\@) Service Workshop Manual Superb II 2015 > Ecition 03.2016 Service Department. Technical Information® Service List of Workshop Manual Repair Groups Repair Group 00- Techical data 45 -Antblock brake system 48 -Brekes - mechanism 47 - Brakes - hydraulics Technical formation should always be available to the foremen and mechanic. because thelr Carell and constant adherence to te net-uctions fs exeental fo ensure vehicle road- worthiness ang Safely. In adcluon. the normal basic eafety precautons for working on motor vehicles must a2 3 ‘matter of couree, be observes, flights roverved Fie ieptedsetion without pie agreement rom publisher Copyright © 2016 SKODA AUTO a. pe00523E82sipewuizess= @) era. Eston 63.20 Contents. 00-Technical data... 1 1 Salty nstuctions + 4 Satet preaautons nen working on vehi ith a tretop ayater + 412 Safty precautions curing oad tet in hie esting and messtring exuipmertis sed. 2 Denomination 2 24 PRumber eaigrmert broke 2 3 Technical cota 3 54 Teohnsal dt for brakes 3 4 Bethe test . 6 6 6 6 7 7 7 41. Ganeral pons f i ‘ 42. Checking vehicles Wi ennheal deve 42 Teatng vehicles With foutuben dve 45 - Antslock brake system 4 General points 44 Rapalriatution for repair wore o# ABS 2 Intalaton locaton eveniaw 10 21 ABSIESP instalition octon overview 10 3 Convot unt and nyerauie unt 2 34 Exploded view ~ cont un end hyarauile unt 2 52. Remeuing ane iting ABS contol unt JOS / ABS hyeraule Unt NSS 16 33. Disconecing the contol unt rom the hyereutc unit a 3:4 Install he conta unt on the nyaraule unt 2 35. Conecing be nes to hyaroule unt } 2 4 Senger 2 41 Assembly oven = seed uansr en on aie 2 42 Ascembly veri - speed sensor on rer axe, 3 43. Removing and nstang th brake ight sensor P 44 Removing aninsaling the brake prestire sender 8 4.5 Removing ang inetaling the handbrake auen % 48 Removing endinstaliog sensor unt for ESP G48 = 47 Removing and istaling fot speed sersore Ges G47 Ps 48 Removing andinsaling the rear speed sensors GE GAS, % mie ese 1 Front brakes Ey 14 Assembly overiow -ontbrakes = 412 Romouing ana netaling brake tinge * 13. Remouing and isting brake cele 2 2 Rearbrakes a7 21 evembly overigu -rearbrakes 22 Removing ane intling bake Inne 23. Remeving andinsialing brake calper 3 Handbrake 34 Assembly overiow - parking bros 52. Remouing and instling contol ue electronic handbrake JS40 33. Remeving and istaling handbrake moter V2E2V283 4 Brake pecs! 4:1 Assembly overview brake peda 42. Removing aninsalirg bearing bracket 43° Separating brake peda om brake serve BRIT BSSB BS‘Super 2015 = @ sen eenssaoe 47 - Brakes - hydraulics... 44 a5 12 2 24 22 3 a4 32 33 34 “4 22 23 “4 5 54 6 64 62 83 64 65 ‘ppg the brake pedal orto he brake serve unit Removing and nstaling broke pedal Frontbrake calipers Explode ver «font brake caer Removing and nstaling bree caliper piston Rear brake caper oreo ‘Asserbyevervaw- rear brake caper Removing and wstaling protective over ‘Brake sen wnt and master brake onder ‘Summary of eompenanis- bake aero unt and mast: brake cyindsr Removing end ntaling brake servo Removing and instaling brake master cinder ‘Cheok ns operaton ofthe brake eero unt \Vecuum system 4 Exploded vee vaciim pump ‘Checking nen ser valve Removing and instaling te pensive sense forthe brake serv unit Inepect he vacuum syste Brake ines paring broke nse Hyeroute yet Dy General notes on brake Aid Prebioedig the nysralc system Bisedng mysrele system olny standord procadire Subsequent beeing of hydraulic system “Test fr oska 103era. wy Technical data 1 Safety instructions (7.000028; Esiton 03 2016) 121.1 Satyprecaions nen working on vehicles wih a star Sopayaienpage +2712 Safty pracautons curing road eta in which testing and Imasauring equipments used page t 1.1 Safety precautions when working on ve- hicles with a start/stop system hen voringan eis wh sadtopsysem,pansectare {he fotouing retraction Te ieytmettnaretorgre setae saan © pooh et ein [Eee abotee SER Pneata + Fomenmr mrt so sent Speen ees ea petites 1.2 Safety precautions during road tests in Which testing and measuring equipment Isused fst and massureg devies are requted during test dives ob- Save the folowing Thee ark of aceon fom detection ons ieuient ing ot aners ane mensuny maument. measurng instruments during civ op- ako detection eee (Ther is en nceases ck of hry tom unsecured testers rd measuring eirumerts, 1 Awaye ston the testing and measurement equipment to fevseeat ne ve 1 ways nave he teatng and measurement equpmentop- ‘rae by ara oreo (Atay operate the testing and measurement equipment ‘rom he fearsest a 1 Do nat operate the testing and measurement equipment fom te ont passenger at + Persone canbe injured the lage ofthe passenger a vert fan aed passene ‘say aenasone 1® ‘Supert il 2015 = Sia. Eston 03 206 2 Denomination 2/21 PR number assignment broke”, page 2 2.1 PRrnumber assignment ~ brake “Tha brake yp instal inthe vehiciisinczates by PR nm or ‘The PR numbers are nstion onthe vals data stoke inthe lUggage compartrert Noor 29 wal ax nthe Santes Schedule Ines aout tetas Wakes canbe fund nthe ELSA To venice sata stem Assignment is dependent on he engine ype > Electronic Cate fogua of Ongina’ Pars niches 2 ap g.c0 Tematasipewuizess= @) E00 63.2016 3 Technical data +23. Technical ets for brates, page 3 3.1 Technical data for brakes 3.1.41 Brake master cylinder and brake servo assignments fogul a nigra endanton th Brake master gy mr Beh evinder= © 3 Brake servo une | ena Righthand ave 3.1.2 Front brakes Assignment i fogue of Orginal Exglanatone concaming PR Numbere ='ST PR number ssttrnen = brs, page? Fron bake PC 57 Fron brake caloe (jpe denomination) | POST) IPR number za [Front brake calper piton=@ 7 Front brake ane == m cc [brake dee tesmess 7 e [rake de minum hianess ry @ Ped tckness without upping pater = imimur pad Bickneoe wiou up ry z porting pate n Frontorake ©60| Front brake caine lupe denorimaion) | C60CP) IPR number cry Front brake caliper piton—@ 6 Front brake cee 7 a Brake de iemess m w [Bake dee minimum hisness a enn ch th engine type > Elecrone Case a rateatite 3® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 [Font bake ealpe (ype denomination) | _ CAO} [PR number 1A, [Pecthiciness winevteuopanng ate m 1% lignoypad Wickens wie sper z long pao m 3.4.3 Rearbrake Acsigament is dependent on the engine ype = Ekctronie Cat (opus o Griina Pare Explanations concerning PR Numbers Rear brake FNeN2 [Rear braun coer typ denomination) | FeNa2 (6) [PR number aKU [Rest erke capac patos 2 [Rear bake dee = = 300 [Brie deo, teinece ™ @ [Bake deo, minimum tloess or cc |Pedtticiness without supparing ate m 7 [ram pad cknece wikect usr z Rear baka FN [Rear bake calber (ype denoninaton) | PueAa2 7) [PR number tz, [Rear bake caper patos 22 [Rear brave dise—O om a0 [rane dies, micmnese ™ 2 [Brake dis, minimum teiness or % [Paathiciness without supparing Bale 7 lima pad Wieknese witeat umm z lpoting pat m 3.4.4 Brake fluid ap g.c0 TemasSupe i 2015 = rato stone -Eotion 03 2016 (Gessiatn] [ony ue new eiginal brake id N 082 768.20 ea pe US landard FHVSS 871.116, OOT dard VW standard S01 1a] [Topp [= Maintenance: Beokiet Super I ®® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 4 Brake test as ra poi’. page 8 24. Testing vehicles wth four-wheel deve’, page & 4.1 General points |The rive is provided by the rll ynarmomter, ‘During the testing the ising speed must 8 Wet on vehicles twin eanaal goatior and fe Sng poten se must be ‘ngaged on Sees wth automate gearon, 1 Yinenconductng the test observe the spedeation provided bythe manufacture ee tet [Ev The brake regulation systems cle ot uncon when iti i Of 4.2 Checking vehicles with front-wheel drive ‘Th brake tect must be pertermes ona singl-anlerolreyna- ‘The maximum est speed mus not exceed 6 kmh ‘The et stands approved by Skoda comply wt hase codons. 4.3 Testing vehicles with four-wheel drive ‘The brake nection must be perlrmed ana contacctatve sine ee ler pe tet stand Tor vehizies wth fou-ores ve. CContacctave means: The tat stand rls oe angle se ‘aor fp fst sand rotate forwards one ove side ara bac (nerds one cher 20 Thus. aranster ofthe braking forces inthe dive trans preven. we ‘The whee whlch rotates forwarc e measured gash ie during ths tess bs Yequres the need of tc braking toes pe ate ‘The maxerum et speed must ot exceed keh ‘The et tendo approved by Skoda comply wth hae condone. 1a tet stand i not svliable fr vehicles wth furutea dve, the brake apecton ca suo be performed on 8 stander sing hero’ pets sand ae folowe = Dive the vehicle foraras onto he rls = Sion of engine and wai2 seconde, ~ Perform brake inspection atte font ~ Star ongine and wat aprox. 