valve.
Insert brake pedal depressor V.A.G 1869/2.

Close bleeder valve and remove bleeder bottle.
Remove brake hose.
Pull both cover caps from bushings of brake caliper.
Loosen both guide pins and remove from brake caliper.

Remove brake caliper from brake carrier.

Remove brake pads from brake caliper.
Installing
Piston is pressed back.

Outer brake pad sits on brake carrier.
Insert inner brake pad with retaining spring in brake caliper (piston).
When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct
installation position has been reached.
Do not damage adhesion surface.
Attach brake caliper to carrier by fastening guide pins.

Install both caps.
Screw brake hose on brake caliper.
Install retaining spring in brake caliper.

Connect harness connector for brake pad wear indicator.
Install wheels.
Tightening torques of wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .
Check brake fluid level.
Guide pin to brake carrier 30 Nm
Brake line to brake caliper 35 Nm
REAR WHEEL BRAKES, SERVICING
Rear wheel brakes CII 38/CII 41, servicing
Use brake charger/bleeder unit VAS 5234 to extract brake fluid from
brake fluid reservoir.
Before removing brake caliper or disconnecting brake hose, brake
pedal depressor V.A.G 1869/2 must be inserted (this relieves pressure).
Fig. 55: Exploded View Of Rear Brake Components (CII 38/CII 41)
2 - Hex socket head bolt, 8 Nm
3 - Multi-point socket head bolt, 90 Nm plus an additional 90 ° ( 1 /4 turn)
Replace each time
5 - Shield plate
8 - Bolt
--> 42 - REAR SUSPENSION
9 - Dust cap
Pressing off and driving on --> 42 - REAR SUSPENSION
10 - Brake disc
Brake caliper CII 38: Diameter 286 mm

Brake caliper CII 41 (15): Diameter 260 mm
Brake caliper CII 41 (16): Diameter 286 mm
Thickness 12 mm
Wear limit 10 mm
Replace both sides if worn.
Remove brake caliper prior to removing
Application Electronic Parts Catalog "ETKA"
11 - Bolt, 4 Nm
12 - Brake pads
Thickness: 11 mm without backing plate

Wear limit: 2 mm without backing plate
Checking thickness 20.1
Removing and installing --> Brake pads for brake caliper CII 38/CII 41, removing and installing
13 - Brake carrier with guide pins and protective cap
Supplied as replacement part assembled with sufficient grease on guide pins

If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate
guide pins
14 - Anti-rattle spring
Always replace when changing pads
15 - Brake caliper
Do not disconnect brake hose when changing brake pads

Removing and installing --> Brake caliper CII 38/CII 41, removing and installing
Servicing --> Rear brake caliper, servicing
After servicing or replacing parking brake cable must be adjusted first.
Adjusting parking brake --> Parking brake, adjusting
16 - Hose retainer
17 - Brake line, 14 Nm
18 - Hex bolt, self-locking, 35 Nm
Always replace
19 - Parking brake cable

20 - Spring clip
21 - Brake hose
Brake pads for brake caliper CII 38/CII 41, removing and installing

Fig. 57: Brake Piston Reset Tool T10165

Resetting and extracting tool T10165
Removing
If reusing brake pads, mark location. Install in same position when installing otherwise uneven
braking will occur!
Remove wheels.
Fig. 58: Removing/Installing Brake Pads

Remove securing bolts from brake caliper housing, while counter-holding on guide pins.
Remove brake caliper and secure with wire so that the weight of the brake caliper does not cause any
stress or damage the brake hose.
Fig. 59: Locating Brake Pads And Anti-Rattle Springs

Remove brake pads and anti-rattle springs - arrows -.
Installing
Before pushing back the piston, extract some of the brake fluid out of the brake fluid reservoir using a
bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause
damage.
Screw in piston by turning knurled wheel of resetting and extracting tool T10165 clockwise, do not
damage protective cap.
Fig. 60: Installing Pistons Using T 10165

To screw in, use plate T10165/1 as an aid.
For pistons that are difficult to move, use a 13 mm open end wrench on the flats - arrow A - provided
for this purpose.
Fig. 61: Locating Brake Pads And Anti-Rattle Springs

Insert anti-rattle springs - arrows - and brake pads into brake carrier.
Fig. 62: Brake Pads Located Correctly In The Anti-Rattle Springs

Make sure that the brake pads are located correctly in the anti-rattle springs - arrows -.
Secure brake caliper using new self-locking bolts.
The repair kit includes four self-locking hex bolts which must be installed in all cases.
Install wheels.
After changing brake pads check brake fluid level.
Torque specification:
Brake caliper to brake carrier 35 Nm
Use new bolts!
Brake caliper CII 38/CII 41, removing and installing

Fig. 64: Brake Pedal Depressor V.A.G 1869/2

Removing
Work procedure applies only for replacing or when performing subsequent service work on brake
caliper.
Remove wheel.
Vehicles with spring clip on parking brake cable
Fig. 65: Identifying Brake Caliper, Brake Cable And Spring Clip
Pry off spring clip - 1 -.

Press lever on brake caliper - 2 - in direction of - arrow - and unhook brake cable - 3 -.
Vehicles with retaining tabs on parking brake cable
Fig. 66: Removing/Installing Parking Brake Cable

Press retaining tabs - arrows - inward.

