Brake System

Service
Workshop Manual
Octavia III 2013 ➤
Brake systems
Edition 12.2012
cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2013 ŠKODA AUTO a. s. D4B802B4AD9

Brake systems - Edition 12.2012
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brake variants and their assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Brake inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Distinguishing features of the ABS systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Fitting location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Summary of components - ABS/ESC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Hydraulic unit, brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Summary of components - hydraulic unit, brake servo unit - left-hand drive . . . . . . . . . . . . 9
3.2 Summary of components - hydraulic unit, brake servo unit - right-hand drive . . . . . . . . . . 10
3.3 Removing and installing control unit and hydraulic unit - left-hand drive . . . . . . . . . . . . . . 11
cardiagn.com
3.4 Removing and installing control unit and hydraulic unit - right-hand drive . . . . . . . . . . . . . . 15
3.5 Removing and installing bracket for hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Assembly overview of the ABS speed sensor on the front axle . . . . . . . . . . . . . . . . . . . . 20
4.2 Assembly overview of the ABS speed sensor on the rear axle . . . . . . . . . . . . . . . . . . . . . . 23
4.3 Sensor unit for ESP G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Repairing front wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 Changing the brake pads of the front brake - Mounting instructions . . . . . . . . . . . . . . . . . . 27
1.2 Repairing front wheel brake, brake caliper PC 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Removing and installing the brake pads of the brake PC 57 . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Removing and installing the brake caliper of the brake PC 57 . . . . . . . . . . . . . . . . . . . . . . 31
2 Repairing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Changing the brake pads of the rear brake - Mounting instructions . . . . . . . . . . . . . . . . . . 34
2.2 Repairing rear brake C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Removing and installing brake pads (C 38) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Removing and installing brake caliper (C 38) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5 Repairing rear brake (PC 38 HRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.6 Removing and installing brake pads (PC 38 HRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7 Removing and installing brake caliper (PC 38 HRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Handbrake lever - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Setting the hand-brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3 Removing and installing the hand-brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 Summary of componentsProtected of brake pedalCopying
by copyright. . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . in. .part
. .or. in. whole,
. . . .is. not
. .permitted
.... 51
4.2 Separating the brake pedal unlessfrom thebybrake
authorised ŠKODAservo
AUTO A.unit andAUTO
S. ŠKODA clipping onto
A. S. does not brake
guaranteeservoor acceptunit
any liability
. . . . . . . . . . . . . . . . . . . . with
. . .respect
. . . .to. the
. . correctness
. . . . . . .of.information
. . . . . . in. this
. . .document.
. . . . . Copyright
. . . . . .by. ŠKODA. . . . .AUTO
. . . A.. .S.��
.. 52
4.3 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.5 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1 Repairing front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
1.1 Repairing brake caliper C 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.2 Removing and installing the piston of the brake caliper C 57 . . . . . . . . . . . . . . . . . . . . . . 57
2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Repairing brake caliper C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2 Repairing brake caliper PC 38 HRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Removing and installing the piston of the brake caliper C 38 / PC 38 HRA . . . . . . . . . . . . 62
2.4 Pre-bleeding the brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Checking the master brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1 Bleeding the brake system of air with the brake filling and bleeding device . . . . . . . . . . . . 65
4.2 Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 Brake Servo Unit/Master Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.2 Removing and installing master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.3 Removing and installing brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6 Brake line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.2 Flaring tool - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
cardiagn.com
6.3 Work instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
ii Contents
00 – Technical data
1 Brakes
(SRL000560; Edition 12.2012)
Brake variants and their assignment ⇒ page 1
Brake fluid ⇒ page 2
Brake inspection ⇒ page 2
1.1 Brake variants and their assignment

Engine 1.2 ltr./63 kW TSI 1.2 ltr./77 kW 1.4 ltr./103 kW 1.8 ltr./132 kW
TSI TSI TSI
Engine code letters: CJZB CJZA CHPA CJSA
Master brake cylinder - ∅ mm 23,81
Brake servo unit - ∅ Inch Left-hand drive: 1
1"
cardiagn.com
Right-hand drive: 7"
/
8"
♦ Front disc brake:
Front brake caliper (type denomina‐ PC 57 PC 57 PC 57 PC 57

tion)
Front brake caliper, piston - ∅ mm 57 57 57 57
Front brake disc - ∅ mm 288 288 288 312
Brake disc, thickness mm 25 25 25 25
Brake disc, minimum thick‐ mm 22 22 22 22
ness
Pad thickness without sup‐ mm 14 14 14 14
porting plate
Minimum pad thickness with‐ mm 2 2 2 2
out supporting plate
♦ Rear disc brake:
Rear brake caliper (type denomina‐ C 38 C 38 C 38 PC 38 HRA

tion)
Rear brake caliper, piston - ∅ mm 38 38 38 38
Rear brake disc - ∅ mm 272 272 272 272
Brake disc, thickness mm 10 10 10 10
Brake disc, minimum thick‐ mm 8 8 8 8
ness
Pad thickness without sup‐ mm 11 11 11 11
porting plate
Minimum pad thickness with‐ mm 3 3 3 3
out supporting plate
Engine 1.6 ltr./77 kW TDI CR 2.0 ltr./110 kW TDI

CR
Engine code letters: unless authorised by ŠKODA AUTO A. CLHA S. ŠKODA AUTO A. S. does not guarantee or accept CKFC
any liability
Master brake cylinder - ∅ mm 23,81
1. Brakes 1
Engine 1.6 ltr./77 kW TDI CR 2.0 ltr./110 kW TDI

CR
Engine code letters: CLHA CKFC
Brake servo unit - ∅ Inch Left-hand drive: 10"
Right-hand drive: 7"/
8"
♦ Front disc brake:
Front brake caliper (type denomination) PC 57 PC 57

Front brake caliper, piston - ∅ mm 57 57
Front brake disc - ∅ mm 288 288
Brake disc, thickness mm 25 25
Brake disc, minimum thickness mm 22 22
Pad thickness without supporting plate mm 14 14
Minimum pad thickness without supporting mm 2 2
plate
♦ Rear disc brake:
cardiagn.com
Rear brake caliper (type denomination) C 38 C 38
Rear brake caliper, piston - ∅ mm 38 38
Rear brake disc - ∅ mm 272 272
Brake disc, thickness mm 10 10
Brake disc, minimum thickness mm 8 8
Pad thickness without supporting plate mm 11 11
Minimum pad thickness without supporting mm 3 3
plate
1.2 Brake fluid

Classification
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTONA.052 766
S. does not according to any liability
guarantee or accept
the USA
with respect to the correctness of information in this document. standard
Copyright by ŠKODA AUTO A. S.��
FMVSS 571.116
DOT4 and VW stand‐
ard 501 14
Top-up First top-up after 3
years, then every 2
years
1.3 Brake inspection

