VW Eos 2006, Golf Mk5 2004, Golf Plus Mk5 2005, Touran 2003 Brake Systems - Workshop Manual (PDFDrive)

Service
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Brake systems
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0058970520

Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Touran 2003 ➤
Brake systems - Edition 05.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Front brakes, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Front brakes, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Front brakes, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Rear brakes, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Rear brakes, front-wheel drive Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Rear brakes, four-wheel drive Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Rear brakes, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Brake master cylinder and brake servo, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Brake master cylinder and brake servo, Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Test for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Test for vehicles with four-wheel drive via a Haldex coupling . . . . . . . . . . . . . . . . . . . . . . 9
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2 Notes for repair work on anti-lock agen
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3 Connecting VAS 5051 and d selecting functions . . . . . . . . . . .u.ar.a . . . . . . . . . . . . . . . . . . . . .
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4 Electrical/electronic acomponents
ut and fitting locations . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . 15
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4.1 ABS Mark 70 (ABS/TCS)
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4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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6 Assembly overview - hydraulic unit, brake servo/brake master cylinder . . . . . . . . . . . . . . 26

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6.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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6.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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7 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 56
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7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 56

7.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) . . 57
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7.3 Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive) . . 58
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8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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8.1 Removing and installing ESP sensor unit G419 (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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8.2 Removing and installing ESP sensor unit G419 (Golf, Eos) . . . . . . . . . . . . . . . . . . . . . . . . 60
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8.3 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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8.4 Removing and installing brake servo vacuum sender G483 . . . . . . . . . . . . . . . . . . . . . . . . 62

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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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1.1 Repairing front brakes, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.4 Repairing front brake, FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i

1.7 Repairing front brake, FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Repairing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Repairing rear brake CI 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Repairing rear brake CII 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.7 Repairing rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.10 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 Removing and installing handbrake cable up to model year 2007 . . . . . . . . . . . . . . . . . . . . 103
3.2 Removing and installing handbrake cable from model year 2008 . . . . . . . . . . . . . . . . . . . . 106
4 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2 Removing and installing brake light switch F from week 45 of 2005 . . . . . . . . . . . . . . . . . . 110
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . .ge.n.A.G..V.ol.ks.w.ag.e.n A. G. d. . . . . . . . . . . . . 113

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1 Repairing front brake caliper . . . . . . . . . . . b.y.V.ol.k . . . . . . . . . . . . . . . . . . . . .no.t .gu. a. . . . . . . . . 113
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1.1 Repairing brake caliper FS III . . . . . . . o.ri.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.ee. . . . . . 113
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1.2 Removing and installing piston for brake au caliper FS III . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . .
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1.3 Repairing brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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1.4 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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1.5 Repairing FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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1.6 Removing and installing piston for FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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2.3 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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4.1 Bleeding brake system using brake filling and bleeding equipment VAS 5234 or V.A.G 1869
...................................................................... 131
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4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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5 Brake servo and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle) . . . . . . . . 133
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5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle) . . . . . . 134
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5.3 Overview - exhauster pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . 136
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5.4 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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5.5 Removing and installing brake servo pressure sensor G294 . . . . . . . . . . . . . . . . . . . . . . 137
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5.6 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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5.7 Removing and installing brake light switch F as of week 45/05 . . . . . . . . . . . . . . . . . . . . . . 138
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6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ii Contents
8 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

8.1 Separating point on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.2 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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Contents iii
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iv Contents
00 – Technical data
1 Brake allocation via PR No.
The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
Example of a vehicle data sticker:
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes -1KQ
♦ Arrow 2 - Front brakes -1ZE
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
♦ The following tables explain the PR numbers. These are rel‐
evant for the brake caliper/brake disc and brake pads.
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1.1 Front brakes, Touran

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Engine PR No. Front brake

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1.6 l - 75 kW 1ZE FN3 (15”)

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1.4 l - 103 kW FSI

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2.0 l -110 kW FSI

1.9 l - 66 kW TDI
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1.9 l - 74, 77 kW TDI

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2.0 l - 100, 103 kW TDI

1.4 l -125 kW FSI 1LJ FN3 (16”)
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2.0 l - 125 kW TDI

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1.6 l - 85 kW FSI 1ZP FN3 (15”)

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1.2 Front brakes, Golf
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1.4 l - 55, 59 kW 1ZF1) / 1ZM FS III (15”)

1.4 l -66 kW FSI
1.6 l - 75 kW
1.6 l - 85 kW FSI2)
2.0 l - 85 kW
1.9 l - 66 kW TDI
1. Brake allocation via PR No. 1

1.9 l - 77 kW TDI 3)
2.0 l -55 kW SDI
1.6 l - 85 kW FSI4) 1ZE FN3 (15”)
1.4 l - 88, 90 kW FSI
1.4 l - 103, 110 kW FSI
2.0 l -110 kW FSI
1.9 l - 77 kW TDI 5)
2.0 l - 100, 103 kW TDI
2.0 l -147 kW FSI 1LJ / 1LL FN3 (16”)
1.4 l -125 kW FSI 1LJ
2.0 l - 125 kW TDI
3.2 l -184 kW 1LM FNR-G (17”)
1) the 1ZE brake was installed at the start of series production.
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1.6 l -75 kW 1ZP FN3 (15”)
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1.9 l - 74 kW TDI
2.0 l -147 kW FSI 1ZD / 1LV FN3 (16”)
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Engine PR No. Front brake f inform
1.6 l - 85 kW FSI 1ZE FN3 (15”)

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2.0 l -147 kW FSI 1LJ FN3 (16”)

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2.0 l - 100, 103 kW TDI

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3.2 l -184 kW
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
2.0 l -147 kW FSI 1ZD FN3 (16”)
3.2 l -184 kW
1.4 Rear brakes, Touran

Engine PR No. Rear brake
1.6 l - 75 kW 1KF CII 41 (15”)
1.6 l - 85 kW FSI
1.4 l -103 kW FSI
2.0 l -110 kW FSI
1.9 l - 66 kW TDI
2 Rep. Gr.00 - Technical data

1.9 l - 74, 77 kW TDI

2.0 l - 100, 103 kW TDI
1.4 l -125 kW FSI 1KJ 1) CII 41 (16”)
2.0 l - 125 kW TDI
1) Gradual switch to 1KF from the end of 2006
1.6 l - 85 kW FSI 1KE CII 41 (15”)
2.0 l -110 kW
1.5 Rear brakes, front-wheel drive Golf

Without Golf Variant:
1.4 l - 55, 59 kW 1KQ / 1KD CI 38 (15”)
1.4 l - 66 kW FSI agen
AG. Volkswagen AG d
oes
lksw not
1.6 l - 75 kW by
Vo gu
ara
ed
is nte
1.6 l - 85 kW FSI hor eo
aut ra
2.0 l - 85 kW ss c
ce
e
nl
1.4 l - 88, 90 kW FSI
pt
du
an
itte
1.4 l - 103, 110 kW FSI
y li
erm
ab
ility
2.0 l -110 kW FSI
ot p
wit
, is n
2.0 l - 55 kW SDI
h re
hole
1.9 l - 66 kW TDI
spec
es, in part or in w
1.9 l - 77 kW TDI
t to the co
2.0 l - 100, 103 kW TDI
2.0 l - 147 kW FSI 1KY CII 38 (16”)
rrectness of i
1.4 l - 125 kW FSI 1KZ 1)
l purpos
2.0 l - 125 kW TDI nform

ercia
1) Gradual switch to 1KD from the end of 2006

m
at
Golf Variant only:

om
ion
c
in t
or

his
ate
do
riv
1.6 l - 75 kW 1KF CII 41 (15”)

p
cum
or
1.6 l - 85 kW FSI
f
en
ng
t.
yi Co
2.0 l - 110 kW FSI Cop py
t. rig
gh ht
1.9 l - 74, 77 kW TDI yri
p by
o Vo
by c lksw
2.0 l - 100, 103 kW TDI cted agen
Prote AG.

1.6 l - 75 kW 1KE CII 41 (15”)
1.6 l - 85 kW FSI
2.0 l -110 kW
2.5 l - 110 kW
2.0 l - 147 kW FSI
1.9 l - 77 kW TDI
2.0 l - 100, 103 kW TDI
1. Brake allocation via PR No. 3

2.0 l - 147 kW FSI 1KV CII 38 (16”)
1.6 Rear brakes, four-wheel drive Golf

2.0 l - 110 kW FSI 1KF CII 41 (15”)
1.9 l - 77 kW TDI
2.0 l - 100, 103 kW TDI
3.2 l - 184 kW 2EL CII 41 (17”)
Engine PR No. Rear
agen
AG. Vbrake
olkswagen AG
does
lksw not
2.0 l - 110 kW 1KE by Vo CII 41 (15”) gu
a
ed ran
oris tee
1.7 Rear brakes, Eos au
th or
ac
ss
ce
e

nl
pt
du
an
itte
1.6 l - 85 kW FSI 1KD CI 38 (15”)
y li
erm
ab
2.0 l - 110 kW FSI
ility
ot p
wit
, is n
2.0 l - 100, 103 kW TDI
h re
hole
2.0 l - 147 kW FSI 1KZ CII 38 (16”)
spec
es, in part or in w
3.2 l - 184 kW
t to the co
rrectness of i
l purpos
2.0 l - 147 kW FSI 1KJ CII 41 (16”)

3.2 l - 184 kW
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Technical data for brakes
2.1 Brake master cylinder and brake servo,

Touran
Brake master cylinder ∅ in mm 22
Brake servo (LHD) ∅ in inches 11
Brake servo (RHD) ∅ in inches 7/8
2.2 Brake master cylinder and brake servo,

Golf, Eos
Brake master cylinder ∅ in mm 22
Brake servo (LHD) ∅ in inches 10
Brake servo (RHD) ∅ in inches 7/8
2.3 Front brakes

2.3.1 Front brakes FS III
Item PR No. 1ZF / 1ZM
1 Brake caliper FS III (15”)
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
back plate
AG. Volkswagen AG d
agen o
3 Brake disc Volksw∅ in 280es not g
ed
by
mm ua
ran
oris tee
Brake autdisc,
h mm 22 or
ac
thickness
ss
ce
e
nl
Brake disc, mm 19
pt
du
an
wear limit
itte
y li
erm
ab
4 Brake caliper ∅ in 54
ility
ot p
piston mm
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Technical data for brakes 5

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Eos 2006 ➤ , Golf 2004 ➤aut,h Golf Plus 2005 ➤ , Touran 2003 ➤ ra
s c
Brake systems - Edition s05.2008
ce
e
nl
pt
du
an
2.3.2 Front brakes FN 3
itte
y li
erm
ab
ility
ot p
Item PR No. 1ZE / 1ZP
wit
, is n
h re
1 Brake caliper FN3 (15”)
hole
spec
2 Brake pad, mm 14
es, in part or in w
thickness
t to the co
limit without
rrectness of i
back plate
l purpos
3 Brake disc ∅ in 288

mm
Brake disc, mm 25
nform
ercia
thickness
m
at
om
Brake disc, mm 22
ion
c
wear limit
in t
or
his
te
a
do
riv
piston mm
p
cum
for
en
ng
t.
yi
Item PR No. 1LJ / 1LL / 1ZD / 1LV
Co
Cop py
ht. rig
1 Brake caliper FN3 (16”)
rig ht
py by
co Vo
by lksw
2 Brake pad, mm Prote
cted 14 AG.
agen
thickness
limit without
back plate
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
piston mm
2.3.3 Front brakes FNR-G

Item PR No. 1LK / 1LM
1 Brake caliper FNR-G (17”)
2 Brake pad, mm 14
thickness
limit without
back plate
mm
Brake disc, mm 30
thickness
Brake disc, mm 27
wear limit
piston mm

2.4 Rear brakes (disc brakes)

2.4.1 Rear brakes CI 38
AG. Volkswagen AG d
Item PR No. lkswagen 1KQ
oes no / 1KD
o t gu
yV
1 Brake
ris
ed b caliper CI 38 (15”)
ara
nte
ho eo
2 autBrake pad, mm 11 ra
ss thickness c
ce
e
nl
pt
du
an
itte
limit without
y li
erm
ab
back plate
ility
ot p
wit
, is n
mm
h re
hole
spec
Brake disc, mm 10
es, in part or in w
thickness
t to the co
Brake disc, mm 8
wear limit
rrectness of i
piston mm
l purpos
2.4.2 Rear brakes CII 38

nf
ercia
orm
m
Item PR No. 1KY / 1KZ / 1KV atio

om
n in
or c
1 Brake caliper CII 38 (16")

thi
te
sd
a
2 Brake pad, mm 11
iv
o
r
rp
cu
thickness
o
m
f
en
ng
t.
Brake pad, wear op
yi
2 Co
limit without
C py
t. rig
gh
back plate
ht
pyri by
Vo
o
by c lksw
3 Prote Brake disc
cted ∅ in AG. 286
agen
mm
Brake disc, mm 12
thickness
Brake disc, 10
wear limit
piston mm
2. Technical data for brakes 7

2.4.3 Rear brakes CII 41

Item PR No. 1KF / 1KE
2 Brake pad, mm 11
thickness
limit without
back plate
mm
Brake disc, mm 12
thickness
Brake disc, mm 10
wear limit
piston mm
Item PR No. 1KJ

2 Brake pad, mm 11
thickness
Brake pad, wear mm 2 wage
es n
limit without yV
olks ot g
ua
back plate ir se
d b ran
tee
o
3 Brake disc ∅ in 286 auth or
ac
mm ss
ce
le
un
pt
Brake disc, mm 12
an
d
itte
thickness
y li
rm
ab
Brake disc, mm 10
pe
ility
ot
wear limit
wit
, is n
h re
hole
spec
piston mm
es, in part or in w
t to the co
Item PR No. 2EL / 2EA
rrectness of i
2 Brake pad, mm 11
thickness
l purpos

limit without nform
ercia
back plate
m

com
tion in
mm
r
te o
thi
Brake disc, mm 22
s
iva
do
thickness
r
rp
cum
fo
Brake disc, mm 20
en
ng
t.
yi Co
wear limit t. Cop py
rig
gh
ht
pyri by
Vo
piston mm
co lksw
by
cted agen
Prote AG.