Press lever on brake caliper - 1 - in direction of - arrow - and disengage parking brake cable - 2 -.
Continued for all vehicles
Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.
Insert brake pedal depressor V.A.G 1869/2.
Close bleeder valve and remove bleeder bottle.
Remove brake line.
Fig. 67: Removing/Installing Brake Pads

Remove both mounting bolts from brake caliper, when doing this, counterhold on guide pin.
Remove brake caliper from brake carrier.
Installing
Piston is pressed back.

Brake pads sit in retaining springs on brake carrier.
Secure brake caliper on brake carrier using new self-locking bolts.

Connect brake line on brake caliper.
Press lever on brake caliper - 2 - in direction of - arrow - and engage parking brake cable - 3 -.
Press spring clip - 1 - on to parking brake cable.

Slide parking brake cable into bracket on brake caliper so that retaining tabs - arrows - engage.
Adjust parking brake --> Parking brake, adjusting.

Install wheel.
Check brake fluid level.
Brake caliper to brake carrier 35 Nm
Use new bolts!

Brake line to brake caliper 14 Nm
Parking brake, adjusting
A new adjustment is necessary only after replacing brake cables, brake calipers or brake discs.
Remove center console --> 68 - INTERIOR EQUIPMENT .

Operate foot brake forcefully at least three times.
Apply parking brake 3 times and then release.
Parking brake lever in rest position.
Fig. 70: Parking Brake Cable And Adjustment Nut

Tighten adjustment nut - 1 - far enough...
Fig. 71: Adjusting Parking Brake

...until levers - 1 - on brake calipers lift off from stop - 2 -.

Distance - a - to stop - 2 - at left and right brake pads together must not fall short 1 mm and not
exceed 3 mm.
Check that both wheels turn freely.
Due to the automatic rear brake adjuster, there is no need to adjust the parking brake after making initial
adjustment.
PARKING BRAKE LEVER, ASSEMBLY OVERVIEW
Parking brake lever, assembly overview
Fig. 72: Parking Brake Lever, Assembly Overview

1 - Parking brake lever
Illustration of Touran
Before removing, remove center console
2 - Hex nut, 15 Nm
3 - Trim for parking brake handle
4 - Relay rod
5 - Compensator bracket
6 - Adjustment nut
7 - Parking brake switch
8 - Parking brake cables
Removing and installing --> Parking brake cable, removing and installing
Parking brake cable, removing and installing
Removing
Release parking brake.

Remove center console --> 68 - INTERIOR EQUIPMENT .

Loosen adjustment nut - 1 - far enough until respective parking brake cable - 2 - can be disengaged
from compensator bracket - 3 -.
Pry off spring clip - 1 -.

Press lever on brake caliper - 2 - in direction of - arrow - and unhook brake cable - 3 -.

Press retaining tabs - arrows - inward.

Press lever on brake caliper - 1 - in direction of - arrow - and disengage parking brake cable - 2 -.
Fig. 76: Parking Brake Cable And Torx Bolt

Remove Torx bolt - 1 - and then loosen mounting clip from parking brake cable - 2 -.
Fig. 77: Hand Brake Cable, Guide Tube And Bracket

Disengage parking brake cable from bracket - 1 - and pull brake cable out of guide tube - 2 -.
Installing
Fig. 78: Hand Brake Cable, Guide Tube And Bracket

Push parking brake cable into guide tube - 2 - and engage it in bracket - 1 -.
Press spring clip - 1 - on to parking brake cable.

Push parking brake cable into bracket on brake caliper so that retaining tabs - arrows - engage.
Fig. 81: Parking Brake Cable And Torx Bolt

Parking brake cable - 2 - must be installed free of tension between bracket on brake caliper and mounting
clip.
Only bolt mounting clip - 1 - on to longitudinal control arm.

Hook parking brake cable - 2 - into compensator bracket - 3 -.

Pre-load parking brake cable using adjustment nut - 1 -.
Adjust parking brake --> Parking brake, adjusting.
BRAKE PEDAL, ASSEMBLY OVERVIEW
Brake pedal, assembly overview
CAUTION: The brake pedal travel must not be restricted by additional floor
coverings.
Grease all bearing areas with grease G 000 602 before assembling.
Fig. 83: Brake Pedal, Assembly Overview

1 - Mounting bracket
2 - Self-locking hex nut, 25 Nm
Replace each time
3 - Brake light switch F

On vehicles from KW 50/05, Brake Light Switch F is located on brake master cylinder --> Brake
booster/brake master cylinder, assembly overview
Clip brake pedal at pressure rod of brake booster before installing brake light switch --> Hold push
rod ball head in front of mounting and push brake pedal in direction of brake booster, so the ball
head locates audibly. under Joining brake pedal to brake booster.
Lubricate tappet head with polycarbamide grease G 052 142 A2.
Adjust brake light switch --> Brake Light Switch F up to KW 50/05, removing, installing and
adjusting
4 - Hex head bolt
5 - Brake pedal
6 - Cover
7 - Ball socket
8 - Wheel hub support
For ball head of brake servo push rod
Replace each time
10 - Bushing
11 - Pivot pin
Separating brake pedal from brake booster
Fig. 84: Release Tool T 10159

Release tool T10159
Remove trim on drivers side --> 70 - INTERIOR TRIM .
Only on vehicles with brake light switch on mounting bracket:
Disconnect connector from Brake Light Switch F.