5 seconde unt adequate vac- = Dive he vehicle formar nt the rear whee are sanding onthe ates = Switch of ena = Perform broke inspection athe res. ~ Star ongine and wat aprox. § seconde unt adequate vac- tum pas bate rd wat 2 econAnti-lock brake system 1 General points 277s Repsicinstructons forrepac work on ABS" page 7 1.1 Repair instructions for repair work on ABS ‘he ABS brake ystam ie duses daponaly. The sane ase {noe s elected posunstesly bythe vacuin bake sav unt Venice ites th ABS do netnave amecnenicel bake sressure reguiatsrSpesticaly matsnessotnare ne ABS osnralunt SRB ruins the brake pressor saributon on te rear ale 1 fe ABS pysraulc unt NSS 2 demaged the ABS conto! ios mist ily optaced wih fe ABS Re ont | Te ABS conto unt J104- canbe separated tom the ABS. Pherae ut MSE es 2s Diecoecting tne conto! unt rm the bye unt ame? (The pycraute pup and ine ABS hye un - NEB mt ‘oto separated fom aach aor 1+ Propiemsrelsted fo the ABS ao pot anette rokng system the ore Sova! The canvertons orate sytem remare Gincicnal ven without ABA change nrg bear 'gto.e reckoned mth Aer the ABS warning rip comes 0 ‘he rear wheels ay ok promatrey dug BraKg rangement ofthe ABS, lelthand dive vehicle 1 - ABS hyeraulic unt- NSS. th ABS contol unt JNO 2. Brake serve ‘rangement of the ABS in righthand deve vehicles 1 Brake sono) 2 ABS hyeraulc unt- NSS wh ABS contra unt-J104- comes 7® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 “The ABS one unt-J108--1- andthe AS hysrauteunt-NS- ‘Berm a ge unt They can any be aepetais afer he ‘mplate unl vamved The ABS cent ct 104 can be Separated tom the ABS ryarauic unt Nes” ses Bisconnadiagine convo\unt om fe yoreule unt 2 Theyre pg “= must nol be separated om ts AS, Fysreue dnt N52, ‘New cont uns susie by the soare parts are ae not cose. ‘They mustbe coded ater natal = Vahew degnosie eae 1 Geto stating ork on antsook bre oysters, query he tert reson to anockr comple Sn Sond pls feutindng 2 Vehicle agroste tester ‘Do natessarst plug connections unis the igitoni etch Oona Pug oy 1 Betoe working on artiock baking systems, switch off the Ignton ane deconnect he ground tap tor the batery = Ehocteal sem: Reo. gr 27 Batery Clocernect and con rei betery ‘tno batory carh svop dlesannectog and connscid. cary (utadatonel opmatons = Ecce Sysan Rop. Gro Baer ‘ Yllsing wrk using electri welding equement may ae! the ABS sjeor + Doing eee commencing woking norkuingc- trealwetdng = Disconnect the enh sap om the negative terminal the Baty and cover the negate termina ~ Connects ear comasion ob alco wnang al {Siy/neuatad pars betowen ine sath cornecton asthe” rating oo ~ Elcroic conto units and etectical wing must nottouchthe tary connection othe welding oasase ‘During painting operation, the ABS contol unit 108, may Eetexpcecd ts manimum lemperstire of 25 far anya Shonbeiod ond foe mauemur of 65 for longer reds ‘eer 2 Rous). 1 Dapaterve the etl the connectors unplugged rom the BBS coneal une wie ‘Absolut leeineslarequres when working on he atk brake system I's nt permed to une any products whch Contin minael ol, suchan ais, greoses ote . hy lean connection pons anesthe sureunng aces oe Satcnreceg et desloge any nen ene ‘gent, such ae brake Gloanorpoveloum tanner cr aenar, {Place removed parts ons clean surace and covet Careful cover ox close opened comconartsitherepaiisnct Soralted mediately (ose plugetomtherepsrkt: HOO Srey Only use inthee dete, Cniy unpack replacement parts immediately prot ting Use only genuine wrapped pat, nen the sytem i open, donot werk wih compressed ai fn'co not ioc the veicwe Bp outs srsnartana yamsipewuizess= @) 100 03,20 Toga con be ABS cont nt -J104- met note The voNe clin the ABS contol unt -JTO4 arnet bere paces ‘The pressure sensor must rot be medfed or damaged “The presoure senor cannet be telaces ‘The sensor housing must tbe subjects to mecharialload Nomeasurerentsmustbe cated ou at the const pont of {he RES sonal unt =o Nomeasoremects mustbe cared out at the contac pont of the RBS hyerauic unt “NEE The vais domes ofthe ABS hysraute unit: NBS. must not be Somages or bent “The contacts on he ABS contol ui - s10% and the ABS hy [Movie unt = NBS. cannot be replaced De not use contact pe, Ne contamination fregnobiect may located between ABS ‘onto unk VGH and ABS pera Unt - RES [Ensure that no brake fis enters connectors (observe the relevantinaructone when handing Brake Mid ‘Aer completing workthatrequtes opering the brake system, bees the Brak stem urn ne brave ing ana bleeang oa! ose. Was Ba 7 » ‘Durng the fra road teat. ensure tata conte brake ast Settles on pobaionemstoe a one peda compares 9® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 2 Installation location overview 22.1 ABSIESP instalation locaton overview page 10 2.1 ABSIESP installation location overview im 1 ifthe AS hycaulc unt NSE Is damaged he ABS control unt - 104 must be tly cepa vith the ABS hyaioute unt NS 1 Me ABS contra unit 104. canbe separated rom the ABS hycrauie unt - NES. 2 YS isconnectng the cond ut om ie crauke unt page 7 1+ The hyetaule puro and the ABS hyoraule unt - NES. mus ot be seperaed tom ach eter 41 ABS conta unt-J106 2 Leeaton on ha hy= tials nt or N3S"nencine compar. rent Odom conn! the plug connection before Fretetdaansai pet, sich of te \gniton bore aoe ecinaepog n ‘The folowing components are irate inte ABS cone! "Sensor unter ESP -G418- 1 Control unter slerene fandorata 0640. 1 Latetel aceleraton sender ‘Ga00. 1 Yaw rate sender - 6202 + Longtudin| acceleration Sender G3eis Sepending chegupment ited) ‘¢ Thecomponeniscannotbe changed naniousy. checking = Vehicle spnosts tester emo and nstating tenes eonolust- ede wah the ABS hye ‘ule une Ns. ae mean ee ta he contol unten th duke unt 2. ABS hyerauli unit-NSS- 1 Lecaton nthe engine compartment on the ron assenger side 10 nap 946 sestccrma yamsipewuizess= @) rake oyetome E500 03 2086, ‘The ABS nytraule unt-NSS- consi cf heoe components: P88 nydraule pup -Vee- ee 1 Bake pressure sender 1 -G201- 1 Vave bloc (containe int and out valve), Do not separate he ABS hyctaulic pump - VES om the valve block removing 2a nstaling 3 Brake pad wari ight -K32- Location: nthe dash panal inst 4-88 warring lamp -K&7- Location: inthe dash panel insert 5- ESP and TCS warring lamp -K155- Location: inthe dash panel inset 6 Brake system warning imp -K18- Location: nthe dash panel inset 7 Brake ght ston =F Location: st rake mestereyinger Removing and istaling = 63 Removing and instaling the brake ight sensor. page 2 = TCS and ESP buton-E256- 2 verons, theceore Znsaatonieeatons 1+ ex button onthe ote conaole ‘+ ve tuneton butons on he nfotenment yaten menu 2 Be baton'a prot etn untae canot be repaced separately = Electra jt: Rep. 8 Diagnostic connection 4 Leeaton: Driver feel caer 10. Steering angle sender = G8S- Location: nthe sewing gear the steering angle ender GES. cannot he changed sparsely 11 -Frontright and le whoo speed sensors - G#5-/-GE7- checking = Vehiie lagnest teat Removing and instaling = 4 Removig/ang instalingiont speed sensors G45 / G47 page 36 12- Whee! hub wh whe! bearing fortron ase Senso ing for ABS is bulk into the whee! hub 18. Resr right ani wheel speed sensors - G44 -G46- checking = Venice lagneete Removing and stating 14 Wes nub we wae! besring 2 forrenr ase Sensor ng fr ABS ia bul noth Whee! Mu anette once 11® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 3 Control unit and hydraulic unit 23.1 Sided view Seon unl sn td aeage i ad iy ers i, 33.3 Dlscomnecng the cont unt fom ihe veraulc unk’ pepe 23.5 Connecting ba Ines to nydrulc uni, age 29 3.1 Exploded view — control unit and hy- "3.3 Diseoanecting the contro! unit from the hydrsulte unit” cee 27. (The hyctale mp and ine ABS hye int - NEB rust rot be soparted rom each other 41 Brake ne fom mastertake. oie sitonst heme 2 Datngiting de Benen arabe sre ‘wthlong teed et a iaNm 2 Brake ine sie hveate A Distngushing footie: Benen and pipe crew ‘wthongihresa Max! a 14Ne 2 Brake ine 1D torearrght bate ca ben A Distagushing feat Boz mmand ae Sew wtniong teas iY a ian |$-Braka ine toon et rake caliper 1 Distngushing texte: Seam and poe ito a isNm 5 Brake ine to hon ight brake caliper Distngushing featre: 9 5:25 mm and pipe sew thong hres M12 x 1 a ine 6 Brake ne 1D torearlet brake caper Distngushing teste: 9 5:25 mm and pipe screw wtlong thes M10 x 1 a une comaintananamacien 15,® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 17- ABS yale unt-NSS-with ABS corrl unt J108- 3 Renoving and instling 2 Daconecng he contol unt am he hea ut ; 2 a he cool unt on he yeaute unt 2554 Racine conse unt ose fy unit” page 28 Tring ecues fn rv forthe ABS conto unt—J108-Pon 3 8- Support 9 Serew 2 8Nm 410 Rubber shock absorber bushing 1M 2 20Nm 12. Support 43-Nut 2 20Nm 14 - Brake sen ifthe are faut replace compltsly 45-8: ne rom master brake cinder (push rd iston Suit) to ABS hycraue uit-NBS- 3 Distngushing feature © 6 mm and ise sew vithlong tess M121 2 16Nm 16- Brake ine tom mester brake ender (eating ston creut) to ABS hyereule unt NSS. Distinguishing feature: © 6 mm and pips ceew with long tread M12 x1 2 1eNm 3.2 Removing and installing ABS control unit - J104- / ABS hydraulic unit - NSS- 2321 Rome, 3.2.1 Removing and instaling the ABS control Unit -J104- / ABS hydraulic unit = N5S- , vehicles with left-hand drive and petrol engine ‘Special tool and workshop equipment required 1 Brake pada load eg, VAG 196092. 1 Ropairkt- 140608 311 A 16 nap 946 sestccrma samera. Removing Location ‘ng ABS contol unt-J404- is bates to the AS nyeraic unt NEB“ ana ie ocatd ne engine compartment on te grt sce (Dw ‘Donot bend he bate ines inthe aree ofthe hycule unt Read out and note he existing contol unit coe. Disconnact att earth strap > Electra system: Rep. gr 27 Battery, Disconnectng 2 connecting batery Irprecen, remove the engine cover Remove protective cover 1-(Favaiabie). Reiaoe he fute plug othe ton of row: ad pl Notte RES cSsboRi “Si6ecastne necro arom Se Scomaintananamacien 17® ‘Supert il 2015 = Sia. Eston 03 206 ~ Poston broke podaliood.2.g,-VAG 1860.2. = Alta the blanca hse ofthe blaacng bata ant tne vent ‘kei eit andres ek rie ester andopenvert ~ Pres down ake pal wth brake pesaload. 