2017 - VW Passat b8 Arteon Brake System Eng PDF

Service
Workshop Manual
Arteon 2018 ➤
Passat 2015 ➤
Passat Variant 2015 ➤
Brake system
Edition 06.2017
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤
Brake system - Edition 06.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Checking vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Checking parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Overview of fitting locations - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Assembly overview - control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 20
3.3 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4 Separating control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.5 Fitting control unit to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3 Removing and installing speed sensors on front axle G45 / G47 . . . . . . . . . . . . . . . . . . . . 49
4.4 Removing and installing speed sensors on rear axle G44 / G46 . . . . . . . . . . . . . . . . . . . . 50
4.5 Checking ABS sensor ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.6 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1 Overview of fitting locations - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 Removing and installing control unit for electromechanical parking brake J540 . . . . . . . . 73
3.3 Removing and installing parking brake motor V282 / V283 . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Contents i
4.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Assembly overview - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing and installing protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.4 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.1 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3 Removing and installing vacuum sender G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.4 Removing and installing electric vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.2 Pre-bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.5 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
ii Contents
00 – Technical data
1 Safety information
(VRL010484; Edition 06.2017)
⇒ “1.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
1.1 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury through insecure testing and measuring instruments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1. Safety information 1
2 Identification
⇒ “2.1 Allocation of PR number - brakes”, page 2
2.1 Allocation of PR number - brakes

⇒ “2.1.1 Front brakes, Passat, Passat Estate”, page 2
⇒ “2.1.2 Front brake, Arteon”, page 2
⇒ “2.1.3 Rear brakes, Passat, Passat Estate”, page 3
⇒ “2.1.4 Rear brakes, Arteon”, page 3
2.1.1 Front brakes, Passat, Passat Estate

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.
The vehicle data sticker can be found in the spare wheel well and
in the service schedule.
– Relevant information about the brake system installed in the
vehicle can also be viewed in the vehicle-specific notes in EL‐
SA.
In this example, the front brake “1LJ” is installed in the vehicle.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA)
♦ The following table explains the PR numbers. These are im‐
portant for the brake caliper/brake disc and brake pads.
Engine PR No. Front brakes
1.4 l - 92 kW TSI 1ZA / 1ZD PC57 (16'')
1.4 l - 110 kW TSI
1.6 l - 88 kW TDI
1.8 l - 132 kW TSI
2.0 l - 110 kW TDI
2.0 l - 140 kW TDI
2.0 l - 162 kW TSI
2.0 l - 176 kW TDI 1LA C60 (17")
2.0 l - 206 kW TSI
2.1.2 Front brake, Arteon

hicle data sticker.
2 Rep. gr.00 - Technical data


SA.
In this example, the front brake “1LJ” is installed in the vehicle.
Engine PR No. Front brakes
1.5 l - 110 kW TSI 1ZA / 1ZD PC57 (16'')
2.0 l - 110 kW TDI
2.0 l - 130/140 kW TDI
2.0 l - 140 kW TSI
2.0 l - 176 kW TDI 1LA C60 (17")
2.0 l - 206 kW TSI
2.1.3 Rear brakes, Passat, Passat Estate

hicle data sticker.
SA.
In this example the rear brake “1KU” is installed in the vehicle.
Engine PR No. Rear brakes
1.4 l - 92 kW TSI 1KU FNc-M42 (16”)
1.4 l - 110 kW TSI
1.6 l - 88 kW TDI
1.8 l - 132 kW TSI
2.0 l - 110 kW TDI
2.0 l - 140 kW TDI
2.0 l - 162 kW TSI
2.0 l - 176 kW TDI 1KZ FNc-M42 (17”)
2.0 l - 206 kW TSI
2.1.4 Rear brakes, Arteon

hicle data sticker.
2. Identification 3

SA.
In this example the rear brake “1KU” is installed in the vehicle.
Engine PR No. Rear brakes
1.5 l - 110 kW TSI 1KU FNc-M42 (16”)
2.0 l - 110 kW TDI
2.0 l - 130/140 kW TDI
2.0 l - 140 kW TSI
2.0 l - 176 kW TDI 1KZ FNc-M42 (17”)
2.0 l - 206 kW TSI

3 Technical data
⇒ “3.1 Technical data for brakes”, page 5
3.1 Technical data for brakes

⇒ “3.1.1 Brake master cylinder and brake servo”, page 5
⇒ “3.1.2 Front brakes”, page 5
⇒ “3.1.3 Rear brakes”, page 6
3.1.1 Brake master cylinder and brake servo

Brake master cylinder, Diameter in mm 23.81 or 25.4
depending on engine
type
Brake servo (LHD), de‐ ∅ in inches 10 or 11
pending on engine type
Brake servo (RHD ve‐ ∅ in inches 8/8
hicles)
3.1.2 Front brakes

Front brake PC57 (16"):
Item PR No. 1ZA / 1ZD
1 Brake caliper PC57 (16")
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc Diam‐ 312
eter in
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
4 Brake caliper Diam‐ 57
piston eter in
mm
Volkswagen Technical Site: http://vwts.ru http://vwts.info
3. Technical data 5
Front brakes C60 (17"):

Item PR No. 1LA
1 Brake caliper C60 (17")
2 Brake pad, mm 13
thickness
limit without
backplate
eter in
mm
Brake disc, mm 30
thickness
Brake disc, mm 27
wear limit
piston eter in
mm
3.1.3 Rear brakes

Rear brake FNcM42 (16"):
Item PR No. 1KU
1 Brake caliper FNc-M42 (16”)
2 Brake pad, mm 11
thickness
limit without
backplate
eter in
mm
Brake disc, mm 12
thickness
Brake disc, mm 10
wear limit
piston eter in
mm

Rear brake FNcM42 (17”):

Item PR No. 1KZ
1 Brake caliper FNc-M42 (17”)
2 Brake pad, mm 11
thickness
limit without
backplate
eter in
mm
Brake disc, mm 22
thickness
Brake disc, mm 20
wear limit
piston eter in
mm
3. Technical data 7
4 Brake test
⇒ “4.1 General information”, page 8
⇒ “4.2 Checking vehicles with front-wheel drive”, page 8
⇒ “4.3 Checking vehicles with four-wheel drive”, page 8
⇒ “4.4 Checking parking brake”, page 9
4.1 General information

♦ The drive is provided by the test rig.
♦ For vehicles with a manual gearbox, ensure that the gear lever
is in neutral for the test. For vehicles with an automatic gear‐
box, ensure that the selector lever is in »N«.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is off.
4.2 Checking vehicles with front-wheel drive

The brake test must be carried out on a single-axle roller dyna‐
mometer.
The maximum test speed is 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
4.3 Checking vehicles with four-wheel drive

⇒ “4.3.1 On a regulated roller dynamometer with counter-rotating
rollers for four-wheel drive vehicles”, page 8
⇒ “4.3.2 Without roller dynamometer for four-wheel drive vehi‐
cles”, page 9
4.3.1 On a regulated roller dynamometer with

counter-rotating rollers for four-wheel
drive vehicles
Note
The brake test must be performed on a controlled contra-rotating

single-axle roller dynamometer for four-wheel drive vehicles.
“Counter-rotating” means that the dynamometer rollers of the sin‐

gle-axle roller dynamometer are driven forwards on one side and
backwards on the other.
The rollers drive the wheels of one axle in opposite directions to
avoid transmitting torque to the other axle.
“Regulated” means that the speed of the brake test stand rollers
is so controlled so that there is no difference in speed during the
brake test.
This prevents the transfer of a force through the stationary wheels
(not on the set of rollers) via the propshaft to the rotating wheels
on the rollers.

The forward rotating wheel is measured during the test, which

means two brake tests per axle must be performed.
The maximum test speed is 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
4.3.2 Without roller dynamometer for four-

wheel drive vehicles
Note
If no test rig is available for four-wheel drive vehicles, the brake

test can also be carried out on a standard single-axle roller dy‐
namometer as follows:
– Drive vehicle forwards onto the rollers.

– Switch off engine 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.
– Switch off engine and wait for 2 seconds.
– Carry out rear brake test.
4.4 Checking parking brake

⇒ “4.4.1 Checking electromechanical parking brake, vehicles with
front-wheel drive”, page 9
⇒ “4.4.2 Checking electromechanical parking brake, vehicles with
all-wheel drive”, page 10
4.4.1 Checking electromechanical parking

brake, vehicles with front-wheel drive
Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Ignition remains switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate for at least 5 seconds at a constant
speed between 2.5 and 9 km/h.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp - K214- lighting up.
Note
In »TÜV mode«, the electromechanical parking brake does not

close fully when the button is first pressed.
4. Brake test 9
The tension is increased gradually by actuating the electrome‐

chanical parking brake button - E538- 4 times in succession.
Actuating the electromechanical parking brake button - E538- a
fifth time releases the electromechanical parking brake.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed under 2.5 km/h or over 9 km/h
• Ignition off.
4.4.2 Checking electromechanical parking

brake, vehicles with all-wheel drive
Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Engine is switched off and ignition is switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate for at least 5 seconds at a constant
speed between 2.5 and 9 km/h.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp - K214- lighting up.
Note
In »TÜV mode«, the electromechanical parking brake does not

close fully when the button is first pressed.
The tension is increased gradually by actuating the electrome‐

chanical parking brake button - E538- 4 times in succession.
Actuating the electromechanical parking brake button - E538- a
fifth time releases the electromechanical parking brake.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed under 2.5 km/h or over 9 km/h
• Ignition off.

45 – Anti-lock brake system

1 General information
⇒ “1.1 Repair instructions for repair work on ABS”, page 11
1.1 Repair instructions for repair work on

ABS
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Note
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
ABS layout in LHD vehicles:

1 - Hydraulic unit and control unit
2 - Brake servo
The control unit and hydraulic are combined in a single compo‐
nent. They can be separated only when removed. Hydraulic pump
must not be separated from hydraulic unit either.
1. General information 11
ABS layout in RHD vehicles:

1 - Brake servo and brake master cylinder
2 - ABS hydraulic unit - N55- and ABS control unit - J104-
The control unit and hydraulic are combined in a single compo‐
nent. They can be separated only when removed. Hydraulic pump
must not be separated from hydraulic unit either.
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using “Guided Fault Finding”.
“Fault finding” is performed with the ⇒ Vehicle diagnostic tester.
♦ With ignition switched off, disconnect battery earth strap.
♦ Before carrying out welding work with an electric welding unit,
see ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 152 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 154 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. Auxiliary items containing mineral oil, e.g. oils,
greases, etc. must never be used.
♦ Thoroughly clean all unions and adjacent areas before loos‐
ening. Do not use aggressive cleaning agents such as brake
cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover them over.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing. (Use seal‐
ing plugs from repair kit 1 H0 698 311 A).
♦ Only use lint-free cloths.
♦ Remove packing from replacement parts immediately prior to
installation and not before.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ The valve coils in the control unit cannot be adjusted.
♦ The valve coils in the control unit cannot be renewed.
♦ Pressure sensor must not be changed or damaged.
♦ The pressure sensor cannot be renewed.
♦ The sensor housing must not be exposed to mechanical
stress.
♦ No measurements must be taken on contact points of control
unit.
♦ No measurements must be taken on contact points of hy‐
draulic unit.
♦ Contact pins of hydraulic unit must not be bent or damaged.
♦ The contacts cannot be renewed.
12 Rep. gr.45 - Anti-lock brake system

♦ No contact sprays may be used on the contacts or the pres‐

sure sensor.
♦ Foreign bodies must not get between the control unit and the
hydraulic unit.
♦ 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). During longer periods (2 hours), the control unit can
be exposed to a maximum temperature of 85°C. Ensure that
no brake fluid enters connectors.
1. General information 13
2 Overview of fitting locations

⇒ “2.1 Overview of fitting locations - ABS/ESP”, page 14
2.1 Overview of fitting locations - ABS/ESP
1 - ABS control unit - J104-

❑ Installation location: on
hydraulic unit, on pas‐
senger side of engine
compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
The following components are
integrated into the control unit:
♦ Control unit for electrome‐
chanical parking brake -
J540-
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
♦ The components cannot be
renewed individually.
❑ Removing and installing
⇒ page 24
2 - ABS hydraulic unit - N55-
❑ Fitting location: on pas‐
senger side of engine
compartment
The hydraulic unit consists of
the components:
♦ ABS hydraulic pump - V64-
♦ Brake pressure sender -
G201-
♦ Valve block (contains inlet and outlet valves).
❑ ABS hydraulic pump - V64- and valve block must not be separated from one another.
❑ Removing and installing ⇒ page 24
3 - Brake pad warning lamp - K32-
❑ Location: in dash panel insert.
4 - ABS warning lamp - K47-
5 - ESP and TCS warning lamp - K155-
6 - Brake system warning lamp - K118-

7 - Brake light switch - F-

❑ Location: On brake master cylinder.
8 - TCS and ESP button - E256-
❑ Two versions, therefore two fitting locations:
♦ Button in centre console
♦ Function button in menu of infotainment system
❑ Removing and installing TCS and ESP button - E256- in centre console ⇒ Electrical system; Rep. gr.
96 ; Controls; Removing and installing TCS and ESP button - E256-
9 - Diagnostic connection
❑ Location: Driver footwell cover.
10 - Steering angle sender - G85-
❑ Fitting location: in steering rack.
❑ The steering angle sender - G85- cannot be renewed separately.
❑ Removing and installing steering ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering rack; Removing
and installing steering rack .
11 - Front right/left speed sensor -G45- / -G47-
12 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing
13 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing (front-wheel drive) ⇒ page 48
14 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing
2. Overview of fitting locations 15