3 Brake test
3.1 General
♦ The drive is provided by the roller dynamometer.
♦ For the test, ensure for vehicles with a manual gearbox that
the gear lever is in neutral and for vehicles with an automatic
gearbox, that the selector lever is in “N”.
♦ For test, observe specifications provided by manufacturer of
roller dynamometer.
Note
The brake regulation systems do not function when ignition is .off.

gen AG
Volkswagen AG
d a oes
ksw not
y Vol gu
b
3.2 Test for vehicles with front-wheel drive
ara
ed nte
oris eo
th
au ra
The brake test must be performed on asssingle-axle roller dyna‐ c
mometer.
ce
le
un
pt
an
d
itte
The maximum test speed must not exceed 6 km/h.
y li
erm
ab
ility
The test rigs authorised by Volkswagen fulfil these requirements.
ot p
wit
is n
3.3 Test for vehicles with four-wheel drive
h re
ole,
spec
via a Haldex coupling
t to the co
3.3.1 The brake test should be performed on
rrectne
a single-axle roller dynamometer with
contra-rotating rollers for four-wheel
ss o
drive vehicles.
cial p
f inform
mer
Contra-rotating means that the dynamometer rollers are driven

atio
m
forwards on one side and backwards on the opposite side.

o
n
c
i
or
This prevents brake forces being transferred to the drive train.

thi
te
sd
iva
The forward rotating wheel is measured during the test, which

pr
cum
r
fo
means two brake tests per axle must be performed.

en
ng
t.
yi Co
op
The maximum test speed must not exceed 6 km/h. C py
t. rig
gh ht
yri
The test rigs authorised by Volkswagen fulfil these requirements.
p by
co Vo
by lksw
cted agen
Prote
3.3.2 If no test rig is available for four-wheel
AG.
drive vehicles, the brake test can also be

carried out on a standard single-axle
roller dynamometer as follows:
– Drive vehicle forwards onto the rollers.
– Switch engine off and wait for 2 seconds.
– Carry out front brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
– Drive vehicle forwards until rear wheels are positioned on roll‐
ers.
3. Brake test 9
– Switch engine off and wait for 2 seconds.

– Carry out rear brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

45 – Anti-lock brake system

1 Generalolnotes agen on anti-lock brake sys‐
AG . Volkswag
en AG
doe
ksw s no
t gu
temrise y V
d b aran
te
tho eo
The ABS brakess
au system is divided diagonally. The servo-assis‐ r ac
tance is effected pneumatically by the vacuum brake servo unit.
ce
e
nl
pt
du
an
Vehicles with ABS are not fitted with a mechanical brake pressure
itte
y li
regulator. Specially matched software in the control unit regulates
erm
ab
the brake force distribution on the rear axle.
ility
ot p
wit
, is n
Faults in the ABS do not influence the brake system and servo
h re
assistance. The conventional brake system remains functional
hole
spec
even without ABS. A change in braking behaviour is to be reck‐
es, in part or in w
oned with. After the ABS warning lamp comes on, the rear wheels
t to the co
may lock prematurely during braking!
ABS layout in left-hand drive vehicle.
rrectness of i
1 - Hydraulic unit and control unit
l purpos
2 - Brake servo
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
The hydraulic unit -2- and control unit -1- form one component. yri
p by
o Vo
They can be separated only when removed. Hydraulic pump -3-
c by lksw
cted agen
must not be separated from hydraulic unit.
Prote AG.
With ABS/EDL/TCS/ESP - separation is not possible in vehicles

with hydraulic brake servo or hill hold assist.
1. General notes on anti-lock brake system 11

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005au ➤ , Touran 2003 ➤
th or
ac
Brake systems - Edition 05.2008 ss
ce
e
nl
pt
du
an
itte
y li
2 Notes for repair work on anti-lock
erm
ab
ility
ot p
brake system
wit
, is n
h re
hole
♦ Before carrying out repair work on the anti-lock brake system,
spec
determine the cause of the fault as well as the control unit code
es, in part or in w
using “Guided Fault Finding”.
t to the co
“Guided Fault Finding” is carried out with the vehicle diagnostic,
testing and information system -VAS 5051- .
rrectness of i
♦ Disconnect battery earth strap with ignition switched off.
♦ Before carrying out welding work with an electric welding unit, l purpos
note ⇒ General Information; Body Repairs, General Body Re‐
nf
ercia
pairs .
orm
m
atio
♦ When working with brake fluid, observe the valid, relevant
om
n in
safety precautions and notes ⇒ page 130 .
or c
thi
te
sd
♦ After work for which the brake system had to be opened, bleed
iva
o
r
the brake system with brake filling and bleeding equipment -

rp
cu
o
m
VAS 5234- or -V.A.G 1869- ⇒ page 130 .
f
en
ng
t.
yi Co
op
♦ During the final road test, ensure that a controlled brake test
C py
t. rig
gh
is performed at least once (pulsations must be felt at the brake
ht
pyri by
Vo
pedal).
co lksw
by
cted agen
Prote AG.
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1 H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Make sure not to touch any contact surfaces on the connector,
pressure sensor and control unit as well as the silicone gel by
hand or with objects.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95 °C for only a short
period, and to a maximum of 85 °C for longer periods (approx.
2 hours). Ensure that no brake fluid enters connectors.
12 Rep. Gr.45 - Anti-lock brake system

3 Connecting -VAS 5051- and select‐

ing functions
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS 5051-
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
lkswage es n
o ot g
WARNING d byV ua
ran
ir se tee
tho
or
♦ During a road test,
au you must always secure testing and ac
ss
measuring equipment on the back seat.
ce
le
un
pt
♦ These devices may be operated only by a passenger while
an
d
itte
y li
the vehicle is in motion.
erm
ab
ility
ot p
wit
is n
– Connect connector of diagnosis cable -VAS 5051/1- or - h re

ole,
VAS 5051/3- to diagnostic connection.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Connecting VAS 5051 and selecting functions 13

lkswage es n
Vo ot g
Eos 2006ed➤ , Golf 2004 ➤ , Golf Plus 2005 ➤
by ua, Touran
ran 2003 ➤
ir s
Braketh systems - Edition 05.2008
o tee
or
au ac
ss
– Switch on tester -arrow-.
ce
e
nl
pt
du
an
The tester is ready for operation when the selector buttons for the
itte
y li
erm
operating modes appear on the screen.
ab
ility
ot p
– Switch on ignition.
wit
, is n
h re
– Touch Guided Fault Finding on screen.
hole
spec
es, in part or in w
– Select one after another:
t to the co
♦ Brand
♦ Type
rrectness of i
♦ Model year
l purpos
♦ Body version
nf
ercia
o
♦ Engine code
rm
m
atio
m
– Confirm data entered.

o
n in
or c
Wait until tester has interrogated all control units in vehicle.
thi
te
sd
iva
o
– Press Go to and select function “Function/component selec‐
r
rp
cu
o
m
tion”.
f
en
ng
t.
yi Co
op
– Select “Running gear” on display. C py
t. rig
gh ht
yri by
– Select “Brake systems” on display. cop Vo
by lksw
cted agen
Prote
– Select “01 Self-diagnosis capable system …” shown on dis‐
AG.
play.
– Select “Anti-lock brake system …” shown on display.
– Select “Function” shown on display.
Now all possible functions from the anti-lock brake system instal‐
led in the vehicle will be displayed.
– Select desired function on display.

4 Electrical/electronic components and

fitting locations
olkswagen AG
en AG. V
4.1 ABS yMark
Vol
ksw 70 (ABS/TCS) es not
ag do
g
b ua
ed ran
oris tee
th or
1 - ABS -J104- control
au unit ac
ss
❑ Fitting location: on the
ce
le
un
pt
hydraulic unit on right in
an
d
itte
engine compartment.
y li
rm
ab
pe
❑ Do not separate con‐
ility
ot
nector before success‐
wit
, is n
fully completing self-di‐
h re
hole
agnosis. Switch ignition
spec
off before disconnecting
es, in part or in w
t to the co
connector.
❑ Removing and installing
⇒ page 28
rrectness of i
2 - ABS hydraulic unit -N55-
l purpos
❑ Fitting location: on right

in engine compartment.
nform
ercia
The hydraulic unit consists of

m
the components:
a
com
tion in
❑ ABS hydraulic pump -
r
te o
thi
V64-
s
iva
do
r
❑ Valve block (includes in‐

rp
cum
fo
let/outlet valves)
en
ng
t.
yi Co
❑ ABS hydraulic pump - Cop py
t. rig
V64- and valve block yri
gh by
ht
must not be separated
op Vo
by c lksw
from one another.
cted agen
Prote AG.
⇒ page 28
3 - Brake pad warning lamp -
K32-
❑ Fitting location: in dash
panel insert.
❑ Function: ⇒ page 23 .
4 - ABS warning lamp -K47-
panel insert.
5 - Traction control system warning lamp -K86-
❑ Fitting location: in dash panel insert.
6 - Brake system warning lamp -K118-
7 - Brake light switch -F- up to week 45/2005
❑ Including brake pedal switch -F47- .
❑ Fitting location: on brake pedal.
❑ Removing, installing and adjusting ⇒ page 110 .
4. Electrical/electronic components and fitting locations 15

8 - Brake light switch -F- from week 45/2005 n AG. Volkswagen AG do

wage es n
❑ Including brake pedal switch -F47- . yV
olks ot g
ua
d b
❑ Fitting location: on brake master cylinder.
o
ir se
ran
tee
th or
❑ Removing and installing ⇒ page s138au ac
s
ce
e
9 - TCS button -E256-
nl
pt
du
an
❑ Fitting location: in centre console.
itte
y li
erm
ab
10 - Diagnostic connection
ility
ot p
wit
❑ Fitting location: driver side footwell cover.
, is n
h re
hole
11 - Front right speed sensor -G45- / front left speed sensor -G47-
spec
es, in part or in w
❑ Removing and installing ⇒ page 56
t to the co
12 - Wheel bearing housing
13 - Wheel bearing/hub unit
rrectness of i
❑ ABS sensor ring is installed in the wheel bearing.
l purpos
14 - Rear right speed sensor -G44- / rear left speed sensor -G46-
nf
ercia
❑ Removing and installing (front-wheel drive) ⇒ page 57
orm
❑ Removing and installing (four-wheel drive) ⇒ page 58
m
atio
om
n in
15 - Rear axle assembly with stub axle
or c
thi
te
16 - Wheel hub with wheel bearing
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP)
1 - ABS control unit -J104-

engine compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
connector.
⇒ page 36
the components:
V64-
❑ Brake pressure sender -
G201-
let/outlet valves)
❑ ABS hydraulic wagpump - olkswagen AG does
en AG. V
s
V64- and Vovalve block
lk not
gu
by
mustris
e not be separated
d ara
nte
from
utho one another. eo
ra
a
ss c
ce
le
⇒ page 36
un
pt
an
d
itte

y li
erm
ab
K32-
ility
ot p

wit
is n
panel insert.
h re
ole,
spec
t to the co

rrectne
5 - ESP and TCS warning lamp -K155-

ss
❑ Only vehicles with ABS/EDL/TCS/ESP.

o
cial p
f in

form
mer
atio
om

c
i
or
n thi
e

t
sd
iva
o
r
p
cum
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8 - Brake light switch -F- from week 45/2005


9 - TCS and ESP button -E256-
10 - ESP sensor unit -G419-
❑ Only vehicles with ABS/EDL/TCS/ESP. n AG. Volkswagen AG do
swage es n
❑ Fitting location in Touran: behind glove box.y Vo l k ot g
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ed ran
❑ Fitting location in Golf and Eos: under oright
ris front seat. tee
th or
❑ Combined lateral acceleration sender
ss
au
-G200- , yaw rate sender -G202- and longitudinal ac acceleration
sender -G251-
ce
le
un
pt
❑ Combined in one housing.
an
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❑ Removing and installing (Touran) ⇒ page 60
rm
ab
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❑ Removing and installing (Golf, Eos) ⇒ page 60 .
ot
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hole
spec
es, in part or in w
t to the co
12 - Steering angle sender -G85-
❑ Fitting location: on steering column between steering wheel and steering column switch.
rrectness of i
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13 - Front right/left speed sensor -G45- / -G47-

nform
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m
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tion in
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16 - Rear right/left speed sensor -G44- / -G46-
r
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Figure for front-wheel drive

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❑ Removing and installing (four-wheel drive) ⇒ page 58
p by
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Prote AG.


4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008

engine compartment.
❑ Do not separate con‐ n AG. Volkswagen AG do
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nector before success‐ byV
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fully completing self-di‐ ir se
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agnosis. Switch ignition uth o
or
off before disconnectingss a ac
connector.
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⇒ page 42
erm
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the components:
rrectness of i
V64-
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G201-
nform
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let/outlet valves)
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ion
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V64- and valve block
in t
or
must not be separated
his
ate
do
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from one another.

p
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or

f
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⇒ page 42
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panel insert.
8 - Brake light switch -F- from week 45/2005

9 - TCS and ESP button -E256-
10 - ESP sensor unit -G419-
❑ Fitting location in Touran: behind glove box.
❑ Fitting location in Golf and Eos: under right front seat.
❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration
sender -G251-
❑ Combined in one housing.
❑ Removing and installing (Touran) ⇒ page 60
❑ Removing and installing (Golf, Eos) ⇒ page 60 .
❑ Fitting location: on steering column between steering wheel and steering column switch.
. Volkswagen AG
gen AG58
❑ Removing and installing (four-wheel drive)lks⇒wapage does
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17 - Wheel bearing housing ris
edb ran
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Figure for front-wheel drive au ac
ss
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Prote AG.
Rep. Gr.45 - Anti-lock brake system
4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008
1-
hydraulic unit on right in n AG. Volkswagen AG do
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engine compartment. byV
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❑ Do not separate con‐ ir se tee
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nector before success‐ aut or
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connector.
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The following components are
wit
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integrated into the control unit:
h re
♦ Lateral acceleration sender
hole
spec
-G200-
es, in part or in w
t to the co
♦ Yaw rate sender -G202-
♦ Longitudinal acceleration
rrectness of i
sender -G251- (in vehicles
with four-wheel drive and
l purpos
hill hold assist)

nform
ercia
⇒ page 51
m
at
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ion
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or
his
ate
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cum
or
the components:
f
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t.
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V64-
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pyri by
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G201-
AG.

let/outlet valves)
V64- and valve block
must not be separated from one another.
3 - Brake pad warning lamp -K32-
7 - Brake light switch -F-

❑ Fitting location: on brake master cylinder. olkswage es n
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❑ Removing and installing ⇒ page 138 d b ua
ran
ir se tee
ho
8 - TCS and ESP button -E256- aut or
ac
ss
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un
pt
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spec
es, in part or in w
t to the co
Note
❑ Fitting location A: on steering column between steering wheel and steering column switch.
rrectness of i
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❑ Fitting location B: in steering box.

nform
ercia

m
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com
ti
on in
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❑ Removing and installing (four-wheel drive) ⇒ page 58 cop Vo
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Prote AG.