General points
♦ The drive is provided by the test rig.
♦ During the testing, the idling speed must be set on vehicles
with manual gearbox and the driving position »N« must be
engaged on vehicles with automatic gearbox.
♦ 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.
2 Rep. gr.00 - Technical data

Test, vehicles with front-wheel-drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The test speed must not exceed 6 km/h.
The test stands approved by Škoda comply with these conditions.
cardiagn.com
1. Brakes 3
45 – Anti-lock brake system

1 General Instructions
The ABS brake system is divided diagonally. The brake servo
assistance is provided pneumatically by the vacuum brake servo
unit.
Vehicles fitted with ABS do not have a mechanical brake pressure
regulator. Specifically matched software in the control unit regu‐
lates the brake pressure distribution on the rear axle.
Problems related to the ABS affect the braking system and the
amplifier. The conventional brake system remains fully functional
also without ABS. One must reckon with a somewhat changed
braking characteristic. The rear wheels can block quite early on
after the ABS warning light lights up!
Arrangement of the ABS on left-hand drive vehicles.
1 - Hydraulic unit and control unit
2 - Brake servo unit
cardiagn.com
Arrangement of the ABS on right-hand drive vehicles.
2 - Hydraulic unit and control unit
The control unit -1- and the hydraulic unit -2- form a single unit. It
is not possible to separate them, the hydraulic pump -3- must not
be separated from the hydraulic unit -2-.
4 Rep. gr.45 - Anti-lock brake system

1.1 Distinguishing features of the ABS sys‐

tems
♦ ABS - wheel control system when braking. It prevents the
wheels from locking during a brake application initiated by the
driver.
♦ ESC - electronic stability control The system recognises criti‐
cal driving conditions and stabilises the vehicle by individual
wheel braking and by intervention in the engine control. This
occurs independently of the brake or accelerator pedal acti‐
vation.
♦ EDL - electronic differential lock is a starting-off aid. A sup‐
porting torque is created for the differential gear by electroni‐
cally controlling the braking of the driven wheel which is
slipping. The engine power is thus available for the gripping
wheel with the better adhesion. This also applies when re‐
versing.
♦ TCS - traction control system. Prevents the driving wheels
from slipping when accelerating by throttling the engine power
output. This is possible over the entire vehicle speed range.
EDL and TCS are mutually supportive when accelerating the
cardiagn.com
vehicle.
♦ MBA - mechanical brake assistance.
♦ HBA - hydraulic brake assistance.
♦ EDC - Engine Drag Torque Control. Prevents the driving
wheels from locking, if suddenly the accelerator pedal is re‐
leased or when braking with a gear engaged.
♦ EBD - electronic brake pressure distribution.
♦ ASC - automatic steering control. Recommends to the driver
a change in the steering position, which under certain condi‐
tions can increase the efficiency of the ESC.
♦ HHC - Hill Hold Control. Enables an easy driving off on uphills,
without the vehicle rolling back and also without operating the
locking brake.
♦ TPM (RKA) - System for tyre pressure inspection
♦ RKA (TPM) - Tyre inspection display
♦ BPS - hydraulic assistance of the brake servo unit. Ensures
the brake pressure increase in case of emergencies for ex‐
ample during numerous or steadily forceful brake applications.
♦ RBS - Brake disc dryer system. By means of briefly braking
(unnoticeable to the driver) it ensures that the brake discs of
the front wheels are dry and clean during rainy weather.
♦ TSA - Trailer Stability Assist. The vehicle tension stability sys‐
tem is a Software upgrade of the brake and stability control
ESC which avoids the dangerous swaying of the trailer.
1.2 Instructions for repair work on ABS

♦ Before commencing work on the ABS systems it is necessary
to interrogate the fault memory in order to check complaints
and conduct specific fault finding.
♦ Do not separate plug connections unless the ignition is switch‐
ed off.
♦ Before commencing work on the ABS systems, switch off the
ignition and disconnect the earth strap at the battery ⇒ Elec‐
trical System; Rep. gr. 27 .
1. General Instructions 5
♦ If the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System; Rep. gr. 27 .
♦ Welding work using electric welding equipment may affect the
ABS system.
♦ Before commencing welding work using electrical welding
tool:
– Disconnect the cable from the negative terminal of the battery
and cover the negative terminal.
– Connect the earth connection of the electric welding tool di‐
rectly to the part to be welded. There must not be any electri‐
cally insulated parts between the earth connection and the
welding point.
– Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
♦ During paintwork, the electronic control unit can be loaded for
a short time at a maximum of 95 °C and for longer period (ap‐
prox. 2 hours) at a maximum of 85 °C.
♦ Do not drive the vehicle if the connector is unplugged from the
control unit.
cardiagn.com
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean connection points and the surrounding area
before disconnecting, but do not use any aggressive cleaning
agents, such as brake cleaner, petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or seal opened components if the repairs are
not carried out immediately (use plugs from repair kit 1HO 698
311 A).
♦ Do not use fluffy cloths.
♦ Remove spare parts from their wrapping immediately before
fitting.
♦ Use only genuine wrapped parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Ensure that no brake fluid is able to flow into the connectors.
♦ Observe the relevant instructions when handling brake fluid.
♦ After completing work which involved opening the brake sys‐
tem, bleed brake system with brake filling and bleeding de‐
vice , e.g. -VAS 5234- .
♦ During the final road test, ensure that at least one controlled
brake application is performed
Protected by copyright. (pulsing
Copying for private must be
or commercial felt on
purposes, the
in part or in whole, is not permitted
brake pedal).

2 Fitting location overview

Summary of components - ABS/ESC ⇒ page 7
2.1 Summary of components - ABS/ESC
1 - ABS/ESC control unit -

J104-
❑ Fitting location: for left-
hand drive in right of en‐
gine compartment
❑ Fitting location: for right-
hand drive in left of en‐
gine compartment
❑ with integrated sensor
unit for ESP -G419-
❑ check ⇒ Vehicle diag‐
nostic tester
❑ Do not disconnect the
plug connection before
cardiagn.com
successfully completing
the self-diagnosis.
Switch off the ignition
before disconnecting
the plug connection.
❑ Removing and installing
control unit and hydraul‐
ic unit ⇒ page 9
2 - ABS hydraulic unit -N55-
❑ Fitting location: for left-
hand drive at the control
unit in right of engine
compartment
❑ Fitting location: for right-
hand drive at the control
unless authorisedunit in left
by ŠKODA of A.engine
AUTO S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect tocompartment
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
The hydraulic unit consists of

these components:
❑ ABS hydraulic pump -
V64-
❑ Brake pressure sender
1 -G201-
❑ check ⇒ Vehicle diagnostic tester
❑ Valve block, (includes the inlet and exhaust valves)
❑ The ABS control unit -J104- and the ABS hydraulic unit -N55- must not be separated from each other
❑ The hydraulic pump -V64- and the ABS hydraulic unit -N55- must not be separated from each other
❑ Removing and installing control unit and hydraulic unit ⇒ page 9
3 - Brake pad warning light -K32-
4 - ABS warning light -K47-
5 - Warning light for ESC and TCS -K155-
6 - Brake system warning light -K118-
7 - Brake light switch -F-
❑ Fitting location: on master brake cylinder
❑ removing and installing ⇒ page 55
2. Fitting location overview 7