3 Control unit and hydraulic unit

⇒ “3.1 Assembly overview - control unit and hydraulic unit”, page
16
⇒ “3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 ”, page 20
⇒ “3.3 Connecting brake lines to hydraulic unit”, page 42
⇒ “3.4 Separating control unit from hydraulic unit”, page 44
⇒ “3.5 Fitting control unit to hydraulic unit”, page 45
3.1 Assembly overview - control unit and hy‐

draulic unit
⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 16
⇒ “3.1.2 Assembly overview - control unit and hydraulic unit, right-
hand drive”, page 18
3.1.1 Assembly overview - control unit and hydraulic unit, LHD
1 - ABS control unit - J104-

⇒ page 24
2 - ABS hydraulic unit - N55-
⇒ page 24
3 - Torx bolt
❑ Tighten new Torx bolts
alternately in 2 stages
❑ Stage 1: preliminary
tightening torque: 1 Nm
to 1.5 Nm (to allow seal
to settle).
❑ Stage 2: final specified
torque: 2.5 Nm.
4 - Brake line
❑ To rear right brake cali‐
per
❑ Identification:
∅ 5.25 mm and flare nut
with thread M12 x 1
❑ With standard tool:
14 Nm
❑ With special tools VAS
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
5 - Brake line
❑ To front left brake cali‐
per
❑ Identification:
with thread M10 x 1
14 Nm
❑ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

6 - Brake line
❑ To front right brake caliper
❑ Identification: ∅ 5.25 mm and flare nut with thread M12 x 1
❑ With standard tool: 14 Nm
7 - Brake line
❑ To rear left brake caliper
8 - Brake line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ Identification: ∅ 6 mm and flare nut with thread M12 x 1
9 - Brake line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
10 - Brake servo
11 - Retainer
12 - Torx bolt
❑ 8 Nm
13 - Rubber damper
14 - Heat shield
Allocation ⇒ Electronic Parts Catalogue (ETKA)
15 - Hexagon nut
❑ 20 Nm
16 - Bracket
17 - Hexagon nut
❑ 20 Nm
3. Control unit and hydraulic unit 17

3.1.2 Assembly overview - control unit and hydraulic unit, right-hand drive
1 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ Identification: ∅ 6 mm
and flare nut with thread
M12 x 1
❑ Repairing brake lines
⇒ page 147
14 Nm
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
2 - Brake line
primary piston circuit to
hydraulic unit
❑ Identification: ∅ 6 mm
and flare nut with thread
M12 x 1
⇒ page 147
14 Nm
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
3 - Brake line
❑ To rear right brake cali‐
per
❑ Identification:
with thread M12 x 1
⇒ page 147
4 - Brake line
❑ To front left brake caliper
❑ Repairing brake lines ⇒ page 147
5 - Brake line
❑ To front right brake caliper
6 - Brake line
❑ To rear left brake caliper

7 - ABS hydraulic unit - N55- with ABS control unit - J104-
❑ Fitting location overview ⇒ page 14
❑ Separating ABS control unit - J104- from ABS hydraulic unit - N55- ⇒ page 44
❑ Attaching ABS control unit - J104- to ABS hydraulic unit - N55- ⇒ page 45
❑ Connecting brake line ⇒ page 43
8 - Bracket
❑ Check for secure seating after installing.
9 - Bolt
❑ Qty. 2
❑ 8 Nm
10 - Rubber damper
❑ Qty. 3
11 - Nut
❑ 20 Nm
12 - Bracket
13 - Nut
❑ Qty. 2
❑ 20 Nm
❑ Assembly overview - brake servo/brake master cylinder ⇒ page 94
❑ Checking brake servo ⇒ page 142
❑ Removing and installing brake servo for vehicles with petrol engines ⇒ page 130
❑ Removing and installing brake master cylinder ⇒ page 104
15 - Brake line
16 - Brake line

3.2 Removing and installing ABS control

unit - J104- and ABS hydraulic unit -
N55-
⇒ “3.2.1 Removing and installing control unit and hydraulic unit,
left-hand drive, petrol engines”, page 20
left-hand drive vehicles with diesel engine”, page 24
right-hand drive”, page 31
LHD vehicles, bi-turbo diesel engine”, page 35
3.2.1 Removing and installing control unit and hydraulic unit, left-hand drive, pet‐
rol engines
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G 1331-

♦ Ring insert tool, open, AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G 1410/7-
♦ Torque wrench - VAS 6854-

♦ Brake pedal depressor - V.A.G 1869/2-

♦ Assembly tool - V.A.G 1410/8-
Plugs - 5Q0 698 311-
1 - Sealing plug M10
Removing
Fitting location:
The control unit is bolted to the hydraulic unit and is located on

right in the engine compartment.
NOTICE
Risk of damage to brake lines if bent.
Never excessively bend the brake lines in the area of the hy‐
draulic unit.
– Read out and note the existing control unit code.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
1.5 l, 1.8 l and 2.0 l petrol engine:
– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐
ing and installing engine cover .
Continued for all vehicles:

– On vehicles with heat shield, remove heat shield -1-.

– Press down retainer catch -arrow A-.
– Release electrical connector -arrow B-.

– Unplug electrical connector -1-.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Connect hose of bleeder bottle -1- to bleeder valve of front left

brake caliper.
– Open bleeder valve.

– Connect hose of bleeder bottle -1- to bleeder valve of rear left

brake caliper.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left and rear left bleeder valve.
– Do not remove brake pedal depressor - V.A.G 1869/2- .
Note
Ensure no brake fluid gets onto contacts.
– Pull cover off bulkhead and unclip brake lines.

– First identify both brake lines from brake master cylinder and
unscrew from hydraulic unit.
– Seal threaded holes immediately using sealing plugs from the
assembly part kit, part no. 5Q0 698 311.
– Mark, unscrew and seal threaded holes of remaining brake
lines (brake calipers).
– Fit dust caps of bleeder valves onto brake lines.
– Pull hydraulic unit together with control unit upwards out of

dampers -arrow-.
– Unbolt bracket from hydraulic unit -arrows- in vehicle.

– Remove hydraulic unit.
Installing
Install in reverse order of removal, observing the following:
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 the hydraulic unit, ensure that the rubber
dampers are not pressed out of bracket.
– Before installing bracket of ABS hydraulic unit - N55- into

bracket, spray rubber dampers with silicone lubricant - D 007
000 A2- .

– Using assembly tool - V.A.G 1410/8- , carefully fit brake lines.
Tightening sequence of brake lines:

– Remove brake pedal actuator - V.A.G 1869/2- .
– Bleed brake system ⇒ page 154 .
– Code radio.
– Code control unit -J104- using ⇒ Vehicle diagnostic tester in
Guided Fault Finding.
To do this, carry out basic setting of steering angle sender - G85- ,
lateral acceleration sender - G200- , longitudinal acceleration
sender - G251- and brake pressure sender - G201- .
Specified torques
Assembly of special tools for tightening brake lines

♦ ⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 16
♦ Battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly
overview - battery
♦ Front bleeder valves
⇒ “1.1 Assembly overview - front brake caliper”, page 86
♦ Rear bleeder valves
⇒ “2.1 Assembly overview - rear brake caliper”, page 90
3.2.2 Removing and installing control unit and hydraulic unit, left-hand drive ve‐
hicles with diesel engine


equipment required

Plugs - 5Q0 698 311-

Engine support - T10533-

Removing:
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
right in the engine compartment.
NOTICE
draulic unit.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover

panel; Removing and installing engine cover panel .
Vehicles with emission control module:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Separate connector -1-.

– Loosen clamp -2- and push to rear.
– Unscrew bolts -1-.

– Loosen bolt -2- and remove clip.
– Remove front exhaust pipe.
Note
Different heat shields -1- are installed depending on the engine.
– Unscrew bolts -arrows- and remove heat shield -1- from steer‐
ing rack.

– Unscrew bolts -1, 2, 3- and remove pendulum support.

Vehicles with emission control module and all-wheel drive:
– Remove tunnel heat shield at front.
– Unbolt propshaft from bevel box at front ⇒ Rep. gr. 39 ; Prop‐
shaft; Assembly overview - propshaft , and lay it to one side.
Continued for vehicles with emission control module:

– Fit engine support - T10533- as shown in illustration, and tight‐
en bolts by hand.
♦ Bolt -3- = original bolt for pendulum support
♦ Screw a bolt M8 x 30 mm -1- fitted with a washer -2- into
threaded hole in noise insulation.
♦ -A- thin end
♦ -B- thick end
Note
For all-wheel drive vehicles, fit a longer bolt into the front hole in
the aluminium section of the pendulum support to serve as a
spacer between the gearbox and the engine support.
– Push engine with engine support - T10533- towards the front.

– Unclip line guide.


– Unplug electrical connector -1-.

brake caliper.


brake caliper.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
Note
– Unbolt upper section of insulation mat from plenum chamber

bulkhead, and fold it over.
– Clip brake lines out of both retainers.
– First identify both brake lines from brake master cylinder and
unscrew from hydraulic unit.

dampers -arrow-.
– Carefully set down hydraulic unit together with control unit in
engine compartment.
– Raise vehicle.


– Guide hydraulic unit out of vehicle.
Installing
Note

000 A2- .

– Code radio.
– Code ABS control unit -J104- using ⇒ Vehicle diagnostic test‐
er.
Specified torques


LHD”, page 16
overview - battery
♦ Bolts for noise insulation ⇒ General body repairs, exterior;
sulation .
♦ Front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes and silenc‐
ers; Removing and installing front exhaust pipe
♦ Pendulum support ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings
3.2.3 Removing and installing control unit and hydraulic unit, right-hand drive

equipment required


Sealing plugs, assembly part no. 5Q0 698 311
Removing
Fitting location of ABS hydraulic unit - N55- and ABS control unit
- J104- in RHD vehicles:
NOTICE
draulic unit.

Vehicles with battery in engine compartment
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery
tray; Removing and installing battery tray .

sulation .

Note
The illustration shows installation position of ABS hydraulic unit -

N55- and ABS control unit - J104- on a LHD vehicle.

– Pull off electrical connector -1-.

brake caliper.
– Open bleed valve.

brake caliper.
– Place sufficiently lint-free cloths under ABS control unit - J104-
and ABS hydraulic unit - N55- .
Note
Make sure no brake fluid gets onto electrical contacts on ABS

control unit - J104- .

– First, mark the two brake lines -A- and -B- coming from brake
master cylinder.
– Disconnect the two brake master cylinder brake lines -A- and
-B- from ABS hydraulic unit - N55- .
– Mark and unscrew remaining brake lines (brake calipers). Seal

threaded holes -2-.
– Pull off ABS hydraulic unit - N55- -1- together with bracket
-2- in -direction of arrow-.
– The rubber dampers -arrows- will be pulled off the studs of
bracket -3- while doing so.
– Guide hydraulic unit out of vehicle.
– If hydraulic control unit is to be renewed, unscrew bolts

-arrows- and remove mounting bracket -1-.
Installing
Install in reverse order. Observe the following:
Note
corresponding brake line is to be fitted.

000 A2- .


– Start brake line union screws in sequence -1- through -6-.
– Tighten break line union screws in sequence -1- through -6-.
– Code radio.
er.
Specified torques

overview - battery
♦ Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation; Assembly overview - noise insulation
3.2.4 Removing and installing control unit and hydraulic unit, LHD vehicles, bi-
turbo diesel engine


equipment required


Engine support - T10533-

Removing
Fitting location:
Control unit is bolted to hydraulic unit -1- and is located on right

in engine compartment.
NOTICE
– Never excessively bend the brake lines in the area of the
hydraulic unit.
– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if
necessary.
Disconnecting and reconnecting battery.
sulation .
– Release and pull off connector -1- for oil level and oil temper‐
ature sender - G266- .
– Release and pull off connector -2- on auxiliary pump for heat‐
ing - V488- .
– To do this, open locking device -3- by pressing in direction of
-arrow- and release connector.
– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes and
silencers; Removing and installing front exhaust pipe .
– Remove pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Removing and installing pendulum support .
– Unbolt propshaft from bevel box at front ⇒ Rep. gr. 39 ; Prop‐
shaft; Assembly overview - propshaft , and lay it to one side.

– Position engine support - T10533- -A- as shown.

– Engine support - T10533/2- -B- is positioned on flat bolt con‐
necting point of engine support - T10533/1- .
– Screw in original bolt of pendulum support -1- in front threaded
hole of pendulum support.
– Screw a bolt M8 x 60 mm -2- with washer into threaded hole
of noise insulation.
– Between high bolt connecting point and subframe, engineer a
distance of 20 mm with washers -a-.
– Tighten bolts hand-tight.
– Push engine with engine support - T10533- as far forwards as
possible.
– Unclip reducing agent supply line -2- on coolant expansion

tank and on toothed belt guard -arrows B-.
– Open plug-in connectors -A- and -B- for fuel lines and pull off
fuel lines. Disconnect plug-in connectors ⇒ Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
CAUTION
The fuel system is pressurised.
Danger of injury from fuel spray.
– Wear safety goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
– Release and pull off connector -2- on coolant expansion tank.

– Unclip, release and pull off connector -4-.
– Unclip retainer for fuel lines on coolant expansion tank
-arrow-.
– Using a screwdriver, release catches -6-.
– Place coolant expansion tank -1- on engine.
– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20 ; Fuel filter; Removing and installing fuel
filter .
– Remove exhaust gas temperature sender 3 - G495- ⇒ Rep.
gr. 26 ; Removing and installing exhaust gas temperature
sender 3 G495 .