Remove Brake Light Switch F by rotating 45 ° toward left.
Procedure for all vehicles:
Fig. 85: Separating The Brake Pedal From The Brake Booster
Press brake pedal in direction of brake booster and hold.
2 - Push rod
3 - Retaining lugs
Insert release tool T10159 and pull in direction of driver seat. When doing this, counter-hold on brake
pedal. (At this moment the pedal must not be allowed to move backward). The mounting retaining
lugs - 3 - will thereby be pressed off the ball head of the push rod - 2 -.
For ease of illustration separating the brake pedal from the brake booster is shown with the pedal cluster
removed.
Pull release tool T10159 and brake pedal together toward the driver seat. (The brake pedal will
thereby be pulled off the ball head of the push rod).
Joining brake pedal to brake booster
Fig. 86: Holding Push Rod Ball Head In Front Of Mounting And Pushing Brake Pedal In Direction
Of Brake Booster
Hold push rod ball head in front of mounting and push brake pedal in direction of brake booster, so
the ball head locates audibly.
Install and adjust Brake Light Switch F --> Brake Light Switch F up to KW 50/05, removing,
installing and adjusting.
Brake Light Switch F up to KW 50/05, removing, installing and adjusting
On vehicles from KW 50/05, brake light switch is located on brake master cylinder --> Brake
booster/brake master cylinder, assembly overview.
Fig. 87: Identifying Brake Light Switch

Removing and installing of the brake light switch must only be performed while operating rod is pressed in,
otherwise the engaging mechanism of the brake light switch will be damaged.
Brake Light Switch must be removed for adjustment.
Remove trim on drivers side --> 70 - INTERIOR TRIM .

Removing
Disconnect connector from Brake Light Switch F.

Remove Brake Light Switch F by turning 45 ° to left.
Installing and adjusting
To ensure secure installation, brake light switch F must NOT be reused after removal
CAUTION: "New style" switches have an internal switch mechanism that will
be damaged if not installed and adjusted according to the
following procedure.
DO NOT depress switch plunger or otherwise rotate the retaining
collar of the switch prior to installation.
Brake pedal must be held in the up position (not depressed)
during switch installation.
Before installing brake light switch, lube the tappet head with polycarbamide grease G 052 142 A2 .
Before installing, pull out plunger completely.
Fig. 88: Installing Brake Light Switch

Guide switch through assembly hole, press against the pedal and secure by rotating 45 ° toward right.
Brake pedal remains always in rest position (not operated).
NOTE: The above action turns the plunger shoe into the correct orientation to
make electrical contacts in switch operate, as well as locks in the
plunger adjustment against the brake pedal.
CAUTION: When installing, switch must be rotated until it is fully locked and the
electrical connector is in the horizontal position. Inspect to ensure
internal stop pin on retaining collar is fully seated against outer shell.
Connect brake light switch connector.
Check function of brake light.

Install trim on drivers side --> 70 - INTERIOR TRIM .
47 - BRAKES - HYDRAULIC COMPONENTS

FRONT BRAKE CALIPER, SERVICING
Brake caliper FN 3, servicing
When carrying out repairs, install all parts supplied in repair kit.
Only use mineral spirits to clean brake parts.
Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals.
Fig. 89: Exploded View Of FN 3 Front Brake Calipers

1 - Dust cap
Install onto bleeder valve

2 - Bleed valve, 10 Nm
Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.
3 - Caps
Insert into bushing
4 - Guide pins, 30 Nm
5 - Bushing
Insert in brake caliper
6 - Brake caliper
7 - Brake carrier
Fastened with brake caliper
8 - Retaining spring
Insert with both ends in holes of brake caliper
9 - Sealing ring
Removing and installing --> FN 3 brake caliper piston, removing and installing
10 - Piston
Apply thin coat of brake cylinder paste G 052 150 A2 on piston
11 - Protective cap
Do not damage when inserting piston
FN 3 brake caliper piston, removing and installing
Fig. 90: Special Tools: FN 3 Brake Caliper Piston, Removing And Installing
Disassembly wedge 3409

Piston resetting tool T10145
Assembly device for protective cap T10146/6
Removing
Fig. 91: Placing Piece Of Wood Into Recess Of Caliper, So That The Piston Is Not Damaged
Force piston out of brake caliper using compressed air - arrow -.
Set a piece of wood into the valley, so that the piston is not damaged.
Fig. 92: Removing Protective Cap From Brake Caliper Using Trim Removal Wedge 3409
Remove protective cap from brake caliper with disassembly wedge 3409.
Fig. 93: Removing Brake Caliper Seal Using Wedge 3409

Remove oil seal using trim removal wedge 3409.