0. VAG ‘Geos seas = Close ont an roe let ~ Dont remave brake pedal load 0.9. -VAG 18682. ~ Pace sutieninon fing the under andarundtre ABS onl unt S108 on the RBS hyaractc unt ake sure rat na rake fui gets ont the contacts ofthe ABS onl unt 3108 1B nap 946 sestccerma samSuper 2015 = era. Eston 63.20 ~ Ma bth brake ings -S. ond fom the master rok cy Inder ana unscrew fom bw ASS Myra unt = Nes” = Close he bake ines nd threaded hale Inmetlatly th Drugs rom te rebar t= 1H0 688 3TT ~ Mark the rake ines or brake caliper) -t-to-4, unscrew and ‘ose nh plugs om he repair at THO 696 341 Removing andinstating lamba probe non ofa con- {erior= Rep. gr 23: Cambsa probe removing ana msg IGmboa probe = Pullne ABS hyeraule unt - NES: andthe ABS cata unt ‘oder and ou othe shock sbsatbers O-~ (ite ABs nyorautc unt SS 19 ABS conto! In Soi be typed the ABS hy sount 1+ Me ABS conta unt J104- canbe septate om the ABS rere ont NSS: apedZ- +The yet puna and in ABS calc unt- NE: mit im sopanle tama Instat Inatalatin is pecormes inthe reverse order, pay tention tthe foibuing ports T) Wwe © Ony then remove pugs om te new ABS hycraute unt NBR thon the esr brave ie eta + tng plugs wer arses removed tom th ABS hyerauteunt ‘en Bate my cage and cg ng ad ‘nbeaig ote ut can ra lange oe goatanoed | Make sure atthe rubber bearing ae ot pressed out ofthe ensaie when aang the racket Aer nealing check fr ef chen rey cased oy a Patton the ABS mehaule nt Ne Observe the ighteing sequence othe brake ines ‘interna sequence of he brake ines = Remove brake pedal lade VAG 18602. ~ Blegs brake aysters ‘due page 108 Code the conto! uni -s04. Veh ogroatitstr Wie deing so, abasic seting of he staring angle sence (GBs: Stra aceleratonaender 6200" inebrake pressure Sense -G201-andtelonptudnal accelerator sender -G2S%- imustbe perormed = Venice Sagnosic water comaintandnamaacirn 19® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 Tightening eoquence ofthe brake lines Tightering toques 3.2.2. Removing and instaling the ABS control Unit -J104- / ABS hydraulic unit = N5S- , vohiclas with left-hand drive and diesel engine ‘Special tool and workshop equipment required 1 Brake pedal load eg. -V.AG 18602. ‘6 Rapatrkt -tHo 608 311 A. 1 Engine support bracket -110533- Removing Location ‘The ABS control unt -104-leboted tthe ABS hy N36“ an located inne engine compartrent on (El ‘Do not bend ne brake ines in te area of te tau unt le unt vanes. “= Read out and note the exiting con! nit code = Discomecttatey earth strep = Electical stom: Rep 27 Batery Bleconnectng ene connecting bats = presen, rove the engine cover ~ Remove the coupling rod = Rag. 10; Power mount. Ing: remove and nota coupling = Remove the sound damparing system = Genera body e- ar, sce’ Ho. gr Ge: Natenauason Summa) Ebmponerts- poe insulation = Ramove tant pat of th exhaust system = Rap. gr. 28 chau ppesistences Removing and tain ont pat of frhaust system 20 pap as- seston syzen‘Super m1 2015 = Unsere serene arrone- and remove eat shield trom boring gear Forvehices wih fone ve Remove propshat rom fort gearbox an sace fo onesie "feo gf 38: Propane Removing ne nstatng rosshah Continued foal vehicles Press he engine wth he ane suport brbeke= 710833 feo = Remove het shi! nahin wth ae ~ Uncip cable ude = Release tne fuse pst. the rection of trow A and pt feoBint = U16e-cs ihe acto ef ran Be ; 5 ; i Scomaintanamamacirn 24‘Super 2015 = Erase ojstome - Eon 03 2016 ~ Poston broke podaliood.2.g,-VAG 1860.2. = Alta the blanca hse ofthe blaacng bata ant tne vent ‘kei eit andres ek rie ester andopenvert ~ Pross down brake peda wth brake pedal lead 0g. VAG ‘Geos at leat mm, = Chote enti and root = Donetremave brake peda! oad 0. 9. -VAG 18662 = Plazes euteens ron utfng cathe unde and round the ABS Corel Un S6e° and tn nee fyaracie une NS” KOE Naka sure rn rake i gta tte contact fh ABS = Detach te top secon of he heat pretecton mating en the fron wal and shits, ~ Ciipth brake lines of the two mounting brackets = Mark btn brake ines 5: and: rom the master brake cy Inder and unter he 8S hyerauie Unk “NBS = Close the bye ines and breaded hots mmedtely wih pugs forte oper kt AH 696 381 5 ~ Markt brake line (er brake caliper --to-4. unsrowand (Sone oth uga fom the ropar bi 160 605 311 ~ Pu he ABS nydraule unt. NS- and the ABS contol unt - Sotiite Sreion site aoe anguish ~ Layne ABS eau unt -NSS. he ABS coro unt. facing neva the engine compartment = Raise veh 22 pap as. sentectan synsipewuizess= @) rake oyetome E500 03 2086, Remove mounting bracket rows nthe vehicle fom the ‘ABS nyarolic unk = NSS = Remove he ABS nya unt. NSS and he ABS cont {iat Ji08 tthe Baton rom the vi, (1) sae © ftp ABS ermal uit NSS she ABS conto! neat mt be yma mth Pe ABS hy ant 4 Me ABS conto unt 104 canbe separate tm the ABS Ahereuie unt NSS. aaa + ie nya the ABS cic unt- NSS mst ioe pata fom sack Instat Inatatatin i pacormed inthe reveraecrdr, ay attention tothe ‘Slowing pos " [i] + Onl then remove plas fom the en ABS ycraue nt Rok annie tes © rie pluge wer aoady removed Fon ihe ABS hytal rit INGE Pon aa to may escape and eau fg and ‘teatig ere untean no ongetbe guaranioe. (Make sure tet he uber baring ar not pressed out ofthe ‘Sansoie hen aang he Bracket ater nstaing check ot eft cnertee fire may be caused by a masuincton ineas ora unt SN Observe the tghteing sequence othe brake ines ig. Tighietng sequence of be brake lnse™ ae = Remove brake pedal esto, VAG 166872. = Bleed brake sytem = Code the control unt -104- = Valle agnostic tts, We doing 20, s base setng of he stetng angle sence (Gas. tne ural acerlerton gender Gata" ihebrakeprsaute Sonat G201- apd te longtudnal accelerator senaer-G25 imustbe perormed = Venise agnosie teat demu ansnarascice 23® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 Tightening eoquence ofthe brake lines Tightering toques re = dive vere’. page f2 2111 Eiploded «ont brake ca n 1 Nai insulation = General body repos, exteac: Rep. gg. Nose naibion Sumer oleae Nabe us 1 Pendulum suppot> Rap. gr 10 Basembly mount Summary of companents- sseerby mounthgs + Etaoin mm spt» apg 26 Ent ‘cara Sinmary of componente sacar «Rove te gona «BO 8, 30: op uray Sreomeonerts-prpehatt 3.2.3 Removing and insteling ABS control unit - J104- ABS hydraulle unit - NBS-, right-hand drive vehicles ‘Special tools and workshop equipment required 1 Broke pada! load eg VAG 18802 1 Repair kt tH0 608341 Reming Location: “The ABS control uit 04-is bolted the ABS hysralcunit= NBS“ ana locatod Inno ange comparimont on fe fst a, Ty) sew ‘Do not bed the brake ines nthe area ofthe hyn ~ Readout and note he exiting conto unt code, = Ramovebattary tay > Electical aye: Rep. gr. 27 Baten, Rlsmovng andnating batery ay 24 pap yab-senteccta syn~ Relaos th fuse pug tin te Stecton of arrow A. and put Refine ABS convo int H10s-amino rection of ero Bs [Dw Tie ustraton shes te cate unt fy ABS MSS. wit con- Jeni er aS Eee GO ean dn ~ Postion take pedalioad og. -V.AG 18692. = Atach ne bleeder nase of the bleeding bate anise vent ‘ston Stheioetandtesr et saecaoe antcpem ent ~ Press down brake posal wth broke pedal oad eg. -VAG [Oeee at lese rm, = Clo rant eft and er a eden vives, ~ Dornot remove brake pedsllosd.€.@ -V.AG 1865/2 Place @ sult non ung cloth under snderaunethe ABS {onto unt= S108" ond the ABS Pyoraulc une” NSS = Mark both brake ings. ang 8. fom the macte iste Inder anc unscrem fom he ASS Hyrule Unt“ NSB = Close he ake Ines and henge hole inmestatly wth Bugs fom the repaint THD 688 ST & ~ Mark the rake ines or brake caliper) -t-to-4, unscrew and ‘ose wh luge om he Yepatr it” THO 808 311 Scomaintandnamacien 25‘Super 2015 = Erase ojstome - Eon 03 2016 ~ Pull ne ABS rydraule unt -NSE- and he ABS contol unt Hotescinthe direction ofthe srows and out oe shock = Remove the 45S conto unt-J108- andthe ABS hysaute Une NSS rom te voile, ce 1 fhe ABs rysaulc nt NSS damage the ABS conto! Sot Si rb fy oplaced wh Be ABS haunt 16 The ABS contra unt. 04. canbe separated om the ABS ‘reraute oot NSS: recone the conte unt om th uot ee 1+ me moral puro ana te ABS nyoraule unt SS: must OT Sealed Rom ooch o Inst Instalatin is partormet nthe reverae order, pay attention tothe ‘Blowag pots: ou + Onyrmen ramove pugs rom te newABS nytaule unt Ek ans rat ake fn tad + re plugs were area removea tom the ABS hydautcunit NSE on brake fad may escage ara aceaceo ing ard ‘hesig ote unt can no ong be pusarsed 1 ee sure hate rbar derngs are net presed cute te orsco uh nataing he sactet Ator iain, eneck or aie armani yt eda ace the 6S nate unt ~ Observe he tghening sequence of tebe see Siehing soon othe bess te ~ Remove brake pesalload og. VAG 188012. = Bleed brake eystem al estg Mrou tem foteing sande sroce- ure’ ae = Code the conto unit J408- = Veh diagnostic ester ine doing 2, a base eoting of te staenng angle sender (GBS® Se tera ecceerston sander -G200" ihabrace presaure Sendrt-G201-and be ongtudia aeseerston sender “G25. 