8 - Switching off the TCS
❑ only possible via the buttons in the menu infotainment system ⇒ Operating instructions
9 - Diagnostic connection
10 - Steering angle sender -G85-
❑ the steering angle sender is installed in the steering gear and cannot be replaced separately
11 - Front right and left wheel speed sensors -G45- / -G47-
12 - Wheel hub with wheel bearing - front axle
❑ Sensor ring for ABS is built into the wheel hub
13 - Rear right and left wheel speed sensors -G44- / -G46-
14 - Wheel hub with wheel bearing - rear axle
cardiagn.com
❑ Sensor ring for ABS is built into the wheel hub

3 Hydraulic unit, brake servo unit

Summary of components - hydraulic unit, brake servo unit - left-
hand drive ⇒ page 9
Summary of components - hydraulic unit, brake servo unit - right-
hand drive ⇒ page 10
Removing and installing control unit and hydraulic unit - left-hand
drive ⇒ page 11
Remove and install control unit and hydraulic unit - right-hand
drive ⇒ page 15
Removing and installing bracket for hydraulic unit ⇒ page 18
3.1 Summary of components - hydraulic unit, brake servo unit - left-hand drive
1 - ABS/ESC control unit -

J104-
❑ removing and installing
⇒ page 11
cardiagn.com
2 - ABS hydraulic unit -N55-
⇒ page 11
3 - Screw
4 - Brake line, 14 Nm
❑ to rear right brake cali‐
per
❑ Distinguishing feature:
∅ 5,25 mm and pipe
screw with long thread
M12 x 1
❑ to front left brake caliper
∅ 5.25 mm and pipe
M10 x 1
❑ to front right brake cali‐
per
∅ 5,25 mm
Protected and pipe
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
screw
unlesswith longby thread
authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
M12with
x 1respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
❑ to rear left brake caliper
M10 x 1
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit
❑ Distinguishing feature: ∅ 6 mm and pipe screw with long thread M10 x 1
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit
3. Hydraulic unit, brake servo unit 9

❑ if there are faults replace completely
11 - Support
12 - Screw, 8 Nm
13 - Rubber shock absorber bushing
14 - Protection against stones
❑ Assignment ⇒ Electronic Catalogue of Original Parts
15 - Nut, 20 Nm
16 - Support
17 - Nut, 20 Nm
3.2 Summary of components - hydraulic unit, brake servo unit - right-hand drive
cardiagn.com
❑ from master brake cylin‐
der (floating piston cir‐
cuit) to ABS hydraulic
unit
∅ 6 mm and pipe screw
with long thread M10 x 1
❑ from master brake cylin‐
der (push rod piston cir‐
cuit) to ABS hydraulic
unit
∅ 6 mm and pipe screw
with long thread M10 x 1
❑ to rear right brake cali‐
per
M12 x 1
❑ to front left brake caliper
M10 x 1 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ to front right brake cali‐
per
M12 x 1

❑ to rear left brake caliper
❑ Distinguishing feature: ∅ 5.25 mm and pipe screw with long thread M10 x 1
7 - Hydraulic unit for ABS -N55- with ABS/ESC control unit -J104-
8 - Support
9 - Screw, 8 Nm
10 - Rubber shock absorber bushing
11 - Nut, 20 Nm
12 - Support
13 - Nut, 20 Nm
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit
cardiagn.com
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit
3.3 Removing and installing control unit and

hydraulic unit - left-hand drive
Special tools and workshop equipment required
♦ Brake pedal load e.g. -V.A.G 1869/2-
♦ Repair kit -1H0 698 311 A-
Removing:
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
the right of the engine compartment.
WARNING
The brake lines around the hydraulic unit must not be bent!
– Read out and note the actual control unit coding.

– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove engine cover.

– Remove protective cover -1-.
– Release the fuse plug -1- -in the direction of arrow A- and pull
it off the control unit in the -direction of arrow 2-.
cardiagn.com
– Position brake pedal load , e.g. -V.A.G 1869/2- .
– Attach the bleeder hose of the bleeding bottle onto the vent
valves of the front left and rear left brake caliper and open vent
valves.
– Press down brake pedal with brake unless
pedal load e.g. -V.A.G
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
1869/2- at least 60 mm. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
– Close front left and rear left bleeder valves.

– Do not remove brake pedal load , e.g. -V.A.G 1869/2- .
– Place a sufficient non-fluffing cloths under and around the
control unit and the hydraulic unit.
Make sure that no brake fluid gets onto the contacts.

– Mark both brake lines -5- and -6- from the master brake cyl‐
inder and unscrew from the hydraulic unit.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
– Mark the brake lines (for brake caliper) -1- to -4-, unscrew and
close.
– Pull hydraulic unit with control unit upwards and out of the
shock absorbers.
WARNING
The ABS control unit -J104- and the ABS hydraulic unit -N55-
must not be separated from each other.
The hydraulic pump and the ABS hydraulic unit -N55- must not
be separated from each other.
Installing:
cardiagn.com
Note
♦ Only then remove plugs from the new hydraulic unit when the
relevant brake line is installed.
♦ If the plugs were already removed from the hydraulic unit, then
brake fluid may escape and adequate filling and bleeding of
the unit can no longer be guaranteed.
♦ Make sure that the rubber bearings are not pressed out of the
console when installing the bracket. After installing, check the
ABS control unit for tight fit, otherwise failure may be caused
by a malfunctioning.
– Installation is carried out in the reverse order.

– Observe the tightening sequence of the brake lines
⇒ page 13 .
Tightening sequence of the brake lines:

– Remove brake pedal load e.g. -V.A.G 1869/2- .
– Bleed brake system.
– Code the control unit -J104-unless
⇒ Vehicle diagnostic tester.
While doing so, a basic setting ofwiththe steering angle sender -
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
G85- , the lateral acceleration sender -G200- , the brake pressure

sender 1 -G201- and the longitudinal acceleration sender -G251-
must be performed ⇒ Vehicle diagnostic tester.