When removing make sure that the surface of the cylinder is not damaged.
Installing
The surface of the piston and seal must only be cleaned with mineral spirits and then dried.
Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.
Insert oil seal into brake caliper.
Fig. 94: Identifying Protective Cap And Assembly Tool T 10146/6

Insert protective cap - A - into assembly tool T10146/6 - 1 -.
Fig. 95: Pressing Protective Cap With Assembly Tool And Piston Resetting Tool Into Brake Caliper
Press protective cap with assembly tool - 1 - and the piston resetting tool T10145 - 2 - into brake
caliper applying equal pressure all around.
Fig. 96: Pulling Protective Cap From Brake Caliper By Hand

Check that the protective cap is completely seated:
Protective cap must no longer be able to be pulled from brake caliper by hand.
Fig. 97: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim
Removal Wedge
Press piston lightly on to protective cap and then secure it in this position using e.g. trim removal
wedge 3409 - 2 -.
Do not angle piston, to avoid damaging the seal sleeve.
Blow compressed air (max. 3 bar) on to protective cap - 1 -. Protective cap springs on to piston.
Fig. 98: Pressing Piston Into Brake Caliper Using Piston Resetting Tool
Press piston into brake caliper using piston resetting tool - 1 -.
The outer seal lip of the protective cap slips into the groove on the piston.
REAR BRAKE CALIPER, SERVICING
Brake caliper CII 38, servicing
New brake calipers are filled with brake fluid and pre-bled.
When carrying out repairs it is essential to pre-bleed the brake calipers (without brake pads) before
installing in the vehicle --> Pre-bleeding brake caliper.
Fig. 99: Assembly Overview, Brake Caliper CII 38

1 - Brake caliper with parking brake cable lever
Replace brake caliper if leaking at parking brake cable lever

After repairing, pre-bleed caliper housing --> Pre-bleeding brake caliper
2 - Dust cap
3 - Bleeder valve, 10 Nm
4 - Self-locking hex bolt, 35 Nm
Always replace
When loosening and tightening counter hold on guide pin
5 - Guide pins
Grease before pulling on protective cap
6 - Protective cap
Pull onto brake carrier and guide pin

guide pins.
8 - Protective cap
Pull outer sealing lip onto piston

Removing and installing --> Brake caliper piston, removing
9 - Piston with automatic adjustment

Before assembling, apply thin coat of assembly paste G 052 150 A2 to piston
10 - Sealing ring
Brake caliper CII 41, servicing
New brake calipers are filled with brake fluid and pre-bled.
In case of repair, brake calipers must always be pre-bled before being installed into vehicle (without
brake pads) --> Pre-bleeding brake caliper.
Fig. 100: Exploded View Of Brake caliper CII 41

1 - Brake caliper with parking brake cable lever
Replace brake caliper if leaking at parking brake cable lever

Pre-bleed brake caliper after repairing --> Pre-bleeding brake caliper
2 - Dust cap
3 - Bleed valve, 10 Nm
4 - Hex bolt, self-locking, 35 Nm
Replace
When loosening and tightening counter hold on guide pin
5 - Guide pin with stepping

Grease before pulling on protective cap

6 - Guide pins
7 - Protective cap
Pull onto brake carrier and guide pin

guide pins.
9 - Protective cap
Pull outer sealing lip onto piston

10 - Piston with automatic adjustment

Before assembling, coat piston thinly with assembly paste G 052 150 A2
11 - Sealing ring
Brake caliper piston, removing
Fig. 101: Brake Piston Reset Tool T10165

Resetting and extracting tool T10165
Fig. 102: Wedge 3409

Disassembly wedge 3409
Screw piston out of brake caliper housing by turning the knurled wheel counter-clockwise.
Insert reset and screw out tool so that collar makes contact on piston.
Fig. 103: Piston Compressing And Extracting Tool Inserted So Collar Makes Contact On Piston
If piston is difficult to move, use a 13 mm open end wrench on the flats - arrow A - provided for this
purpose.
Fig. 104: Removing Seal Using Wedge 3409

Remove oil seal using trim removal wedge 3409.
Brake caliper piston, installing
The surface of the piston and seal must only be cleaned with mineral spirits and then dried.
Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.
Fig. 105: Identifying Protective Seal With The Outer Sealing Lip On The Piston
Place protective seal with outer sealing lip on the piston.
Fig. 106: Inserting The Inner Sealing Lip Into The Grove In The Cylinder Using Wedge 3409
Using trim removal wedge 3409 , insert inner sealing lip into cylinder groove.
When doing this, hold piston in front of brake caliper.
Fig. 107: Installing Pistons Using T 10165

Screw piston into housing by turning knurled wheel clockwise.