– Unclip line guide.

– Pull off electrical connector -1-.

brake caliper.


brake caliper.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
Note
– First, mark the two brake lines -5- and -6- from brake master
cylinder, and unscrew them from the hydraulic unit.
– Unscrew both brake lines -5- and -6- on brake master cylinder
⇒ page 110 .
– Unclip the brake lines on the bulkhead as far as possible.
– Remove front right brake line -3-.

dampers -arrow-.


– Guide hydraulic unit downwards out of vehicle.
Installing
Note
♦ When installing the hydraulic unit, ensure that rubber dampers
are not pressed out of bracket.

000 A2- .

– Code radio.
er.
Specified torques


LHD”, page 16
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- front exhaust pipe
♦ ⇒ Rep. gr. 26 ; Exhaust gas temperature control; Assembly
overview - exhaust gas temperature control
♦ ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - propshaft
♦ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview -
assembly mountings
♦ ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter
3.3 Connecting brake lines to hydraulic unit

⇒ “3.3.1 Connecting brake lines to hydraulic unit, LHD”,
page 42
⇒ “3.3.2 Connecting brake lines to hydraulic unit, RHD”,
page 43
3.3.1 Connecting brake lines to hydraulic unit,

LHD
On tandem brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: ∅ 6 mm and flare nut with thread M12 x 1
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
1 - From hydraulic unit to front left brake caliper
3 - From hydraulic unit to rear left brake caliper
4 - Hydraulic unit to rear right brake caliper

On hydraulic unit:
- Identification: ∅ 5.25 mm and flare nut with short thread M12 x
1
- Identification: ∅ 5.25 mm and flare nut with thread M10 x 1
3 - From hydraulic unit to front right brake caliper.
1
5 - From hydraulic unit to secondary piston circuit of brake master
cylinder.
6 - From hydraulic unit to primary piston circuit of brake master
cylinder.
Specified torque
LHD”, page 16
3.3.2 Connecting brake lines to hydraulic unit,

RHD
On tandem brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.

To ABS hydraulic unit - N55- :

2 - From hydraulic unit to front right brake caliper.
1
1
Specified torque
3.4 Separating control unit from hydraulic

unit
Special tools and workshop equipment required
♦ ESD workplace - VAS 6613-
♦ Torx bit T25

♦ If a control unit is defective, the control unit must be discon‐
nected from the hydraulic unit and only the control unit re‐
newed.
♦ If the hydraulic unit is defective, the hydraulic unit must be re‐
newed together with the control unit.
♦ To separate the control unit from the hydraulic unit, the ESP
unit must be removed first.
NOTICE
Risk of damage to hydraulic unit caused by removal of the return
flow pump.
– Never detach the return flow pump from the hydraulic unit.
NOTICE
Risk of damage to control unit caused by static charge and dirt.
– Discharge any static charge: touch an ESD workplace (earth
yourself).
– Protect interior of control unit from moisture and dirt.

– Before working on electric components, touch an earthed ob‐

ject, ESD workplace - VAS 6613- . Do not directly touch
connector contacts or electronic components.
– Lay down hydraulic unit together with control unit on ESD
workplace - VAS 6613- .
– Unscrew the 3 Torx bolts from control unit and lay them aside
immediately (to avoid interchanging with the new Torx bolts).
– Set hydraulic unit with control unit facing upwards on ESD
workplace - VAS 6613- .
– Taking care not to cant control unit, pull it off hydraulic unit.
– Cover control unit solenoids with a lint-free cloth.
– Check cleanliness of hydraulic unit sealing surface; clean with
methylated spirits and a lint-free cloth if necessary.
Hydraulic unit sealing surface must not be worked with a file,
metal scraper, sandpaper or similar.
If hydraulic unit sealing surface is damaged (e.g. scoring, scratch‐
es), hydraulic unit must be renewed together with control unit.
The seal of the control unit may not be pulled out or raised.
The seal of the control unit cannot be renewed.
3.5 Fitting control unit to hydraulic unit

♦ ESD workplace - VAS 6613-
♦ Torque screwdriver - V.A.G 1624-
♦ Torx bit T25
Note
Severe shocks (e.g. dropping, impact) may destroy the control

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

– Place control unit on hydraulic unit, ensuring it is not canted
when doing so.

– Tighten hydraulic unit and control unit alternately in 2 stages

to specified torque using new Torx bolts provided.
Note
The threads of the hydraulic unit for securing the control unit must
not be recut. If the threads are damaged (bolts difficult to turn in
by hand or cannot be tightened to the specified torque), then the
hydraulic unit must be renewed.
Specified torque
LHD”, page 16
Note
♦ A new control unit may be mounted on an existing hydraulic

unit max. three times 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.

4 Sensors
⇒ “4.1 Assembly overview - speed sensor on front axle”,
page 47
⇒ “4.3 Removing and installing speed sensors on front axle G45 /
G47 ”, page 49
⇒ “4.2 Assembly overview - speed sensor on rear axle”,
page 48
⇒ “4.4 Removing and installing speed sensors on rear axle G44 /
G46 ”, page 50
⇒ “4.5 Checking ABS sensor ring”, page 51
⇒ “4.6 Removing and installing ESP sensor unit G419 ”,
page 52
⇒ “4.7 Removing and installing steering angle sender G85 ”, page
53
⇒ “4.3 Removing and installing vacuum sender G608 ”,
page 141
4.1 Assembly overview - speed sensor on front axle
1 - ABS speed sensor

❑ Clean inside surface of
hole before inserting
sensor
❑ Coat inside surface with
high-temperature paste
- G 052 112 A3-
⇒ page 49
2 - Bolt
❑ 8 Nm
3 - Drive shaft
❑ Assembly overview ⇒
Running gear, axles,
steering; Rep. gr. 40 ;
Drive shaft; Assembly
overview - drive shaft .
⇒ Running gear, axles,
Drive shaft; Removing
and installing drive
shaft .
4 - Wheel hub with wheel bear‐
ing unit
❑ The ABS sensor ring is
integrated in the wheel
bearing unit.
Wheel bearings; Re‐
moving and installing
wheel bearing unit .
4. Sensors 47
4.2 Assembly overview - speed sensor on

rear axle
⇒ “4.2.1 Assembly overview - speed sensor on rear axle, front-
wheel drive”, page 48
⇒ “4.2.2 Assembly overview - speed sensor on rear axle, all-wheel
drive”, page 49
4.2.1 Assembly overview - speed sensor on rear axle, front-wheel drive

sensor
- G 052 112 A3-
⇒ page 50
2 - Bolt
❑ 8 Nm
ing unit
bearing unit.

4.2.2 Assembly overview - speed sensor on rear axle, all-wheel drive

sensor
- G 052 112 A3-
⇒ page 51
2 - Bolt
❑ 8 Nm
3 - Drive shaft
❑ Assembly overview ⇒
Running gear, axles,
Drive shaft; Assembly
overview - drive shaft .
Drive shaft; Removing
and installing drive
shaft .
ing unit
bearing unit.
4.3 Removing and installing speed sensors

on front axle -G45- / -G47-
Note
Removal and installation is described for the front left speed sen‐
sor. Removal and installation of the front right speed sensor is
analogous.
Removing
– Raise vehicle.
4. Sensors 49
– Disconnect connector -3- from front left speed sensor - G47-

-1-.
– Unscrew bolt -2-, and pull front left speed sensor - G47- -1-
out of wheel bearing housing.
Installing
– Clean inside surface of hole before inserting speed sensor.
Coat speed sensor all-round with high-temperature paste - G
052 112 A3- .
Specified torque
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page
47
4.4 Removing and installing speed sensors

on rear axle -G44- / -G46-
⇒ “4.4.1 Removing and installing speed sensor on rear axle G44 /
G46 , vehicles with front-wheel drive”, page 50
⇒ “4.4.2 Removing and installing speed sensor on rear axle G44 /
G46 , vehicles with all-wheel drive”, page 51
4.4.1 Removing and installing speed sensor

on rear axle -G44- / -G46- , vehicles with
front-wheel drive
Note
Removal and installation is described for the rear left speed sen‐
sor. Removal and installation of the rear right speed sensor is
analogous.
Rear left speed sensor - G46- -1-:

Removing
– Raise vehicle.

– Disconnect connector -2- from rear left speed sensor - G46- .

– Unscrew bolt -1- and pull speed sensor out of wheel bearing
housing.
Installing
Coat speed sensor all-round with high-temperature paste
G 052 112 A3.
Specified torques
♦ ⇒ “4.2.1 Assembly overview - speed sensor on rear axle, front-
4.4.2 Removing and installing speed sensor

on rear axle -G44- / -G46- , vehicles with
all-wheel drive
Note
Removal and installation is described for the rear left speed sen‐
sor. Removal and installation of the rear right speed sensor is
analogous.
Removing
– Raise vehicle.
– Disconnect connector -3- from rear left speed sensor - G46-
-1-.
– Unscrew bolt -2-, and pull rear left speed sensor - G46- -1- out
of wheel bearing housing.
Installing
Coat speed sensor all-round with high-temperature paste - G
052 112 A3- .
Specified torques
♦ ⇒ “4.2.2 Assembly overview - speed sensor on rear axle, all-
4.5 Checking ABS sensor ring

4. Sensors 51
♦ Sensor gauge - T10473-
Procedure
• Wheel bearing unit is removed.
– Using sensor gauge - T10473- , check ABS sensor ring -2- all
around, as shown in illustration.
1 - Wheel bearing unit
2 - Seal with integrated ABS sensor ring
Test pattern for ABS sensor ring:

A - ABS sensor ring is OK
B - ABS sensor ring is defective
4.6 Removing and installing ESP sensor

unit - G419-
The lateral acceleration sender - G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender - G251- are in‐
stalled together with the control unit for electromechanical parking
brake - J540- in the ABS control unit - J104- .
The components cannot be renewed individually.
– Removing and installing ABS control unit - J104- ⇒ page 24 .

4.7 Removing and installing steering angle

sender - G85-
The steering angle sender - G85- is installed in steering rack.
The steering angle sender - G85- cannot be renewed separately.
– Removing and installing steering ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering rack; Removing and installing
steering rack .
4. Sensors 53
46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brakes”, page 54
⇒ “1.2 Removing and installing brake pads/linings”, page 56
⇒ “1.3 Removing and installing brake caliper”, page 58
1.1 Assembly overview - front brakes

⇒ “1.1.1 Assembly overview - front brakes”, page 54
1.1.1 Assembly overview - front brakes
Note
♦ 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.
♦ Use the brake filling and bleeding equipment - VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
this, release pressure in system).
Assembly overview - front brakes PC57 and C60:
54 Rep. gr.46 - Brakes - mechanism

1 - Cover plate
2 - Torx bolt
❑ 12 Nm
3 - Brake disc
❑ Internally ventilated
❑ Wear limits ⇒ page 5
❑ Always renew on both
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
4 - Torx bolt
❑ 4.5 Nm
5 - Brake carrier
❑ Apply thin coat of lithium
grease G 052150 A2 to
brake pad guide surfa‐
ces.
6 - Brake pads
❑ Thickness 14 mm not in‐
cluding backplate
❑ With front right brake
pad wear indicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm), the warn‐
ing lamp in the dash
panel insert comes on.
Sensors can be re‐
newed individually.
❑ Wear limit: 2 mm ex‐
cluding backing plate.
❑ Check thickness:
⇒ Maintenance ; Booklet ; Front and rear brake discs and pads: Checking condition of discs and thickness
of pads
❑ Always renew on both sides of an axle.
7 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Repairing ⇒ page 86
8 - Hexagon bolt (self-locking)

❑ Renew after removal
❑ 35 Nm
9 - Countersunk bolt with double nip
❑ Clean if reusing.
❑ 200 Nm
10 - Wheel bearing housing
❑ With bolted brake carrier
1. Front brakes 55
11 - Brake hose with banjo union and banjo bolt

❑ Ensure correct installation position
❑ 35 Nm
12 - Retaining clip
13 - Retainer
14 - Bolt
❑ 8 Nm
1.2 Removing and installing brake pads/lin‐

ings
⇒ “1.2.1 Removing and installing brake pads, front brakes”, page
56
1.2.1 Removing and installing brake pads,

front brakes
♦ Piston resetting appliance - T 10145-
Removing
Note
♦ Mark brake pads or linings when removing if they are to be

reused. Fit in same position when installing, or braking will be
uneven.
♦
– Remove wheels.
– Disconnect connector for brake pad wear indicator.

The brake pad wear indicator is installed on front right.

– Unscrew both securing bolts from brake caliper, counter hold‐
ing on guide pin.
– Remove brake caliper -1- and secure with wire so that weight
of brake caliper does not strain or damage brake hose.
– Remove brake pads -2 and 3- from brake carrier -4-.
Cleaning:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
Note
Use only methylated spirits for cleaning the brake caliper housing.
Installing
Note
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
1. Front brakes 57
– Press piston back.