AG. Volkswagen AG d
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5 Faults display via warning lamps tho eo
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Warning lamps, Touran
nl
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5. Fault display via warning lamps 23

Warning lamps, Golf

Item Description
1 Traction control system warning lamp -K86-
ESP and TCS warning lamp -K155-
2 Brake pad warning lamp -K32-
3 ABS warning lamp -K47-
4 Brake system warning lamp -K118-
Brake pad warning lamp -K32-
♦ If the brake pad warning lamp -K32- -2- does not go out 3 sec‐
onds after the ignition is switched on, or it comes on during
vehicle operation, the fault may be:
-a- The brake pads are worn.
Check brake pads/linings on front and rear axles. Renew worn
brake pads/linings.
-b- There is a wiring fault. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
ABS warning lamp -K47-
♦ If the ABS warning lamp -K47- -3- does not go out after switch‐
ing ignition on and completion of test sequence then the fault
may be:
-a- The voltage supply is below 10 volts.
-b- There is a fault in the ABS. agen
AG. Volkswagen AG d
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In the event of an ABS fault -b-, the anti-lock brake system
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remains switched off, but the brake system remains fully op‐
pt
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-c- A temporary speed sensor fault occurred since the vehicle was
h re
last started.
hole
spec
es, in part or in w
In this case, the ABS warning lamp will go out automatically after
t to the co
the engine is restarted and the vehicle speed exceeds 20 km/h.
-d- The connection from dash panel insert to ABS control unit -
J104- is interrupted. ⇒ Current flow diagrams, Electrical fault rrectness of i
finding and Fitting locations
l purpos
-e- The dash panel insert is defective.

nform
ercia
ABS warning lamp -K47- and brake system warning lamp -K118-
m
♦ If the ABS warning lamp -K47- -3- goes out but the brake sys‐
at
om
io
tem warning lamp -K118- -4- remains on, then the fault may
n
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in t
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be:
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-a- The handbrake is applied.

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-b- The brake fluid level is too low (the warning lamp flashes).
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Three warning tones are audible after ignition is switched on. t. C rig
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-c- There is a fault in the wiring to brake system warning lamp -
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K118- . ⇒ Current flow diagrams, Electrical fault finding and Fitting Prote AG.
locations
♦ If the ABS warning lamp -K47- -3- and the brake system warn‐
ing lamp -K118- -4- light up, then the ABS is defective. A
change in braking behaviour is to be reckoned with.

WARNING
After the ABS warning lamp -K47- and the brake system warn‐
ing lamp -K118- have lit up, it is possible that the rear wheels
will lock up earlier.
Traction control system warning lamp -K86-

♦ If the traction control system warning lamp -K86- -1- does not
go out after switching ignition on and completion of test se‐
quence then the fault may be:
There is a fault present which only affects the TCS. The ABS and
EBD safety systems on the vehicle remain fully functional ⇒ In‐
terrogate fault memory.
-a- Short-circuit to positive in TCS button -E256- .
-b- There is a fault in the activation of the traction control system
warning lamp -K86- ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
-c- The TSC system was shut off by the TCS button -E256- .
If traction control system warning lamp -K86- flashes while the
vehicle is in motion, the TCS is regulatingksthe n AG. Volkswagen AG do
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♦ If the TCS warning lamp -K86- is-1-
ed does not light up during the
b ua
ran
self-test, the fault may be: thor tee
or
u ac
sa
-a- The TCS warning lamp -K86-
s is defective ⇒ perform electrical
ce
e
check.
nl
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ESP and TCS warning lamp -K155-
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♦ If the ESP and TCS warning lamp -K155- -1- does not go out
wit
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after ignition is switched on and test sequence is completed,

h re
then the fault may be:
hole
spec
A fault in the system affecting only the TCS/ESP. The ABS/EDL
es, in part or in w
t to the co
and EBD safety systems on the vehicle remain fully functional ⇒
Interrogate fault memory.
-a- Short-circuit to positive in TCS and ESP button -E256- .
rrectness of i
-b- There is a fault in the activation of the ESP and TCS warning
l purpos
lamp -K155- ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations.
nf
ercia
-c- The TCS/ESP system was shut off by the TCS and ESP button
rm
m
atio
-E256- .
om
n in
c
If the ESP and TCS warning lamp -K155- flashes while the vehicle
or
thi
e
is in motion, the TCS or ESP system is regulating the system.

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♦ If the ESP and TCS warning lamp -K155- -1- does not light up
o
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f
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ng
during the self-test, the fault may be:

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-a- The ESP and TCS warning lamp -K155- is defective ⇒ perform
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electrical check. p by
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Prote AG.
5. Fault display via warning lamps 25

6 Assembly overview - hydraulic unit,

brake servo/brake master cylinder
6.1 ABS Mark 70 (ABS/TCS) AG. Volkswagen AG d

agen oes
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1 - ABS control unit -J104- orise nte
eo
h
ut
❑ Removing and installing ss a ra
c
⇒ page 28
ce
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nl
pt
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⇒ page 28
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3 - Brake line
hole
spec
❑ From primary piston cir‐
es, in part or in w
cuit of brake master cyl‐
t to the co
inder to hydraulic unit
❑ Identification: union nut
with thread M 10 x 1
rrectness of i
4 - Brake line
l purpos
❑ From secondary piston

circuit of brake master
nf
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o
cylinder to hydraulic unit
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5 - Brake line
t
sd
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❑ To front left brake cali‐
o
m
f
per
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❑ Identification: union nut C py
ht. rig
with thread M 12 x 1 rig ht
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6 - Brake line cted agen
Prote AG.
❑ To front right brake cali‐
per
7 - Brake line
❑ To rear left brake caliper
8 - Brake line
❑ To rear right brake caliper
❑ Identification: union nut with thread M 10 x 1
9 - Torx socket head bolt, 5.5 Nm
❑ Use new bolts.
10 - Bracket
11 - Hexagon bolt, 8 Nm
12 - Seal
❑ For brake servo.
13 - Brake servo
❑ On petrol engines, the required vacuum is taken from the intake manifold.
❑ Diesel engines are fitted with an exhauster to create the required vacuum ⇒ page 136 .

❑ Functional check:
. Volkswagen AG
a gen AG d
– With engine switched off, depress brake pedal firmlyVolseveral times. (This will release
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oes
not
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the vacuum in the
unit.) ed by ara
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– Now step on and hold brake pedal with medium sa
u pressure and start engine. If the brake servo isr acfunctioning
properly, the brake pedal will be felt to gos down as the servo takes effect.
ce
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pt
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❑ If faulty renew complete (check all vacuum lines first).
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itte
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14 - Sealing ring
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15 - Brake master cylinder
hole
spec
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) . es, in part or in w
t to the co
❑ Cannot be repaired. If faulty, renew as a complete unit.
rrectness of i
16 - Hexagon nut, 25 Nm
l purpos
❑ Always renew after removing

17 - Sealing plug
nform
ercia
❑ Moisten with brake fluid and press into brake fluid reservoir.
m
at
om
18 - Brake fluid reservoir
ion
c
in t
or
19 - Cap
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20 - Sealing plug
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❑ Connection for vacuum hose

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21 - Vacuum hose
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❑ Fit in brake servo
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22 - Brake servo pressure sensor -G294-
AG.
❑ On vehicles with FSI engine without HBV (Hydraulic Brake with Vacuum servo)
6.1.1 Connecting brake lines from brake mas‐

ter cylinder to hydraulic unit
On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: union nut with thread M 10 x 1
B - Secondary piston circuit of master brake cylinder to hydraulic
unit.
1 - From hydraulic unit to front left brake caliper.
3 - Hydraulic unit to rear right brake caliper.
4 - Hydraulic unit to rear left brake caliper.
6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 27

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
2 - From hydraulic unit to front right brake caliper.
6.1.2 Removing control unit and hydraulic unit
Special tools and workshop

equipment required
AG. Volkswagen AG d
♦ Torque wrench -V.A.G ksw
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1331- by
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♦ Torque wrench -V.A.G ut
hor eo
1410- ss a ra
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♦ Brake pedal depressor -

nl
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V.A.G 1869/2-
itte
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rrectness of i
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Prote AG.

Sealing plugs repair kit, Part No. 1H0 698 311 A

The transport protection for the contact pins must always be
placed on the hydraulic unit after the control unit has been dis‐
connected from the hydraulic unit.
No warranty can be assumed for hydraulic units without transport
protection.
1 - Transport protection for contact pins (foam)
2 - Sealing plug M 10
Removing
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
right in the engine compartment.
WARNING
n AG. Volkswagen AG
Do not bend the brake lines in the area
olks
wage of the hydraulic unit!
does
no
yV t gu
db ara
ir se nte
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– Read out and note the
aut existing control unit code. ra
ss c
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– Note or request radio code on vehicles with coded radio if

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pt
du
necessary.
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itte
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erm
ab
– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
ility
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connecting and reconnecting battery .
wit
, is n
h re
– Remove engine cover panel.
hole
1.4 l TSI engine: spec

es, in part or in w
t to the co
– Remove pressure pipe and intake connecting pipe with regu‐
lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct
injection engine, turbocharger and compressor); Rep. Gr. 24 ;
rrectness of i
Injection system; Part I - assembly overview - intake manifold .

l purpos
– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l

direct injection engine, turbocharger and compressor); Rep.
nform
ercia
Gr. 21 ; Charge air system .

m
– Clamp off hose from coolant expansion tank and pull it off.
at
om
ion
c
1.9 l diesel engine:

in t
or
his
ate
– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel

do
priv
engine (2 valve); Rep. Gr. 21 ; Removing and installing charge

um
for
air system with turbocharger .

en
ng
t.
yi Co
op py
– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel t. C rig
gh ht
engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐ yri
p by
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ture preparation - injection .
c by lksw
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Prote AG.
– Touran vehicles only: remove plenum chamber middle bulk‐
head ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assem‐
bly overview - plenum chamber bulkhead .
– Remove connecting pipe between intake hose and turbo‐
charger.
– Remove toothed belt guard upper part.

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gen AG does
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Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤y V, Touran 2003 ➤
olk not
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Brake systems - Edition 05.2008 rised
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Diesel engines with diesel particulate filter: ss c
ce
le
un
pt
– Unscrew exhaust gas pressure sensor 1 -G450- , separate
an
d
itte
electrical connectors, unscrew and lower diesel particulate fil‐
y li
rm
ab
ter ⇒ Rep. Gr. 26 ; Assembly overview - front exhaust pipe
pe
ility
with particulate filter .
ot
wit
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Continuation for all vehicles:
hole
spec
es, in part or in w
– Release connector on control unit in direction of arrow -1- and
t to the co
pull off -2-.
– Apply brake pedal depressor -V.A.G 1869/2- .
rrectness of i
– Connect bleeder bottle hose to front left brake caliper bleeder
l purpos
valve and rear left brake caliper bleeder valve and open bleed‐
er valves.
nform
ercia
– Depress brake pedal at least 60 mm using brake pedal de‐

pressor -V.A.G 1869/2- .
m
a
com
tion in
– Close front left and rear left bleeder valve.
r
te o
thi
– Do not remove brake pedal depressor -V.A.G 1869/2- .
s
iva
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cum
– Place sufficient lint-free cloths under the control unit and hy‐
fo
en
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draulic unit.
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.
Ensure no brake fluid gets onto contacts.
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– First identify the two brake master cylinder brake lines Prote AG.
-A and B- and unscrew from the hydraulic unit.
– Immediately seal brake lines and threaded holes with seal
plugs from repair set Part No. 1H0 698 311 A.
– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.
– Pull hydraulic unit with control unit upwards out of dampers.
6.1.3 Unbolting control unit from hydraulic unit

– Place hydraulic unit with control unit upwards on a clean flat
level surface.

– Remove Torx socket head bolts -arrows-.
AG. Volkswagen AG d
agen oes
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– Without canting it, pull control unit off from hydraulic unit
h re
-arrow-. hole
spec
es, in part or in w
– Carefully pull all seals from hydraulic unit contact pins.
t to the co
WARNING
rrectness of i
♦ The printed circuit board becomes visible when the control
l purpos
unit is removed.
♦ No moisture or particles of dirt may enter the control unit.
nform
ercia
♦ Hydraulic pump must not be separated from hydraulic unit.

m
at
om
ion
♦ Avoid electrostatic charge!
c
in t
or
his
ate
do
priv
cum
or
– Cover control unit solenoids with a lint-free cloth.

f
en
ng
t.
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After separating control unit and hydraulic unit, use transport pro‐ Cop py
tection for contact pins.
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pyri by
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co lksw
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Prote AG.
6.1.4 Installing new control unit
WARNING
Severe shocks (e.g. dropping, impact) may destroy the control

unit. The control unit must not then be used.
• Clean surfaces before assembling.

– Push all seals -A- over contact pins slightly.
– Without canting it, place control unit onto hydraulic unit.
The seals are thus moved to end position.
– Bolt hydraulic unit and control unit with enclosed, new Torx
socket head bolts.
Note
♦ A new control unit may be mounted on an existing hydraulic

unit max. twice to guarantee impermeability of the elastic seal.
♦ A control unit which has already been operated in a vehicle
must not be installed a second time.

6.1.5 Installing control unit and hydraulic unit
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ When installing, ensure that rubber dampers are not pressed
out of bracket.
– Install in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- . n AG. Volkswagen AG do
lkswage es n
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– Bleed brake system ⇒ page 130 . ir se
d b ua
ran
o tee
h
– Code radio. aut or
ac
ss
– Code control unit -J104- with ⇒ Vehicle diagnosis, testing and
ce
le
un
pt
information system VAS 5051 in ”Guided fault finding”.
an
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itte
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erm
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Specified torques:
ility
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Control unit to hydraulic unit 5.5 Nm
wit
is n
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♦ Use new bolts!
ole,
spec
Hexagon bolt of hydraulic unit to bracket 8 Nm
t to the co
Brake lines to ABS assembly:
Thread M 10 x 1 14 Nm
rrectne
ss o
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⇒ page 36
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and union nut with long
thread M 12x1.
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per
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with short thread M 12x1.
6 - Brake line
❑ To front right brake caliper
❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.
7 - Brake line
❑ Identification: ∅ 5.25 mm and union nut with short thread M 12x1.
8 - Brake line
❑ Use new bolts.
10 - Bracket
12 - Seal

13 - Brake servo
❑ On petrol engines, the required vacuum is taken from the intake manifold.
❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump
⇒ page 137 .
❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 62 .
– With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the
unit.)
– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning
properly, the brake pedal will be felt to go down as the servo takes effect.
14 - Sealing ring
15 - Brake servo vacuum sender -G483-
❑ Only on vehicles having HBV
16 - Brake master cylinder agen
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agen
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unit.

olkswagen AG Brake systems - Edition 05.2008
ag en AG. V does
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equipment required
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The transport protection for the contact pins must always olks be
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mer
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– Read out and note the existing control unit code.
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1.4 l TSI engine:
– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel
engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐
charger.