To screw in, use plate T10165/1 as an aid.
Insert reset and screw out tool so that collar makes contact on brake caliper.
When moving the piston using piston resetting tool T10145 or by depressing brake pedal, the
automatic adjustment in the brake caliper is destroyed.
Pre-bleeding brake caliper
Fig. 108: Identifying Bleed Valve, Standard Bleeder Bottle & Threaded Hole
Open bleeder valve - arrow A - and fill with brake fluid using standard bleeder bottle until brake fluid
flows out of threaded hole (end of brake hose) - arrow B - without bubbles. Close bleeder valve.
Position brake caliper as illustrated to pre-bleed.
PRESSURE LEAK TEST

Pressure leak test
Fig. 109: Brake Pressure Gauge V.A.G 1310 A

Brake pressure gauge 0-250 bar V.A.G 1310 A

Adapter M 10 V.A.G 1310/6
Test conditions:
Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) operating properly and free of
leaks.
Remove bleeder valve at one of the front brake calipers. Connect brake pressure gauge V.A.G 1310 A
and bleed.
Apply pressure to brake pedal until the gauge indicates a pressure of 50 bar. The pressure must not
drop by more than 4 bar during the test period of 45 seconds. Replace master cylinder if pressure
drops greatly.
BRAKE SYSTEM, BLEEDING
Brake system, bleeding
Description covers bleeding of brake system using the brake filler and bleeder tool VAS 5234.
NOTE: Bleeding the braking system on vehicles with ABS is carried out as for
vehicles with conventional braking systems.
Only use new brake fluid conforming to US standard FMVSS 116 DOT 4.
Genuine VW/Audi brake fluid conforms to this specification.
Brake fluid is poisonous. Also due to its corrosive effect brake fluid
must not come into contact with paintwork.
Brake fluid is hygroscopic, which means it absorbs moisture from the
ambient air and should always be stored in air tight containers.
Rinse off spillages, by using plenty of water.
There must be a pressure of 2 bar to bleed the hydraulic unit.
Brake system, bleeding using brake filler/bleeder tool VAS 5234
Fig. 110: Brake Filler And Bleeder Unit VAS 5234

Brake filler/bleeder unit VAS 5234
Brake filler/bleeder unit suction adapter V.A.G 1869/4
NOTE: If one chamber of brake fluid reservoir has been run completely empty
on vehicles with ABS/ASR or ABS/EDL/ASR/ESP (e.g. leaks in brake
system), a pre-bleeding of the brake system must be performed first.
Remove rear wheels.
Pre-bleed:
Connect brake filler/bleeder unit VAS 5234.
Bleeding sequence:
1 - Bleed left front and right front brake caliper together simultaneously
2 - Bleed left rear and right rear brake caliper together simultaneously
Leave bleeder screw open, with brake fluid hose connected, until brake fluid is free from air bubbles
out of the bleeder screw.
The hydraulic unit must be bled once more via function "Basic setting" using.
Initiate basic setting (to bleed brake system):
Connecting VAS 5051 and selecting functions --> Vehicle Diagnostic, Testing and Information
System VAS 5051 , connecting and selecting functions.
Then bleed brake system normally
Bleeding (normal):
Adhere strictly to work sequence when bleeding brake system.
Connect brake filler and bleeder unit VAS 5234.

Open bleeder valves in the specified order and bleed brake calipers.
1 - Left front brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
Use suitable bleeder hose. It must fit tightly on bleeder valve so that no air can enter brake system.
Leave brake caliper bleeder valve open, with bleeder hose connected, until brake fluid discharges free
of air bubbles.
Subsequent bleeding
A second technician is required to assist:
Depress brake pedal forcefully and hold.

Open bleeder valve at brake caliper.
Press brake pedal down onto stop.
Close bleeder screw with pedal depressed.
Release brake pedal slowly.
This bleeding procedure must be performed 5 times per brake caliper.
Bleeding sequence:
1 - Left front brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
A road test must be performed after bleeding. During this, at least one ABS regulation must be
performed!
Install rear wheels.
Changing brake fluid (every 2 years)
Changing brake fluid
BRAKE BOOSTER/BRAKE MASTER CYLINDER, ASSEMBLY OVERVIEW
Brake booster/brake master cylinder, assembly overview
NOTE: Use only new brake fluid. Observe information on brake fluid reservoir!
Fig. 111: Brake Booster/Brake Master Cylinder, Assembly Overview

1 - Brake pedal mounting bracket

Replace each time
3 - Gasket
For brake booster
4 - Brake booster
On gasoline engines the vacuum required is taken from the intake manifold.
Some vehicles with gasoline engine and automatic transmission are equipped with a Brake System
Vacuum Pump V192 --> Brake system vacuum pump V192.
A vacuum sensor is installed in vehicles with OHB-V --> Brake Booster Vacuum Sensor G483 ,
removing and installing.
To produce vacuum with diesel engines, a vacuum pump is equipped --> Vacuum pump for brake
booster (Diesel vehicles), overview
Functional check:
With engine switched off, depress brake pedal firmly several times (to deplete vacuum in brake
booster).

5 - Sealing ring
6 - Brake Booster Vacuum Sensor G483
Only for vehicles with OHB-V

Removing and installing --> Brake Booster Vacuum Sensor G483 , removing and installing
7 - Brake master cylinder without brake light switch

8 - Brake master cylinder with brake light switch

9 - Brake light switch F

On vehicles before KW 50/05, Brake Light Switch F is located on brake pedal --> Brake pedal,
assembly overview
10 - Inner Torx bolt, 5 Nm
11 - Heat shield
Replace each time it is removed
15 - Sealing plug
Coat with brake fluid and press into brake fluid reservoir
17 - Cap
18 - Sealing plug
19 - Vacuum hose
Vacuum pump for brake booster (Diesel vehicles), overview
Fig. 112: Tandem Pump, Vacuum Hose And Fuel Lines

Vacuum pump for 4 cyl. Diesel engine (2 valve):
1. Tandem pump (vacuum pump and Fuel Pump (FP))

2. Vacuum hose to brake booster with check-valve
3. Supply hose
4. Return hose
Removing and installing tandem pump --> 20 - FUEL SUPPLY .
Check-valve, checking
Fig. 113: Locating Check Valve

Check valve - A - must allow air to flow through in direction of - arrow -.