Tightening torques:
Screw for hydraulic unit to bracket 8 Nm
Bracket for hydraulic unit to body 20 Nm
Brake lines to ABS unit:
Thread M 10 x 1 14 Nm
cardiagn.com
14
3.4 Removing and installing control unit and

hydraulic unit - right-hand drive
♦ Repair kit -1H0 698 311 A-
Removing:
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
the left in the engine compartment.
WARNING
The brake lines around the hydraulic unit must not be bent!
– Read out and note the actual control unit coding.

cardiagn.com
– Remove battery tray ⇒ Electrical System; Rep. gr. 27
– Release the fuse plug -1- -in the direction of arrow A- and pull
it off the control unit in the -direction of arrow B-.
Note
The illustration shows the ABS hydraulic unit -N55- with the ABS/
ESC control unit -J104- on left-hand drive vehicles.
– Position brake pedal load , e.g. -V.A.G 1869/2- .

valves of the front left and rear left brake caliper and open vent
valves.
– Press down brake pedal with brake
Protected pedal load
by copyright. e.g.
Copying -V.A.G
for private or commercial purposes, in part or in whole, is not permitted
1869/2- at least 60 mm. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Close front left and rear left bleeder valves.
– Do not remove brake pedal load , e.g. -V.A.G 1869/2- .
– Place a sufficient non-fluffing cloths under and around the
control unit and the hydraulic unit.
Make sure that no brake fluid gets onto the contacts.
15
– Mark both brake lines -A- and -B- from the master brake cyl‐
inder and unscrew from the hydraulic unit.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
– Mark the brake lines (for brake caliper) -1- to -4-, unscrew and
close.
– Pull the hydraulic unit with the control unit -1- out of the shock
absorbers -arrows- -in direction of arrow-.
– Remove the ABS control unit -J104- and the ABS hydraulic
unit -N55- from the vehicle.
WARNING
The ABS control unit -J104- and the ABS hydraulic unit -N55-
must not be separated from each other.
The hydraulic pump and the ABS hydraulic unit -N55- must not
be separated from each other.
cardiagn.com
Installing:
Note
♦ Only then remove plugs from the new hydraulic unit when the
relevant brake line is installed.
♦ If the plugs were already removed from the hydraulic unit, then
brake fluid may escape and adequate filling and bleeding of
the unit can no longer be guaranteed.
♦ Make sure that the rubber bearings are not pressed out of the
console when installing the bracket. After installing, check the
ABS control unit for tight fit, otherwise failure may be caused
by a malfunctioning.

– Observe the tightening sequence of the brake lines
⇒ page 16 .
Tightening sequence of the brake lines:

– Code the control unit -J104- ⇒ Vehicle diagnostic tester.
While doing so, a basic setting of the steering angle sender -
G85- , the lateral acceleration sender -G200- , the brake pressure
sender 1 -G201- and the longitudinal acceleration sender -G251-
must be performed ⇒ Vehicle diagnostic tester.
16
Tightening torques:
cardiagn.com
17
3.5 Removing and installing bracket for hy‐

draulic unit
Removing
– Remove the hydraulic unit ⇒ page 11 .
– Unscrew nuts -4-.
– Remove the bracket -3- from the vehicle.
Install
cardiagn.com
18
Tightening torques:
cardiagn.com
19
4 Sensors
Assembly overview of the ABS speed sensor on the front axle
⇒ page 20
Assembly overview of the ABS speed sensor on the rear axle
⇒ page 23
Sensor unit for ESP -G419- ⇒ page 26
Steering angle sender -G85- ⇒ page 26
4.1 Assembly overview of the ABS speed sensor on the front axle
1 - ABS wheel speed sensor

❑ clean the inner surface
of the hole before insert‐
ing the sensor and
brush over with a hot
bolt paste -G 052 112
A3- .
cardiagn.com
⇒ page 20
2 - Screw, 8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ Sensor ring for ABS built
into the wheel bearing
4 - Drive shaft
4.1.1 Removing and installing the ABS speed

sensor on the front axle
Removing:
– Raise vehicle.
20
– Separate plug connection -1- wheel speed sensor/wheel

speed sensor cable.
– Release screw -2- from the wheel-bearing housing.
– Take the ABS-speed sensor out of the wheel bearing housing.
Installing:
– Clean the inner surface of the hole before inserting the speed
sensor and brush over the speed sensor with a hot screw
paste -G 052 112 A3- .
– Insert the wheel speed sensor in the bore of the wheel-bearing
housing and tighten the screw.
– Connect plug connection to wheel speed sensor.
cardiagn.com
4. Sensors 21
Tightening torque:
Wheel speed sensor in wheel-bearing housing 8 Nm
cardiagn.com
22
4.2 Assembly overview of the ABS speed sensor on the rear axle

ing the sensor and
bolt paste -G 052 112
A3 - .
⇒ page 23
2 - Screw, 8 Nm
ing
❑ Sensor ring for ABS built
into the wheel bearing
cardiagn.com
4.2.1 Removing and installing the ABS speed

sensor on the rear axle
Note
The procedure for removal and installation of the ABS speed sen‐
sor is the same for the torsion beam axle as well as for the multi-
link suspension.
Removing:
– Raise vehicle.
23
– Separate plug connection -1- wheel speed sensor/wheel

speed sensor cable.
– Release screw -2- from the wheel-bearing housing.
– Take the ABS-speed sensor out of the wheel bearing housing.
Installing:
– Clean the inner surface of the hole before inserting the speed
sensor and brush over the speed sensor with a hot screw
paste -G 052 112 A3 - .
– Insert the wheel speed sensor in the bore of the wheel-bearing
housing and tighten the screw.
– Connect plug connection to wheel speed sensor.
cardiagn.com
24
Tightening torque:
Wheel speed sensor in wheel-bearing housing 8 Nm
cardiagn.com
25
4.3 Sensor unit for ESP -G419-

The ESP sensor unit -G419- is integrated in the ABS control unit
-J104- .
The sensor unit for ESP -G419- includes: the lateral acceleration
sender -G200- , the yaw rate sender -G202- and the longitudinal
acceleration sender -G251-
The sensor unit for ESP -G419- cannot be replaced separately,
only the removal of the ABS control unit -J104- is possible
⇒ page 9 .
4.4 Steering angle sender -G85-