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pull off -2-.
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Note
Prote AG.
Separation of the control unit and hydraulic unit is not possible in

vehicles with hydraulic brake servo or hill hold assist.
– Place hydraulic unit with control unit downwards on a clean

flat level surface.
– Remove Torx socket head bolts E5 -arrows- from hydraulic
pump.
WARNING
Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

– The hydraulic pump must therefore be secured onto the hy‐

draulic unit with the red retainer -1- from the repair kit and two
sealing plugs -2-.
– Carefully lift hydraulic unit with hydraulic pump at joint -1- up‐
wards off control unit.
When pulling off the control unit, ensure that the hydraulic unit
contact pins are not canted against the control unit solenoids.
Item 2 adapter for pump motor.
After separating control unit and hydraulic unit, use transport pro‐
AG. Volkswagen AG d
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ss
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inform
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atio
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om
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thi
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pressure sensor and control unit as well as the silicone gel and
iva
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the sealing components by hand or with objects to prevent

p
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en
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39
Prote AG.
6. Assembly overview - hydraulic unit, brake servo/brake master cylinder
– Press adapter into adapter guide to stop; it must then be en‐

gaged.
– Bolt hydraulic unit and control unit with the new Torx bolts
which are enclosed.
Note

Note

– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 130 .
AG. Volkswagen AG d
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du
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spec
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c
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ate
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lkswage es n
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ss c
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⇒ page 42
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at
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3 - Brake line
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t.
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C py
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AG.
thread M 12x1.
4 - Brake line
thread M 12x1.
5 - Brake line
per
with short thread M 12x1.
6 - Brake line
❑ To front right brake caliper
7 - Brake line
❑ Identification: ∅ 5.25 mm and union nut with short thread M 12x1.
8 - Brake line
❑ Use new bolts.
10 - Retainer
12 - Seal

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Volkswagen AG
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Brake systems - Edition 05.2008 Volksw not
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13 - Brake servo tho
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pt
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⇒ page 137 .
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spec
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es, in part or in w
t to the co
unit.)
– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning
rrectness of i
properly, the brake pedal will be felt to go down as the servo takes effect.
l purpos

nform
ercia
14 - Sealing ring
m
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❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) . t. Cop py
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17 - Heat shield
19 - Sealing plug
21 - Cap
22 - Sealing plug
23 - Vacuum hose

unit.

On hydraulic unit:
cylinder.
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equipment required
1331-
1410-
V.A.G 1869/2-
AG. Volkswagen AG d
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pyri by
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placed on the hydraulic unit after the control unit has been dis‐
connected from the hydraulic unit.
No warranty can be assumed for hydraulic units without transport
protection. gen AG
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1 - Transport protection
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1.4 l TSI engine:

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C py
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injection engine, turbocharger and compressor); Rep. Gr. 24 ; by c lksw
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charger.



pull off -2-.
er valves. AG. Volkswagen AG d
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– Depress brake pedal at least 60 mm using brake pedal d bde‐
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c
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or

f
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t.
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t. rig
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yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
Separation of the control unit and hydraulic unit is not possible in
vehicles with hydraulic brake servo or hill hold assist.
– Place hydraulic unit with control unit downwards on a clean

flat level surface.
– Remove Torx socket head bolts E5 -arrows- from hydraulic
pump.
WARNING
Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

– The hydraulic pump must therefore be secured onto the hy‐

draulic unit with the red retainer -1- from the repair kit and two
sealing plugs -2-.
lkswage es n
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d ran
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When pulling off the control unit, ensure that the hydraulic unit
n
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ate
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Item 2 adapter for pump motor.

p
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After separating control unit and hydraulic unit, use transport pro‐ t. C rig
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tection for contact pins. yri
p by
co Vo
by lksw
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WARNING

♦ Before the new control unit can be installed, the pump motor
adapter must be inserted to stop and must engage. Make sure
not to damage the adapter guide.
♦ The adapter supplied as a spare part for the control unit can
only be engaged once and then cannot be removed.
♦ The white paste on the bottom of the control unit serves as
sealant and must not be removed.
♦ Make sure not to touch any contact surfaces on the adapter,
pressure sensor and control unit as well as the silicone gel and
the sealing components by hand or with objects to prevent
them from being dirty or damaged.

Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Touran 2003
gen A➤
G. Volkswagen AG d
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Brake systems - Edition 05.2008 yV
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tho
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– Code radio.
Specified torques:
♦ Use new bolts!


AG. Volkswagen AG d
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ee 05.2008
th or
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⇒ page 51
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and union nut with
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per
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mm and union nut with thread M 12x1.
8 - Brake line
9 - Brake line
10 - Brake servo
❑ See ⇒ page 133 .
11 - Retainer
❑ Check for secure seating after installing.

12 - Torx bolt, 8 Nm
13 - Rubber damper
14 - Hexagon fitted bolt, 8 Nm
15 - Bracket
16 - Rubber damper
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cylinder.


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placed on the hydraulic unit after the control unit has been dis‐ AG. Volkswagen AG d
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connected from the hydraulic unit. by Vol not
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charger.


– Remove heat shield (if installed).

pull off -2-.
er valves.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor -V.A.G 1869/2- .
draulic unit.

– Turn hexagon fitted bolt out of retainer. AG. Volkswagen AG d
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– Pull hydraulic unit together with control unit and edretainer side‐
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– Unbolt retainer from hydraulic unit in engine compartment and
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– Place hydraulic unit with control unit upwards on a clean flat

level surface.
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– Unscrew Torx socket head bolts out of control unit.

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– Without canting it, pull control unit off from hydraulic unit
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– Carefully pull all seals from hydraulic unit contact pins.
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♦ The printed circuit board becomes visible when the control
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After separating control unit and hydraulic unit, use transport pro‐
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The seals are thus moved to end position.
– Tighten hydraulic unit and control unit diagonally in stages to
specified torque with enclosed new Torx socket head bolts.
Note

Note

WARNING
Ensure that rubber dampers of retainer are not pressed out of

bracket when installing. After installing, check hydraulic unit
with control unit for proper seating, otherwise malfunctions can
occur.

– Code radio.
Specified torques:
Control unit to hydraulic unit 2 Nm + 0.8
♦ Use new bolts! Nm
Torx bolt of hydraulic unit to bracket 8 Nm

Hexagon fitted bolt, retainer to bracket 8 Nm
AG. Volkswagen AG d
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AG.
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7 Removing and installing parts of ABS

system on front and rear axle
7.1 Removing and installing parts of ABS system on front axle
1 - ABS speed sensor

❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
⇒ page 56
2 - Hexagon socket head bolt,
8 Nm
❑ ABS sensor ring is in‐
stalled in the wheel
bearing.
4 - Drive shaft
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7.1.1 Removing and installing speed sensor

inform
on front axle
mer
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– Separate connector -1- from speed sensor wire and from

speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature 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 wire.
7.2 Removing and installing parts of anti-lock brake system on rear axle (front-
wheel drive)

and coat with high-tem‐ AG. Volkswagen AG d
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7. Removing and installing parts of ABS system on front and rear axle 57

on rear axle
Removing
– Raise vehicle.
speed sensor.
Installing
G 052 112 A3.
7.3 Removing and installing parts of anti-lock brake system on rear axle (four-
wheel drive)

❑ Before inserting sensor, gen AG. Volkswagen AG d
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on rear axle
Removing
– Raise vehicle.
speed sensor.
Installing
G 052 112 A3.
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7. Removing and installing parts of ABS system on front and rear axle 59
8 Removing and installing parts of ESP

system
8.1 Removing and installing ESP sensor

unit -G419- (Touran)
The lateral acceleration sender -G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender -G251- are in‐
stalled together in one housing behind the glove compartment.
After exchanging the ESP sensor unit -G419- , perform basic set‐
ting for lateral acceleration sender -G200- .
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit -G419- . The ESP sensor unit -G419- may not then
be used any further.
Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trims .
– Pull connector -1- off ESP sensor unit -G419- .
– Remove the two securing nuts -arrows-.
– Remove ESP sensor unit -G419- .
Installing
When installing the ESP sensor unit -G419- , make sure it is cor‐
rectly seated in its bracket and is free of stress. . Volkswage AG n AG d
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– Tighten securing nuts to 9 Nm.

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Connecting -VAS 5051- and selecting functions ⇒ page 13 .

spec
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8.2 Removing and installing ESP sensor

unit -G419- (Golf, Eos)
rrectness of i
The lateral acceleration sender -G200- , the yaw rate sender -

l purpos
G202- and the longitudinal acceleration sender -G251- are in‐

stalled in a housing under the right front seat.
nf
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After exchanging the ESP sensor unit -G419- , perform basic set‐
orm
ting for lateral acceleration sender -G200- .

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Rep. Gr.45 - Anti-lock brake system
agen
Prote AG.
WARNING
Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit -G419- . The ESP sensor unit -G419- may not then
be used any further.
Removing
– Remove right front seat together with seat frame ⇒ General
body repairs, interior; Rep. Gr. 72 .
– Remove sill panel trim ⇒ General body repairs, interior; Rep.
Gr. 68 ; Sill panel trims .
– Lift carpet and lay to the side.
AG. Volkswagen AG d
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– Pull connector -1- off ESP sensor unit -G419- .
rrectness of i
– Remove the two securing nuts -arrows-.
l purpos
– Remove ESP sensor unit -G419- .

Installing
nform
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m
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When installing the ESP sensor unit -G419- , make sure it is cor‐
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unit -G419- .
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– Tighten securing nuts to 9 Nm.

– Perform basic setting of lateral acceleration sender -G200- .
8.3 Removing and installing steering angle

sender -G85-
The steering angle sender -G85- is located between the steering
wheel and steering column switch.
Removing and installing
⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - ex‐
terior; Steering column switch .
– Then perform basic setting of steering angle sender -G85- .
8. Removing and installing parts of ESP system 61

Note
In vehicles equipped with an electromechanical power steering of

the 3rd generation, the steering angle sender is located in the
steering box from week 22/2008.
8.4 Removing and installing brake servo

vacuum sender -G483-
Removing agen
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– Removing and installing d b battery ⇒ Electrical system; Rep.guGr.
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27 ; Removing and thoriinstalling battery . eo
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– Remove battery
s tray.
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– Disconnect connector -1- from brake servo vacuum sender -
du
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– Now press circlip -1- out of groove until brake servo vacuum
or
sender -G483- -2- can be pulled out of brake servo.

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46 – Brakes - mechanism olksw

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1 Repairing front brakes or eo
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1.1 Repairing front brakes, FS III brake cal‐
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Note
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♦ Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
rrectness of i
♦ Use the brake filling and bleeding equipment -VAS 5234- or
l purpos
the extraction unit -V.A.G 1869/4- to draw off brake fluid from
the brake fluid reservoir.
nf
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♦ Before removing a brake caliper or disconnecting a brake
orm
hose, fit brake pedal depressor -V.A.G 1869/2- (when doing
m
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❑ Replace hexagon bolt
by lksw
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with hexagon bolt and
AG.
Torx bolt with Torx bolt

2 - Brake disc
❑ Ventilated, ∅ 280 mm
❑ Thickness: 22 mm
❑ Wear limit: 19 mm
❑ Always renew on both
sides of an axle.
❑ Unscrew brake caliper
prior to removing.
3 - Cross head screw / Torx
screw, 4 Nm
4 - Brake pads
❑ Thickness: 14 mm with‐
out backplate
❑ With break pad wear in‐
dicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Pad wear limit: 2 mm
without backplate
❑ Check thickness
⇒ Maintenance ; Book‐
let 18.1 .
sides of an axle.
1. Repairing front brakes 63

5 - Connector
❑ Brake pad wear indicator
6 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Repairing ⇒ page 113
7 - Guide pin, 30 Nm
8 - Cover cap
❑ Remove
9 - Brake hose with banjo union and banjo bolt, 35 Nm
11 - Cover cap
❑ Remove
12 - Bolt
13 - Bracket
❑ With integrated brake carrier.
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
16 - Hexagon socket head bolt, 8 Nm
18 - Splash plate
AG. Volkswagen AG d
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1.2 Removing byV
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Special toolsssand workshop equipment required
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♦ Torque wrench -V.A.G 1331-

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Rep. Gr.46 - Brakes - mechanism Prote AG.
♦ Piston resetting tool -T 10145-
1.2.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
– Remove wheels.
– Disconnect connector -1- for brake pad wear indicator.
– Remove cover caps -arrows-.

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65
AG.
1. Repairing front brakes
– Unscrew both guide pins -arrows- and remove from brake cal‐
iper.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pads out of brake caliper.
Cleaning:
WARNING
Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
G. Volkswagen AG d
Use only methylated spirits for cleaning the brake caliper
lksw
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1.2.2 Installing au
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Before pressing piston back into cylinder with piston resetting tool,
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pt
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– Insert inner brake pad (piston side) -1- and outer brake pad
r
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♦ Outer brake pad with small 3-finger clip -2- (coloured black).
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66 Rep. Gr.46 - Brakes - mechanism

– First position brake caliper with brake pads at bottom -arrow-

of brake carrier.
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– Reconnect connector for brake pad wear indicator.
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Note
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♦ Check brake fluid level after changing brake pads.
nform
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Specified torque:
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Guide pin to brake carrier 30 Nm
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1.3 Removing and installing brake caliper

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♦ Brake pedal depressor -V.A.G 1869/2-
1.3.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Separate connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal depressor -V.A.G. 1869/2-
Volkswag
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– Loosen both guide pins and remove from brake caliper.

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1.3.2 Installing
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• Piston is pressed back.

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– Insert inner brake pad (piston side) -1- and outer brake pad
-2- into brake caliper with retaining springs.
rrectne
♦ Inner brake pad (piston side) with large 3-finger clip -1-.
ss
♦ Outer brake pad with small 3-finger clip -2- (coloured black).
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– First position brake caliper with brake pads at bottom -arrow-

of brake carrier.
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spec
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– Fit both cover caps.
– Bolt brake hose to brake caliper.
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– Fit wheels.
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operating position. Prote AG.
♦ Check brake fluid level.
Specified torques:
Brake hose to brake caliper 35 Nm
1.4 Repairing front brake, FN 3 brake cali‐

per
Note

Assembly overview, FN3, 15 inches:

1 - Cross head screw / Torx

screw, 4 Nm
2 - Brake disc
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
3 - Brake pads
out backplate
dicator
lamp in the dash panel agen
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❑ Pad wear limit: 2 mm orise nte
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⇒ Maintenance ; Book‐
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⇒ page 72
spec
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4 - Retaining spring
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❑ Insert into both holes in
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5 - Brake carrier
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❑ Bolt to wheel bearing housing.

6 - Brake caliper
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10 - Ribbed bolt, 190 Nm
AG.
❑ Clean if reused.
11 - Bolt
12 - Bracket
❑ With bolted brake carrier.