Check-valve must remain closed for opposite direction.
Observe correct installation position!
Brake system vacuum pump V192
Location of Brake System Vacuum Pump V192 is located on automatic transmission at front in direction of
travel.
It is not possible to service the Brake System Vacuum Pump V192. If there is a malfunction, replace Brake
System Vacuum Pump V192.
Removing
Fig. 114: Identifying Vacuum Hose, Harness Connector, Bracket And Brake System Vacuum Pump
Disconnect vacuum hose - 1 - from Brake System Vacuum Pump V192.

Disconnect harness connector - 2 - for Brake System Vacuum Pump V192.
Remove remaining harness connectors and wires from bracket - 3 -.
Remove bolts - arrows - bracket - 3 - with Brake System Vacuum Pump V192.
Fig. 115: Locating Brake System Vacuum Pump V192 And Bracket
Remove bolts - arrows - Brake System Vacuum Pump V192 - 1 - from bracket - 2 -.
Installing
Brake System Vacuum Pump V192 to bracket 8 Nm
Bracket to automatic transmission 25 Nm
Brake Light Switch F from KW 50/05, removing and installing
On vehicles before KW 50/05, brake light switch is located on brake pedal.
Removing

On some vehicles, intake hose must be removed.
Fig. 116: Removing/Installing Brake Light Switch F From Kw 45/05

Disconnect connector - 1 - from Brake Light Switch F.

Remove bolt - 2 - from brake master cylinder.
Pull Brake Light Switch F - 3 - downward and off from the brake master cylinder and remove it from
the retaining tab at the top - 4 -.
Installing
Tightening torque:
Torx bolt to brake master cylinder 5 Nm
BRAKE MASTER CYLINDER, REMOVING AND INSTALLING
Brake master cylinder, removing and installing
Fig. 117: Identifying Special Tools -- Brake Booster, Removing And Installing
Hose clamps 3094

Brake filler/bleeder unit V.A.G 1869
Removing
Note or request radio code on vehicles with coded radio if necessary.

Battery, removing and installing. --> 27 - STARTER, GENERATOR, CRUISE CONTROL .
Remove battery carrier.
Place sufficient lint-free cloths in area of engine and transmission.

Extract as much brake fluid as possible from brake fluid reservoir using brake filler and bleeder unit
VAS 5234 or extraction device V.A.G 1869/4.
For vehicles with manual transmission:
Fig. 118: Identifying Clutch Master Cylinder, Supply Hose And Fluid Level Warning Indicator
Sensor Connector
Disconnect clutch master cylinder supply hose - B - using Hose Clamps Up to 25 mm dia. 3094.
Pull off supply hose - B - for clutch master cylinder.
Continued for all vehicles:
Disconnect connector - A - from floating warning indicator sensor.

Disconnect connector from Brake Light Switch F (only on vehicles from KW 50/05).
Remove brake fluid reservoir. To do this press locking tabs on the reservoir outward and
simultaneously pull brake fluid reservoir out of sealing plugs.
Fig. 119: Brake Master Cylinder, Brake Lines And Nuts

Unfasten brake lines - 1 - at brake master cylinder and plug brake lines using sealing plugs from repair
kit Part No. 1H0 698 311 A.
Remove nuts - 2 - from main brake cylinder.

If equipped, remove heat shield.
Carefully take brake master cylinder out of brake booster.
Installing
Installation is performed in the reverse sequence.
Observe the following points when installing:
When installing the brake master cylinder and brake booster, make sure that the push rod is correctly
located in the brake master cylinder.
Bleed braking system --> Brake system, bleeding
Brake master cylinder to brake booster 25 Nm
Use new nuts!

Brake lines to brake master cylinder 14 Nm
Battery holder to body 20 Nm
BRAKE BOOSTER, REMOVING AND INSTALLING
Brake booster, removing and installing
Fig. 120: Identifying Special Tools - Brake Booster, Removing And Installing
Hose clamps 3094

Brake filler/bleeder unit V.A.G 1869
Fig. 121: Hose Clamps 3093

Hose clamps 3093
Removing
Note or request radio code on vehicles with coded radio if necessary.

Disconnect battery. --> 27 - STARTER, GENERATOR, CRUISE CONTROL
Battery, removing and installing. --> 27 - STARTER, GENERATOR, CRUISE CONTROL .
Remove battery carrier.
Place sufficient lint-free cloths in area of engine and transmission.

Extract as much brake fluid as possible from brake fluid reservoir using brake filler and bleeder unit
VAS 5234 or extraction device V.A.G 1869/4.
Fig. 122: Clutch Master Cylinder And Supply Hose

Disconnect clutch master cylinder supply hose - B - using Hose Clamps Up to 25 mm dia. 3094.
Pull off supply hose - B - for clutch master cylinder.
Disconnect connector - A - from floating warning indicator sensor.