26 rap gas- seston syzensipewuizess= @) 2 Beton 032096 Tightening soquence ofthe brake lines Tightening terques 3.3 _Disconneeting the control unt from the hydraulic unit 1+ Inthe case of amatuncton ofthe ABS contol unt 104. the Corral unt uate deconneted rom ine ABS yereuic Ut NS ane replaced evil + Inthe case of a matuncton of the ABS hyseaule unt NSS- {ha ASS nyarul unt Nob mute compiety ronesd {ogether wth he ABS cool unk (Bw + The yt la Vso A89ycrauic unt - NS. ‘that be separated Ror © Ona disconnected ABS cont! enit-J1O4., the printed circuit Birds eipones 1+ Nomaitre and no art eerolee must genatat if the nt ave the ASS sonal d168 1 Elecpostate charge can cause matncion ofthe ABS con. ovum vier 1 Botere handling the ABS conta unit -J1O4.. the fechnician muse amet elecbostacaiy. The lecrosiate a ~ Remove ie ABS hyeraut nt-NSS- th ibe ABS conto 2 Removing spd installa ABS cone unt ~ Layne AB nara unt NSS wine ABS contol unt - ‘Pa eaan fat stare fang unwanss ~ Ungerou te fing ecowa arava. ofthe ABS contol unt - ‘Hoi and place @ ane ado mmedstely (ange of ang ‘athneu sere) comauntandnamacien 27® ‘Supert il 2015 = Sia. Eston 03 206 = Separate the AS contol unt -J104 rom the ABS nysravio links NSerin he ection of aon es Rie The ABS cont unt - 1. may not when ts ule of rom BABS hrm uni NSS" = Cover the solani eis ofthe ABS contl unit =J104 witha ronfuing et ter gparaing torn he ABS con it J10%- ae the ABS fete ANE ots erent seston teva = Check the seaing sudace of the ABS hysraule unt NSS: for Seaniness:Hrecessary claan wth wie spits and a none ‘hing et. rm _ om 1 Me selng sure ofthe ABS contol unt -J104.maynot be ‘pared sng fie etal scraper amar | re sein srtace ie daraged, opace the seating sutace Ofte 488 contot ond Oe 1 Me sealofthe ABS contolunt-J04. mustnot be damazed. © Teseaiis not cesione as spare par, soit part ofthe new WBS Sono ete oes 3.4 Install the control unit on the hydraulic tnt OD ne rong viratons (2. fl, knock) can eestoy te ABS contol nt D104. The ABS convovunt ioe mustno gerbe used, + The contac surtaoss must bs leaned before ssaembing +The seal ofthe ABS conrelunk-J1O4- must netbe damage. = Poston he ABS cont unt - 104 who tiing onto the RBS nyerache ond NSS. 2B rap as- seston syzenI sipewuizess= @) E00 63.2016 ~ Stay toting be ABS cone unt Ji one ABS ‘revit NS by hand using new seen tus [B] we + ‘Anew ABS sotol unt 104, may only be natal on the ‘marin ABD hyautc int N&S- gmat ersrse times [order ensure wah ighiness of alas sea, 1 fine ABS contol unt-J106 as armas mounted andused Ine vene, rust nt be mount a socons tre (6 Metres inte ABS hye unt - NSS. must nt be e- Bored orrecat + rte traaa ie samaged, th ABS hye auie Unt -55-must Boreplced ~ Tihtonthe sores in wo tages 3.8 Connecting brake lines to hydraulicunit +5°35.1 Connect ng brake nes tote hydraule unt ‘seal Sage ng nee he ecnaicangt tn +2352 Connect ih brake ins to he hyde ign sie yniela page 20 3.6.1 Connect the brake lines to the hydraulic unit, left-hand drive vehicle Atbrake matter ofincee [A= Primay ton creut ot rake masta eyinger 19 ABS ny- rasleunt WS = ai Datnguahng etre: 6mm ands sere with rend M2 8 Seconda pon rel ake rasa yd o ABS hy ful unt| Datngushing etre: 6mm andi sre ith vend 12 1 from he ABS hydraulic unt -NS-to he fontletbrake caper 2-tromtne ABS hyraulicunt-NES-tothe rear rghtbrake caper 3-from the ABS hyeraulic ut-NSS-totherearletbrake caper Scomauntandnamaucien 20® ‘Supert il 2015 = Sia. Eston 03 206 (nthe ABS ryrautic unt -NBS- ‘A= Prema pion eeu of brake master ynder to ABS hye Gracie und NSS _Bitnguinig etre: 26 mm and ip screw th reas M12 Secondary piston ecu of brake matter inde ABS hye Srauie une RSS Binning etre: 6mm andip seh read 1 fromthe ABS hydaulcunt-NSS.otherearightbrakecaliper = Distngshing featre 5.25 mm and pipe sre wh shark need end fe 2 ram the ABS hydraulic unt-NSS-ta the font lt ke caliper < Distngushing feature: © 525 mm and pine crew weh tread ition’ 3 om the ABS hydraulic unt NS-to the nf igh ras eae iber «Distinguishing featur: © 5.25 mm and pipe screw wih shot ‘enc tad 4 tom he ABS hyeraulo unt-NSS-to he rerletbrak caliper < Dstinguishing feature: © 5.25 mm and pipe screw Wh tread iio 3.5.2 Connect the brake lines to the hydraulic Unit, right-hand drive vehicle ‘brake maser onder ‘= Peay piston ecu of brake mester yinder to ABS hye Groute unt Ss Binning et: Oem anip sre wh tras 12 8. Secondary plston cut ot rake master jira ABS hy frase ne RS 2 hi =Disingushingfeatre: 6mm anc ip serow wthtnveas 12 1 = Bea serv ith broke master eyinder 30 rap as- teeter synsipewuizess= @) Eston 63.20 (nthe ABS hydraulic unt -NSE- ‘A. Primary piston cet of rake maar elinder to ABS hy rale unt ss _Betnuetng ere: c @mmandspe soe win treaa 12 Secondary piston erout of brake master eyinder to ABS hy- Srauic unt KES Dainguahng etre: 26 mm andi screw with vend 12 1 -tomtne ABS hyraulount-NSS-totherearightbrake caliper Distinguishing feature: 2 525 mm and pipe see with short euas ae 2sfrenthe ABS hyraulcunt-NSS-othefrontetbake caper 5 Pigquenna teat: 2 525m end pipe sew wh tess 4.rom the ABS hysraue ut NSS tothe rn ight rake eae iver Distinguishing feature: 2 5.25 mm and pipe crew wth short itveod WB e4 |4-trom he ABS hyeraulc unt -NES-t th earl rake caper Disinguishing Feature: 2 525 mm and pipe screw with trea wore Scomauntanamamacirn 34® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 4 Sender 244, ioniew- speed eenaar on front axe 1 Asem vere secs onon ne SET” or 2 Assan Becton ‘ceahnague of nana bs 2 ean er ston She Re reset itoine sensor and Scholar aot fetpenis 6 052 2 z Repo and nstaing 2+ Serew 2 8Nm Whee hub wih wheelbesr- ina Sensor ng fo ABS ia bait e anos! nab 4- Dive shat 32 rap gat- sentra ayesipewuizess= @) era. E00 63.2016 4.2. Assembly overview - speed sensor on rear axle 41 -Assembiy oveview- speed SET Sig epee Assignment = Elstron- fecatlogue of Orginal! Par clean thllmar aula! ‘Stine noe Saree frathe eonec ane Dish over thant Bat pante- os? 112 = a Remeving ansinetaing ‘alin hese toeee ‘enoore Gt ae page 2-Serew a 8Nm 3. Whee db wth hee bear ina ‘2 Sensor tng tors ie Dina 0 weet hab sana 33.® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 4.3 Removing and installing the brake light Sieet page = 37 ending brake lat sensor ahthand aves poae 8 4.3.1 Removing and installing brake light sen- ‘or, left-hand drive Removing ~ Flemove connecting hose to iniake manifold fap ~ Repo Bf charge a sytem, Summary ofcomponerts charge sir Siem = Disconnect the plug 2 fromthe Brake ight etch = F-2. = Unscrew fang sere fom th brake fight svtch =F. = Remove brake bght oureh =F natal Instalain is prtrmedin the rovers order, pay attention tothe fotowng pnts: 34 pap at-sentectan synsipewuizess= @) era. E00 63.2016 = Tha wake ght outen-F--s-must ven contact ith ne 208 “iow of is brake mastr cy, “Tightening terques 43.2, Removing and installing brake light sen= sor, right-hand drive Removing ~ isconnact the pug-2- rm Be brake igh Wc - = Unserewiing see-saw rm he brakelight bck Fs = Remove brake light ston -F--1 Instating Inattation i erormes nthe reveraecrer, ay tention tothe fotowing poms = Thebeakelght auton -F-t-must beim cantsct wth ease “arrow ofthe brake matter cya, Tightening terques ‘2°32 Summary of components brake serv unter ‘rake under. fahttiand rive vehices-aace Te ssnae 35® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 4.4 Removing and installing the brake pres- ‘sure sender ‘The brake srseureeonder censor 1 -.G201- Ie ineartes inthe BS hyerate unt - ans cannot be removes separate. trae pressure err 1 G20 a erage ABS const Unteybe wah the ABS nycrauc unt Nee moat be ly Bice 4.5 Removing and installing the handbrake ‘switch ‘Te handbrake sucha integrated ita housing wth the vee ive cenvel locking switch =. Eecreal system: Rep gt 86 Eonvels 4.8 Removing and installing Sensor unit for ESP-G419- ‘The ESP sensor unt - C449. Winegratad Ita the ABS cel Unt SJt08" end ancl be removed seperately Itipe ESP soncor unt -G#10- ie damaged, tha ABS contol unt TOE trust Be retaced jp theanestnaegeneluntromthenysmsieun aoe 4.7 Removing and installing front speed sensors -G45-/.G47- Removing = Raise ven = Digconect plug connecton-1-for speed sensor on front ale ee ea = Unscrew bot 3 = Pulspees sensor on front ale -G45-/-G47--2-out ofthe ‘whoo! baanng housing natal = Installation i cave out inthe reverse oer. ‘Tightening torques 48 Removing and installing the rear speed sensors -G44-/.G46- Removing = Raise veh, 36 rep ras. seetectn ayesipewuizess= @) rake oyetome E500 03 2086, = Discennest pl eanneeton-1- for spees censor ont ale reser ee rs = Unscrew tot 2 = Pullne speed sensors onthe rar axle - | G46- outer {he ave ss and trae caer nat = Instaatin is cared utin the reverse order. Tihiening torques ‘342 Ascembly overien - peed sensor on rar ae. p98 B sana 37) ‘Superb i 2015 = Erase ojstome - Eon 03 2016 Perec ore SUA 1 Front brakes 21.1 Assembly oveniew- ont rakes’, page 38 '="1.2 Removing and isang brake rings page 40 21.3 Remeving and instaling brake caine page 43 1.1 Assembly overview - front brakes Note 1+ observe ne neretone fr changing ned SPE Changing ie brake pack ofthe fon brake - Mounting nsuctons’pege 40 (Brake iapecton = 4 Braie lat” page 6 Aer repacing the brake pad dopase brake pedi soverl ree when the voice etatenary 0 ensure fe brake pace are prover seated hav naval opera poston + Use orate ing ar eng cece eg -VAS E34 aan he rae Md om he rae hd se the brake peda oad. -VA.G 1869.2.,before removing a brake calineror separating a rake hase from te orate catoor BB rap g40-rme-mecrertensipewuizess= @) era. Eston 63.20 4 -Heat ahi > Sema SS Pa 2- Screw a 12h 3 Brake ase intemal vertistod Dimensions and wae a ‘25.1 Technica stator rates pene 1D alays replace ale. Unseraw ne brake eae pe efor removing Donatus fore io sap sta he bake dice ‘fom na unest subst evesuary use fata. ‘onto you coud oth sities camoge he Siaveines Aasignment = Elan {etGotaigue of ina Pore 4-800 2 45Nm 5 Brake backlate a) screnecioniothe shent ‘ecrmg housing 6 Brake pads co not unsere the ‘rate hose wnen replacing he rare pad |. Removing nd nsteling 1/22 Removing ed insoling brake ning. pee 4 Thickness, wasrimt ~'2.1 Tecrncsl est for oreker 2 singys replace axe Assignment = Elacront Catalogue of Original Parts Observe the tutions fr changing he ped . 