16 - Splash plate
17 - Hexagon bolt / Torx bolt, 12 Nm
❑ M6x10 hexagon bolt revised to M6x12 Torx bolt
❑ Replace hexagon bolt with hexagon bolt and Torx bolt with Torx bolt
Assembly overview, FN3, 16 inches:
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3 - Torx bolt, 4 Nm
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4 - Brake pads
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❑ Insert into both holes in
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6 - Brake carrier
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7 - Brake caliper

9 - Cover cap
❑ Remove AG. Volkswagen AG d
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10 - Brake hose with banjo dunion
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11 - Guide pin, 30 Nmut ho eo
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12 - Cover cap s
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14 - Bracket
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-arrow- with a screwdriver and remove.
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– Take brake pad out of brake caliper or from brake carrier.
Cleaning:
WARNING

– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.
Use only methylated spirits for cleaning the brake caliper housing.
AG. Volkswagen AG d
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1.5.2 Installing y V gu
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Before pressing piston back into cylinder with piston
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h re
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spec
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t to the co
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When positioning the brake caliper, ensure that the brake pad
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correctly.
ss o
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– Insert retaining spring into brake caliper.
– Fit wheels.
AG. Volkswagen
Specified torque of wheel bolts
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Specified torque:
t to the co
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1.6.1 Removing
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.


open bleeder valve.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Pull both cover caps out of sleeve bearings of brake caliper.
– Remove brake pads from brake caliper.
1.6.2 Installing
• Outer brake pad is seated on brake carrier.
(piston).
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When positioning the brake caliper, ensure that wthe
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wit
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– Fit wheels.
s

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Brake hose to brake caliper 35 Nm

1.7 Repairing front brake, FNR-G brake cal‐

iper
Note

1 - Splash plate
3 - Brake disc
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spec
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under brake carrier.
rrectness of i
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8 - Brake pads
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❑ Check thickness ⇒ Maintenance ; Booklet 18.1 .
❑ Always renew on both sides of an axle.

9 - Brake caliper
❑ Do not disconnect brake hose when changing brake pads.
❑ Must not be unbolted from one another.
11 - Cover cap
❑ Remove AG. Volkswagen AG d
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12 - Washer d byV
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15 - Dust cap
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16 - Retainer
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17 - Bolt, 15 Nm
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18 - Brake line, 14 Nm
spec
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19 - Brake hose
t to the co
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21 - Retainer
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22 - Spring clip
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– Remove wheels. AG. Volkswagen AG d
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– Lever brake caliperbretaining
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rise
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ce
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un
vent loss.
pt
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– Take brake pads out of brake caliper.
Cleaning:
WARNING
AG. Volkswagen AG d
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– Thoroughly clean brake carrier and contact
ed by surfaces for brake
V gu
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pads and remove corrosion. horis nte
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pt
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1.8.2 Installing
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Before pressing piston back into cylinder with piston resetting tool,
hole
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
spec
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damage.
rrectness of i
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nf
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wit
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spring and press under brake carrier.
h re
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spec
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– Fit wheels.
rrectness of i
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Note
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1.9.1 Removing d byV
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pt
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erm
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spring using a screwdriver. To do this, position screwdriver
ility
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wit
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hole
spec
vent loss.
es, in part or in w
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open bleeder valve.
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nf
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– Disconnect brake hose.
rm
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– Pull both cover caps out of sleeve bearings of brake caliper.

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1.9.2 Installing rig ht
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• Piston is pressed back. Prote AG.
(piston).
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– Fit brake caliper with brake pads onto brake carrier.
– Connect brake hose to brake line from brake caliper.
– Insert brake caliper retaining spring into brake pad retaining
spring and press under brake carrier.
– Bleeding brake system
– Fit wheels.


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Specified torques:
ole,
spec
t to the co
Brake hose to brake line 14 Nm
rrectness o
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mer
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Cop py
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AG. Volkswagen AG d
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Eos 2006 ➤ , eGolf d b 2004 ➤ , Golf Plus 2005 ➤ , Touran
y gu
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Brake systems
thor - Edition 05.2008 eo
au ra
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2 un Repairing rear brake
pt
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2.1 Repairing rear brake CI 38
wit
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Note
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s
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form
mer
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perature paste
AG.
G 052 112 A3.

8 Nm
3 - Multi-point socket head bolt,
90 Nm and turn 90° further
❑ Always renew after re‐
moving
5 - Splash plate
6 - Hexagon bolt, 9 Nm / Torx
bolt, 12 Nm
❑ M6x10 hexagon bolt re‐
8 - Brake disc
❑ ∅ 255 mm
❑ When worn, renew on
both sides of axle.
prior to removing.
9 - Cross-head screw, 4 Nm
10 - Bolt
11 - Brake pads
❑ Thickness: 11 mm without backplate

AG. Volkswagen AG d
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2003 ➤
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05.2008
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❑ Pad wear limit: 2 mm without au
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12 - Brake carrier with guide pin(s) and protective cap
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❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
hole
spec
❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
es, in part or in w
t to the co
guide pins.
13 - Brake caliper
rrectness of i
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nf
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❑ Adjust handbrake cable first after repairing or replacement.
orm
❑ Adjusting handbrake ⇒ page 101 .
m
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14 - Hose retainer
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16 - Self-locking hexagon bolt, 35 Nm
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17 - Handbrake cable
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18 - Spring clip
19 - Brake hose

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2. Repairing rear brake 85

Brake systems - Edition 05.2008 olksw AG. V agen AG
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♦ Resetting and removal tool -T 10165- db
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2.2.1 Removing
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nf
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hold on guide pins.

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Cleaning:
ht
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WARNING

– Clean brake caliper, particularly the bonding surfaces for the
brake pads. These must be free of adhesive and grease res‐
idues.
2.2.2 Installing
Before pressing pistons back, draw off some brake fluid from res‐
ervoir with a bleeder bottle. Otherwise, particularly if reservoir has
been topped up, fluid will overflow and cause damage.
– Screw in piston by turning knurled wheel of resetting and re‐
moval tool - T 10165 - clockwise, do not damage protective
cap when doing this.

– To aid screwing in, use special tool T10165/1.

♦ If pistons are difficult to move, use a 13 mm open jaw spanner
on flats -arrow A- provided for this purpose.
– Pull protective foil off backing plates for brake pads.
– Insert brake pads into brake carrier.

When positioning the brake caliper, ensure that the brake pads
do not stick to the brake caliper before it is positioned correctly.
– Secure brake caliper with new self-locking bolts.
♦ The repair kit includes four self-locking hexagon bolts which
must always be installed.
– Fit wheels.
Note

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Specified torque: d b ua
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Hexagon bolt, brake caliper to brake carrier
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ac
♦ Use new bolts! ss
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pt
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spec
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2.3.1 Removing
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– Remove wheels.
es, in part or in w
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rrectness of i
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in t
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ate
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2.3.2 Installing
• The brake pads are seated on the brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts.
– Screw brake line to brake caliper.
– Hook in handbrake cable and secure on retainer with spring
clip.
– Adjusting handbrake ⇒ page 101 .
– Fit wheels.

Note

operating position.
♦ Check brake fluid level. agen
AG. Volkswagen AG d
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Specified torques: horis nte
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Hexagon bolt, brake caliper to brakesscarrier
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2.4 Repairing rear brake CII 38
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perature paste
G 052 112 A3.
8 Nm
3 - Multi-point socket head bolt,
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5 - Splash plate
7 - Wheel bearing/hub unit agen
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10 - Bolt
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11 - Brake pads
ss
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❑ Pad wear limit: 2 mm without backplate
nform
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12 - Brake carrier with guide pin(s) and protective cap

p
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❑ Supplied as genuine part, assembled with sufficient grease on guide pins. yi

t.
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guide pins.
ht
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13 - Pad retainer
cted agen
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❑ Always renew when changing pads.
14 - Brake caliper

15 - Hose retainer
17 - Self-locking hexagonn AGbolt,
. Volks35 Nm
wagen AG
swage does
❑ Renew.by Vo lk not
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18 - Handbrake
tho
ri cable tee
or
au ac
❑ss Adjusting handbrake ⇒ page 101 .
ce
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nl
19 - Spring clip
pt
du
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itte
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20 - Brake hose
erm
ab
ility
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es, in part or in w
ings
t to the co
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♦ Resetting and removal tool -T 10165- Prote
cted AG.
agen
2.5.1 Removing
– Remove wheels.


hold on guide pins. AG. Volkswagen n AG do
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– Remove brake caliper and secure with olks so that weight of
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brake caliper does not strain or damage
ris
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es, in part or in w
– Remove brake pads and pad retainers -arrows-.
t to the co
Cleaning:
rrectness of i
WARNING
l purpos
nform
ercia

m
a
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tion in
– Thoroughly clean contact surfaces for pad retainers (brake
r
te o
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pads) on brake carrier, and remove corrosion.
s
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2.5.2 Installing cop Vo
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– Insert pad retainers -arrows- and brake pads into brake carrier.
– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Secure brake caliper with newAself-locking
G. Volkswagenbolts.
A gen G do
swa es
♦ The repair kit includes
by
Volfour self-locking hexagon bolts
k not which
gu
must always berisinstalled.
ed
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– Fit wheels. s au ac
s
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pt
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wit
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es, in part or in w
several times with vehicle stationary, so that brake pads are t to the co
rrectness of i
Specified torque:
l purpos
Hexagon bolt, brake caliper to brake carrier 35 Nm

♦ Use new bolts!
nf
ercia
orm
m
atio
om
n in

or c
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2.6.1 Removing
ot
wit
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es, in part or in w
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– Remove wheels.
rrectness of i
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nform
ercia
open bleeder valve.

m
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r

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counterhold on guide pin. t. Cop py
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– Pull brake caliper off brake carrier. pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.6.2 Installing
• The brake pads are seated in the retaining springs on the
brake carrier.
bolts.
clip.
– Fit wheels.


Note

operating position.
Specified torques:
♦ Use new bolts!
2.7 Repairing rear brake CII 41

Note
lkswage es n
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♦ Every time
uth after changing pads, depress brake pedalefirmly
o
or
several
ss times with vehicle stationary, so that brake padsc are
a a
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spec

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I - Assembly overview, front-wheel drive

rrectness of i
II - Deviations, four-wheel drive

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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
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pyri by
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by
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Prote AG.


perature paste
G 052 112 A3. AG. Volkswagen AG d
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lksw not
2 - Hexagon socket head bolt, d by Vo gu
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8 Nm orise nte
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3 - Multi-point socket head
ss a bolt, c
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pt
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moving
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5 - Splash plate
hole
spec
6 - Hexagon bolt, 9 Nm / Torx
es, in part or in w
t to the co
bolt, 12 Nm
❑ M6x10 hexagon bolt re‐
rrectness of i
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nf
ercia
orm
m
8 - Brake disc
atio
om
n in
❑ 15 inches: ∅ 260 mm;
or c
thi
16 inches: ∅ 286 mm;
te
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17 inches: ∅ 310 mm
iv
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❑ Thickness, 15 and
o
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16 inches: 12 mm; 17 in‐

t.
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ches: 22 mm
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❑ Wear limit, 15 and p by
co Vo
lksw
16 inches: 10 mm; 17 in‐
by
cted agen
Prote
ches: 20 mm
AG.

both sides of axle.
❑ Unscrew brake caliper prior to removing.
10 - Bolt
❑ Front-wheel drive only
11 - Brake pads
❑ Thickness: 11 mm without backplate
❑ Pad wear limit: 2 mm without backplate
12 - Brake carrier with different guide pins and protective cap
guide pins.
❑ Installation instructions ⇒ page 97
13 - Pad retainer
❑ Always renew when changing pads.

14 - Brake caliper
AG. Volkswagen n AG do
wage es n
15 - Hose retainery Volks ot g
ua
b
ed ran
16 - Brake line,
tho
ris 14 Nm tee
or
au ac
17 - Self-locking
ss hexagon bolt, 35 Nm
ce
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nl
❑ Renew.
pt
du
an
itte
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18 - Handbrake cable
erm
ab
ility
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19 - Spring clip
hole
spec
20 - Brake hose
es, in part or in w
t to the co
Installation instructions for brake caliper CII 41, 15 inches, from
rrectness of i
week 32/2004:
l purpos
1- Shorter guide pins with steps -arrows-, leading side

2- Longer guide pins, phasing out
nf
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or
3- Balance weight, phasing out
m
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Cop py
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Vo
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by
cted agen
Prote AG.

ings

♦ Resetting and removal tool -T 10165-
2.8.1 Removing
– Remove wheels.
hold on guide pins.
– Remove brake pads and pad retainers -arrows-. AG. Volkswagen AG d

agen oes
olksw not
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Cleaning: d by ara
rise nte
tho eo
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c
WARNING ss
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un
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rm
ab
pe
ility
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wit
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– Thoroughly clean contact surfaces for pad retainers (brake

hole
spec
pads) on brake carrier, and remove corrosion.

es, in part or in w
t to the co

rrectness of i
2.8.2 Installing
l purpos
nform
ercia

m
a
com
tio

n in
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Cop py
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by
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Prote AG.


. Volkswagen AG
gen AG does
– Insert pad retainers -arrows- and brake pads into brake carrier.
Vol
ksw
a
not
by gu
ara
ed nte
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th
au ra
c
ss
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nl
pt
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
– Ensure that brake pads are seated correctly in pad retainers
rrectness of i
-arrows-.
l purpos
– Secure brake caliper with new self-locking bolts.

♦ The repair kit includes four self-locking hexagon bolts which
nf
ercia
must always be installed.
orm
m
– Fit wheels.
atio
om
n in
c

or
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e

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♦ Every time after changing pads, depress brake pedal firmly py by
co Vo
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AG.
Specified torque:
♦ Use new bolts!


AG. Volkswagen AG d
agen oes
Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤V,oTouran
lksw 2003 ➤ not
gu
by
Brake systems - Edition 05.2008 rised ara
nte
tho eo
au ra
♦ Torque wrench -V.A.G 1331- ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.9.1 Removing
– Remove wheels.
open bleeder valve.
– Remove both securing bolts from brake caliper; to do this,
counterhold on guide pin.
2.9.2 Installing

• The brake pads are seated in the retaining springs on the

brake carrier.
bolts.
clip.
– Fit wheels.
Note

operating position.
Specified torques:
♦ Use new bolts!
2.10 Adjusting handbrake

New adjustment is only necessary after renewing
wage
handbrake
n AG. Volkswagca‐
en AG
does
bles and brake calipers. yV
olks not
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ed ran
– Depending on equipment version ho of centre console, remove
ris tee
only cup holder, rear cover ors acomplete
ut centre console ⇒ or
ac
General body repairs, interior;
s Rep. Gr. 68 ; Compartments,
ce
e
covers and trims .

nl
pt
du
an
itte
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– Depress foot brake hard at least three times.

erm
ab
ility
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– Firmly pull on and then release handbrake three times.

wit
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Below the first notch, the handbrake lever must return to its re‐
hole
leased position.
spec
es, in part or in w
t to the co
• Handbrake lever in rest position.

rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
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Prote AG.