– Apply a thin coat of lithium grease G 052150 A2 to brake pad
guide surfaces on brake carrier.
– Place brake pads -1- together with retaining springs -2- in re‐
cess of brake carrier -3-.
Note
After fitting brake pads, check that all retaining springs -2- are
properly seated -arrow-.
– Carefully place brake caliper on brake carrier.
– Secure brake caliper to brake carrier with new self-locking

bolts, counter holding on guide pin.
– Connect brake pad wear indicator connector.
– Install wheels.
Specified torques
♦ ⇒ “1.1.1 Assembly overview - front brakes”, page 54
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Note
♦ 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.
♦ After changing brake pads/linings, check brake fluid level.
1.3 Removing and installing brake caliper

⇒ “1.3.1 Removing and installing brake caliper”, page 58
1.3.1 Removing and installing brake caliper


Note
This procedure is only relevant when replacing or repairing the

brake caliper.
Removing
– Remove wheels.
– Disconnect connector for brake pad wear indicator.
– Connect bleed bottle bleeder hose -1- to bleeder valve of
brake caliper.
1. Front brakes 59

– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
– Unscrew both securing bolts from brake caliper, counter hold‐

ing on guide pin.
– Pull brake caliper off brake carrier.
Installing
• The piston is pressed back.
• The two brake pads are seated in the retaining springs on the
brake carrier.
– Carefully place brake caliper on brake carrier.
bolts, counter holding on guide pin.
– Screw brake hose onto brake caliper.
– Connect brake pad wear indicator connector.
– Install wheels.
Specified torques
♦ ⇒ “1.1.1 Assembly overview - front brakes”, page 54
♦ Bleed valve
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads/linings are properly seated in their
normal operating position.
♦ Check brake fluid level.

2 Rear brakes
⇒ “2.1 Assembly overview - rear brakes”, page 61
⇒ “2.2 Removing and installing brake pads/linings”, page 63
⇒ “2.3 Removing and installing brake caliper”, page 67
2.1 Assembly overview - rear brakes

Assembly overview - rear brakes:
Note
♦ Use the brake filling and bleeding equipment - VAS 5234- to

draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
this, release pressure in system).
1 - Splash plate for brakes

❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
2 - Torx bolt
❑ 12 Nm
3 - Brake disc
❑ Wear limits ⇒ page 6
❑ Never remove brake
discs from wheel hub by
force. If necessary use
penetrating fluid, be‐
cause otherwise brake
discs can be damaged.
❑ When worn, renew on
both sides of axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
4 - Torx bolt
❑ 8 Nm
5 - Brake caliper
❑ Do not disconnect brake
hose when changing
pads.
⇒ page 67
❑ Repairing ⇒ page 90
❑ Following repair or re‐
placement, perform
“Basic setting” using
⇒ Vehicle diagnostic
tester.
6 - Multi-point socket head bolt
❑ Remove and install using socket insert - T10035- ⇒ page 63 .
❑ 90 Nm +90°
2. Rear brakes 61
7 - Brake carrier
8 - Retaining spring
9 - Outer brake pad
❑ Thickness 11 mm not including backplate
❑ Wear limit: 2 mm excluding backing plate.
❑ Check thickness: ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads: Checking condition
of discs and thickness of pads
10 - Inner brake pad
❑ With spring
❑ Thickness 11 mm not including backplate
❑ Wear limit: 2 mm excluding backing plate.
❑ Check thickness: ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads: Checking condition
of discs and thickness of pads
11 - Spring
❑ Fitted only on inner brake pad
❑ Ensure correct installation position
12 - Brake line
❑ 14 Nm
13 - Bracket
14 - Retaining spring for brake hose to retainer
15 - Brake hose with banjo union and banjo bolt
❑ To brake caliper 35 Nm
❑ Connection to brake line, 14 Nm
❑ Connection to brake line using special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm
16 - Guide pin
❑ 35 Nm
17 - Caps
❑ For guide pins
18 - Sealing ring
❑ For parking brake motor
❑ Renew
19 - Hexagon socket head bolt
❑ 8 Nm
20 - Parking brake motor

Hexagon bit, long reach - T10035-
2.2 Removing and installing brake pads/linings

equipment required
♦ Vehicle diagnosis, testing and information system - VAS 5051-

♦ Tool set for brake bleeding - VAS 6564-
♦ Insert tool with ratchet - VAS 6784-
♦ Bit attachment (7 mm) - T10503-
2. Rear brakes 63
♦ Piston resetting appliance - T10145-

Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
Note
Do not separate connectors of parking brake motors.
• Electromechanical parking brake not operated.

– Remove wheels.
The electromechanical parking brake pistons must be moved
back using ⇒ Vehicle diagnostic tester.
Note
Before resetting pistons, draw off brake fluid from brake fluid res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Move back pistons using ⇒ Vehicle diagnostic tester.
CAUTION
Risk of injury due to tensioned retaining spring.
The retaining spring might jump out and cause injury to eyes
and skin.
– Make sure to firmly hold the retaining spring.
– Use a screwdriver -A- to lever retaining spring -1- for brake

pads out of brake caliper -arrow- while supporting retaining
spring with the other hand.
– Remove protective caps -arrows-.

– Unscrew both guide pins from brake caliper using 7 mm bit -

T10503- and insert tool with ratchet - VAS 6784- .
– Remove brake caliper -1- and secure it with wire -A- so that
weight of brake caliper does not strain or damage brake hose.
Note
It is essential that the pistons are reset using ⇒ Vehicle diagnostic

tester. The thrust nut in the piston is fitted on a floating bearing,
so that the piston can only be compressed but not pulled back.
Only the spindle with the thrust nut will be moved back.
• The piston must be reset beforehand with ⇒ Vehicle diagnostic

tester.
– Press piston back fully using piston resetting appliance -

T10145- .
– Remove brake pads -2 and 3-.

Cleaning:
WARNING
Health hazard due to poisonous dust from brake system.
Risk of irreversibly deposited dust particles in the lungs. Risk of
respiratory health problems.
– Never blow out the brake system with compressed air.
– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
Note
Use only methylated spirits for cleaning the brake caliper housing.
Installing
2. Rear brakes 65
– Insert inner brake pad -2- and outer brake pad -3- into brake
carrier.
– Secure brake caliper.
– Insert cover caps -arrows-.

– Insert brake pad retaining spring into hole in brake caliper

-arrow-.
Note
Make sure that the retaining spring is seated properly in the holes
in the brake caliper.
– Move pistons forwards using ⇒ Vehicle diagnostic tester.

– Install wheels.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 61
Note
After changing brake pads/linings, check brake fluid level.
2. Rear brakes 67

equipment required
♦ Vehicle diagnosis, testing and information system - VAS 5051-

♦ Insert tool with ratchet - VAS 6784-
♦ Bit attachment (7 mm) - T10503-

Removing
Note
This procedure is only relevant when replacing or repairing the

brake caliper.
Note
Do not separate connectors of parking brake motors.
– Remove wheels.
The electromechanical parking brake pistons must be moved
back using ⇒ Vehicle diagnostic tester.
Note
Before resetting pistons, draw off brake fluid from brake fluid res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Move back pistons using ⇒ Vehicle diagnostic tester.

– Unscrew bolts -arrows- for parking brake motor.
– Pull off parking brake motor and place it to one side without
disconnecting the connector.
– Connect bleed bottle bleeder hose -1- to bleeder valve of

brake caliper.
– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
CAUTION
Risk of injury due to tensioned retaining spring.
The retaining spring might jump out and cause injury to eyes
and skin.
– Make sure to firmly hold the retaining spring.
2. Rear brakes 69
– Use a screwdriver -A- to lever retaining spring -1- for brake

pads out of brake caliper -arrow- while supporting retaining
spring with the other hand.
– Remove protective caps -arrows-.

– Unscrew both guide pins from brake caliper using 7 mm bit -

T10503- and insert tool with ratchet - VAS 6784- .
– Pull brake caliper off brake carrier.
Installing
• The brake pads are seated in the retaining springs on the
brake carrier.
bolts.
Note
The annular groove and the contact surface of the parking brake
motor must be clean.
– Install new sealing ring.

– Turn spindle back slightly using an E11 Torx socket until park‐
ing brake motor can be properly fitted.
– Carefully fit parking brake motor, while ensuring that seal is
correctly seated.
– Turn parking brake motor until bolt hole and thread align.
Note
Make sure that parking brake motor is flush with brake caliper.
Never pull parking brake motor onto brake caliper using securing
bolts.
– Start new hexagon socket head bolts by hand and tighten

them.
– Attach brake hose to brake caliper.
After moving the pistons forwards using ⇒ Vehicle diagnostic
tester, carry out a basic setting of brake system.
– Carry out basic setting of brake system using ⇒ Vehicle diag‐
nostic tester.
– Install wheels.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 61
♦ Bleed valve
Note
Check brake fluid level.
2. Rear brakes 71
3 Parking brake
⇒ “3.1 Overview of fitting locations - parking brake”, page 72
⇒ “3.2 Removing and installing control unit for electromechanical
parking brake J540 ”, page 73
⇒ “3.3 Removing and installing parking brake motor V282 / V283
”, page 73
3.1 Overview of fitting locations - parking brake
1 - Electromechanical parking
brake button - E538-
❑ Located in centre con‐
sole
2 - Electromechanical parking
brake warning lamp - K213-
❑ Location: in electrome‐
chanical parking brake
button - E538- .
3 - Auto-hold button - E540-
❑ Located in centre con‐
sole
4 - Auto-hold warning lamp -
K237-
❑ Location: in auto-hold
button - E540-
5 - Dash panel insert
❑ With electric parking
brake and handbrake
fault warning lamp -
K214-
❑ With brake system
warning lamp - K118-
❑ With acoustic signal
6 - Control unit for electrome‐
chanical parking brake - J540-
❑ Integrated into ABS
control unit - J104- and
cannot be renewed indi‐
vidually
ABS control unit - J104-
⇒ page 20
7 - Rear brake calipers
8 - Sealing ring
9 - Parking brake motors
❑ Left parking brake motor - V282- , fitting location: on rear left brake caliper.
❑ Right parking brake motor - V283- , fitting location: on rear right brake caliper.
10 - Torx socket head bolt
❑ 12 Nm

3.2 Removing and installing control unit for

electromechanical parking brake - J540-
The control unit for electromechanical parking brake - J540- is
integrated into the ABS control unit - J104- and cannot be re‐
newed individually.
– Removing and installing ABS control unit - J104- ⇒ page 20 .
3.3 Removing and installing parking brake

motor -V282- / -V283-
♦ Vehicle diagnostic tester

Removing
Note
Switch off ignition for at least 30 seconds before disconnecting

connector.
– Disconnect connector -2- from parking brake motor -1-.
3. Parking brake 73
– Unscrew both hexagon socket head bolts -arrows- from park‐

ing brake motor.
– Pull parking brake motor off brake caliper while twisting park‐
ing brake motor back and forth slightly.
– Take out seal.
Note
Take care not to damage annular groove for seal and contact
surface on parking brake motor.
– Clean annular groove and contact surface of parking brake

motor.
Installing
– Lightly grease new seal and install it, taking care not to twist
or damage it.
– Grease Torx socket on input shaft of parking brake motor
completely.
Note
The sealing ring must not be allowed to turn out while the parking
brake motor is being installed!
– Carefully push parking brake motor onto brake caliper while

ensuring that seal is seated correctly.
Note
If necessary, turn input shaft back slightly using an E11 Torx

socket -A- until parking brake motor can be properly fitted.
– Turn parking brake motor until bolt hole and thread align.
Note
Make sure that parking brake motor is flush with brake caliper.
Never pull parking brake motor onto brake caliper using securing
bolts.

– Position hexagon socket head bolts -arrows- by hand and

tighten them.
– Install connector -1-.
– Carry out basic setting of brake system using ⇒ Vehicle diag‐
nostic tester.
Specified torque
♦ ⇒ “3.1 Overview of fitting locations - parking brake”, page 72
3. Parking brake 75
4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 76
⇒ “4.2 Separating brake pedal from brake servo”, page 79
⇒ “4.3 Connecting brake pedal to brake servo”, page 80
⇒ “4.4 Removing and installing brake pedal”, page 80
⇒ “4.5 Removing and installing mounting bracket”, page 81
4.1 Assembly overview - brake pedal

⇒ “4.1.1 Assembly overview - brake pedal, left-hand drive”, page
76
⇒ “4.1.2 Assembly overview - brake pedal, right-hand drive”, page
78
4.1.1 Assembly overview - brake pedal, left-

hand drive
Note
♦ The handbrake pedal travel must not be restricted by addi‐

tional floor coverings.
♦ Do not lubricate or grease the pivot pin. The pivot pin must
remain dry.