7 Brake caper Removing and instaling = 13 Removing and instaling brake caliper ge 43 Summary eompanents > ".1 Exiaded iw ont brake caliper, page 71 2 Aesgnment™ Electron Ceislegue of Orginal Pers 8. Serew a setHlocking Replace ater ieaseomty 2 35Nm 9 Serew 1 lean when using eas a 200m 10 Wheo-bearing housing wth Bote brake coir retire 39® ‘Supert il 2015 = Sia. Eston 03 206 Assignment» Eletonie Ctalogue of ginal Pate 11-Brake pose wah ban unin end halo screw pay atientin ocorect instalation postion 3 35Nim 12. Retaining elp 13- Support 14 -Serew 2 8Nm 1.2 Removing and installing brake linings ‘21.2.1 Changing the brake sade ofthe font bake < Mounting rama aaah ‘ 1.2.4 Changing the brake pads of the front brake - Mounting instructions \Winon changing the pads ay attertin tothe fotow ls = Check protective clio rake callper iton, Replace protective ap if domazes, When replacing the protective cap: = Chak he contact aut ofthe brake piston andthe brat SBipertorany oe (ots) Corfu clean he piston a wala the brake caliper arty and replace he song csp = Cheek the broke piston and he brake cape cosion, Bopecsanite one ofa Sra sua) opiate rake caliper comity #03" Fr brake clips piston, pass it the intl poston: = Checkitthe ston canbe sigh presse into the brake esl per Ite ploton cant be eighty pressed int the brake alps. = Chek ee clean the bake pon a wl asthe bake caliper, Feplace soning steve and protective ca Fepiace the brake caliper completly i damaged 1.2.2 Removing and installing brake linings ‘Special tools and workshop equement required {Peto reseting appliance -T10145- 40 rap r40- tree -macretensipewuizess= @) rake oyetome E500 03 2086, () sae + Steere me inetuctone fo chaning te ad ‘isto oane td ‘nen removing mar th brake pag inne, ever) you nena [Dlaop using hata the game osaton, ss Cbarise Os may cause waver braking 1 Donotunserow the rake hase whan replacing te brake pod Removing = Remove wheel = Discannect he plug connacton torte brake pad wer in- ester —Unaerow Both ing aerove whe courtney the gud bee na sng trie 44® ‘Supert il 2015 = Sia. Eston 03 206 ia anc tach suai areresanaaaete = Remove brake pads 2-and-3- trom te brake caper Clean Donat hs he brake system wih comresed 8 The cust Thali gorwrate fe Razarcous tal ~ Toeougny ian guiding surac for brake aden brake ~ Glen he brake caliper. T) see Use sorts only tociean the rake caper house. Inst (F) now + tears reruns caro te 2a ‘avoctore pene 40 (¢ Me aaherend forthe brake pads must be tee hom ge res. i ard raose | Drain tne bake mtd ram he brake ta reservo using & entation Stie etre resting the ton Ciervice brake Ei can foot ad ead damage Fake Rd was and | nen reseting the ton with piston resetting devoe the arate ak te rake calardostoyee Broke Pid i tox and must never be eveked uo by moutht ~ Pras he piston into he broke caper using the siaton reset egies Hons. ~ Lighty gree gusigsurtee or brake pads on rake caer ‘nh gtobo ram he Yop. p= ‘Do ot intchange the nse at outsce brake pac, Pay at ‘enlon Stsentfeaion 42 rap 40. tte -macrertensipewuizess= @) E00 63.2016 ert ako pads -2- wth etaning springs the rose inthe beke carters cP Covet place the brake caliper onthe broke cae, = Screw the brake caper onto the brake carer th new se leeeng acres sie ountemoidg ne ude core = Mount pig conection -=for brake pad wear incl. = Atacn ne wneela (Dw * (atelaoaatcy Canin te ake fade one ak ma Sherine pation 1+ check rake Rut ve aterrepiacig he brake pace Tenening traues 4 =" Assembly overview ont brakes pe 38 4+ Weal bots > Running gear sales, stein: Rep ot 44 ‘Weal yes; Spectataue fra bala 1.3. Removing and instaling brake caliper ‘paca ols and workshop espa requ + Brake peal eg. VAG 18892. trie 43® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 * (pltnolang itarinthe sane scaler ss abahroe foe may cause uneven being! 1+ Donot unscrew te eake hose when resicing te bake Pad The procedye azotes ony fo the replacement fr ef bike rear wath onthe be cle Renewing = Remove whee ~ Deconneetho connector fre brake pad weer neesta. = Postion broke pedal lod eg VAG 188072 ress down brake pedal wth brake pecalload eg. VAG ‘ee5i2 alent 60'mm, = Teten he atin pug = Do netremave brake peda! load «VAG 18682 = Remove brake hose 44 pap 40. -macretensipewuizess= @) E00 63.2016 = Unaerow Both ing aeove whe counthoaing the guide bree na sng he = Pulleff brake caliper tom brake ese, clesn 1a mt uh the brake ayter wih compressed ai The dust thats generated s nazarecusto rest Thorough lan guiding ures for brake pad on brake ~ Glan te brake caliper [Hm oo [i] me + Sbsane ne inetuctone fr chaning te a 1+ Te aaharen tor tho brake pad must be fee tom gue res. es and presse. 1 Dian the orate us tr the brake fd reserve using 2 ‘errlaton tie cefrefaseting ihe piton Cberwice Sake ‘ican food andoadtscanageVorake tis eceed ‘+ Uinen resting te plton wth a piston essing device the uismote rast nt rate onper doer tyee Brake fu i tx and mua never be sucked up by mouth = Press he piston ino the brake caper using te piston rset. ‘gig Toss. a Light grease guting sutocefor brake pads on brake caer ‘wih arse rom te fepr kt, [Hl w= Donet interchange th insite and outece bake pad. Payot fevlan to wanaheston trie 45,‘Super 2015 = Sia. Eston 03 206 ~ Ince brake pada-2- wi rearing pring rt th recoes: cointtetre cere neemores = Carey pace the brake caer on the broke cari = Sere the brake caliper nt the beak carvan ne sl loping eres, wive sounterisng he gue bok = Mount plug connection = for rake pac wear indicator = Install brake nose ~ Remove brake pesalload og. V.AG 188012. = Bleed brake system gus Seeds Msraut ten fokovng standard aoce dure age 10 ‘attach the wheel @ - tsewe ne rauctone chara ne pad oF 2 peda several times with while siaton. ‘Siyao tate bake pads ste eropery seated thay Maa) Speratng postion 1 Check brake Rut oveL Tigtering torques (6 2°11 Assembl oveviow- root brates’ page 38 1 ect balis = Running ger, aes, steering: Rep. gr. 44 Whee res; Specie fare er uns bate 46 rap 40. ree-mecrertenwos @) 100 032016 2°23 Remeving and instalng brke cape pane 52 2.4 Assembly overview - rear brakes Dm agate lf LW aliemenpretrie ger nlesne te Sea eaveeeeaces + enwaly igen Oe tate iene serers oa toning torque of 14 Nm. iy Use ake poco baa. 9. VAG 18802. beteré removing irate incor,» rake ear or bfore separsing 3 Oras 1 Areacy used brake id must never bo used again Use a bleeding bot, ht ony comes ino contact wth he broke fsa to an bake ud rom he orate fd reserva Brake fui toni and must naverbe suse up by mouth Ee arent 473 Brake se itera vertlsted 3. Benesons and wear IE Teoria dtator iaesbage always replace axe. unsere te brake ca per Setar rung OF Donetuse fre a sep- fate the rave dace from he shee hub Feces uve ut 2. Vert es youcouls oh truss samage ie rake dees, Aslgnment~ Electon- fe Catalogue of Cigna! Pare 4-serew 2 8Nm 5 Brake caper donot unsere he fraternaoe nen Placing the brake pod 2 rerevng ard instaing 2p aRaneang snd Hating babe ealoer aus Observe the instruc oro Se cnanaing he pod 6-Serew 2 Replace ater disassemiy 3 90Nm+ 90° = Outer rake pac 1 inansion and wear bit = 31 Techn dat for rakes’ page 3 3 alvays esiace ae-wse removing and nstaling = "22 Removing and insaling Bae nngs. nage 4 Observe the instructions for cnanging the pas 10- nner bake pas Dnansions and wear lit = "3.1 Tecnica sta for brakes" page 3 always replace ale.nae removing and nsaling = '2.2 Removing ad nsaling brake ngs page 4 Onsecve tn nsrctons for enanging the 230 27232 Changing he brake paso the rear brake - Meunng instructions’. page 4 © 4B rap 40-mee-mecrertensipewuizess= @) era. Eston 63.20 11 Sprng 2 Onyon inna brake pa Check feng postion 12-Brakeline a 14Nm 13- Brake ine holder 14 Retaining ep 15- Brake hose 16 Guid bot 2 35Nm 17 Cover capa 48 Sealing rng fornanabrake contre moter Replace ater dlesssembly 18-Scew a 8Nm 20- Hanecrake mol-V282-|-V283- Removing and staling = "3.5 Removing ond nstaling handbrake mate V262/V2E5" page 59 2.2 Removing and installing brake linings 22.2.1 Changing tn brake pads of the rac brake - Mounting insrcion’s age 42 '2°222 Removing nd instaling brake ting". page 50 2.2.1 Changing the brake pads of the rear brake - Mounting instructions, Wen changing the pcs, pay ateton to he fotowing pots: = Check protective cla of brake caliper ison. Replace proactive cap f damages. Wen replacing the protective cap = Chace contac suraces of th brake piston an the brake ‘alper or any are onyatn) Careful isan tre piston a wel asthe brake capri ity and feploce te selng con Check he rok pcton andthe brake calpse (caelon, yopres an he eta of he onde suas fepace he ake calper completely camages Fer brake caliper pston, pes nto th intl poston: heck piston canbe slighty pressed int he brake ca- Irie piston cannot be sight pressed into the brake caer: hack and clean the brake piston as wo asthe brake calpr. Feplace coaing olosre and protec cap Replace the brake caper completly if damaged, 2 renirwe 49® ‘Supert il 2015 = Sia. Eston 03 206 2.2.2 Removing and installing brake linings ‘Special tool and workshop equoment required 1 Vehicle lagna, masuerant and information asta | Tool et fr brake beosing - VAS 6584. and VAS 6564/0. 