– Tighten adjusting nut -arrow (enlargement)- until ...
AG. Volkswagen AG d
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o lksw not
byV gu
ara
d
– ... lever -1- lifts off the brake caliper
or ise stop -2-. nte
h eo
ut ra
– The total distance -a- to stopsss a -2- on left and right brake cali‐ c
pers must not exceed 1.5 mm.
ce
e
nl
pt
du
an
– Check that both wheels turn freely.
itte
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erm
ab
Due to the automatic rear wheel brake adjustment there is no re‐
ility
ot p
quirement to adjust the handbrake after making new/initial ad‐
wit
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justment.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Assembly overview - handbrake lev‐

er
. Volkswagen AG
gen AG does
The illustration shows the assembly overview
Vol
kfor
swathe Touran. not
by gu
ara
ed nte
oris eo
1 - Handbrake lever th
au ra
c
ss
❑ Before removing take
ce
e
nl
out centre console.
pt
du
an
itte
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erm
ab
ility
ot p
3 - Handbrake lever trim
wit
, is n
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❑ Pull off forwards.
hole
spec
❑ Lever up release tab in
es, in part or in w
rear, lower area of han‐
t to the co
dle -arrow- with a screw‐
driver.
rrectness of i
❑ If leather upholstery is
fitted, leather is cut in
l purpos
area of locking mecha‐

nism.
nform
ercia
4 - Pull rod
m
at
5 - Compensator
om
ion
c
in t
r
6 - Adjustment nut
o
his
ate
❑ Adjusting handbrake
do
priv
c
⇒ page 101 .
um
for
en
ng
t.
yi
7 - Handbrake cables
Co
Cop py
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up to model year 2007 copy Vo
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⇒ page 103 cted agen
Prote AG.
from model year 2008
⇒ page 106
8 - Handbrake warning switch
3.1 Removing and installing handbrake ca‐

ble up to model year 2007
3.1.1 Removing
– Release handbrake
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
3. Assembly overview - handbrake lever 103

– Release adjustment nut -1- until relevant handbrake cable

-2- can be detached from compensator -3-.
– Lever spring clips off -1-.

– Press lever on brake caliper -2- in direction of arrow and de‐
tach handbrake cable -3-.
– Unscrew Torx bolt -1- and then release fastening clip from
handbrake cable -2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
– Detach handbrake cable from bracket -1- and pull handbrake

ot
wit
, is n
cable out of guide tube -2-.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Eos
AG. Vol2006
kswage➤
n A,GGolf 2004 ➤ , Golf Plus 2005 ➤ , Touran 2003 ➤
agen does
olksw not
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edb ara
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3.1.2 Installing
aut
ho eo
ra
ss c
– Push handbrake cable into guide tube -2- and attach it into
ce
le
un
pt
bracket -1-.
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Press lever on brake caliper -2- in direction of arrow and attach
nform
ercia

m
– Press spring clips -1- onto handbrake cable.
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Handbrake cable -2- must be installed without tension between

brake caliper bracket and fastening clip.
– Therefore, fastening clip -1- should only now be screwed onto
trailing arm.
– Attach handbrake cable -2- into compensator -3-.

– Pretension handbrake cable with adjustment nut -1-.
– Adjust handbrake ⇒ page 101 .

3.2 Removing and installing handbrake ca‐

ble from model year 2008
3.2.1 Removing
– Release handbrake
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
– Release adjustment nut -1- until relevant handbrake cable
-2- can be detached from compensator -3-.
– Press lever on brake caliper -2- in direction of arrow and de‐

tach handbrake cable -3-.
– Compress locking lugs -1- together and pull handbrake cable
agen
AG. Volkswagen AG d
oes
out of bracket on brake caliper. Volksw not
g y ua
db ran
rise tee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– First pull handbrake cable -1- off locking lugs, then pull com‐ spec
pletely out of bracket -2-.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Detach handbrake cable from bracket -1- and pull handbrake

cable out of guide tube -2-.
3.2.2 Installing
– Push handbrake cable into guide tube -2- and attach it into
bracket -1-.
– Insert handbrake cable -1- through aperture, then clamp it to

bracket -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
– Push handbrake cable into bracket on brake caliper until both

ot p
wit
locking lugs -1- engage.

, is n
h re
hole
– Press lever on brake caliper -2- in direction of arrow and attach

spec

es, in part or in w
t to the co
The handbrake cable must be installed without tension between

the brake caliper bracket and the bracket on the trailing arm.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Attach handbrake cable -2- into compensator -3-.

– Pretension handbrake cable with adjustment nut -1-.
– Adjust handbrake ⇒ page 101 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Assembly overview - brake pedal
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
Grease all mountings before installing with grease Part No.

G 000 602.
1 - Mounting bracket
2 - Self-locking hexagon nut,
25 Nm
❑ Including brake pedal
switch -F47- .
❑ In vehicles from week
45/2005, the brake light
switch -F- is located on
the brake master cylin‐
der ⇒ page 133 .
❑ Before installing brake
light switch, connect
brake pedal to brake
servo push rod
⇒ page 110 .
❑ Grease head of push
rod with polycarbamide gen AG
. Volkswagen AG
does
swa
grease G 052 142 A2. yV
olk not
gu
d b ara
❑ Removing and installing orise nte
eo
brake light switch aut
h
ra
⇒ page 110 ss c
ce
e
nl
pt
4 - Hexagon bolt
du
an
itte
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erm
5 - Brake pedal
ab
ility
ot p
6 - Cap
wit
, is n
h re
7 - Ball socket
hole
spec
es, in part or in w
8 - Mounting
t to the co
❑ For ball head of brake

servo plunger rod.
rrectness of i

25 Nm
l purpos
10 - Sleeve bearing
nf
ercia
11 - Pivot pin
orm
m
atio
om
n in
or c
4.1 Separating brake pedal from brake ser‐

thi
te
sd
iva
vo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Assembly overview - brake pedal 109

♦ Release tool -T 10159-
– Remove trim on driver's side ⇒ General body repairs, interior;

Rep. Gr. 70 ; Dash panel
Vehicles with brake light switch on mounting bracket only:
– Pull connector off brake light switch.
– Remove brake light switch by turning 45° to left.
– First press brake pedal in direction of brake servo and hold.
2 - Push rod
3 - Retaining lugs
– Insert release tool -T 10159- and pull in direction of driver seat.
When doing this, counter-hold on brake pedal. (At this stage
the pedal must not be allowed to move backwards.) This action en AG. Volkswagen AG
will press retaining lugs -3- of mounting off ball head of plunger
olks
wag does
not
rod -2-. ed
byV gu
ara
is nte
or
For the sake of clarity, separation of brake pedal from
au
th brake servo eo
ra
is shown with pedal cluster removed. ss c
ce
le
un
pt
– Pull release tool -T 10159- and brake pedal together towards
an
d
itte
driver seat. (This action will pull the brake pedal off the ball
y li
erm
ab
head of the plunger rod).
ility
ot p
wit
is n
h re
ole,
spec
t to the co
4.1.1 Clipping brake pedal to brake servo

rrectne
– Hold ball head of plunger rod in front of mounting and push

brake pedal in direction of brake servo, so that the ball head
ss
clicks into place.

o
cial p
f in
Continue installation in reverse order.

form
mer
Vehicles with brake light switch on mounting bracket only:

atio
om
n
c
– Install brake light switch ⇒ page 110 .

or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
4.2 Removing and installing brake light
cted agen
Prote AG.
switch - F- from week 45 of 2005

Including brake pedal switch -F47-

AG. VEos
olksw2006
agen A➤
G d,o Golf 2004 ➤ , Golf Plus 2005 ➤ , Touran 2003 ➤
agen
Volksw es n
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d by ua
ran
ise
or tee
In vehicles fromuthweek 45/2005, the brake light switch is located or
on the brake smaster
s a cylinder ⇒ page 133 . ac
ce
4.2.1 le Brake light switch, old version
un
pt
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♦ After removing the old brake light switch (see figure
spec
N46-0359), replace it with a new one (see figure N46-10145).
es, in part or in w
t to the co
♦ Distinguishing features ⇒ page 112 .
rrectness of i
Removing
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– If necessary, remove footwell vent ⇒ Heater, air conditioning

system; Rep. Gr. 80 ; Repairing heater; Removing vent .
m
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thi
The brake light switch may be removed only while operating rod
s
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do
is pressed in (brake pedal is not operated), or the locking mech‐
r
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anism of the brake light switch will be damaged.
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Installing, adjusting and locking p by
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Because old brake light switches may no longer be used, the de‐ Prote AG.
scription has been omitted.

Installing, adjusting and locking new brake light switch
⇒ page 112 .
4. Assembly overview - brake pedal 111

4.2.2 Brake light switch, new version
Note
♦ Use only new brake light switches.

♦ The most noticeable difference
to the old brake light switch is the new, bright tip of the plunger
-A-.
Removing
– If necessary, remove footwell vent ⇒ Heater, air conditioning
system; Rep. Gr. 80 ; Repairing heater; Removing vent .
The brake light switch may be removed only while operating rod
is pressed in (brake pedal is not operated), or the locking mech‐
anism of the brake light switch will be damaged.
– Remove brake light switch by turning 45° to left.
Installing, adjusting and locking
Before assembling the brake light switch, grease the bright tip of
the plunger head with polycarbamide grease G 052 142 A2.
• The brake pedal must remain at rest position while the brake
light switch is being installed. The brake pedal must not be
touched by anything but the plunger head throughout the en‐ G. Volkswage
tire installation. lksw
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– Guide brake light switch through fitting hole -arrow ho
ris 1- and tee
press it against pedal with head of plunger.s aThenut turn brake or
ac
light switch 45° to right -arrow 2- until it cans be felt to engage. ce
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– Fit brake light switch connector. an

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– Check function of brake light.
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– Install footwell vent ⇒ Heating and air conditioning system;

, is n
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Rep. Gr. 80 ; Repairing heating; Removing vents .

hole
spec
– Install trim on driver's side ⇒ General body repairs, interior;

es, in part or in w
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Prote AG.

47 – Brakes - hydraulics
1 Repairing front brake caliper
1.1 Repairing brake caliper FS III

♦ When carrying out repairs, install all parts supplied in repair
kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inder, piston and sealing ring.
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Cover caps AG. Volkswagen AG d
agen oes
❑ Insert into sleeve bear‐Volksw not
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ing. sed b ara
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4 - Guide pin, 30 Nmaut or
ac
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5 - Sleeve bearing
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❑ Insert into brake caliper.

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6 - Brake caliper
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7 - Protective cap
h re
hole

spec
⇒ page 113
es, in part or in w
t to the co
❑ Take care not to dam‐

age when inserting pis‐
ton.
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8 - Piston
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⇒ page 113
nform
ercia

sembly paste
m
at
om
G 052 150 A2 to piston

ion
c
before installing.
in t
or
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ate
9 - Sealing ring
do
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or

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⇒ page 113
n
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1.2 Removing and installing piston for brake
caliper FS III
1. Repairing front brake caliper 113

♦ Removal wedge -3409-
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1.2.1 Removing
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– Press piston out of brake caliper using compressed air.
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spec
Place a piece of wood in the recess to prevent damage to the
es, in part or in w
piston.
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– Remove seal using wedge 3409.

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1.2.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
114 Rep. Gr.47 - Brakes - hydraulics

– Apply a thin coat of assembly paste G 052 150 A2 to piston

and seal before inserting.
– Insert seal into brake caliper.
– Place outer sealing lip of protective cap on the piston.
– Insert inner sealing lip into groove in cylinder using wedge
3409.
AG. Volkswagen AG d
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When doing this, hold piston in front of brake caliper.
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– Press piston into brake caliper with piston resetting tool.

thi
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The outer sealing lip on the protective cap will then spring into the
o
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piston groove.
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Prote AG.
1.3 Repairing brake caliper FN 3

kit.


1 - Dust cap
sembly paste
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
5 - Sleeve bearing
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
❑ Insert with both ends in
holes in brake caliper.
wage
9 - Sealing ring olks es n
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❑ Removing and installing ir se
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⇒ page 116 autho
or
ac
ss
10 - Piston
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⇒ page 116
erm
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spec
es, in part or in w
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11 - Protective cap
❑ Take care not to damage when inserting piston.
rrectness of i
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1.4 Removing and installing piston for brake

nform
ercia
caliper FN 3
m
at
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on
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Prote AG.

AG. Volkswagen AG d
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♦ Piston resetting tool -T 10145- orise nte
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spec
t to the co
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♦ Assembly tool for protective caps -T 10146/6-
ss o
cial p
f inform
mer
atio
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n
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pr
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Cop py
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Prote AG.
1.4.1 Removing
piston.

– Lever off protective cap from brake caliper using wedge 3409.
AG. Volkswagen AG d
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olksw not
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– Remove seal using wedge 3409. horis nte
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When removing ensure that thes surface of the cylinder is not
s c
damaged.
ce
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ility
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es, in part or in w
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1.4.2 Installing
l purpos
nform
ercia

m
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and seal before inserting. tion in

r
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thi
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– Fit protective cap -A- in assembly tool T10146/6 -1-.

rp
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
– Press protective cap onto brake caliper so that seal is fitted

correctly all round using assembly tool -1- and piston resetting
tool -2-.
Check seat of protective cap:

– At this stage it should not be possible to remove protective cap

from brake caliper by hand.
– Press piston lightly onto protective seal and lock it in this po‐
sition with, for example, an assembly wedge -2-.
Keep piston straight to prevent damagewto
agesealing
n AG. Volcollar.
kswagen AG
doe
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Vol t gu
– Blow into protective cap using ed compressed air (max 3 bar)
by ara
-1-. During this step protective
thoris cap will spring on piston. nte
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ss
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nl
pt
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erm
ab
ility
ot p
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spec
– Press piston into brake caliper using piston resetting tool -1-.
es, in part or in w
t to the co
piston groove.
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
1.5 Repairing FNR-G brake caliper

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♦ When carrying out repairs, install all parts supplied in repair C py
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♦ Use only methylated spirits for cleaning the brake. Prote
cted AG.
agen


1 - Dust cap
sembly paste
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
5 - Sleeve bearing
6 - Brake caliper
❑ Must not be unbolted
from one another.
❑ Insert into brake pad re‐
taining spring and press
under brake carrier.
8 - Brake carrier AG. Volkswagen AG d
agen oes
❑ Bolt onto brake caliper. Volksw not
gu
by ara
d
9 - Sealing ring rise nte
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u
❑ Removing and installing ss a ra
c
⇒ page 120
ce
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nl
pt
du
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10 - Piston
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ab

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⇒ page 120
wit
, is n

h re
hole
sembly paste
spec

es, in part or in w
t to the co
before installing.
11 - Protective cap
rrectness of i

❑ Take care not to damage when inserting piston.
l purpos
nform
ercia
1.6 Removing and installing piston for FNR-

m
at
G brake caliper
om
ion
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or

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ate
do
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Cop py
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Prote AG.

♦ Assembly tool for protective caps -T 10146/6-
AG. Volkswagen AG d
agen oes
olksw not
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1.6.1 Removing
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erm
ab
ility
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wit
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hole
spec
piston.
es, in part or in w
t to the co
– Lever off protective cap from brake caliper using wedge 3409.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
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121
by lksw
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Prote 1. Repairing front brake caliper
AG.