Disconnect connector from Brake Light Switch F (only on vehicles from KW 50/05).
Remove brake fluid reservoir. To do this press locking tabs on reservoir outward and simultaneously
pull brake fluid reservoir out of sealing plugs.
Fig. 123: Brake Master Cylinder, Mounting Nuts And Brake Lines
Unfasten brake lines - 1 - at brake master cylinder and plug brake lines with sealing plugs from repair
kit Part No. 1H0 698 311 A.
Remove nuts - 2 - from brake master cylinder.
If equipped, remove heat shield.
Carefully take brake master cylinder out of brake booster.
Pull vacuum hose out of brake booster.
Fig. 124: Identifying Cable And Mounting Bracket

Loosen cable - 1 - , unscrew bracket - 2 - and set it aside -->

34 - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 0A4 -- JETTA (A5
PLATFORM)
34 - CONTROLS, HOUSING for 6 SPD. DIRECT SHIFT AUTOMATIC TRANSMISSION
02E FRONT WHEEL DRIVE -- JETTA (A5 PLATFORM)
34 - MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL
TRANSMISSION 02Q -- JETTA (A5 PLATFORM)
.
For vehicles with automatic transmission:
Fig. 125: Clamping Off Automatic Transmission Coolant Lines

Clamp off coolant line at cooler for automatic transmission using hose clamp 3093 and two hose
clamps 3094 and disconnect from cooler for automatic transmission.
Remove drivers side footwell trim --> 68 - INTERIOR EQUIPMENT .
Fig. 126: Identifying Brake Light Switch And Connector

Disconnect connector - 1 - from brake light switch.
Remove Brake Light Switch - 2 - by rotating 45 ° toward left.

Disconnect brake pedal from brake booster --> Separating brake pedal from brake booster.
Fig. 127: Identifying Brake Booster Fasteners

Remove nuts - 1 - from brake booster.

Carefully remove brake booster from vehicle.
Installing
Observe the following points when installing:
Clip brake pedal together with brake booster --> Hold push rod ball head in front of mounting and
push brake pedal in direction of brake booster, so the ball head locates audibly. under Joining brake
pedal to brake booster
Connect battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL
Bleed brake system --> Brake system, bleeding and clutch -->
34 - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 0A4 -- JETTA (A5
PLATFORM)
34 - CONTROLS, HOUSING for 6 SPD. DIRECT SHIFT AUTOMATIC TRANSMISSION
02E FRONT WHEEL DRIVE -- JETTA (A5 PLATFORM)
34 - MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL
TRANSMISSION 02Q -- JETTA (A5 PLATFORM)
after installing.
Adjust brake light switch --> Brake Light Switch F up to KW 50/05, removing, installing and
adjusting.
Brake booster to pedal assembly/bulkhead 25 Nm
Use new nuts!

Brake master cylinder to brake booster 25 Nm
Use new nuts!

Brake lines to brake master cylinder 14 Nm
Battery holder to body 20 Nm
BRAKE LINE REPAIRS
Brake line repairs
Flare brake lines with 5 mm outer diameter using brake line flaring appliance VAS 6056 without damaging
coating. In this way, brake lines can be inexpensively partially replaced in certain cases.
Working with the flaring appliance V.A.G 1356 is not permitted due to the coating and the diameter of the
black brake lines.
NOTE: Brake lines must not be bent more than 90 ° , otherwise they kink or
deform causes unacceptable constriction in the line.
Disconnect brake lines preferably at vehicle floor.
Position of intermediate pieces should be selected so that they cannot
rub against moving parts.
Do not lubricate spindle, clean only with mineral spirits.
Fig. 128: Brake Line Flaring Appliance VAS 6056

Brake line flaring appliance VAS 6056
Fig. 129: Brake Filler And Bleeder Unit VAS 5234

Listing of individual tools:
Fig. 130: Brake Line Repair Tools
1 - Flaring appliance VAS 6056/1
Two flaring jaws VAS 6056/6 are installed in the flaring appliance VAS 6056/1
2 - Tube cutter VAS 6056/2
3 - Brake line shearing tool VAS 6056/3
The threaded pins (in shaft and at sides) are set and must not be adjusted!
4 - Self-grip pliers with plastic clamping jaws VAS 6056/4
5 - Line bending tool VAS 6056/5
6 - SW6 angle screwdriver
7 - Flaring jaws VAS 6056/7
Flaring tool - assembly overview
Fig. 131: Flaring Tool, Assembly Overview

1 - Upper part of flaring tool
Remove to change flaring jaws
2 - Hand grip mount
Must be removed to reach retaining screw for upper part
3 - Retaining screw
For upper part of flaring tool
4 - flaring jaws threaded pins
Center and hold the flaring jaws

2 mm hex socket head
5 - Flaring jaws
Various
Assembly instructions --> Flaring jaws assembly instructions:
Flaring jaws assembly instructions:
Fig. 132: VAS 6056/6 (Dark) For Black Brake Lines And VAS 6056/7 (Light) For Green Brake Lines
VAS 6056/6 (dark) for black brake lines