1 - Hexagon nut, self-locking

❑ Bolting sequence
⇒ page 78
❑ 25 Nm
2 - Pivot pin
❑ To remove, remove
mounting bracket first
❑ Removal: turn pivot pin
clockwise until pivot pin
tabs break off
❑ Renew pivot pin
❑ Do not lubricate or
grease the pivot pin.
The pivot pin must re‐
main dry.
❑ Installation: Turn pivot
pin anti-clockwise until
tabs engage audibly on
stop.
3 - Pedal cluster with mounting
bracket
⇒ page 81
4 - Bearing bush
❑ Cannot be renewed in‐
dividually; ensure cor‐
rect installation position
5 - Brake pedal
❑ Separating brake pedal
from brake servo
⇒ page 79
❑ Connect brake pedal to
brake servo
⇒ page 80
6 - Cap
7 - Bearing bush
❑ Cannot be renewed individually; ensure correct installation position
8 - Bearing shell
9 - Support
❑ For ball head of brake servo plunger rod.
10 - Securing clip
❑ Renew
❑ Insert into both holes in mounting bracket.
4. Brake pedal 77
Bolting sequence:
4.1.2 Assembly overview - brake pedal, right-hand drive
Note
♦ The handbrake pedal travel must not be restricted by additional floor coverings.
♦ Do not lubricate or grease the pivot pin. The pivot pin must remain dry.
1 - Bolt
❑ 20 Nm
2 - Mounting bracket
⇒ page 83
3 - Nut
❑ 25 Nm
4 - Securing clip
❑ Renew
❑ Insert into both holes in
mounting bracket.
5 - Nut
❑ To secure brake servo
❑ Qty. 2
❑ 25 Nm
6 - Pivot pin
❑ To remove, remove
mounting bracket first
❑ Removal: turn pivot pin
clockwise until pivot pin
tabs break off
❑ Renew pivot pin
❑ Do not lubricate or
grease the pivot pin.
The pivot pin must re‐
main dry.
❑ Installation: Turn pivot
pin anti-clockwise until
tabs engage audibly on
stop.
7 - Bearing bush
❑ Cannot be renewed in‐
dividually; ensure correct installation position

8 - Brake pedal
❑ Separating brake pedal from brake servo ⇒ page 79
❑ Connect brake pedal to brake servo ⇒ page 80
9 - Bearing shell
10 - Support
❑ For ball head of brake servo plunger rod.
11 - Bearing bush
❑ Cannot be renewed individually; ensure correct installation position
12 - Cap
4.2 Separating brake pedal from brake ser‐

vo
♦ Release tool - T10159B-
– Remove footwell cover on driver side ⇒ General body repairs,

interior; Rep. gr. 68 ; Compartments/covers .
– First press brake pedal -1- in direction of brake servo and hold.
1 - Brake pedal
2 - Push bar
3 - Retaining lugs
4 - Mounting bracket
– Insert release tool - T10159B- -A- and pull it in direction of
driver seat. When doing this, counter hold on brake pedal -1-
(at this stage, the pedal must not be allowed to move towards
driver seat). This action will press retaining lugs -3- of mount‐
ing off ball head of plunger rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool - T10159B- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).
Specified torque
♦ Remove footwell cover on driver side ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Overview of fit‐
ting locations - compartments/covers .
4. Brake pedal 79
4.3 Connecting brake pedal to brake servo

– Hold ball head of plunger rod in front of mounting, and push
brake pedal in direction of brake servo -arrow- so that ball head
engages audibly.
– Check engagement by pulling briefly on brake pedal.
Further installation is performed in reverse sequence.
4.4 Removing and installing brake pedal

⇒ “4.4.1 Removing and installing brake pedal, left-hand drive ve‐
hicles”, page 80
4.4.1 Removing and installing brake pedal,

left-hand drive vehicles
It is not possible to remove the brake pedal separately.
– First remove pedal cluster/mounting bracket ⇒ page 81 ,
then remove brake pedal.
Note
Removing brake pedal with mounting bracket removed

– Turn pivot pin clockwise in direction indicated by -arrow-.

-1- = 14 mm hex socket wrench
Note
This action will break off the tabs -B-. Renew pivot pin.
– Remove securing clip from pivot pin.

– Pull out pivot pin towards right.
– Remove brake pedal from mounting bracket.
Installing
Note
Renew pivot pin and securing clip.
Note
Do not lubricate or grease the pivot pin. The pivot pin must remain
dry.
– Slide pivot pin from right to left through mounting bracket and
brake pedal.
– Fit securing clip to pivot pin while at the same time inserting
the securing clip into both holes in mounting bracket.
– Turn pivot pin anti-clockwise (-motion arrow-) until tabs -A-

engage audibly behind stop -B- in mounting bracket.
– Install pedal cluster/mounting bracket ⇒ page 81 .
4.5 Removing and installing mounting

bracket
⇒ “4.5.1 Removing and installing mounting bracket, left-hand
drive”, page 81
⇒ “4.5.2 Removing and installing mounting bracket, RHD”,
page 83
4.5.1 Removing and installing mounting

bracket, left-hand drive
– Remove dash panel trim on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments/covers; Removing
and installing dash panel trim on driver side .
4. Brake pedal 81
– Remove knee airbag -1- ⇒ General body repairs, interior; Rep.

gr. 69 ; Knee airbags; Assembly overview - knee airbag .
– Remove footwell vent on driver side ⇒ Heating, air condition‐

ing system; Rep. gr. 87 ; Air duct system; Assembly overview
- air duct system and air distribution in passenger compart‐
ment .
– Remove interface for entry and start system - J965- ⇒ Elec‐
trical system; Rep. gr. 94 ; Entry and start authorisation;
Renewing and installing entry and start authorisation control
unit J518 .
– Unbolt crash bar for brake pedal and lay it to one side ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Dash panel central
tube; Assembly overview - dash panel central tube .
– Unscrew bolt -2-, detach crash bar -1-, and push it to one side.
– Remove headlight range control unit - J431- / control unit for

cornering light and headlight range control - J745- -1-, and lay
it to one side ⇒ Electrical system; Rep. gr. 94 ; Automatic
headlight range control; Removing and installing headlight
range control unit .
– Separate brake pedal from brake servo ⇒ page 79 .
– Pull connector off accelerator pedal position sender.

– Unscrew nuts -1 to 4-.

– Carefully remove foot pedal cluster.
Installing
– Connect brake pedal to brake servo ⇒ page 80 .
Tightening sequence for securing nuts:

Specified torques
♦ ⇒ “4.1.1 Assembly overview - brake pedal, left-hand drive”,
page 76
♦ Crash bar ⇒ General body repairs, interior; Rep. gr. 70 ;
Central tube for dash panel; Assembly overview - central tube
for dash panel
♦ Footwell vents ⇒ Heating, air conditioning system; Rep. gr.
87 ; Air duct; Assembly overview - air duct and air distribution
in passenger compartment .
♦ Knee airbag ⇒ General body repairs, interior; Rep. gr. 69 ;
Knee airbags; Assembly overview - knee airbag .
♦ Covers on driver side ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments/covers; Overview of fitting locations -
compartments/covers
4.5.2 Removing and installing mounting

bracket, RHD
Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
4. Brake pedal 83
– Unscrew bolt -1-.

– Remove storage compartment on driver side ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments/covers .
– Remove knee airbag ⇒ General body repairs, interior; Rep.
– Observe safety precautions for working on airbags ⇒ General
body repairs, interior; Rep. gr. 00 ; Safety information; Safety
precautions for working with pyrotechnic components .
– Remove steering column ⇒ Running gear, axles, steering;
Rep. gr. 48 ; Steering column; Removing and installing steer‐
ing column .
– Remove footwell vent on driver side -1- ⇒ Heating, air condi‐

tioning; Rep. gr. 87 ; Air duct system; Assembly overview - air
duct system and air distribution in passenger compartment .
– To do this, unscrew bolt -2- and remove footwell vent on driver
side -1-.
– Unbolt crash bar for brake pedal and lay it to one side ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Dash panel central
tube; Assembly overview - dash panel central tube .
– Release and pull off connector -arrows-.
– Unclip wiring harness -2- from mounting bracket -1- -arrows-.

– Remove nuts -arrows- from mounting bracket -1-.
– Secure brake servo -1- against falling.

Installing
– Ensure to route wiring harness -2- correctly so that it is not

trapped.
– Clip wiring harness -2- to mounting bracket -1- -arrows-.
Specified torques
♦ ⇒ “4.1.2 Assembly overview - brake pedal, right-hand drive”,
page 78
for dash panel
♦ Steering column ⇒ Running gear, axles, steering; Rep. gr.
48 ; Steering column; Removing and installing steering column
compartments/covers
♦ Windscreen wiper system ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Assembly overview - windscreen
wiper system
♦ Plenum chamber cover ⇒ General body repair, exterior; Rep.
gr. 50 ; Plenum chamber bulkhead; Assembly overview - ple‐
num chamber cover
4. Brake pedal 85
47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.2 Removing and installing brake caliper piston”, page 87
1.1 Assembly overview - front brake caliper

⇒ “1.1.1 Assembly overview - brake caliper PC57 and C60”, page
86
1.1.1 Assembly overview - brake caliper PC57 and C60

♦ Install complete repair kit when servicing.
♦ Only use methylated spirits to clean brakes.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inders, pistons and seals.
1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
❑ 10 Nm
3 - Hexagon bolt
❑ Renew after removal.
❑ 35 Nm
4 - Guide pin
5 - Protective cap
❑ Insert into brake carrier
and guide pin groove;
grease groove before‐
hand, use repair kit
grease pack.
6 - Brake carrier
❑ Supplied as pre-assem‐
bled replacement part
with greased guide pins
and protective caps.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Protective cap
86 Rep. gr.47 - Brakes - hydraulics

⇒ page 87
❑ When inserting piston,
take care not to damage it.
8 - Piston
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
9 - Sealing ring
10 - Brake caliper

piston
⇒ “1.2.1 Removing and installing PC57 brake caliper piston”,
page 87
1.2.1 Removing and installing PC57 brake

caliper piston
♦ Removal wedge - 3409-
Removing
– Press piston out of brake caliper using compressed air.
1. Front brake caliper 87

– Place a piece of wood in the recess to prevent damage to the

piston.
– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Insert seal in brake caliper.
– Place protective cap with outer sealing lip on piston.
– Insert inner sealing lip into groove in cylinder using wedge

3409.
When doing this, hold piston in front of brake caliper.

– Press piston into brake caliper using piston resetting appli‐

ance.
The outer sealing lip of the protective cap will then lock in the
groove of the piston.
1. Front brake caliper 89

2 Rear brake caliper

⇒ “2.2 Removing and installing protective cap”, page 90
2.1 Assembly overview - rear brake caliper

♦ Install complete repair kit when servicing.
♦ Only use methylated spirits to clean brakes.
♦ New brake calipers are filled with brake fluid and are pre-bled.
1 - Brake caliper
2 - Damper bushes
3 - Guide pin
4 - Caps
5 - Hexagon socket head bolt
❑ 8 Nm
6 - Parking brake motor
7 - Sealing ring
❑ Renew
8 - Thrust nut
not possible
9 - Sealing ring
not possible
10 - Piston
not possible
11 - Protective cap
⇒ page 90
Note
The brake caliper does not need to

be removed in order to renew the
protective cap; do not unbolt the
break hose.
12 - Bleeder valve
❑ Apply thin coat of as‐
sembly paste G 052 150 A2 to thread before screwing in.
❑ 10 Nm
13 - Dust cap
2.2 Removing and installing protective cap


♦ Removal wedge - 3409-
♦ Thrust piece - T10146/5- for rear brake FNc-M42 (17”)
♦ Piston resetting appliance - T 10145-
Removing
Only the protective cap is intended to be renewed.
Note
The brake caliper does not need to be removed in order to renew

the protective cap; do not unbolt the break hose.
• Piston has been moved back.

• Parking brake motor has been removed.
NOTICE
Risk of damage to ball screw assembly due to removal of piston
and compressor nut.
– Never unscrew piston and compressor nut completely.
2. Rear brake caliper 91

– Unscrew piston (-direction of arrow-) by maximum of 20 mm

(-dimension a-) using an E11 Torx socket.
– Lever protective cap off brake caliper using wedge 3409

-arrows-.
Installing
– The surfaces of the piston and brake caliper must be cleaned
only with methylated spirits, and then dried.
– Insert protective cap into groove -arrow- in piston.
– Screw piston back in (-direction of arrow-).

– Push protective cap onto brake caliper using assembly tool -

T10502- -2- and piston resetting appliance - T 10145- -1- in
such a way that protective cap lies against brake caliper all
around its circumference.
2. Rear brake caliper 93

3 Brake servo and brake master cylin‐

der
⇒ “3.1 Assembly overview - brake servo/brake master cylinder”,
page 94
⇒ “3.2 Removing and installing brake light switch”, page 99
⇒ “3.3 Removing and installing brake master cylinder”,
page 101
⇒ “3.4 Removing and installing brake servo”, page 114
3.1 Assembly overview - brake servo/brake

master cylinder
⇒ “3.1.1 Assembly overview - brake servo/brake master cylinder,
left-hand drive vehicles”, page 94
⇒ “3.1.2 Assembly overview - brake servo/brake master cylinder,
3.1.1 Assembly overview - brake servo/brake

master cylinder, left-hand drive vehicles
Note
Only use new brake fluid conforming to VW standard

(VW 501 14).


❑ Bolting sequence
⇒ page 96
❑ 25 Nm
2 - Pedal cluster with mounting
bracket
3 - Bulkhead
❑ 25 Nm
5 - Brake master cylinder
❑ Cannot be repaired. If
faulty, renew complete.
⇒ page 101
⇒ page 99
7 - Bolt
❑ 8 Nm
8 - Brake line
secondary piston circuit
to hydraulic unit
❑ 14 Nm
6854, VAG 1410/7 and
VAG 1410/6: 12 Nm
9 - Brake line
primary piston circuit to hydraulic unit
❑ 14 Nm
10 - Plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
11 - Warning contact for brake fluid level - -F34--
12 - Brake fluid reservoir
❑ Securing bolt, 8 Nm
13 - Vacuum hose
❑ With non-return valve
❑ Fit in brake servo.
❑ On some vehicles with petrol engines, vacuum sender - G608- is installed in brake servo ⇒ page 141
14 - Sealing cover
15 - Seal
❑ Renew if damaged
❑ Ensure that seals are correctly seated
❑ Between brake master cylinder and brake servo
3. Brake servo and brake master cylinder 95

16 - Sealing ring
❑ Vacuum hose for brake servo
17 - Brake servo
❑ On petrol engines, the required vacuum is taken either from the intake manifold or generated by a me‐
chanical vacuum pump.
❑ Diesel engines are fitted with a vacuum pump to generate the necessary vacuum pressure
⇒ page 137 .
❑ Operation check:
– With engine switched off, depress brake pedal firmly several times (to exhaust any negative pressure in
the unit).
– Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the brake pedal will now give perceptibly under foot (servo assistance becomes activated).
❑ If faulty renew complete
❑ Checking brake servo vacuum system ⇒ page 142
18 - Seal
❑ Renew
❑ Bonded (only when originally assembled at factory)
❑ Bonded joint at brake servo and bulkhead does not have to be renewed
Bolting sequence:
3.1.2 Assembly overview - brake servo/brake

master cylinder, right-hand drive
Note
Only use new brake fluid conforming to VW standard

(VW 501 14).