When removing ensure that the surface of the cylinder is not
damaged.
1.6.2 Installing
AG. Volkswagen AG d
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olksw not
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spec
– Fit protective cap -A- in assembly tool T10146/1 -1-.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
– Press protective cap onto brake caliper so that seal is fitted

um
r
fo
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ng
correctly all round using assembly tool -1- and piston resetting
t.
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tool -2-. t. Cop py
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Check seat of protective cap: p by
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– At this stage it should not be possible to remove protective cap Prote AG.
from brake caliper by hand.

– Gently press piston onto protective seal using an extension

and ratchet insert -1- and then hold in this position.
Keep piston straight to prevent damage to sealing collar.
– Blow into protective cap using compressed air (max 3 bar)
-2-. During this step protective cap will spring on piston.
– Press piston into brake caliper by hand, subsequently press‐
ing with piston resetting tool if necessary.
piston groove.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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pt
du
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es, in part or in w
t to the co
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nform
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at
om
ion
c
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or
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ate
do
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Cop py
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Prote AG.

2 Repairing rear brake caliper

kit.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ When repairs are performed, it is essential to appropriately
pre-bleed brake calipers (without brake pads) before installing
in vehicle ⇒ page 128 .
Assembly overview of brake calipers CI 38 and CII 38:
1 - Brake caliper with hand‐

brake cable lever
❑ If there is a leak at hand‐
brake cable lever, re‐
new brake caliper.
❑ Following repair work,
pre-bleed brake caliper
⇒ page 128 .
2 - Dust cap
3 - Bleeder valve, 10 Nm lkswage es n
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byV ua
❑ Apply thin coat of as‐ ir se
d ran
tee
sembly paste utho
or
G 052 150 A2 to thread ss
a ac
before screwing in.
ce
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an
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4 - Self-locking hexagon bolt,

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35 Nm
ab
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ility
❑ Renew.
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❑ When loosening and
hole
tightening, counterhold
spec
on guide pin.
es, in part or in w
t to the co
5 - Guide pin
❑ Grease before fitting
rrectness of i
protective cap.
l purpos
6 - Protective cap
❑ Fit onto brake carrier
and guide pin.
nform
mercia
7 - Brake carrier with guide pin

a
com
ti
(s) and protective cap

on in
r
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❑ Illustration for CII 38

thi
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brake
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❑ Supplied as genuine
fo
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part, assembled with

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sufficient grease on C py
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guide pins.
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guide pins.
Prote AG.
8 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.

9 - Piston with automatic adjustment

❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
10 - Sealing ring
. Volkswagen AG
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Assembly overview of brake caliper CII 41:Volkswa not
by gu
ara
15 inches from week 32/2004: ed nte
oris eo
th
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ss
1 - Brake caliper with hand‐
ce
le
un
pt
brake cable lever
an
d
itte
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❑ If there is a leak at hand‐
rm
ab
pe
brake cable lever, re‐
ility
ot
new brake caliper.
wit
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❑ Following repair work,
hole
spec
pre-bleed brake caliper
es, in part or in w
⇒ page 128 .
t to the co
2 - Dust cap
rrectness of i
l purpos
sembly paste
before screwing in.
nform
mercia
4 - Self-locking hexagon bolt,
a
com
ti
35 Nm
on in
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❑ Renew.
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❑ When loosening and
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tightening, counterhold
fo
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on guide pin.
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Cop py
5 - Guide pins with steps
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❑ Shorter than item 6
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Prote
AG.
protective cap.
6 - Guide pin
❑ Longer than item 5
protective cap.
7 - Protective cap
❑ Fit onto brake carrier
and guide pin.
8 - Brake carrier with balance
weight
guide pins.
9 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
10 - Piston with automatic adjustment
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
2. Repairing rear brake caliper 125

11 - Sealing ring
2.1 Removing
♦ Resetting and removal tool -T 10165-
– Screw piston out of brake caliper by turning thumb wheel anti- agen
AG. Volkswagen AG d
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Apply resetting and removal tool so that collar of tool is
tho
resting
ris on e or
piston. sa
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nl
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es, in part or in w
t to the co
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nform
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at
om
ion
c
in t
or
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ate
do
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for
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Cop py
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126
cop Vo
by lksw
Rep. Gr.47 - Brakes - hydraulics Prote
cted AG.
agen
2.2 Installing
– Place protective cap with outer sealing lip onto piston.
– Insert inner sealing lip into groove in cylinder using wedge
3409.
When doing this, hold piston in front of brake caliper.

– Screw in piston by turningolkthumb
sw
wheel clockwise.
AG. V agen AG
agen does
olksw not
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es, in part or in w
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♦ Apply resetting and removal tool so that collar of tool is resting

on brake caliper.
rrectness of i
♦ If the piston is pushed back with a piston resetting tool (e.g.

T10145) or by operating the foot brake the automatic adjust‐
l purpos
ment in the brake caliper is destroyed.

nform
mercia
at
om
ion
c
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or
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ate
do
priv
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for
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Cop py
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127
cop Vo
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Prote
cted AG.
agen 2. Repairing rear brake caliper
2.3 Pre-bleeding brake caliper

– Open bleeder valve -arrow A- and, using a commercially avail‐
able bleeder bottle, fill with brake fluid until bubble-free brake
fluid flows from threaded hole of brake hose connection
-arrow B-. Close bleeder valve. n AG. Volkswagen AG do
lkswage es n
Position brake caliper as illustrated to pre-bleed. byV
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Prote AG.

olkswagen AG
wag en AG. V
Eos 2006 ➤ , Golf
olks2004 ➤ , Golf Plus 2005 s➤
doe
not, Touran 2003 ➤
yV gu
sed b Brake systems - Edition
ara
n
05.2008
ri tee
ho
aut or
ac
ss
3 Pressurised leak test
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♦ Tester for brake pressure regulator -V.A.G 1310 A-
ot
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♦ Adapter M10 -V.A.G 1310/6-
h re
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es, in part or in w
t to the co
rrectness of i
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nform
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tion in
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thi
s
3.1 Test prerequisites:
iva
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Brake system (hydraulic unit, brake hoses, brake lines and brake
en
ng
t.
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calipers) operating properly and free of leaks.
Co
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– Remove bleeder valve at one of front brake calipers. Connect
rig by
opy Vo
pressure gauge -V.A.G 1310 A- and bleed. by c lksw
cted agen
Prote AG.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.
3. Pressurised leak test 129

4 Bleeding brake system

Bleeding the brake system is described for brake filling and bleed‐
ing equipment -VAS 5234- and -V.A.G 1869- .
AG. Volkswagen AG d
Note agen oes
olksw not
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♦ Bleeding brake system on vehiclesthwith
or ABS is performed in eo
the same way as on vehicles with
s a a conventional brake sys‐
u ra
c
tem. s
ce
e
nl
pt
du
♦ Only use new brake fluid conforming to US standard
an
itte
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FMVSS 116 DOT 4.
erm
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ility
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♦ Genuine VW/Audi brake fluid conforms to this specification.
wit
, is n
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♦ Brake fluid is poisonous. Also due to its corrosive effect brake
hole
spec
fluid must not come into contact with paintwork.
es, in part or in w
t to the co
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air tight containers.
rrectness of i
♦ Wash away spilt brake fluid using plenty of water.
l purpos
nform
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at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
4.1 Bleeding brake system using brake fill‐

ing and bleeding equipment -VAS 5234-
or -V.A.G 1869-
Special tools and work‐
shop equipment re‐
quired
♦ Brake filling and
bleeding equipment -
VAS 5234-
♦ or
♦ Brake filling and
bleeding equipment -
V.A.G 1869-
♦ Upgrade kit and ex‐
traction unit -V.A.G
1869/4-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
Commercially available
es, in part or in w
tool:
t to the co
rrectness of i
Note
l purpos
If, in vehicles with EDL,

EDL/TCS or EDL/TCS/
ESP, a chamber in brake
nform
ercia
fluid reservoir is com‐

m
pletely empty (e.g. brake

at
om
io
system leaking), brake

n
c
in t
r
system must be pre-bled

o
his
te
first.
a
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for
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4.1.1 Pre-bleeding:
Co
Cop py
ht. rig
rig ht
by
– Connect brake filling and bleeding equipment -VAS 5234- or copy Vo
by lksw
-V.A.G 1869- . Prote
cted AG.
agen
Bleeding sequence:
4. Bleeding brake system 131

1 - Bleed front left and front right brake calipers simultaneously.

2 - Bleed rear left and rear right brake calipers simultaneously.
– Leave bleeder valves open with brake fluid hoses connected
until brake fluid free from air bubbles flows out.
Then hydraulic unit must be bled again via function “Basic setting”
of tester -VAS 5051- .
Initiate basic setting (to bleed brake system):
– Then bleed brake system as normal.
AG. Volkswagen AG d
4.1.2 Bleeding (normal): olksw
agen oes
not
V gu
by ara
Adhere strictly to work sequence when bleeding
rised
brake system. nte
ho eo
ut
– Connect brake filling and bleeding
ss aequipment -VAS 5234- or ra
c
-V.A.G 1869- .
ce
e
nl
pt
du
an
– Open bleeder valves in specified order and bleed brake cali‐
itte
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pers.
erm
ab
ility
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1 - Front left brake caliper
wit
, is n
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2 - Front right brake caliper
hole
spec
es, in part or in w
3 - Rear left brake caliper
t to the co
4 - Rear right brake caliper
Use suitable bleeder hose. It must sit tightly on the bleeder valve
rrectness of i
so that no air can enter the brake system.
l purpos
– Leave bleeder valve of each brake caliper open with bleeder

hose fitted until brake fluid discharges free of air bubbles.
nform
ercia
4.1.3 Subsequent bleeding

m
at
om
This requires the assistance of a second mechanic: ion

c
in t
or
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e
– Depress brake pedal firmly and hold.

at
do
priv
– Open bleeder valve on brake caliper.

um
for
en
ng
t.
yi
– Fully depress brake pedal.
Co
Cop py
t. rig
gh
– Close bleeder valve with pedal held down.
ht
pyri by
Vo
o
by c lksw
– Release brake pedal slowly.
cted agen
Prote AG.
This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
A road test must be carried out after the brakes have been bled.
When doing this an ABS regulation must be performed at least
once!
4.2 Changing brake fluid
4.2.1 Changing brake fluid

⇒ Maintenance ; Booklet 18.1

AG. Volkswagen AG d
agen
5 Brake Vservo and master brakeot g cylin‐
w es n o
olks
by ua
der ed ran
ris tee
tho
o
au ra
c
ss
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nl
pt
5.1 Assembly overview - brake servo/brake
du
an
itte
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master cylinder (left-hand drive vehicle)
erm
ab
ility
ot p
wit
, is n
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Note
hole
spec
es, in part or in w
t to the co
Use only new brake fluid. Observe information on brake fluid res‐
ervoir!
rrectness of i
1 - Pedal cluster
l purpos

25 Nm
nf
ercia
or
m
m
atio
m
moving
o
n in
or c
3 - Seal
thi
te
sd
iva

o
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rp
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f
4 - Brake servo
en
ng
t.
yi Co
op
❑ On petrol engines, the C py
t. rig
required vacuum is tak‐
gh ht
yri by
en from the intake mani‐
cop Vo
by lksw
cted
fold.
agen
Prote AG.
❑ Certain vehicles with a

petrol engine and an au‐
tomatic gearbox are
equipped with a brake
vacuum pump -V192- .
⇒ page 137
❑ A vacuum sender is fit‐
ted in vehicles with HBV
⇒ page 62 .
❑ Diesel engines are fitted
with an exhauster to cre‐
ate the required vacuum
⇒ page 136 .
– With engine switched
off, depress brake pedal
firmly several times.
(This will release the
vacuum in the unit.)
– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning properly, the brake pedal will be felt to go down as the servo takes effect.
5 - Sealing ring
5. Brake servo and master brake cylinder 133

wage es n
❑ Removing and installing ⇒ page 62 yV
olks ot g
ua
d b ran
e
7 - Brake master cylinder without brake light switchhoris tee
ut or
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA)
ss
a . ac
ce
e
nl
pt
du
an
itte
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erm
ab
8 - Brake master cylinder with brake light switch
ility
ot p
wit
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
, is n
h re
hole
spec
❑ Removing and installing ⇒ page 139 es, in part or in w
t to the co
rrectness of i
❑ In vehicles prior to week 45/2005, the brake light switch -F- is located on the brake pedal ⇒ page 109 .
l purpos

nform
ercia
11 - Heat shield
m
at
om
io
12 - Self-locking hexagon nut, 25 Nm
n
c
in t
or
his
ate
do
riv
p
cum
for
en
g
❑ From secondary piston circuit of brake master cylinder to hydraulic unit

n
t.
yi Co
Cop py
14 - Brake line, 14 Nm ht. rig
rig ht
py by
❑ From primary piston circuit of brake master cylinder to hydraulic unit co Vo
by lksw
cted agen
Prote AG.
15 - Sealing plug
17 - Cap
18 - Sealing plug
19 - Vacuum hose
5.2 Assembly overview - brake servo/brake

master cylinder (right-hand drive vehi‐
cle)
Note
Use only new brake fluid. Observe information on brake fluid res‐
ervoir!

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Eos 2006 ➤ , Golf 2004 ➤ , Golf
nte Plus 2005 ➤ , Touran 2003 ➤
h eo
aut Brake
r a systems - Edition 05.2008
c
ss
ce
e
nl
1 - Pedal cluster
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
25 Nm
h re
hole
spec
moving
es, in part or in w
t to the co
4 - Seal
rrectness of i
5 - Brake servo
l purpos
❑ On petrol engines, the

required vacuum is tak‐
en from the intake mani‐
nf
ercia
o
fold.
rm
m
atio
❑ Certain vehicles with a
om
n in
petrol engine and an au‐
or c
thi
tomatic gearbox are
te
sd
a
equipped with a brake

iv
o
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cu
vacuum pump -V192- .
o
m
f
en
ng
⇒ page 137 yi
t.
Co
op
❑ A vacuum sender is fit‐
C py
t. rig
gh
ted in vehicles with HBV
ht
pyri by
Vo
⇒ page 62 .
o
by c lksw
cted agen
Prote
❑ Diesel engines are fitted
AG.
with an exhauster to cre‐

ate the required vacuum
⇒ page 136 .
– With engine switched
off, depress brake pedal
firmly several times.
(This will release the
vacuum in the unit.)
– Now step on and hold

brake pedal with medi‐
um pressure and start engine. If the brake servo is functioning properly, the brake pedal will be felt to go
down as the servo takes effect.
6 - Sealing ring
8 - Sealing plug
9 - Vacuum hose
❑ With brake light switch -F- from week 45/2005
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .

12 - Heat shield
AG. Volkswagen AG d
13 - Hexagon nut, 50 Nm lksw
agen oes
not
Vo gu
y
14 - Twelve point bolt, 25 Nm rise
d b ara
nte
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15 - Brake line, 14 Nm s au ra
c
s
❑ From secondary piston circuit of brake master cylinder to hydraulic unit
ce
le
un
pt
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itte
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ility
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is n
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ole,
spec
t to the co
18 - Sealing plug
rrectne
s
❑ From primary piston circuit of brake master cylinder to hydraulic unit
s o
cial p
f
inform
mer
21 - Cap
atio
om
n
c
i
or
n thi
te
sd
a
5.3 Overview - exhauster pump for brake

iv
o
pr
cum
r
servo (diesel vehicles)

fo
en
ng
t.
yi Co
op
Exhauster pump for 4-cylinder diesel engine (2-valve):
C py
t. rig
gh ht
yri by
Must not be dismantled. cop Vo
by lksw
cted agen
Prote AG.
Tandem pump -1- (exhauster pump and fuel pump)
Vacuum hose to brake servo -2- with non-return valve.
Fuel lines -3 and 4-.
– Removing and installing tandem pump ⇒ 4-cylinder diesel
engine (2-valve); Rep. Gr. 20 ; Removing and installing parts
of fuel supply system .
Exhauster pump for 4-cylinder diesel engine (4-valve):
Must not be dismantled.

Tandem pump -4- (exhauster pump and fuel pump)
Vacuum hose to brake servo -1- with non-return valve.
Fuel lines -2 and 3-.
– Removing and installing tandem pump ⇒ 4-cylinder diesel
engine (4-valve); Rep. Gr. 20 ; Removing and installing parts
of fuel supply system .

5.4 Checking non-return valve

♦ Air must pass through non-return valve -A- in direction of ar‐
row. agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Non-return valve must remain closed in opposite direction.
ed
by
V ua
ran
ris tee
Observe correct installation position! autho or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
5.5 Removing and installing brake servo
spec
es, in part or in w
pressure sensor -G294-
t to the co
rrectness of i
– Pull vacuum hose together with brake servo pressure sensor
-G294- out of brake servo.
l purpos
– Release clips with pliers -1-.
nform
ercia
– Carefully lever off brake servo pressure sensor -G294- -2-.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.6 Vacuum pump for brakes -V192-

Installation location for vacuum pump for brakes -V192- is on au‐
tomatic gearbox at front in direction of travel.
No provision is made for repairs to vacuum pump for brakes -
V192- . If a fault occurs, the vacuum pump for brakes -V192- must
be renewed.
Can be tested in “Guided fault finding” using -VAS 5051- .
5.6.1 Removing
– Pull vacuum hose -1- off vacuum pump for brakes -V192- .
– Disconnect connector -2- for vacuum pump for brakes -V192- .
– Remove remaining connectors and lines from bracket -3-.
– Unscrew -arrows- bracket -3- together with vacuum pump for
brakes -V192- .

– Then unscrew -arrows- vacuum pump for brakes -V192- -1-

from bracket -2-.
5.6.2 Installing
Install in reverse order.
Specified torques:
Brake vacuum pump -V192- to bracket 8 Nm
Bracket to automatic gearbox 25 Nm
5.7 Removing and installing brake light

switch -F- as of week 45/05
In vehicles prior to week 45/05, brake light switch was located on
brake pedal.
Removing
– In certain vehicles, the intake hose must be removed.
– Separate connector -1- from brake light switch -F- . agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Remove bolt -2- from brake master cylinder. d by ara
rise nte
o eo
– Pull brake light switch -F- -3- from brake master cylinder
aut at
h
ra
bottom and remove from locking lug at top -4-. ss c
ce
le
un
pt
Installing
an
d
itte
y li
erm

ab
ility
ot p
wit
Specified torque:
is n
h re
ole,
Torx bolt on brake master cylinder 5 Nm spec

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6 Removing and installing brake mas‐

ter cylinder
♦ Brake filling and bleeding equipment -VAS 5234-
♦ Torque wrench -V.A.G 1331- AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
6.1 Removing rrectness of i

l purpos
necessary.
nf
ercia

orm
m
atio
– Removing and installing battery ⇒ Electrical system; Rep. Gr.

om
n in
27 ; Removing and installing battery .

or c
thi
te
Except for Eos V6; in this case, remove air filter housing.
sd
iva
o
r
rp
cu
– Remove battery trim.

o
m
f
en
ng
t.
yi Co
– Place sufficient lint-free cloths in area of engine and gearbox. Cop py
ht. rig
rig ht
– Draw off as much brake fluid as possible from brake fluid res‐ py by
co Vo
ervoir using brake filling and bleeding equipment -VAS 5234-
by lksw
cted agen
Prote
or extraction unit -V.A.G 1869/4- .
AG.
6. Removing and installing brake master cylinder 139

Vehicles with manual gearbox:

– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐ wage
es n
inder with a commercially available tool, e.g. Hazet 4590, and y V olks ot g
ua
then pull off. ised b ran
r tee
ho
Continuation for all vehicles: aut or
ac
ss
– Pull connector -A- off float warning indicator sender.
ce
e
nl
pt
du
an
itte
– Separate connector from brake light switch -F- (vehicles from
y li
erm
ab
week 45/2005 only).
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove brake fluid reservoir. To do this press locking tabs on
reservoir outwards and simultaneously pull brake fluid reser‐
voir out of sealing plugs.
rrectness of i
– Disconnect brake lines -1- on brake master cylinder and seal
l purpos
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
nf
ercia
or
m
m
atio
om
– Carefully take brake master cylinder out of brake servo.
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
6.2 Installing Cop py
ht. rig
rig ht
py by
– Install in reverse order. co Vo
by lksw
cted agen
Prote
Observe the following important points when installing:
AG.
– When assembling brake master cylinder with brake servo,

make sure plunger rod is properly positioned in brake master
cylinder.
Specified torques:
Brake master cylinder to brake servo 25 Nm
♦ Use new nuts!
Brake lines to brake master cylinder 14 Nm

7 Removing and installing brake servo

AG. Volkswagen
♦ Brake filling and bleeding equipment
lksw
agen -VAS 5234- AG does
n o ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
7.1 Removing copy Vo
by lksw
cted agen
Prote AG.
necessary.
Vehicles with diesel engine:
– Disconnect wiring connector -1- and loosen rear spring-type
clip on intake hose.
7. Removing and installing brake servo 141

– Loosen spring-type clip -arrow- and pull hose off air cleaner
housing
– Remove securing bolt from air cleaner housing -arrow-.

– Pull air filter housing upwards out of brackets and remove it.
– Removing and installing battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .
– Remove battery tray.
– Place sufficient lint-free cloths in area of engine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment -VAS 5234-
or extraction unit -V.A.G 1869/4- .
– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
AG. Volkswagen AG d
agen
– Pull connector -A- off float warning indicator sender. Volksw
oes
not
by gu
d ara
– Separate connector from brake light switch -F- (vehicles from orise nte
eo
week 45/2005 only). aut
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Remove brake fluid reservoir. To do this press locking tabs on wit

is n
reservoir outwards and simultaneously pull brake fluid reser‐

h re
ole,
voir out of sealing plugs.

spec
– Disconnect brake lines -1- on brake master cylinder and seal

t to the co
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
rrectne

s
– Carefully take brake master cylinder out of brake servo.

s o
cial p
f i
– Pull vacuum hose out of brake servo.

nform
mer

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Release cables -1-, unbolt support bracket -2- and place it to

side ⇒ Rep. Gr. 34 ; Repairing selector mechanism .
– Remove trim on driver side ⇒ General body repairs, interior;
From week 45/2005, the brake light switch is no longer located
on the mounting bracket.
– Pull connector -1- off brake light switch.

– Remove brake light switch -2- by turning 45° to left.
– Remove air duct -3-.
– Remove cover -4-.
– Separate brake pedal from brake servo ⇒ page 109 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Unscrew nuts -1- from brake servo. s
ce
e
nl
pt
du
– Remove both upper nuts -2- from mounting bracket.
an
itte
y li
erm
ab
– Carefully remove brake servo from vehicle.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
7.2 Installing
nform
ercia

m
at
om
io
Observe following points when installing:

n
c
in t
or
his
e
– Clip brake pedal to brake servo ⇒ page 110 .

at
do
priv
– After installing, bleed brake system ⇒ page 130 and clutch.

um
for
en
ng
t.
yi
Vehicles up to week 45/2005 only:
Co
Cop py
t. rig
– Install brake light switch ⇒ page 110 .
gh ht
pyri by
Vo
co lksw
by
cted
Specified torques:
agen
Prote AG.
Brake servo to pedal cluster and bulkhead 25 Nm

♦ Use new nuts!
Brake master cylinder to brake servo 25 Nm

♦ Use new nuts!
Brake lines to brake master cylinder 14 Nm
7. Removing and installing brake servo 143

8 Brake lines
8.1 Separating point on underbody
Old connection:
1- Union nut, 14 Nm
2- T-piece, counterhold when tightening.
New connection:
1- Union nut, 14 Nm
2- Ring
3- Flange F
4- Flange E, cannot be pinched
5- Nut, counterhold when tightening.
AG. Volkswagen AG d
agen oes
olksw not
V
8.2 Repairing brake lines by gu
d ara
rise nte
tho eo
The flanging tool for brake lines -VAS 6056- can
s a be used to flange
u ra
c
brake lines with an outer pipe diameter of 5 mm without damaging
s
ce
e
nl
the coating. In certain cases, this allows sections of brake lines

pt
du
an
to be renewed at less expense.
itte
y li
erm
The use of flanging tool V.A.G. 1356 is not permitted due to the ab
ility
ot p
coating and the diameter of the black brake lines. wit

, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict the cross-section
rrectness of i
of the line to an impermissible degree.

l purpos
♦ Preferably separate brake lines at vehicle floor.

♦ The positions of the intermediate pieces must be selected so
nf
ercia
that they cannot chafe on moving parts.

orm
m
atio
♦ Do not grease spindle; merely clean with methylated spirits.

om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Flanging tool for brake lines -VAS 6056-
♦ Brake filling and bleeding equipment -VAS 5234-

List of individual tools:
1 - Flanging tool -VAS 6056/1-

❑ Flanging tool -VAS
6056/1- contains flang‐
ing jaws -VAS 6056/6-
2 - Pipe cutter -VAS 6056/2-
3 - Brake line scraper -VAS
6056/3-
❑ Grub screws (in shaft
and at side) are adjus‐ AG. Volkswagen AG d
agen
ted and must not be Volksw
oes
not
readjusted! d by gu
ara
rise nte
o eo
4 - Set of grips with plastic jaws auth
ra
-VAS 6056/4- ss c ce
le
un
pt
5 - Pipe bending tool -VAS

an
d
itte
6056/5-
y li
rm
ab
pe
ility
6 - Special wrench, 6 mm
ot
wit
, is n
7 - Flanging jaws -VAS 6056/7-

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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8. Brake lines 145

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upper part
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3 - Retaining screw
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4 - Grub screws for flanging
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Flanging jaw assembly instructions:

♦ 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 flanging jaws must point to
the edge of the housing, and the straight side of the flanging jaws
must be installed towards the spindle, or the flange will not be
formed correctly.
8.2.2 Work instructions

– Unbolt relevant brake line at brake caliper or wheel brake cyl‐
inder; catch escaping brake fluid and dispose of this as per
regulations.

– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.
– Clamp brake line tightly in set of grips -4- so that approx. 50

mm project from plastic jaws.
– Clamp scraper -3- into a drill and position onto brake line.
– At slow drill speed and with gentle pressure on brake line,
scrape coating off brake line.
Length of scraping is determined by stop in scraper.
– Withdraw scraper from brake line and remove residue from
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– Remove set of grips and slide union bolt -D- onto brake line.
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– Slide brake line -B- up to stop -A- in flanging tool.

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Brake line must be positioned against stop when the hexagon

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– Tighten brake line in flanging tool until brake line can no longer
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head bolts diagonally using special wrench -C-. Prote
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8. Brake lines 147

– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Loosen hexagon socket head bolts diagonally.
– Remove brake line from flanging tool, clean and check brake
line and flange. gen AG
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Briefly flush the section of brake line remaining in thed bvehicle:
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– Connect brake filling and bleeding unit -VASuth5234-
o , connect eo
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bleeder bottle hose to brake line flange and
s allow brake filling
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and bleeding unit -VAS 5234- to run briefly until a little brake
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– Blow out new brake line to be inserted with compressed air.
ab
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– Join brake lines using connector -E-.
h re
hole
spec
– Install brake line.
es, in part or in w
t to the co
rrectness of i
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VW Eos 2006, Golf Mk5 2004, Golf Plus Mk5 2005, Touran 2003 Brake Systems - Workshop Manual (PDFDrive)

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VW Eos 2006, Golf Mk5 2004, Golf Plus Mk5 2005, Touran 2003 Brake Systems - Workshop Manual (PDFDrive)

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Service

Service Department. Technical Information

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Copyright © 2010 Volkswagen AG, Wolfsburg K0058970520

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 Assembly overview - hydraulic unit, brake servo/brake master cylinder . . . . . . . . . . . . . . 26

6.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 56

8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.1 Removing and installing ESP sensor unit G419 (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.3 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.4 Removing and installing brake servo vacuum sender G483 . . . . . . . . . . . . . . . . . . . . . . . . 62

1.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . .ge.n.A.G..V.ol.ks.w.ag.e.n A. G. d. . . . . . . . . . . . . 113

2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5 Brake servo and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

5.4 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

8 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1 Front brakes, Touran

Engine PR No. Front brake

1.6 l - 75 kW 1ZE FN3 (15”)

1.4 l - 103 kW FSI

2.0 l -110 kW FSI

1.9 l - 74, 77 kW TDI

2.0 l - 100, 103 kW TDI

2.0 l - 125 kW TDI

Country-specific brake for Japan:

Engine PR No. Front brake

1.6 l - 85 kW FSI 1ZP FN3 (15”)

1.4 l - 55, 59 kW 1ZF1) / 1ZM FS III (15”)

1. Brake allocation via PR No. 1

Engine PR No. Front brake

Engine PR No. Front brake f inform

1.6 l - 85 kW FSI 1ZE FN3 (15”)

2.0 l -110 kW FSI

2.0 l -147 kW FSI 1LJ FN3 (16”)

2.0 l - 100, 103 kW TDI

1.4 Rear brakes, Touran

2 Rep. Gr.00 - Technical data

1.9 l - 74, 77 kW TDI

1.5 Rear brakes, front-wheel drive Golf

1.4 l - 88, 90 kW FSI

1.4 l - 103, 110 kW FSI

2.0 l - 125 kW TDI nform

1) Gradual switch to 1KD from the end of 2006

Golf Variant only:

Engine PR No. Rear brake

1.6 l - 75 kW 1KF CII 41 (15”)

Country specific brake for North America / Japan:

1. Brake allocation via PR No. 3

2.0 l - 147 kW FSI 1KV CII 38 (16”)

1.6 Rear brakes, four-wheel drive Golf

Engine PR No. Rear brake

1.6 l - 85 kW FSI 1KD CI 38 (15”)

2.0 l - 100, 103 kW TDI

2.0 l - 147 kW FSI 1KZ CII 38 (16”)