1 Brake flag and beding device, 9, VAS 234. {Piston resetting appliance -T10145- Removing Mouning © Wren ark the rake pad innr cute) ou infor ‘Dhoeo wang neta fe same locaton, as oorse Pas ‘ray eovse uneven braking | Donot daconnect the connector ofthe hander ot, ‘© Me acharond fore brake cade mist be fee ftom gue ree. es and grease ‘lig can fow out ond aa io danage bake hugs aed Inthe meanting {© Donctunserew the brake hose when epiacng te rake pad {© Donotonerte the handbrake fr ay reason ifthe handbrake Seperate brake caiper is peimanenty damaged Brake fi is fxs and must never be sucked up by mouth + Eletone ansteoke not atuaes = Remove wheels = Reset ne ston forthe electronic encbrke = Veh Sgnocic eter = {aero tani peng 1 forthe brake pads out ofthe broke calper-sravr wt erouarvor BO rap 40. rmee-macrertenRemove capa -arowe = Remove bos gue bls rm the brake espe. Remove th ake calipr an secre wth wir in sch ‘Suray Oat na waht oth bre cage de net oad or ‘demage me brake rece (D) swe + Donotoperte tne handrateforany reason! ifthe habe ‘Boperaod ine brake calpor i pomanerdy damage. 1 You must et back he pst with he > Vice alapnastc Earmetbe pul ack. Othe sae is ven Back Wi the Sopraseorat ~ Push back te piston completly wt As ston esating too 2renirwee 51® ‘Supert il 2015 = Sia. Eston 03 206 = Remove braks pads -2-and 3 een KOE Donat fish he brake eyetom wih compressed a. The dust alls generate fe Razarcous to hoa ~ Though caan guiding surac for brake pads en brake ~ Clean the brake caper. [Bw Use sorts only to clean the brake caper housing. Note + obsene pe netuetne fr changig te SEE Bartel arte Mating inert Bote «+ Teachernet rake pas must fee fo gure Reser grace (bran ne rake ft tom ne rake fut resanot wang @ {otlatan te te reso te aon Cure ke ‘ham Row ot ad eas damage rake hd was aed ‘© Donotoparate te handbrake fr any reason the hanerake ‘Seperaied fe brake calper's permanently camaget ‘rake tid toe and must never be evekes uo by mouth ~ Insert iner-2- an cuter -3-brake pads the brake cater. = Install both aki calper guide pins. 52 rap a0. tmee-mecrertennae capa-arrowe- ~ rgerttaning ssn for bak cit te ore ftitrake (Dm Ensure hat the retaining sping corecty sented the bores of tho brake caloor ~ Bring the rake system base poston = Vehiceeignottic fone = ataenne wnesle [Ew Check brake tu leve i necessary too up wth bake Mu Tihteingtrques 2°21 Assembly overview tar brakes” page 47 + vest bats = Running ger, aves tering: Rep. ot ‘neste: Spoctod orgie fr ihe bala 23 Removing and installing brake caliper ‘Special tools and workshop equipment requred 1 Vehicle dlagncele, measurement and infomation estan 1 Too se fr brke bleeding - VAS 8864. and VAS 65840. ‘Piston esting appliance -THo1es- 4 Bike pedalioad-V.A.G 186872. arene 5S‘Super 2015 = Erase ojstome - Eon 03 2016 Removing (© Me procedure apes any fo the replacement fr heft Dhitg recoi wath onthe brake ler teewe he hatuctone chara te ped ‘isto nage <0 When remeving mar he bake psd nner, cute you ian) ‘olegp wang ‘ratalin fe sane locaton, as aeraise Pas ‘ay eoize uneven braking 1 Donat ieconnect the connecter of the hanceake mot The adherend fe the brake pads must be hee am glue re. ‘as and gradee. | Drain th take tid tom the Brak Rud reservoir using a entation bette befre resting the ton ier wise brake ‘© Donctoperate a andorake fr any reason the harake [Beperaied, te brake capers permanent) camaged rake fd toe and must never be evekea uo by mouth! + Electronic hanstirake fot actus = Remove hoes ~ Reset he pistons forthe slactronichancbrake = Vehicle fgnoste tester = Ramove handbrake motor 53 Removing ad iaallng handbeake moter Vag? 269 = Poston bake padal loss a.g, VAG 1860.2 Bd rap r40-tmee-macrertensipewuizess= @) rake oyetome E500 03 2086, ~ Fte blesdor hoe fhe bgsding bot -1-onto the lseder ‘ale and rlzese Hooda vee = Press doun broke pedal ith brake ped lod og, VAG ooo atleset rm, Tighten the dain pug = Donot remove bake pedal lesa. g VAG 1868/2. = Unsere take hose ~ Lover he retaicng sping tf the broke pads out ofthe Drake cakoer-orste wi a scouarver"® 2 rewirwe 55® ‘Supert il 2015 = Sia. Eston 03 206 ~ Remove cape rons = Remove bath gue als fom the brake caper Pulloff brake caliper om brake cart esr onet hah he rake sae wn corpresed ak. The i Thali gorwrate fe Razareous to al ~ Theis onan auing aura or brake pads en brake = Clean the bake caliper. se sorts only to clean the brake caper housing Insta T) sew 1 bear te nstuetions fer chanaing he pad + Reseryoner te eae cscs must to mrs. | Drain tne oke ua om he brake Aud rasan using a onolaton bette borers resting tha ton Cterwioe brake ian ow ou and osd sarge rate Rtas ned | Donctoperate ma andrake fr any reason the hanake |Beperaied, te brake capers permanently camage + Thgbrake pase tein te reanng stngs on here = Ftbreke calie tothe brake cate = nstalboth brake caliper ide pins = neal nandbeaks motor 253 Reruns sd stalin handorake motor V282 / V2 Bott brake nose to brake caper = Bleed brake system 3b sleeeg israutcevston oboving standard proce = Perform basic sting ofthe brake sytem withthe = Veh faagroctelecer a = stan the 56 rep 40. ree-mecretensipewuizess= @) rake oyetome E500 03 2086, () sae Check Brae Mud eve necessary oo up with rake Rs Tightening terques 2°21 Assembly ovendiew- reac brakes’ page 47 4 2°21 Assembiy overview. rar brake calpe page 74 + yes! pate = Running ger, aves, stenng: Rep. ot. ‘nee, ree Spocoe orgie for hee! bats 2renirue 57‘Super 2015 = Erase ojstome - Eon 03 2016 Handbrake w= parking broke, page $8 123.3 Removing ng netaing handbrake moter V282 263 ee 3.1 Assembly overview - parking brake 4 AUTO HOLD button -E540- vin AUTO HOLD neater Tigres Summary of compo. rent en sane con- so 2. Repoving and natating Fiep.gr 96 Conte: Reming and tat Eitan fralacreome hasalnencbrake = Summary ofgompe- Se M 2 Renovng and neta EeceRal oyster Beo-gr 38 Cont Binune Srelecrome ‘hecalnencbraa = Este auton ter Ale TOHOD" ese, 3- Dash pane insert wah feu amp fr eae. None serirginene- broke oat wah bree eytem arn. Ingenta 2 wan scout signal 44 Control unt for electron fancoana "3540. 2 integrated into the ABS contol unit JHOS and carnctbe replaced separately 3 Repoving and intaling ABS conta unt 1108 5: Rear broke caliper 8 Seating ng 7+ Handbrake motor Let handtrake motor 282 instalation locaton: n roa ft brake caliper ight nanabrake motor -V283, nealaton locaton: en rear rat bake calser removing and insisting = "3.3 Removing ad instaling handbrake mater V282 /V283 page 59 5B rap 40. tmee-macrertensipewuizess= @) rake oyetome E500 03 2086, 8- Screw a 12Nm 3.2 Removing and installing control unit for electronic handbrake - J540- It's rot possible remove these parts separately Getolunt for elegant nance - 40: reseed it the Secon Semon i ataling ABS contol unt J104 ABS 3.3 Removing and installing handbrake mo- tor -V282- /-V283- ‘Special tools and workshop equipment aqured 1 Vehicle ciagnesis tester Removing (Dm The inion mus be sstched fe at east 50 second before Mesanecing re conmastor = Pulleutthe plug connector rom the ol pressure ich Pull connector of he heake moog, Unscrew crave arrove- ote handbrake mot = Pullthe handbrake motor fhe brake caliper, ering the Randbroke rotor back ond for sgh es you do so = Take cut seating cing iw Mok sre ate anv goo tne sealing ing andthe ‘ontac suru of the handbrake ot ore ro caged. Clean he annular groove anne contetSutace ol hash bre mein Insaing sane 59® ‘Supert il 2015 = Sia. Eston 03 206 ~ Yanraraemencycnsngeap armen inal rag = Fully grote the erive shalt ofthe handbrake moter. Note The gaaing ing must not be twisted out while asserting the Kendsate mote = Cereuty age the nenabrake motor ont the brake eae, ‘hie ensuring hat the seating Ieee ore. rie necessary cive back te ive shat signty wih an E11 Tore ‘erie 50 that you ca poston the harabake tr cOrect = Twine hendbrake motor unl he srew hles and tend sre aigned ‘ak sure the hank moors rae th take cae ‘er Dont tghten the acts the hondake mater not enioc ite rake cater = Serewinthe serene rou, = Raconnseteonnttor = Connect the speed sensor pug ~ ring he brake sytem to base poalton = Vehicle dagnoatc fener Tightening torques 2°21 Assembly overview parking brake" page 52 60 rap 40. -macretensipewuizess= @) rake oyetome E500 03 2086, 4 Brake pedal 4.1 Assembly oveniow brake poder pogo 81 24.2 Removing an instaling beaing bracket’ page 05 24.9 Separating brake pedal om brake sano’. page 68 12.4 Cloning he brake pedal ono te brake sen un, ‘age reece . 