1 - Sealing cover
2 - Brake fluid reservoir
❑ With brake fluid level
warning contact - F34-
3 - Brake servo
⇒ page 114
❑ Operation check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust any negative
pressure in the unit).
– Now depress brake
pedal with average foot
pressure, hold and start
engine. If the servo unit
is working properly, the
brake pedal will now
give perceptibly under
foot (servo assistance
becomes activated).
❑ If faulty renew complete
❑ Checking brake servo
vacuum system
⇒ page 142
4 - Seal
❑ Vacuum hose for brake
servo
❑ Ensure that seals are
correctly seated
5 - Vacuum line
6 - Seal
❑ Bonded (only when originally assembled at factory)
❑ Remove adhesive residue
❑ Bonded joint at brake servo and bulkhead does not have to be renewed
7 - Nut
❑ Qty. 2
❑ 25 Nm
8 - Mounting bracket with brake pedal
❑ Removing mounting bracket ⇒ page 83
❑ Removing brake pedal ⇒ page 80
❑ Separating brake pedal from brake servo ⇒ page 79
❑ Connect brake pedal to brake servo ⇒ page 80
9 - Seal
❑ Between brake master cylinder and brake servo
10 - Brake master cylinder

❑ Connecting brake line ⇒ page 43
❑ When attaching brake master cylinder to brake servo, make sure plunger rod is properly positioned in
brake master cylinder.
12 - Bolt
❑ 8 Nm
13 - Bolt
❑ 8 Nm
14 - Heat shield
❑ On brake fluid reservoir.
15 - Heat shield
❑ For brake servo
16 - Nut
❑ Qty. 2
❑ Self-locking
❑ 25 Nm
17 - Brake line
❑ 14 Nm
18 - Plug
❑ Moisten sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder
❑ Between brake master cylinder and brake fluid reservoir
19 - Brake line
❑ 14 Nm
20 - Spreader rivet
❑ For securing brake fluid reservoir

3.2 Removing and installing brake light

switch
⇒ “3.2.1 Removing and installing brake light switch, LHD”,
page 99
⇒ “3.2.2 Removing and installing brake light switch, right-hand
drive”, page 100
3.2.1 Removing and installing brake light

switch, LHD
Removing
Vehicles with diesel engine:
– Remove air intake hose between turbocharger and air filter
housing ⇒ Rep. gr. 23 ; Air filter; Assembly overview - air filter
housing .
Vehicles with 1.5 l, 1.8 l and 2.0 l petrol engine:
housing .
Vehicles with bi-turbo diesel engine:
– Remove air intake hose and air filter housing ⇒ Rep. gr. 23 ;
Air filter; Assembly overview - air filter housing .
– Release and pull off electrical connector -2- from brake light
switch - F- -1-.
– Pull off brake light switch - - -1- from bottom of brake master
cylinder.
Installing

– Make sure that brake light switch - F- -1- seats properly against
edge -arrow- of brake master cylinder.
Specified torque
♦ ⇒ “3.1.1 Assembly overview - brake servo/brake master cyl‐
inder, left-hand drive vehicles”, page 94
♦ ⇒ Rep. gr. 23 ; Air filter; Assembly overview - air filter housing
3.2.2 Removing and installing brake light

switch, right-hand drive
Removing
– If fitted, remove engine cover panel ⇒ Rep. gr. 10 ; Engine
cover panel; Removing and installing engine cover panel .
Vehicle with diesel engine:
– To create the needed working space, remove fuel filter, and
lay it to one side ⇒ Fuel supply - diesel engines; Rep. gr. 20 ;
Fuel filter; Removing and installing fuel filter .
– Release and pull off electrical connector -1-.
– Using a screwdriver, release catches -arrow-.
– Place coolant expansion tank on engine.
– Remove upper toothed belt guard ⇒ Rep. gr. 15 ; Toothed
belt drive; Removing and installing toothed belt guard .

– Release connector -2- and pull off brake light switch -1-.
– Unscrew bolt -arrow-.
– Remove brake light switch -1- from brake master cylinder.
Installing

– Make sure that brake light switch - F- -1- seats properly against
edge -arrow- of brake master cylinder.
Specified torques
inder, right-hand drive”, page 96
♦ ⇒ Rep. gr. 15 ; Toothed belt drive; Assembly overview -
toothed belt guard
3.3 Removing and installing brake master

cylinder
⇒ “3.3.1 Removing and installing brake master cylinder, left-hand
drive”, page 101
⇒ “3.3.2 Removing and installing brake master cylinder, RHD”,
page 104
⇒ “3.3.3 Removing and installing brake master cylinder, LHD ve‐
hicles, bi-turbo diesel engine”, page 110
3.3.1 Removing and installing brake master

cylinder, left-hand drive
♦ Brake filling and bleeding equipment - VAS 5234-

♦ Engine bung set - VAS 6122-
♦ Socket Torx T 30 - T10405-
Removing:
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;
housing .
Vehicles with 1.5 l, 1.8 l and 2.0 l petrol engine:
housing .
Vehicles with battery in engine compartment


– 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- .
Vehicles with manual gearbox:

– Place sufficient lint-free cloths in area of engine.
– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch master cylinder -3- with engine
bung set - VAS 6122- -1- or hose clips to 25 mm - 3094- .
– Raise return hose -2- and tie it in place.
– Pull off connector of brake fluid level warning contact - F34-

-3- from vacuum sender - G608- -2- (if fitted) and from brake
light switch - F- -1-.
– Unscrew Torx bolt -1- and pull brake fluid reservoir -2- out of
sealing plugs.

– Unscrew brake lines -1- from brake master cylinder, and seal
brake lines with plugs from repair kit with part no.
1H0 698 311 A.
– Unscrew nuts -2- from brake master cylinder.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
– Unscrew brake light switch - F- from brake master cylinder.
Installing
Install in reverse order. Observe the following when doing this:
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
– When joining brake master cylinder to brake servo, make sure
seal ⇒ Item 15 (page 95) is properly seated.
– Ensure that seals ⇒ Item 10 (page 95) are correctly seated in
– Moisten sealing plugs ⇒ Item 10 (page 95) with brake fluid
before pressing brake fluid reservoir into brake master cylin‐
der.

– Check seals -2- for damage and renew if necessary.
– Make sure that seals -2- engage correctly in supply hose -1-.
– Connect supply hose -1-.
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism;
Bleeding clutch mechanism .
Specified torques
overview - battery
3.3.2 Removing and installing brake master cylinder, RHD


equipment required


♦ Sealing plug repair kit - 1H0 698 311 A-
♦ Socket Torx T 30 - T10405-
♦ Ring spanner insert set AF 11 - V.A.G 1331/2-
Fitting location of brake master cylinder in RHD vehicles:

Removing
Vehicles with diesel engine and SCR system:
– Remove lines for injector for reducing agent - N474- at top of
toothed belt cover ⇒ Rep. gr. 15 ; Toothed belt drive; Re‐
moving and installing toothed belt cover .
– Remove injector for reducing agent - N474- on exhaust gas
cleaning module and lay aside with lines attached ⇒ Rep. gr.
26 ; SCR system (Selective Catalytic Reduction); Removing
and installing injector for reducing agent .
– Remove differential pressure sender - G505- and exhaust gas
pressure sensor 1 - G450- from cylinder head ⇒ Rep. gr. 23 ;
Senders and sensors; Removing and installing differential
pressure sender G505 .
– Remove exhaust gas temperature sender 3 - G495- ⇒ Rep.
gr. 26 ; Removing and installing exhaust gas temperature
sender 3 .


– Mark installation position and allocation of hoses in relation to
pipes.
– Release hose clips -1- and detach hoses.
– Unclip pipe -2- and remove it together with pressure differen‐
tial senders.

– Place sufficient lint-free cloths in area of engine.
– If present, remove heat shield.

– To do so, remove clamping washer -4- from bulkhead.
– Open snaps -1- to -3- on heat shield.
– Pull vacuum line off brake servo.

– Pull return hose -2- for clutch sender cylinder -3- off brake fluid
reservoir -4-.
– Seal return hose -2- for clutch master cylinder -3- with engine
bung set - VAS 6122- -1- or hose clips to 25 mm - 3094- .
– Raise return hose -2- and tie it in place.


– Remove heat shield -1- if present.
– Also unscrew screw -3- with Torx screwdriver bit T30 -
T10405- .
– Pull heat shield -1- upwards out of retainers -arrows- on brake
fluid reservoir -2-.
– Release connector -2- and pull off brake light switch - F- -1-.
– Release electrical connector -2- for brake fluid level warning

contact - F34- and pull it off brake fluid reservoir -1-.
– Open retainers -arrows- for refrigerant line -1-.

– Pull out spreader rivet -3- in -direction of arrow-.

– Pull brake fluid reservoir -1- upwards and towards right off
brake master cylinder -2-.
– When doing this, gently press refrigerant line upwards.
– Mark position of brake lines -2- on brake master cylinder -1-.

– Unscrew brake lines -2- from brake master cylinder -1-.
– Seal threaded holes immediately using sealing plugs - 1H0
698 311 A- or sealing plugs with assembly part number 5Q0
698 311.
– Seal brake lines using plugs from repair set part number 1H0
698 311 A or bung set for engine - VAS 6122- . As appropriate,
fit dust caps from bleeder valves onto brake line.
– Remove nuts -arrows-
– Remove heat shield -3-.
– Carefully remove brake master cylinder from brake servo.
Installing
cylinder.
der.
– Spreader rivet can be pushed in from other side.


– When tightening using ring insert tool, open, AF 11 - V.A.G
1410/6- , universal joint - V.A.G 1410/7- and torque wrench -
VAS 6854- , set torque to 12 Nm.
Vehicles without manual gearbox:

Specified torques
♦ ⇒ “3.3.2 Connecting brake lines to hydraulic unit, RHD”, page
43
toothed belt guard
♦ ⇒ Rep. gr. 26 ; SCR system (Selective Catalytic Reduction);
Assembly overview - injector for reducing agent
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit
3.3.3 Removing and installing brake master

cylinder, LHD vehicles, bi-turbo diesel
engine

Removing
Disconnecting and reconnecting battery.
– Release, pull off and unclip electrical connectors -2- to -5-.
– Unclip retainer -1- on bulkhead.
– Release and pull off connector -2- at solenoid valve -1-.

– Place solenoid valve -1- on engine together with vacuum lines.
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .

– Press release tabs on crankcase breather hose -4-, and re‐

move hose from intake hose -1-.
– If fitted, release and pull off connector on hose -4-.
– Pull off vacuum hoses -2- and -3-.
– Release screw-type clip -5- and pull off intake hose from tur‐
bocharger.
– Lay out sufficient lint free clothes in area of engine and gear‐
box.
– Release and pull off electrical connectors from brake fluid level
warning contact - F34- -3- and from brake light switch - F-
-1-.
– Unclip wiring harness on brake master cylinder.
– Unclip wiring harness for control unit for NOx sender - GX30-
on brake master cylinder.
– Unscrew Torx bolt -1- and pull brake fluid reservoir -2- out of
sealing plugs.

– Disconnect brake lines -1- from brake master cylinder and seal
holes using sealing plug - 1H0 698 311 A- .
– Unscrew nuts -2- from brake master cylinder.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
– Unscrew brake light switch - F- from brake master cylinder.
Installing
cylinder.
der.
Specified torques
Component Specified torque

Solenoid valve to plenum chamber bulkhead 6 Nm

♦ ⇒ Rep. gr. 23 ; Injection system; Overview of fitting locations
- injection system

3.4 Removing and installing brake servo

⇒ “3.4.1 Removing and installing brake servo, LHD vehicles, pet‐
rol engine”, page 114
⇒ “3.4.2 Removing and installing brake servo, left-hand drive ve‐
hicles with diesel engine”, page 119
⇒ “3.4.3 Removing and installing brake servo, LHD vehicles, bi-
turbo diesel engine”, page 125
⇒ “3.4.4 Removing and installing brake servo, RHD vehicles, pet‐
rol engine”, page 130
⇒ “3.4.5 Removing and installing brake servo, right-hand drive
with diesel engine”, page 134
3.4.1 Removing and installing brake servo,

LHD vehicles, petrol engine
Note
If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 142 .


♦ Hot air blower, e.g. hot air blower - VAS 1978/14A-
Removing:
– Remove air intake hose between air filter housing and turbo‐
charger ⇒ Rep. gr. 24 ; Air filter; Assembly overview - air filter
housing .
Battery in engine compartment


Battery in luggage compartment
– Remove air filter carrier ⇒ Rep. gr. 24 ; Air filter; Removing
– Remove bolt -5-.
– Unclip wiring harness -2- -3-.
– Release potential distributor -1- on bracket -arrow-.
– Release and pull off connector -4-.
– Move potential distributor -1- to one side.

box.