The steering angle sender -G85- is installed in the steering gear
and cannot be replaced separately.
– Basic setting of the steering angle sender -G85- ⇒ Vehicle di‐
agnostic tester.
cardiagn.com
26
46 – Brakes - mechanism
1 Repairing front wheel brake
Changing the brake pads of the front brake - Mounting instruc‐
tions ⇒ page 27
Repairing front wheel brake, brake caliper PC 57 ⇒ page 28
Removing and installing the brake pads of the brake PC 57
⇒ page 29
Removing and installing the brake caliper of the brake PC 57
⇒ page 31
1.1 Changing the brake pads of the front

brake - Mounting instructions
When changing the pad, observe the following:
– Check protective collar of brake caliper piston.
Replace the protective collar if damaged.
cardiagn.com
When replacing the collar:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing sleeve.
– Check the brake piston and the brake caliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake caliper completely if damaged.
For brake caliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.
1. Repairing front wheel brake 27

1.2 Repairing front wheel brake, brake caliper PC 57
Note
♦ Observe the instructions for changing the pad ⇒ page 27

♦ Brake inspection ⇒ page 2 .
♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
ensure the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding device e. g. -VAS 5234- to drain the brake fluid from the brake fluid
reservoir.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2 - before removing a brake caliper or separating a brake hose
from the brake caliper.
1 - Cover plate
2 - Torx screw, 12 Nm
3 - Brake disc
cardiagn.com
❑ Brake disc thickness
and wear limit ⇒ page 1
❑ always replace axle-
wise
❑ unscrew the brake cali‐
per before removing
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
4 - Screw, 4.5 Nm
5 - Brake carrier
❑ screwed onto the wheel-
bearing housing
6 - Brake pads
❑ Brake lining thickness
⇒ page 1
❑ with wear indicator
❑ with a corresponding
wear (limit: approx. 4
mm) a warning light in
the dash panel insert
lights up
❑ Wear limit ⇒ page 1
❑ always replace axle-
wise Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ removing and installing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ page 29
Parts
❑ Observe the instructions for changing the pad ⇒ page 27
7 - Brake caliper
❑ do not unscrew the brake line when replacing the brake pad
❑ Repairing ⇒ page 56 .
28 Rep. gr.46 - Brakes - mechanism

8 - Screw, 35 Nm
❑ self-locking
❑ replace after each removal
9 - Screw, 200 Nm
❑ clean when using again
10 - Wheel-bearing housing
❑ with bolted brake carrier
11 - Brake hose with banjo union and hollow screw, 35 Nm
12 - Spring clip for brake line
13 - Support
14 - Screw, 8 Nm
1.3 Removing and installing the brake pads
cardiagn.com
of the brake PC 57
♦ Piston jig -T10145-
Removing:
When removing mark the brake pads you intend to keep using.
Install in the same location, as otherwise this may cause uneven
braking!
– Remove wheels.
– Disconnect the plug connection -1- for the brake pad wear in‐
dicator.

– Unscrew both fixing screws while counterholding the guide

bolts.
– Remove the brake caliper -1- and secure with wire in such a
cardiagn.com
way that the weight of the brake caliper does not burden or
damage the brake hose
– Remove brake pads -2- and -3- from the brake
Protectedcaliper -4-.
Cleaning: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
WARNING
Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!
– Thoroughly clean guiding surface for brake pads on brake

carrier and remove corrosion.
– Clean the brake caliper.
Only use alcohol to clean the brake caliper.
Installing:
Drain the brake fluid from the brake fluid reservoir before the pis‐
ton is pushed with the piston jig into the cylinder. Otherwise brake
fluid can flow out and lead to damage if brake fluid was added in
the meantime.
– Press the piston into the brake caliper using the piston reset‐
ting jig -T10145- .
– Lightly grease guiding surface for brake pads on brake carrier
with grease from the repair kit.

– Insert brake pads -2- with retaining springs -1- into the recess‐
es in the brake carrier -3-.
– Carefully position the brake caliper on the brake carrier.
– Screw the brake caliper onto the brake carrier with new self-
locking screws, while counterholding the guide bolts.
cardiagn.com
– Mount plug connection -1- for brake unless
pad wear indicator.
– Attach the wheels.
Note
♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after replacing the brake pads.
Tightening torque:
Brake caliper to brake carrier 35 Nm
♦ always use new screws
Wheel bolts 120 Nm
1.4 Removing and installing the brake cali‐

per of the brake PC 57
Observe the instructions for changing the pad ⇒ page 27 .

Removing:
Note
The procedure applies only for the replacement or for the follow‐
ing repair work on the brake caliper.
– Remove wheels.
– Disconnect the plug connection for the brake pad wear indi‐
cator.
valve of the brake caliper and then open then bleeder valve.
– Position brake pedal load e.g. -V.A.G 1869/2- .
– Close the vent valve and remove the bleeding bottle.
– Remove brake hose.
– Unscrew both fixing screws while counterholding the guide
bolts.
cardiagn.com
– Pull off brake caliper from brake carrier.
Installing:
• The piston is pushed back.
• Both brake pads are inserted into the recesses in the brake
carrier with retaining springs.
– Fit brake caliper to the brake carrier.
While doing so, use new screws.
– Install brake hose.
– Mount the plug connection of the brake pad wear indicator.
Note
♦ Forcefully apply the brake pedal repeatedly to ensure the

brake pads go into their normal operating position.
♦ Inspecting the brake fluid level. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

Tightening torques:
♦ always use new screws
Brake line to brake caliper 35 Nm

Wheel bolts 120 Nm
cardiagn.com
33
2 Repairing rear brake

Changing the brake pads of the rear brake - Mounting instructions
⇒ page 34
Repairing rear brake (C 38) ⇒ page 35
Removing and installing brake pads (C 38) ⇒ page 36
Removing and installing brake caliper (C 38) ⇒ page 40
Repairing rear brake (PC 38 HRA) ⇒ page 42
Removing and installing brake pads (PC 38 HRA) ⇒ page 43
Removing and installing brake caliper (PC 38 HRA)
⇒ page 46
2.1 Changing the brake pads of the rear

brake - Mounting instructions
When changing the pad, observe the following:
– Check protective collar of brake caliper piston.
cardiagn.com
Replace the protective collar if damaged.
When replacing the collar:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing sleeve.
– Check the brake piston and the brake caliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake caliper completely if damaged.
For brake caliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.
34
2.2 Repairing rear brake C 38
Note
♦ Observe mounting instructions ⇒ page 34

♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
ensure the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding device e. g. -VAS 5234- to drain the brake fluid from the brake fluid
reservoir.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2- before removing a brake caliper or separating a brake hose
from the brake caliper.
1 - Screw, 8 Nm
cardiagn.com
ing the sensor and
bolt paste -
G 052 112 A3 - .
3 - Screw, 90 Nm + 90°
❑ replace after each re‐
moval
4 - Brake line
5 - Assembly carrier Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
6 - Hand-brake cable unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Setting the hand-brake
⇒ page 48
7 - Cover plate
Parts
8 - Axle stud
9 - Screw, 30 Nm + 90°
moval
10 - Wheel hub with wheel
bearing
Parts
11 - Screw, 200 Nm + 180°
moval
❑ Loosening and tightening ⇒ chassis, axles, steering; Rep. gr. 42
12 - Brake disc
❑ Brake disc thickness, wear limit and ∅ ⇒ page 1
❑ if worn replace axle-wise
❑ unscrew the brake caliper before removing
2. Repairing rear brake 35