4.1 Assembly overview - brake pedal 24:11 summary of componsets brake pedal. lt-hend ve 194.12 Summary ofeomponens brake pedal ih-hand ve", ‘age 6 44. Summary of components - brake pedal, left-hand drive 1 Grease a bearing surtaces wt polyarbamite grease «G52 142 AZ before ase 16 Ms rake ht sth Fad brake pedal st -F47. are ota on the maetr bake eying. cama 61® ‘Supert il 2015 = Sia. Eston 03 206 4eNat 2 setlecing Replace ater ses soni 2 sheer tore ie ea ot tation ings paces a 25Nm 2 Bracket se SF Reolce ater diss Sno removing = Remodg bracket ST 2romovngangin. = Turn bearing bots ant ockmen, he barn botestenes ve! bre om ~ Pullout bearing bot te Donetorease ne Bean bot mas te inataaten our in reverse ore Note Re 2 2- Bearing brace removing and ineating = 8.2 Remevng ad instalna bearing tracer. 65 4 love beng ete tet ire poston 5 ate pia cap 7 Sher bong 4G] We ret ig poston 8: steve boning 8- Support 2 forbll heed of precsure rod of brake sero unit 62 rap a0. rmee-mecrertenera. 40- Retaining ep Replace ater disassembly I ingerted int bth bering bracket eves order of tightening 4.1.2 Summary of components - brake pedal, right-hand drive 4 some paa 63® ‘Supert il 2015 = Sia. Eston 03 206 Ty) sew | Grae a Searing sures wih poNcarbamie grease -G 052 142 A2- before assem (6 Me rake ight swt - and brake pedal ston 7. ar loeted on the master bake cinder 4 -Serew 2 20Nm 2. Bearing bracket 3 reroving ad nstating SotgRenevana sng ‘Baling bepring bake st omets ant 2 sstlecing 3 25Nm 4- Retaining op SF Reoice ater dias Sone inserted into bath ba Ing racket bores: Sonat 2 selecking 3 25Nm 6 Bracket se Replace ater das sembly Donel grasa te aang bot. The ‘Beannp bot mas romano the installation ocx reverse order — ‘sro for the bearing bot must Sec es ten oh 64 rap r40- tte -macrertenera. 1 Slove bearing te oo — rail 10- Support for ba hass of presaure rod ot rake 11. Sienve bearing (F) soe 12142: Removing ond naling bearing bracka. hthand chive 4.24 Removing and installing bushing, lef hhand drive vehicles Removing ~ Disconnect batery earth stop = Electrical syst: Rep BF 2 Battery: Daconnecing and comecing bate = Remove ins aoag > General body repr, Intrcr Re. (8, 09, Knee arbage, Remoung and ining Woes bog Stenionter - SEU Gey wettest ‘vara fone Wt = Remove data bus diagnoate interface J535-— Electrica) System: Rep g°_ 67 ‘Cantal unis Romoving and ling ‘ie bus lagnoate notace -J835. = Remove ne impact absorber. General body rapa ne fecr Rep gr 1 Daehaoard cent pipe Removing and Inetaling pact abecrbers soma 65® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 ~ Daconectpug-2-romthe con un or valor ng ~ Remove the drive shat quad forthe steering column. = Remove the accelerator pedl= Rep. gr 20; hate convo = Separating the brake peo the brake servo unt = Release the nuts 1-104, = Detach athe electric! eabes ham the bering bracket = Remove bracket Instating Instalsion ie estermesin the revere ord, ay atentonto the FBtowng port Clip brake ceca to brake serve age 68 = cbserve heer of ahtening us Tiohterng torques 24.1.1 Summary of components brake pede. ethan aivepage 6 1 Remove theimpact absorber = General boy apart Fop gr 70: eshiocers coral pseRemovingara retaling Impad azecrbor 4 nse sioag=_ General boxy reps, interior Rep. 69: KRneeabge; Remoung and nsaing knee sebog wthigrter ‘ Aovwerster pessl= Rep. gr 20; Accelerator contl 4.2.2. Removing and installing bearing brack- t, right-hand drive vehicles: ~ Remove indscrogn wiper motor ith Irkage > Elec! ‘year ep. Wincacoen ow ayer: Remove Sd naling indscoen wosr motors 66 rap 40. ree -macreten= Rama one ag Carr ody ep, aor a. 5°38 "tee sage Reming snd lang eae orp Sener’ ~ Rena avr ide ota et = Henn tee Eres spore feng SA dud Ronen an oat ~ Rerove dts anno prc 159. Sec! Sioa A og earl is Remevna ond esng ‘She bis ogseteiooce 355 = erov te ipe ea Gabry ep der Bexige 10 Bsttenet ara po Ronernsenaalny ed abner ~ Removethe acelrato:pacal= Rep. 20; tte contr! ~ Beconestug-2- oth cennORETVtabtt a- na = Discennest wing loom 2: rom besring back 1. = Separating the brake pedal om the brke serv uit Secure brake servo to prevent rm fling out 4 soma 67® ‘Supert il 2015 = Erase ojstome - Eton 03 2016 ~ Release fing nuts -orowe = Remove brace Instaling Instalain ig partormeln the reveras order, py tention tothe ‘Blowag pots: = Clip brake sess! to brake carve sees page 68 Tiaterng torques ¢ 22412 Summary of components Hk onda righthand staan 82 ‘+ Ramovetheimpact absorber ~ Generalbosy repaints Rep gt 70: Dashboard coral paw Removing aa stling Impsdt absorber jroag=_ General boty repai,ntrior Rep 68 itoage Remoung and ns knen aoa hig 4 Accelerator pedsl~ Rep. gr 20; Accelerator contol 1 Wiper mote with inkage = Electreal sytem: Rep. ot. 92 Winaecroen wiper system: Summary of somone wn sereen weer systern 43 Separating brake pedal from brake ser- vo ‘Speclaltools and workshop equement required 1 Release toot. T101598- of 7101596. ~ rote rake ets crac ne bate sano unt nant 2. Punger rod 3- Relating lugs ~ Insert release tool. TS01S9A. cr -T101506. and pul in the (dracon otha carseat hs Soutersng te Grae Bedale pede must not move Sacards dug ths one Stan) Tis scton wi prego retaring lugs of owning of Bat head of unger rod 2 ‘The fg, sows the separation of the brake pedal rom he brake Bnotine wen te foes conte emaves or lary = Pullen tool -T10508- of T101506- ona brake (guitar lovarde ta civers teat Gis chon wl pul ae bre pedal of the all head af he unger fod) 6B rap a0. tmee-macrerten poteexes fees, B®) Tae aap ns ra pd ons a ~ Hold ba nea o purges rosin rnt of mourtng ana push brake pada drecbon of brake sv. so tat haba hens leks bro sacs ~ Check tna tis comectiy locked i plac by brit puting on ebrakepedss pase by ey paling 4.5 Removing and installing brake pedal It snot patible to remove the brake peclin the vehi Removing = Removing bracket, S°T2'Reinona and intling Bearing bracket’ page 65 Letenand ve Unscrew bearing bot in-rection of he aro. ‘The see 6: break ot Figh-hand dive soma 69® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 = Unscrew beorng bot against rection ofthe arrow “The ses A ek of Contes er al vicies ~ Pullout bearing bot. ~ Remove brake pedal Instating OD) nae 16 Replace bearing bl with serew fey Bearing bot + Donorerees te Besing tel. Te Beare bt musta = Insert the brake pede the be ~ Insert new bearing bt. = Teen bushings ‘The efety tbe forthe bearing Bot muet lx avs in see = Fit nen rearing lp fo ha besring tat SEE TRbserbly overion-«bipke bedat-page 81 ~ lnaanng racket ring baeket 70 ap 7 40-rtee-mecrertenexes fees, B®) ele hcrd draulics 1 Front brake calipers 277.1 Exolosed vow -ontbrake caliper. pace 71 12712 Removing and intaling brake color pston’. age 72 1.1 Exploded view - front brake caliper ie 1 insta the complete ropa set when undertaking repers 1 Use only metyited spine for cleaning. 1 Thin coat bake einer, piston and gaskel ng with ith grease -G 052 150 A2. 4 -Dust cap 2. Vert ave tiny cost ne win herr grease 6 052 "oR Stetoe acenng 4 Guide bot 5- Collar Dia core” and tthe Guise sr reac e Sern cas Backing tome rep fe ment art eemtee hie pa re ‘Ssequste quarty of (Grasse on guce ine a there is any dam fhe proachm cape Setfeae the endooed ‘reses pacing br 7 Boot removing 24 nstaling 72 Removing and naling bake caliper pion’ rage 72 one damage when inserting the peon, 8. Piston removing nd instaling = 1.2 Removins and intalng bake calprsston’. page 72 Pomartacapen 71® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 2 Sesing ing removing and instatng =“.2 Removing and instaling bake caper psn". 2age 72 10- rake caliper Removing and intling = 1.3 Removing sn istaling brake calina’.nage 43 1.2 Removing and installing brake caliper piston ‘Special tole and workshop equoment required 1 Piston resetting appliance -T10145- 1 Disassmbiy wedge - 2400 1 Liium gresse -@ 052 15082. Removing = Ramove brake caliper S73 Bemeung ahd nt ~ Inet wooden pelosi ebmagnateistonss Rag Pressea out = Press he piston ox ofthe brake caper housing sing Som preosed a -orow [Ew ‘ake sue that te cy surtce snot damaged when ramo%. Ing the gasket one = Remove gasket ng wih aassembly wedge - 3408- Insta Note | Aluays instal te complete repar kit when regarng he bake ator 1 Usecny metyisea spits or cleaning he brake 1 Newrake calves re filed win bake fui an ae pre-e 4 tie goeottay naseasay, pate ae being undertaken 12 preced th rate capers Bote ating the ve ‘ile niout rake pace) pases = Clee piston and gasket sng with white ste and ay ot = Getreintatngthe piston and gasket ring inthe brake caliper thn coat wit lin presse "@ 082 18D AZ" = Insert new gasket ing inthe graove ofthe brake ele. 72 pap. 47 rte -matcssipewuizess= @) era. E00 63.2016 ~ Postion he proactive cap with the outer coating ip onthe ator 7 ~ Irae inna aang lip ofthe pectacve cap wth desasemby ‘neoge" S0B-n he geove ce ince Todo so tol the piston wth the hand ~ ross he piston into the brake caliper using the piston reset fgg Toss ome Dm The outer sealing ip ofthe protective ap wil ole no the piston broove Instat brake caper = (3 Removang and instlingbaiaize page 42 Presiding the brake ste Setup brake caine fo prebiedaing ae shown in the fg = Open vent ve raw A, = Using 2 commercial brake fo une bube ‘ded bo brake hove connec) = Close vent vive trentwncapen 73® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 2 Rear brake caliper mat io 4 2.1 Assombiy overviow - rear brake caliper FT) sew | Insta he complete repair set hen unseating epare 1 Use only metyistea sprit tor ceanig. | Minty coat brake vince, pstn are gasket ng with lium grease @ 082 150 Az. 1 Brake caper housing 3 tele bate caper Dehandbrace cobs notessed 2 Damping sieeve 2 Guide bot 4-c0p 5-Serew Tieton ere peed 6 Handbrake contel motor Removing and stating saute? 