– Seal supply hose -1- for clutch master cylinder with engine
bung set - VAS 6122- or hose clips to 25 mm - 3094- .


– Dissipate vacuum in brake servo by depressing brake pedal
several times.
– Pull vacuum hose -1- out of brake servo -2-.

– Disconnect brake lines from brake master cylinder and from
hydraulic unit, and seal holes using sealing plugs -
1H0 698 311 A- .
– Unclip both brake lines to brake master cylinder from retainers,
and lay them to one side.


ment .

– Unscrew nuts -3 and 4- from brake servo.

– Pull brake servo off bulkhead, applying force to separate bon‐
ded joint.
– Carefully remove brake servo from the vehicle.
– Unscrew nuts for brake master cylinder.
– Remove heat shield, if fitted.
Installing
Note
♦ The brake servo is given the additional bonded joint only dur‐
ing factory assembly.
♦ The adhesive bond between the brake servo and the bulkhead
does not need to be renewed, but the seal does.
– Remove adhesive residue from brake servo and plenum

chamber bulkhead.
– To do so, apply gentle heat from hot air blower to the adhesive
residue and pull it off.
– Thoroughly clean surfaces.
– Renew brake servo seal ⇒ Item 18 (page 96) .
– Carefully insert brake servo and tighten nuts.
cylinder.
der.


Specified torques
Bolt for potential distributor on holder 6 Nm
Earth wire to holder on bulkhead 9 Nm
for dash panel
compartments/covers
overview - battery

left-hand drive vehicles with diesel en‐
gine
Note



Removing:
Battery in engine compartment:
Battery in luggage compartment:
– If installed above left assembly mounting, remove air filter car‐
rier ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
housing .
– Remove air intake hose, air filter housing and intake hose ⇒
Rep. gr. 23 ; Air filter; Removing and installing air filter hous‐
ing .
box.


– Seal supply hose -1- for clutch master cylinder -3- with engine
bung set - VAS 6122- or hose clips to 25 mm - 3094- .

several times.

– Remove air pipe ⇒ Rep. gr. 21 ; Charge air system; Removing
and installing air pipe .
– Remove lifting eyes from cylinder head ⇒ Rep. gr. 15 ; Cyl‐
inder head; Assembly overview - cylinder head .
Vehicles with dual clutch gearbox:
– Remove selector cable and cable support bracket from gear‐
box ⇒ Rep. gr. 34 ; Selector mechanism; Assembly overview
- selector mechanism .

– Unbolt connector strip with connectors -1 to 4- from plenum
chamber bulkhead, pull it off, and lay it to one side.
– Disconnect brake lines from brake master cylinder and from
hydraulic unit, and seal holes using sealing plugs -
1H0 698 311 A- .
– Unclip both brake lines to brake master cylinder from retainers,
and lay them to one side.



ment .

– Unscrew nuts -3 and 4- from brake servo.

ded joint.
– Unscrew nuts for brake master cylinder.
– Remove heat shield, if fitted.
Installing
Note

chamber bulkhead.
cylinder.
der.


Specified torques
♦ ⇒ Rep. gr. 15 ; Cylinder head; Assembly overview – cylinder
head
♦ ⇒ General body repairs, interior; Rep. gr. 70 ; Central tube
for dash panel; Assembly overview - central tube for dash
panel
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air duct; Assembly
overview - air duct and air distribution in passenger compart‐
ment .
♦ ⇒ General body repairs, interior; Rep. gr. 69 ; Knee airbags;
Assembly overview - knee airbag .
♦ ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments/
covers; Overview of fitting locations – compartments/covers
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery

LHD vehicles, bi-turbo diesel engine
Note


Removing
– Remove brake master cylinder ⇒ page 110 .
– Remove air filter carrier ⇒ Rep. gr. 23 ; Air filter; Removing
– Remove air pipe ⇒ Rep. gr. 21 ; Charge air system; Removing
and installing air pipe .
– Remove vacuum unit with regulating flap potentiometer -
G584- ⇒ Rep. gr. 21 ; Turbocharger; Renewing vacuum unit
for turbocharger .
several times.

Coupling point for coolant pipes, version 1:

– Unscrew nuts -arrows B-.
– Remove bracket -1- from gearbox mounting -3-.
– Release and pull off coolant lines -4- from bracket -arrow A-.
– Lay down coolant pipes.
Coupling point for coolant pipes, version 2:

– Remove retainer -1- from water pipe -4- and gearbox mounting
-3-.
– Lay down coolant pipes.

– Unscrew line -arrow- and lay aside.

– Remove retainer -1-. To do this, drill out both pop rivet -2- using
a suitably sized drill bit.

Note
♦ When drilling out the two pop rivet, parts will fall down into the
body profile of the plenum chamber -2-.
♦ The two pop rivets cannot be removed.
♦ To prevent any knocking »noise« from developing, the re‐
mains are bonded to the body profile by spraying on cavity
sealant.
♦ The cavity sealant is sprayed above both holes -arrows-.
♦ Spray on cavity sealant several times.
♦ Continue to spray on cavity sealant until it is clearly seen to
escape at the transition to the top of the wheel housing -1-.
♦ The openings should not be blocked with cavity sealant.
Check for blockage.
♦ Allow a period of time between spray applications.
♦ Once the period of time has elapsed, repeat the spray appli‐
cation each time.
♦ For allocation of cavity sealant, see ⇒ Electronic parts cata‐
logue .
– Spray cavity sealant sufficiently over both holes.


– Unscrew nuts -3- and -4- from brake servo.

ded joint.
– Spray cavity sealant sufficiently over both holes ⇒ page 128 .
Installing
Note

chamber bulkhead.
Install in reverse order. Observe following points when installing.
– Carefully insert brake servo.
– Check that push rod is in front of mounting in brake pedal.
– Tighten nuts for brake servo.
cylinder.
– Rivet potential compensation bracket to body.
– For allocation of both pop rivets, see ⇒ Electronic parts cata‐
logue .
– After installation, bleed brake system ⇒ page 154 .
Specified torques
♦ ⇒ Rep. gr. 21 ; Charge air system; Assembly overview -
charge air system
♦ ⇒ Rep. gr. 21 ; Turbocharger; Assembly overview - turbo‐
charger


Bracket between water pipe and 20 Nm
gearbox mounting

RHD vehicles, petrol engine
Note

♦ Engine support - T10533-
Fitting location of brake servo in RHD vehicles:

Removing
sulation .

– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Removing and installing pendulum support .
– Remove catalytic converter ⇒ Rep. gr. 26 ; Cleansing exhaust
emissions; Removing and installing catalytic converter .
– Remove exhaust system bracket from engine ⇒ Rep. gr. 26 ;
Emission control; Assembly overview - emission control .
Vehicles with seat heating:
– Remove coolant pipes on bulkhead ⇒ Auxiliary heater, sup‐
plementary heating system; Rep. gr. 82 ; Coolant circuit with
auxiliary heater/supplementary heating system .
Vehicles with dual clutch gearbox:
– Remove selector lever cable from gearbox ⇒ ; Rep. gr. 34 ;
Selector mechanism; Removing and installing selector lever
cable .
– Release and pull off connector for mechatronic unit for dual
clutch gearbox - J743- ⇒ Rep. gr. 34 ; Mechatronic unit .
– Detach wiring harness from front of gearbox and push up‐
wards.
– Disconnect gear selector cable and gate selector cable from
gearbox. Then, unbolt cable support bracket and lay it to one
side, together with cables ⇒ Rep. gr. 34 ; Selector mecha‐
nism .


– Position engine support - T10533- as shown.
– Engine support - T10533/2- is positioned on flat bolt connect‐
ing point of engine support - T10533/1- .
– Screw in original bolt of pendulum support -2- in front threaded
hole of pendulum support.
– Screw an M8 × 40 mm bolt -1- fitted with a washer -2- into left
threaded hole in noise insulation.
– If necessary, engineer a sufficiently sized gap between gear‐
box and engine support - T10533- .
– To do this, use shims or washers and a bolt of a sufficient
length at the threaded connections.
– Tighten bolts hand-tight.
– Push engine and gearbox with engine support - T10533- as
far forwards as possible.
– Ensure that electrical connection from starter does not contact
battery tray.
repairs, interior; Rep. gr. 68 ; Compartments/covers .

– Remove nuts -arrows- from mounting bracket.

ded joint.
– Remove brake servo downwards.
– Guide out brake servo between engine, subframe and longi‐
tudinal member.
– When doing this, turn and tilt brake servo accordingly.
Installing
Note
♦ The adhesive bond at the bulkhead/brake servo does not have
to be renewed.

chamber bulkhead.
– Install brake master cylinder ⇒ page 104 .
Specified torques
♦ ⇒ “3.3.2 Connecting brake lines to hydraulic unit, RHD”, page
43
♦ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview -
assembly mountings
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Assembly overview - drive shaft
♦ ⇒ Rep. gr. 19 ; Coolant pipes; Assembly overview - coolant
pipes
♦ ⇒ Rep. gr. 26 ; Emission control system; Assembly overview
- emission control system
- silencer
♦ ⇒ Auxiliary heater, supplementary heating system; Rep. gr.
82 ; Coolant circuit with auxiliary heater/supplementary heat‐
ing system
tion; Assembly overview - noise insulation



right-hand drive with diesel engine
Fitting location of brake servo in RHD vehicles:

Removing
Vehicles with emission control module:
– Remove emission control module ⇒ Rep. gr. 26 ; Emission
control; Removing and installing emission control module .
Vehicles with particulate filter or catalytic converter:
– Remove particulate filter ⇒ Rep. gr. 26 ; Emission control;
Removing and installing particulate filter .
Vehicles with auxiliary heater:
– Remove coolant pipes on bulkhead ⇒ Auxiliary heater, sup‐
plementary heating system; Rep. gr. 82 ; Coolant circuit with
auxiliary heater/supplementary heating system .

several times.
– Pull vacuum line -1- out of brake servo -2-.
repairs, interior; Rep. gr. 68 ; Compartments/covers; Over‐
view of fitting locations - compartments/covers .

– Remove nuts -arrows- from mounting bracket.

ded joint.
– Remove brake servo downwards.
Installing
Note

chamber bulkhead.
cylinder.
der.
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
– Install brake master cylinder ⇒ page 104 .
Specified torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview - subframe
♦ ⇒ Rep. gr. 19 ; Coolant pipes; Assembly overview - coolant
pipes
♦ ⇒ Rep. gr. 26 ; Emission control system; Assembly overview
- emission control system
♦ ⇒ Rep. gr. 26 ; Exhaust gas recirculation; Assembly overview
- exhaust gas recirculation


- silencer
toothed belt guard
♦ ⇒ Auxiliary heater, supplementary heating system; Rep. gr.
82 ; Coolant circuit with auxiliary heater/supplementary heat‐
ing system
tion; Assembly overview - noise insulation .

4 Vacuum system
⇒ “4.1 Assembly overview - vacuum pump”, page 137
⇒ “4.2 Checking non-return valve”, page 141
⇒ “4.3 Removing and installing vacuum sender G608 ”,
page 141
⇒ “4.4 Removing and installing electric vacuum pump”,
page 141
⇒ “4.5 Checking vacuum system”, page 142
4.1 Assembly overview - vacuum pump

⇒ “4.1.1 Assembly overview - vacuum pump, vehicles with diesel
engine”, page 137
⇒ “4.1.2 Assembly overview - vacuum pump, vehicles with 1.8 l
and 2.0 l petrol engine”, page 137
⇒ “4.1.3 Assembly overview of vacuum pump for brakes V192 ,
vehicles with 1.4 l petrol engine”, page 138
⇒ “4.1.4 Assembly overview of vacuum pump for brakes V192 ,
vehicles with 1.5 l petrol engine”, page 139
4.1.1 Assembly overview - vacuum pump, ve‐

hicles with diesel engine
The vacuum pump is installed in the oil pump.
– Removing and installing vacuum pump/oil pump ⇒ Rep. gr.
17 ; Oil pan/oil pump; Assembly overview - sump/oil pump .
4.1.2 Assembly overview - vacuum pump, vehicles with 1.8 l and 2.0 l petrol en‐
gine
4. Vacuum system 137

1 - Seal
2 - Vacuum pump
❑ No provision is made for
the vacuum pump to be
dismantled
⇒ Rep. gr. 15 ; Cylinder
head; Removing and in‐
stalling vacuum pump
3 - Vacuum hose
❑ To brake servo
4 - Bolts
❑ Tightening torque ⇒
Rep. gr. 15 ; Cylinder
head
4.1.3 Assembly overview of vacuum pump for brakes - V192- , vehicles with 1.4 l
petrol engine
Vacuum pump for brakes - V192- is located on rear right of gear‐
box.