13 - Screw, 8 Nm
14 - Dust cap
❑ pressing off and driving in ⇒ chassis, axles, steering; Rep. gr. 42
15 - Brake carrier with guide bolts and protective caps
16 - Brake pads
❑ Brake disc thicknnes and wear limit ⇒ page 1
❑ always replace axle-wise
17 - Brake caliper
❑ one must adjust the hand-brake cable after undertaking repair or replacement work
❑ Setting the hand-brake ⇒ page 48
cardiagn.com
18 - Self-locking screw, 35 Nm
2.3 Removing and installing brake pads (C

38)
♦ Resetting tool -T10165-
Removing:
braking!
– Remove wheels.
– Unscrew the fixing screws of the brake carrier while counter‐
holding the guide bolts.
– Remove the brake caliper and e.g. secure with wire in such a
damage the brake hose.
36 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
– Take out the brake pads -arrows-.
Note
♦ Observe the instructions for changing the pad ⇒ page 34 .

♦ Use alcohol only to clean the brake caliper housing.
♦ The adherend for the brake pads must be free from glue res‐
idues and grease.
– Clean the brake caliper.

Installing:
Note
♦ Drain the brake fluid from the brake fluid reservoir using a
ventilation bottle before resetting the piston. Otherwise brake
fluid can flow out and lead to damage if brake fluid was added
in the meantime.
cardiagn.com
♦ When resetting the piston with a piston resetting device the
automatic reset in the brake caliper is destroyed.
Caution
Brake fluid iswith
toxic and must never be sucked up by mouth!
– Screw in the piston by turning the knurled wheel clockwise on

the resetting tool -T 10165- , during this procedure do not
damage the protective cap.
– To screw in, use the special tool -T 10165/1- .
♦ Use open-jawed spanner on a provided spanner surface
-arrow A- if the piston is difficult to move.
Note
Turn the resetting tool -T10165- simultaneously when resetting

the piston, in order to initiate pressure onto the piston.
– Insert the new brake pads -arrows- in the brake carrier.

– Remove the protective foil from the supporting plate of the
brake pad.
Note
There are four self-locking screws in the repair set, which must
be fitted.
2. Repairing rear brake 37

– Secure the brake caliper to the brake carrier using new self-
locking screws.
Hold the guide bolts while tightening the screws.
– Connect up the plug connection for the brake pad wear indi‐
cator (where the vehcile is fitted with this - only right vehicle
side).
Note
♦ After each brake pad replacement, forcefully apply the brake

pedal repeatedly to ensure the brake pads go into their normal
operating position.
♦ Check brake fluid level after replacing the brake pads, if nec‐
essary top up with brake fluid.
– Depress brake pedal firmly several times when the vehicle is

stationary
– Setting the hand-brake.
– Attach the wheel.
cardiagn.com
38
Tightening torques:
♦ Use new screws!
Wheel bolts 120 Nm
cardiagn.com
39
2.4 Removing and installing brake caliper

(C 38)
♦ Brake pedal load , e.g. -V.A.G 1869/2-
Removing:
– Remove wheels.
– Press the lever -2- in the -direction of the arrow- and while
doing so unhook the hand-brake cable -3-.
– Slacken the spring bushing -1- for the hand-brake cable from
the bracket on the brake caliper.
valve of the brake caliper and open bleeder valve.
– Position the brake pedal load , e.g. -V.A.G 1869/2 - and press
down the brake pedal at least 60 mm.
cardiagn.com
– Unscrew the brake line.

– Remove brake caliper from brake carrier
Installing:
• The piston is pushed back. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
• The brake pads are fitted in the retaining springs on the brake
caliper.
locking screws.
– Screw the brake line onto the brake caliper.
– Install hand-brake cable.
Note

♦ Inspecting the brake fluid level.
40
Tightening torques:
♦ Use new self-locking screws!
Hollow screw for brake line to brake caliper 35 Nm

Wheel bolts 120 Nm
cardiagn.com
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�� 41
2.5 Repairing rear brake (PC 38 HRA)

Observe mounting instructions ⇒ page 34
Brake inspection ⇒ page 2 .
After replacing the brake pads, depress brake pedal firmly several
times when the vehicle is stationary to ensure the brake pads are
properly seated in their normal operating position.
Use the brake filling and bleeding device e. g. -VAS 5234- to drain
the brake fluid from the brake fluid reservoir.
Use the brake pedal load , e.g. -V.A.G 1869/2- before removing
a brake caliper or separating a brake hose from the brake caliper.
1 - Screw, 8 Nm
2 - Brake disc
❑ Brake disc thickness,
wear limit and ∅
⇒ page 1
❑ if worn replace axle-
wise
cardiagn.com
❑ unscrew the brake cali‐
per before removing
Parts
3 - Screw, 200 Nm + 180°
moval
❑ Loosening and tighten‐
ing ⇒ chassis, axles,
steering; Rep. gr. 42
ing
Parts
5 - Screw, 12 Nm
6 - Cover plate
7 - Wheel-bearing housing
Parts
9 - Screw, 8 Nm
10 - Screw, 90 Nm + 90° Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ replace after each removalunless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
12 - Hand-brake cable
13 - Brake caliper
42
❑ one must adjust the hand-brake cable after undertaking repair or replacement work
14 - Brake carrier with guide bolts and protective caps
15 - Brake pads
❑ Brake disc thicknnes and wear limit ⇒ page 1
❑ always replace axle-wise
16 - Brake line
17 - Dust cap
❑ pressing off and driving in ⇒ chassis, axles, steering; Rep. gr. 42
2.6 Removing and installing brake pads (PC

38 HRA)
cardiagn.com
Removing:
braking!
– Remove wheels.
– Remove the brake caliper and e.g. secure with wire in such a
damage the brake hose.
– Take out the brake pads -arrows-.