VAS 6056/7 (light) for green brake lines
NOTE: The arrow on the rounded side of the flaring jaws must face toward
edge of housing and the straight side of the flaring jaws must be
installed toward spindle, otherwise flared head will not be formed
correctly.
Instructions
Remove affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid
and dispose of it correctly.
Fig. 133: Disconnecting Brake Line At Appropriate Location With Line Cutter
Disconnect brake line at appropriate location (straight, accessible part) with line cutter - 2 -.
Remove piece to be exchanged.
Lubricate brake line surface.
Fig. 134: Brake Line Clamped In Self-Grip Pliers

Clamp brake line in self-grip pliers - 4 - so that 50 mm of the plastic clamping jaws show.
Clamp shearing tool - 3 - in a drill and place it on brake line.
Shear coating from brake line at a slow drill RPM and with light pressure against the line.
NOTE: The length of the sheared-off portion is determined by the stop in the
shearing tool.
Remove shearing tool from brake line and remove shearing remains.
Fig. 135: Identifying Self-Grip Pliers, Tube Fitting And Brake Line
Remove self-grip pliers and tube fitting - D - from brake line.
Fig. 136: Sliding Brake Line Against Stop In Flaring Tool

Slide brake line - B - against stop - A - in flaring tool.
NOTE: Brake line must contact stop when hex socket heat screws are
tightened, otherwise flared head will not be formed correctly.
Clamp brake line in flaring tool until it cannot be moved any more. Fold stop - A - up and tighten hex
socket head screws diagonally with angle screw driver - C -.
Fig. 137: Turning Spindle To Stop In Flaring Tool

Turn spindle to stop in flaring tool.

Turn spindle back.
Loosen hex socket head screws diagonally.
Remove brake line from flaring tool, clean and check brake line and flared head.
Briefly rinse part of brake line remaining in vehicle.
Connect brake charger/bleeder unit VAS 5234 , place bleeder container hose on flanged head of brake
line and run brake charger/bleeder unit VAS 5234 briefly until some brake fluid runs through.
Blow out brake line to be inserted with compressed air.
Fig. 138: Brake Lines Joined With Connecting Piece

Join brake lines with connecting piece - E -.

Assemble brake line.

Frenos VW Jetta-Bora 2009.

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2009 Volkswagen Jetta SEL

2005-2007 BRAKES Brake System - Jetta (A5 Platform)

Brake System - Jetta (A5 Platform)

00 - GENERAL, TECHNICAL DATA

Allocation Electronic parts catalog "ETKA".

Front wheel brakes

Engine version PR No. Front brakes

Rear wheel brakes

Engine version PR No. Rear brakes

TECHNICAL DATA, BRAKES

Brake master cylinder and brake booster

Brake master cylinder Diameter in mm 22

Fig. 1: Exploded View Of Front Brake Calipers (FN 3)

Item Pr.- No. 1ZE/1ZP

Item Pr.- No. 1LL/1ZD

Rear brake (disc brake)

Rear brake CII 38

Fig. 2: Exploded View Of Rear Brake CII

Item Pr.- No. 1KY

Rear brake CII 41 (15)

Fig. 3: Exploded View Of Rear Brake CII

Item Pr.- No. 1KE/1KF

Rear brake CII 41 (16)

Fig. 4: Exploded View Of Rear Brake CII

Item Pr.- No. 1KJ

45 - ANTI-LOCK BRAKE SYSTEM

ABS allocation in Left Hand Drive (LHD) vehicles.

1 - Hydraulic unit and control module

Fig. 6: Identifying Control Module, Hydraulic Unit And Hydraulic Pump

NOTES FOR REPAIR WORK ON ANTI-LOCK BRAKE SYSTEM

Notes for repair work on Anti-lock Brake System

Only use genuine packed parts.

VEHICLE DIAGNOSTIC, TESTING AND INFORMATION SYSTEM VAS 5051 , CONNECTING

Special tools, testers and auxiliary items required

Fig. 7: VAS 5051 Vehicle Diagnosis, Testing and Information System

Vehicle diagnostic, test and information system VAS 5051

Fig. 8: Identifying VAS 5051 And VAS 5051/1

Connect diagnostic cable - 2 - connector to Data Link Connector (DLC).

Fig. 9: Identifying Volkswagen Tester VAS 5051, On Switch

Touch Guided Fault Finding on screen.

Confirm entered data.

Select "01-On Board Diagnostic (OBD) capable system..." indicated on display.

Select desired function on display.

ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLATION LOCATIONS

ABS Mark 70 (ABS/ASR)

1 - ABS control module J104

Location: On hydraulic unit on right side of engine compartment.

2 - ABS Hydraulic Unit N55

Location: In engine compartment, right side

The hydraulic unit consists of the following components:

ABS hydraulic pump V64

Valve block (contains inlet and outlet valves)

Removing and installing

3 - Brake Pad Wear Indicator Lamp K32

Location: In the instrument cluster

4 - ABS Warning Lamp K47

Location: In the instrument cluster

5 - Traction Control Indicator Lamp K86

Location: In the instrument cluster

6 - Brake System Warning Lamp K118

Location: In the instrument cluster

7 - Brake Light Switch F up to KW 50/05

Includes Brake Pedal Switch F47