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.
1 - Vacuum pump for brakes -

V192-
– For vehicles with 1.2 l
engine and 1.4 l engine
and special emission
standard
2 - Bracket
3 - Bolt
❑ Qty. 2
❑ 8 Nm
4 - Bolt
❑ Qty. 2
❑ 23 Nm
5 - Bracket
6 - Rubber damper
❑ Ensure proper seating
❑ When installing, ensure
that rubber dampers are
not pressed out of
bracket
4.1.4 Assembly overview of vacuum pump for brakes - V192- , vehicles with 1.5 l
petrol engine
Vacuum pump for brakes - V192- is located on the front right-hand
side in engine compartment.


be renewed.
1 - Vacuum pump for brakes -

V192-
❑ For vehicles with 1.5 l
engine
⇒ page 141
2 - Hexagon nut
❑ 7 Nm
3 - Washer
4 - Rubber damper
❑ Top
5 - Vacuum sender - G608-
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
⇒ page 141
6 - Non-return valve
7 - Vacuum line
8 - Bracket
9 - Rubber damper
❑ Bottom
10 - Hexagon bolt
11 - Clip
❑ Retainer for connector
12 - Hexagon bolt
❑ 8 Nm

4.2 Checking non-return valve

Test procedure
– Carefully pull non-return valve with vacuum line -1- out of
brake servo.
– Blow small amount of air through non-return valve -1- in one
direction first, then in other direction.
• Air must pass through non-return valve -1- in
-direction of arrow-.
• The non-return valve -1- must remain closed in the opposite
-direction of arrow-. If this is not the case, renew non-return
valve or, if necessary, complete vacuum line.
Note
When installing the vacuum line with non-return valve, ensure the
correct installation position relative to the brake servo.
4.3 Removing and installing vacuum sender

- G608-
Note
The vacuum sender - G608- is only installed in selected petrol

engines.
Removing
– Disconnect connector -3- from vacuum sender - G608- -1-.
– Unclip vacuum sender - G608- -1- from vacuum line -2-.
Installing
Note
♦ Make sure to check the seal for damage before installing the
vacuum sender - G608- .
♦ If the seal is damaged, the vacuum sender must be renewed.
4.4 Removing and installing electric vacuum

pump
For vehicles with 1.5 l engine.
Vacuum pump for brakes - V192- is located on the front right-hand
side in engine compartment.


be renewed.
Note
There are two versions of the vacuum pump relay - J318- : it can
be either an integral part of the vacuum pump for brakes - V192-
or fitted externally to the bracket.
Removing
– Release vacuum line -1-, and pull it off vacuum pump for
brakes - V192- -5-.
– If fitted, unbolt vacuum pump relay - J318- -2- together with
bracket, and lay it aside.
– Disconnect electrical connector -3- from vacuum pump for
brakes - V192- -5-.
– Release connector -3-, and pull it out of clip.
– Unbolt vacuum pump for brakes - V192- -5- together with
bracket -4-.
– Unbolt vacuum pump for brakes - V192- -5- from bracket -4-.
Installing
Install in reverse order.
Specified torques
♦ ⇒ “4.1.4 Assembly overview of vacuum pump for brakes
V192 , vehicles with 1.5 l petrol engine”, page 139
4.5 Checking vacuum system

The following instructions are intended to help you find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or in the event of a so-called »hard brake
pedal«.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if there is one)
When evaluating the measuring results, bear in mind that they will
be influenced by the geographical location. The higher your lo‐
cation is above sea level, the lower the air pressure will be.
Before checking the vacuum system, please take note of the fol‐
lowing prerequisites for checking:
♦ Inspect all vacuum hoses for damage (e.g. cracks or marten
bite) and to ensure that they are correctly and firmly attached
♦ Ensure cleanliness when working on vacuum system
♦ Before starting work, clean engine compartment if necessary

♦ Vacuum gauge for brake servo - VAS 6721-
4.5.1 Connecting vacuum gauge for brake

servo - VAS 6721-
– Pull vacuum hose out of brake servo.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.
– Place brake servo vacuum gauge - VAS 6721- between them
-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if there is one, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-
C Cut- In direction of brake servo

off
valve
– Push hose -A- of brake servo vacuum gauge - VAS 6721- onto
vacuum hose and press adapter -C- into brake servo.

4.5.2 Checking vacuum generation
Note
♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 143 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine (>60°C), press accelerator briefly (engine
speed above 2000 rpm).
– Read indicated measured value.
Usually (see notes), the vacuum that is generated should be be‐
tween 600 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213- ⇒ page 146 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.5.3 Checking for leaks
Note
♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.
– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 143 .
– Open cut-off valve -A-.

– Close cut-off valves -B+C-.

– Start warm engine (>60°C), press accelerator briefly (engine
speed above 2000 rpm).
Usually (see notes), the vacuum that is generated should be be‐
tween 600 and 950 mbar (depending on engine size).
– Open cut-off valve -C- to evacuate brake servo.

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
If the vacuum decrease is greater, check for leaks in the vicinity
of
1- Brake servo
or
2- non-return valve, vacuum hoses with connectors or vacuum
pump/intake pipe
if the leak can be found there.
If there are large leaks, the vacuum decreases steeply within a
few seconds.
Vacuum check in vicinity of brake servo:
– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake pipe:
– After generation of a vacuum, close cut-off valve -C- in order

to check vacuum system from brake servo vacuum gauge -
VAS 6721- to intake pipe or to vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

4.5.4 Vacuum generation with manual vac‐

uum pump - VAS 6213-
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump - VAS 6213- in certain cases.
– To do this, connect manual vacuum pump - VAS 6213- to vac‐
uum hose from connection -B- on brake servo vacuum gauge
- VAS 6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump - VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge - VAS 6721- .
– Then, carry out the corresponding checks.

5 Brake lines
⇒ “5.1 Repairing brake lines”, page 147
5.1 Repairing brake lines

The flanging tool for brake lines - VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this enables partial brake line sec‐
tions to be renewed at less expense.
The use of flanging tool V.A.G. 1356 is not permitted due to the
coating and the diameter of the black brake lines.
Note
♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or reveal deformations which constrict the line cross-sec‐
tion to an impermissible degree.
♦ Preferably separate brake lines at vehicle floor.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle; merely clean with methylated spirits.

♦ Flanging tool for brake lines - VAS 6056-
List of individual tools:
5. Brake lines 147

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‐
ted and must not be
tampered with!
4 - Set of grips with plastic jaws
- VAS 6056/4-
5 - Pipe bending tool - VAS
6056/5-
6 - Special wrench, 6 mm
7 - Flanging jaws - VAS
6056/7-

5.1.1 Assembly overview - flanging tool
1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws.
2 - Fastening for handle
❑ Must be removed to ac‐
cess retaining screw for
upper part
3 - Retaining screw
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ For centring and holding
flanging jaws
❑ Allen head bolt, 2 mm
5 - Flanging jaws
❑ Various.
❑ Assembly instructions
⇒ page 149 .
Flanging jaw assembly instructions:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (light) for green brake lines
Note
Arrow on rounded side of flanging jaws must point to edge of

housing, and straight side of flanging jaws must be installed to
spindle, as flanging head is not otherwise formed correctly.
5.1.2 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.
5. Brake lines 149

– 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 grip wrench -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
scraping.
– Remove set of grips and slide union bolt -D- onto brake line.
– Slide brake line -B- up to stop -A- in flanging tool.
Note
Brake line must be positioned against stop when the hexagon

socket head bolts are tightened, or the flange will not be formed
correctly.
– Tighten brake line in flanging tool until brake line can no longer
be moved. Fold up stop -A- and now tighten Allen head bolts
diagonally using Allen wrench -C-.

– 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.
Briefly flush the section of brake line remaining in the vehicle:
– Connect brake filling and bleeding unit - VAS 5234- , connect
bleeder bottle hose to brake line flange and allow brake filling
and bleeding unit - VAS 5234- to run briefly until a little brake
fluid has run through.
– Blow out the new brake line to be inserted with compressed
air.
– Join brake lines with the connector -E-.

– Install brake line.
5. Brake lines 151

6 Hydraulic system
⇒ “6.1 General notes on brake fluid”, page 152
⇒ “6.2 Pre-bleeding hydraulic system”, page 152
⇒ “6.3 Bleeding hydraulic system following standard procedure”,
page 154
⇒ “6.4 Subsequent bleeding of hydraulic system”, page 155
⇒ “6.5 Testing for leaks”, page 156
6.1 General notes on brake fluid
Note
♦ Only use new brake fluid conforming to VW standard

(VW 501 14).
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
6.1.1 Changing brake fluid

⇒ Maintenance ; Booklet ; Brake and clutch system: change
brake fluid.
6.2 Pre-bleeding hydraulic system

Bleeding the hydraulic system using brake filling and bleeding
equipment - VAS 5234- is described.
A pre-pressure of 2 bar is required for bleeding the ABS hydraulic
unit - N55- .

♦ Special tool - VAS 6564/9-
Carry out pre-bleeding:

♦ if a chamber in the brake fluid reservoir in vehicles with EDL,
EDL/TCS or EDL/TCS/ESP is completely empty. This occurs
e.g. in the case of brake system leaks.
Additional work for vehicles with diesel engine:
– Unbolt pressure converter or solenoid valve block from brack‐
et and lay to side.
– Connect brake filling and bleeding equipment - VAS 5234- .
Bleeding sequence:
1 - Bleed front left and front right brake calipers simultaneously.
6. Hydraulic system 153

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.
Hydraulic unit must then be bled again by means of the function
“Basic setting” with the ⇒ Vehicle diagnostic tester.
Initiate basic setting (to bleed brake system):
Connect ⇒ Vehicle diagnostic tester and select function.
– Then bleed brake system as normal.
6.3 Bleeding hydraulic system following

standard procedure
Bleeding the hydraulic system using brake filling and bleeding
equipment - VAS 5234- is described.
A pre-pressure of 2 bar is required for bleeding the ABS hydraulic
unit - N55- .

♦ Special tool - VAS 6564/9-
Note
If, in vehicles with EDL, EDL/TCS or EDL/TCS/ESP, a chamber

in brake fluid reservoir is completely empty (e.g. brake system
leaking), brake system must be pre-bled first ⇒ page 152 .
Perform the following steps:

Additional work for vehicles with diesel engine:
– Unbolt pressure converter or solenoid valve block from brack‐
et and lay to side
Strictly adhere to work sequence when bleeding brake system.
– Connect brake filling and bleeding equipment - VAS 5234- .
– Open bleeder valves in specified order and bleed brake cali‐
pers.
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
Use suitable bleeder hose. It must sit tightly on the bleeder valve
so that no air can enter the brake system.
– Leave bleeder valve of each brake caliper open with bleeder
hose fitted until brake fluid discharges free of air bubbles.
6.4 Subsequent bleeding of hydraulic sys‐

tem
Carry out subsequent bleeding when:
♦ brake pedal travel is too long or so-called »soft brake pedal«
Subsequent bleeding requires the assistance of a second me‐
chanic.
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
– Release brake pedal slowly.
6. Hydraulic system 155

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!
6.5 Testing for leaks

♦ Tester for brake pressure regulator - V.A.G 1310 A-
♦ Adapter M10 - V.A.G 1310/6-
Prerequisites for testing:

• Brake system (hydraulic unit, brake hoses, brake lines and
brake calipers) operating properly and free of leaks.
Perform the following steps:
Checking
– Remove bleeder valve at one of front brake calipers.
– Connect pressure gauge -V.A.G 1310 A- and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
during the test period of 45 seconds. Renew brake master
cylinder if drop in pressure exceeds specification.

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2017 - VW Passat b8 Arteon Brake System Eng PDF

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Service

Service Department. Technical Information

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

4.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.1 Allocation of PR number - brakes

2.1.1 Front brakes, Passat, Passat Estate

2.1.2 Front brake, Arteon

2 Rep. gr.00 - Technical data

– Relevant information about the brake system installed in the

2.1.3 Rear brakes, Passat, Passat Estate

2.1.4 Rear brakes, Arteon

– Relevant information about the brake system installed in the

4 Rep. gr.00 - Technical data

3.1 Technical data for brakes

3.1.1 Brake master cylinder and brake servo

3.1.2 Front brakes

Volkswagen Technical Site: http://vwts.ru http://vwts.info

Front brakes C60 (17"):

3.1.3 Rear brakes

6 Rep. gr.00 - Technical data

Rear brake FNcM42 (17”):

4.1 General information

The brake regulation systems do not function when ignition is off.

4.2 Checking vehicles with front-wheel drive

4.3 Checking vehicles with four-wheel drive

4.3.1 On a regulated roller dynamometer with

The brake test must be performed on a controlled contra-rotating

“Counter-rotating” means that the dynamometer rollers of the sin‐

8 Rep. gr.00 - Technical data

The forward rotating wheel is measured during the test, which

4.3.2 Without roller dynamometer for four-

If no test rig is available for four-wheel drive vehicles, the brake

– Drive vehicle forwards onto the rollers.

4.4 Checking parking brake

4.4.1 Checking electromechanical parking

In »TÜV mode«, the electromechanical parking brake does not

The tension is increased gradually by actuating the electrome‐

4.4.2 Checking electromechanical parking

In »TÜV mode«, the electromechanical parking brake does not

The tension is increased gradually by actuating the electrome‐

10 Rep. gr.00 - Technical data

45 – Anti-lock brake system

1.1 Repair instructions for repair work on

ABS layout in LHD vehicles:

ABS layout in RHD vehicles:

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

♦ No contact sprays may be used on the contacts or the pres‐

2 Overview of fitting locations

2.1 Overview of fitting locations - ABS/ESP

1 - ABS control unit - J104-

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

7 - Brake light switch - F-

2. Overview of fitting locations 15

3 Control unit and hydraulic unit

3.1 Assembly overview - control unit and hy‐

3.1.1 Assembly overview - control unit and hydraulic unit, LHD

1 - ABS control unit - J104-

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

3. Control unit and hydraulic unit 17

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

3. Control unit and hydraulic unit 19

3.2 Removing and installing ABS control

Special tools and workshop