Installing: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Drain the brake fluid fromwiththe brake
respect fluid reservoir
to the correctness using
of information a document.
in this venti‐ Copyright by ŠKODA AUTO A. S.��
lation bottle before resetting the piston. Otherwise brake fluid can
flow out and lead to damage if brake fluid was added in the mean‐
time.
43
– Screw in the piston by turning the knurled wheel clockwise on

the resetting tool -T10165- , during this procedure do not dam‐
age the protective cap.
– To insert use the special tool -T10165/1- .
– Insert brake pads -2- with retaining springs -1- into the recess‐
es in the brake carrier -3-.
– Secure the brake caliper using new self-locking screws.
♦ There are four self-locking screws in the repair set, which must
be fitted.
cardiagn.com
Note

♦ After each brake pad replacement, forcefully apply the brake
pedal repeatedly to ensure the brake pads go into their normal
operating position.
♦ Check brake fluid level after replacing the brake pads.
44
Tightening torques:
Wheel bolts 120 Nm
cardiagn.com
45
2.7 Removing and installing brake caliper

(PC 38 HRA)
♦ Brake pedal load , e.g. -V.A.G 1869/2-
Removing:
– Remove wheels.
– Press the lever -2- in the -direction of the arrow- and while
doing so unhook the hand-brake cable -3-.
valve of the brake caliper and open bleeder valve.
– Position the brake pedal load , e.g. -V.A.G 1869/2 - and press
down the brake pedal at least 60 mm.
cardiagn.com
– Unscrew the brake line.

– Remove brake caliper from brake carrier
Installing:
• The piston is pushed back.
• The brake pads are fitted in the retaining springs on the brake
caliper.
locking screws.
– Screw the brake line onto the brake caliper.
– Install hand-brake cable.
Note with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��

♦ Inspecting the brake fluid level.
46
Tightening torques:
Hollow screw for brake line to brake caliper 35 Nm

Wheel bolts 120 Nm
cardiagn.com
47
3 Handbrake
Handbrake lever - Summary of components ⇒ page 48
Setting the hand-brake ⇒ page 48
Removing and installing the hand-brake cable ⇒ page 49
3.1 Handbrake lever - Summary of components
1 - Handbrake lever
❑ Remove the centre con‐
sole before removal
2 - Screw, 20 Nm + 90°
moval
3 - Tension rod
4 - Compensating clamp
5 - Adjusting nut
cardiagn.com
❑ Setting the hand-brake
⇒ page 48
6 - Hand-brake cable
⇒ page 49
7 - Switch for hand-brake con‐
trol
8 - Covering for the hand brake
lever
Parts
3.2 Setting the hand-brake

Resetting is only requiredwith
after replacing
respect the hand-brake
to the correctness cable,
of information in this document. Copyright by ŠKODA AUTO A. S.��
the brake carrier or after replacing the brake discs.
– Remove armrest ⇒ Body work; Rep. gr. 68 .
– Forcefully apply the brake pedal (at least 3 times).
– Pull the handbrake on and release it three times.
• Put the hand brake lever in its rest position.
48
– Tighten adjusting nut -arrow- so far, ...
– ... that the levers -1- rise from the stop -2- on the brake cali‐
pers.
– The distance -a- to the stop -2- on the left and right brake cal‐
iper must together not exceed 1.5 mm.
– Check whether the wheels rotate freely.
Resetting of the hand-brake is not required after a new setting
procedure due to the automatic resetting of the rear wheel-brake.
cardiagn.com
3.3 Removing and installing the hand-brake
cable
Removing:
– Put hand-brake back.
– Remove armrest ⇒ Body work; Rep. gr. 68 .
– Release the adjusting nut -1- so far until the respective hand-
brake cable -2- can be unhooked from the compensating
clamp -3-.
– Press the lever at brake caliper -2- in the
-direction of the arrow- and unhook the hand-brake cable -3-.
– Unscrew screw for hand brake cable from trailing arm.
Vehicles with torsion beam axle
– Pull hand-brake cable from guide tube.
Vehicles with multi-link suspension
3. Handbrake 49
– Unhook the hand-brake cable from the retaining clip -1- and
pull out of the guide tube.
Installing:
Vehicles with torsion beam axle
– Push the hand-brake cable into the guide tube and attach it to
the bracket.
Vehicles with multi-link suspension
– Fit the hand-brake cable in the retaining clip -1-.
cardiagn.com
– Press the lever at brake caliper -2- in the direction of the arrow
and hook on the hand-brake cable -3-.
– Press the spring clip -1- onto the hand-brake cable.
The hand-brake cable must be fitted free of stress between the
brake caliper support and the retaining clip.
– Hook the hand-brake cable -2- into the compensating clamp

-3-.
– Tension the hand-brake cable with the adjusting nut -1-.
– Setting the hand-brake ⇒ pageunless
48 . authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
50
4 Brake pedal
Summary of components of brake pedal ⇒ page 51
Separating the brake pedal from the brake servo unit and clipping
onto the brake servo unit ⇒ page 52
Removing and installing brake pedal ⇒ page 53
Removing and installing bracket ⇒ page 54
Removing and installing brake light switch ⇒ page 55
4.1 Summary of components of brake pedal
WARNING
The travel of the brake pedal must not be shortened by addi‐

tional floor coverings.
Grease all bearing surfaces with polycarbamide grease -G 052

142 A2- before assembly.
cardiagn.com
Brake light switch -F- and brake pedal switch -F47- mounted onto
the master brake cylinder.
1 - Self-locking nut, 25 Nm
moval
❑ observe the order of
tightening up
⇒ page 52
2 - Bearing bolt
moval
❑ removing
– Removing bracket
⇒ page 54 .
❑ Loosen the screw for the
bearing bolt anti-clock‐
wise
⇒ Item 10 (page 52)
❑ Pull out bearing bolt.
Caution
Do not grease the bear‐

ing bolt. The bearing bolt
must remain dry.
❑ the installation occurs in

reverse order.
Note
3 - Bearing bracket
⇒ page 54
4. Brake pedal 51
4 - Bushing
Note
5 - Brake pedal
6 - Cap
7 - Bushing
Note
8 - Bearing shell
9 - Support
❑ for ball head of pressure rod of brake servo unit
10 - Screw for bearing bolt
Tightening order
cardiagn.com
4.2 Separating the brake pedal from the
brake servo unit and clipping onto brake
servo unit
♦ Release tool -T10159A- unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Removing:
– Removing driver side trim panel ⇒ Body Work; Rep. gr. 70 .
52
– Press the brake pedal towards the brake servo unit and hold
it in position.
2 - Pressure rod
3 - Retaining lugs
– Insert release tool -T10159A- and pull it in the direction of the
driver's seat while counterholding the brake pedal (the pedal
must not move backwards during this operation). This causes
the retaining lugs -3- of the support to be pressed off the
spherical head of the push rod -2-.
The fig. shows the separation of the brake pedal from the brake
servo unit with the foot controls removed for clarity.
– Now pull the release tool -T10159A- and the brake pedal jointly
towards the driver's seat. (This causes the brake pedal to be
pulled off the spherical head of the pressure rod).
Installing:
Clipping the brake pedal onto the brake servo unit
– Hold the ball knob of the pressure rod against the support in
cardiagn.com
the brake pedal and press the brake pedal in the direction of
the arrow towards the brake servo unit so that the ball knob is
heard to click into the support.
Further installation occurs in reverse order.
4.3 Removing and installing brake pedal

It is not possible to remove the brake pedal in the vehicle.
Removing
– Removing bracket ⇒ page 54 .
– Release the screw for the bearing bolt -in direction of arrow-.
The fuses -A- break off.
– Pull out bearing bolt.
– Remove brake pedal. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Install
Replace bearing bolt with screw for bearing bolt.
Caution
Do not grease the bearing bolt. The bearing bolt must remain
dry.
– Insert the brake pedal in the bearing bracket.