7 Seaing ng Replace ater dss cab 8 Compressor nut Cannot be removed 8 Seaing rng Cannot be removes 10-Piston Cannot be removed 11-Be0t 3 Repoting and stating 2 PaRengana andi ‘Salina seciactes soe-nage 78 12. Vanevahe thn com thread with thi grense =< 052 150 A2- before sereing in 3 10Nm 49 -Dusteap TA pap 47 -rta-marcesipewuizess= @) era. Eston 63.20 2.2 Removing and installing protective cov- ‘Special toot and workshop equipment requred {Piston resting appliance -T10125- 1 Aasemby dolce. T10146- {Disassembly wedge - 3408. Removing (Oni the protective cover ana hast be repised (ss {rie protective covers replaced the brake caper dbes rothave {biberamoved arte eae hose unscrewed + ison peassed ack + Handake contol moter as been removed 1 When the piston and compressor nut se removed, the trends destayed + Never completly untrew ne compressor nuts and piston! Unscrew te piston in ection af arrow by maximum of Bir a = Usethe disassembly wedge - 2400-toramave te protctive over rom he broke caper (Dm se cnt metiyited spirits for cleaning the bak. = The piston aurtaces ana brake caper mustbe cleaned with Tieden tae ato ay 2 rearetactper 75® ‘Supert il 2015 = Sia. Eston 03 206 ~ Ftprotectve cover it he groove -aro- onthe piaton = Screwingiston in rection of aon = Pros he protective cover th th pon resting tot TiGia6.-{and saeemey device T1080) -2ora the roke capers hot rem santo’ osu the arcomferance ine brake caer 76 rap 47 tremorsSuper 2015 = ® 3 Brake servo unit and master brake cylinder +232 Removing and intling brake sarc’ page £0 age 2-234 Check the operation of he brake serv un” page 68 3.1 Summary of components = brake servo Unit and master brake cylinder 2314 ‘of eompanents- brake servouniicter brake inde. end ave veces! page 7? A Tihtenng oraue SEEN Surmary of ‘Somaonenis ake Bont 2- Bearing brecket a cannot be repared. = pace complete ‘ent aus Removing ananataling Sng t Semoun and ‘taalioa maser ate ‘inde eichand dive ‘ohils”page 4 ‘Assignment Elecvor- icGaiogue of Cog! 6 Brake light ween -F a) Removing andinstaling eae E00 63.2016 ‘3 Botesanouatandnaser take oprae 77® ‘Supert il 2015 = Erase ojstome - Eon 03 2016 checking = Vehile Ssonoei tector 7- Screw 2 8Nm 8 Brake tne rom masier brake cylinder (eating piston crcl fo ABS hysraucunit-NSS- 3 hiring eae 8 Brae fre hom master brake cylinder (pushrod leton eu) ABS hyde uit NSS A Tehonng eu TERETE des vw conse unt and hye nt. et hand erve venice ae 12 10. Pugs moisten wth broke fu set inthe brake clade en press inthe brake fue reser 11 Brake uid lov! waning conact- Fe 12. ake uid reserve 13- Vacuum ne © Acsgnment > Electronic Catalogue of Original Pats Nome vale (rn vacuum hose}; Functonal test = é2.Checking nonrelum vie" page 91 14 cover 15- Gasket tease damaged 16 - Casket 17 Brake ser Assignment > Electronic Catalogue of Original Pats separate ftom brake pedal = 42 Separating brake pedal fom bake savage Remon and instling = 32 Removing and instling brake servo, page 3 Inapect proper operation = 3.4 Check the operaton ofthe Brake sero unt, pags £9 2 tthe are faut replace completely 18. Gosket 2 Replace ater dlasesemsy TB rap 47 tree -marsceexes fees, B®) 345 onary a copa Gra ae Naor be ed soe 1 cer 2 Brake fis resenor psp rove: opera 24 Chacha aera: iqaineggeome there are autre place comply 4 Cashet 5 Vasu ine a) Aeegnment~ Elsen {eataiogue of gina Pers Non-return vais in [ce hone Fane. Toh a) selocking | Tightening torque = 1.1.2 Summary of components «rake bed. chi-hand re". page 63 8 Bearing bracet 9 Gesket repli aragod 40. Brake mastrcyinder |B cannot be repaired, replace completly inthe overt ffuts Removing and vetsing a Aesignment > Elecrone Ceislogue of Orginal Pate 11 Brake ight ston - Removing and isting chack > Vehicle clgnostic eter ‘3 Rotesanouatandnaser ake oprae 79)® ‘Supert il 2015 = Sia. Eston 03 206 12-Serow 2 8Nm 19 Sere 2 8m Hest hes 2 Asignment > Electronic Catalogue of Original Pats 15- Protection pate 2 Aesgnment > Elecrone Catalogue of Orginal Parts 2 settockng Repsce ator daaszemoy 3 251m 17 - Beak ine tom master brake eye Moting ton Creu to ABS hycreule unt NSS. 9 TRIE ee ven ndtv unten mcrauicunks dard dive vehi’ page 15 18-Pugs 2 mosten wih bake thi, iaet inthe brake cinder and res inthe brake fue reer 19- Brake ine rom master brake elinder (gush so ston crcut) # ABS hyeraue uit-NBS- 3 Thing eave 20-Expancing ret 3.2 Removing and installing brake servo 12323 Removing and inaalig sk ive 3.2.1 — Removing and installing brake servo Unit, left-hand drive vehicles ‘Special tool an workshop equipment required 1 Brake filing and bleeding device ,.g. VAS 5234. ‘¢ Exracion bot commarilyavalaie) 46 Repsirkt-1H0658:311 A Removing = By preccing te brake ec! eoveral ties, alminste re vae- ‘Simin the brake sar ont ~ Remove macir brake cinder ‘Samsung sno isang brake master cyingar = Pullvacuum hove outer broke servo, “= Remove knee aibag = General body reps, intror, Rep. 8 7, 68" Knee arbags: Removing an rscling ‘in igniter BO rap 47 tree -marscesipewuizess= @) rake oyetome E500 03 2086, ~ Barove se et owe ver = Hest tm, a ca jonng sys ject Remove nia verde fuel it ~ Separate brake pedal rom brake sero = Release th nuts -2 and. Carat remove the bake eee unt fom the vile, Instating Inattatin i ecormes nthe reverse orer, ay tention tthe foisurg orks oY = Olp brake pedal to brake servo ean 8 = Fitup with new brake fi = Bloes make system Vehicle ted wih a manual garbox ~ Bled te cich = Rep. $0; Clutch mechahsr: Blaodthe ‘Suter mechanism Tightening trques 2°31 Summary of components brake sero unilmaser ‘rake sxnder.ftone ce ehiles page 77 6 Ad Spano amped © p00 airbag = General by repairs, terion Rap. 9”. 695 Knee avbage Summary ocomtponets: kee sag 3.2.2 Removing and installing brake servo, right-hand drive - diesel engines ‘Spec tool and workshop equipment requred 1 Brake fing snd bieding davies & g -VAS S234. ‘Extraction bot (commercial avaiable) © Repairh 1H0 898 31 A ‘Voices wih ise parce iter Removing = Remove desl patie ter > Rap. 28; Exhaust ‘Seaning remoting ane stling esl parle ter Remove master brake cyinder 32) erin ond nln brake master cinder, ae. ‘3 Rotosanovatantnaser tae opra 81Eston 03 206 = Detach tne vacuum nose ttm the brake eer unt 2 ~ Disconnect brake servo brake pedal Release fing nuts -arous- = Remove the bake se unt counwarce out of he venie Insta Instalin is partrmedin the roveras order. pay tention tothe fotowng pnt: ~ Clip brake ped obra servo ~~ Filup wth new bake fui ~ Bleed brake system Vehicles tea win a manual gearbox = Bleed the cutch = Rep. gt. 30; Cutch mechanism Blaedthe Sich mecnenam, ‘Tightening torques (23.12 Summary of comsonents brake seve untimeser ‘rake vince rahhond ve vices page 78 “+ Dest sortcle ler Aen. or. 28. Exhaust gas eons, Binmdy ei campenens euhaua ges Sear Vehicles wihout dase partici iter Removing = Remove calaic converte = Rep. gf 26: Exhaust eaningtomoving oh nstalng ell convey = Remove masier brake cinder 225 amen nd naling brake master cinder, sage 8 B2 rap ar ree -marsceSuper 2015 = 2 Beton 032096 Detach the vatuum hoes 1 rom the brake serv unit-2 = Diseanneet brake serve tom bake pedal ~ Release fing nuts rows ~ Louse font ne wih stsang goat orice poston = Rin- gingore oes, star Rep 40; Asser cari me asembly carer = Remove he brake servo unt Sourwarde out oft Instat Instn i ertormes nthe reverse order, ay atetion tothe fotowing poms: ~ Olp rake pedal to brake servo 2.4 Ciapna ne brake pedal onto he brake 2ervo unit, eae hice ~ Fitup with now brake fui ~ Blogs brake ater 3 iced Nyda oyster fl ‘Vehicles ted wth a manval gearbox = Bln he clutch = Rep. $0; Clutch mechan Bleed the ‘ute meshanam “Thang torques +2531 2Gumm psp 2Senpan ot cponet trate cl ecard + cata converter = Ras. gr 26 Exnaust ga clean SSnevaryofcomporenta-ethausigasceetng 3.2.3 Removing and installing brake servo, right-hand drive - petrol engines ‘Speci toot and worktop equipment equres 1 Brake fring and bleeding devew 9g -VAS 5234. ‘Extraction bot (commercial avaiable) © Ropairkt- 1H0 698.311 Remove the pre-exhaus pipe wi cally cverter = Rep. 9,28. Proarhaust neeuslonce: remove ana instal fort Binsust pe = Remove master bake cyieder Pages ‘3 Rotosanoatandmaser take oprae BS