– Insert new bearing bolt.
4. Brake pedal 53
– Tighten the screw for the bearing bolt -in direction of arrow-.
The fuses -B- must click audibly into place.
– Installing bracket ⇒ page 54 .
4.4 Removing and installing bearing bracket

Removing
– Remove knee airbag ⇒ Body Work; Rep. gr. 69 .
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
cardiagn.com
– Remove Gateway control unit ⇒ Electrical System; Rep. gr.
97 .
– Remove crash strut -1-.
– Disconnect the plug from the cornering light and AFS headlight
range control unit.
– Disconnect the plug from the accelerator pedal.
– Separating the brake pedal from the brake servo unit
⇒ page 52 .
– Release the nut -1- and carefully pull off the foot mat -2-
-in direction of arrow-.
54
– Release the nuts -1- to -4-.

– Detach all the electrical cables from the bearing bracket.
– Remove bracket.
Install
Installation is carried out in the reverse order.
4.5 Removing and installing brake light

switch
Removing
– Remove connecting hose to intake manifold flap ⇒ Engine;
Rep. gr. 21 .
cardiagn.com
– Disconnect the plug -1- from the brake light switch -F- -2-.
– Unscrew fixing screw of brake light switch -F- -2-.
– Remove brake light switch -F- -2-.
Install
Tightening torque with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
Brake light switch -F- to master brake cylinder 8 Nm
4. Brake pedal 55
47 – Brakes - hydraulics
1 Repairing front brake caliper
Repairing brake caliper C 57 ⇒ page 56
Removing and installing the piston of the brake caliper C 57
⇒ page 57
1.1 Repairing brake caliper C 57
Note
♦ Install the complete repair set when undertaking repairs.

♦ Use only methylated spirits for cleaning the brake.
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease -G 052 150 A2- .
cardiagn.com
1 - Dust cap
2 - Bleeder valve, 10 Nm
❑ thinly coat thread with
lithium
Protected grease
by copyright. -Gfor052
Copying private or commercial purposes, in part or in whole, is not permitted
150 A2- before screwing
in
3 - Screw, 35 Nm
moval
4 - Guide bolt
5 - Collar
❑ insert into the slot of the
brake carrier and of the
guide pin; grease the
slot first using grease
packing from the repair
kit
6 - Brake carrier with guide
bolts and protective caps
❑ is supplied as replace‐
ment part assembled
with guide pin and pro‐
tective caps as well as
adequate quantity of
grease on guide pins
❑ if there is any damage to
the boots or guide bolts
fit a repair set (use the
enclosed grease pack‐
ing to grease the guide
bolts)
7 - Protective cap
⇒ page 57
❑ do not damage when inserting the piston
8 - Piston
56 Rep. gr.47 - Brakes - hydraulics

9 - Sealing ring
10 - Brake caliper
1.2 Removing and installing the piston of the

brake caliper C 57
♦ Piston jig -T10145-
♦ Plastic wedge -3409-
♦ Lithium grease -G 052 150 A2-
Removing:
– Insert wooden plate to avoid damaging the piston as it is being
pressed out.
– Press the piston out of the brake caliper housing using com‐
pressed air -arrow-.
cardiagn.com
Note
Make sure that the cylinder surface is not damaged when remov‐
ing the gasket ring.
– Take out gasket ring with plastic wedge -3409- .

Installing:
– Clean piston and gasket ring with white spirits and dry off.
– Before installing the piston and gasket ring in the brake caliper
housing thinly coat with lithium grease -G 052 150 A2- .
– Insert new gasket ring in the groove of the brake caliper.
– Position the new protective cap with the outer sealing lip on
the piston.
1. Repairing front brake caliper 57

– Insert the inner sealing lip of the collar into the groove of the
cylinder using the plastic wedge -3409- .
To do so hold the piston with the hand.
– Press the piston into the brake caliper using the piston reset‐
ting jig -T10145- .
Note
The outer sealing lip of the protective cap will engage in the piston
groove.
cardiagn.com

2 Repairing rear brake caliper

Repairing brake caliper C 38 ⇒ page 59
Repairing brake caliper PC 38 HRA ⇒ page 61
Removing and installing the piston of the brake caliper C 38 / PC
38 HRA ⇒ page 62
Pre-bleeding the brake caliper ⇒ page 63
2.1 Repairing brake caliper C 38
Note

♦ The brake calipers must absolutely be pre-bled before installing them in the vehicle (without brake pads) in
cardiagn.com
case of a repair or when replacing them with new brake calipers ⇒ page 63 .
1 - Brake caliper with lever for

the handbrake cable
❑ replace brake caliper if
the lever for the hand‐
brake cable is not
sealed
❑ pre-bleed brake caliper
after undertaking re‐
placement ⇒ page 63
2 - Dust cap
lithium grease -
G 052 150 A2 - before
screwing in
❑ replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ counterhold unless
on theauthorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
guide bolt whenwithreleas‐
ing and tightening
5 - Guide bolt
❑ grease before fitting
protective cap
6 - Protective cap
❑ pull onto brake carrier
and guide bolt
7 - Brake carrier with guide
bolts and protective caps
❑ must be assembled with
sufficient grease on the
guide bolt, supplied as a
spare part
❑ fit a repair set if there is
2. Repairing rear brake caliper 59

any damage to the pro‐

tective caps or guide bolts, use the enclosed grease packing to lubricate the guide bolts
8 - Protective cap
❑ pull with outer sealing lip onto the piston
9 - Piston with automatic adjusting device
❑ thinly coat piston with assembly paste -G 052 150 A2- before fitting
10 - Sealing ring
cardiagn.com
60 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
Rep. gr.47 - Brakes - hydraulics
2.2 Repairing brake caliper PC 38 HRA
Note

♦ The brake calipers must absolutely be pre-bled before installing them in the vehicle (without brake pads) in
case of a repair or when replacing them with new brake calipers ⇒ page 63 .
1 - Brake caliper with lever for

the handbrake cable
❑ replace brake caliper if
the lever for the hand‐
brake cable is not
sealed
cardiagn.com
❑ pre-bleed brake caliper
after undertaking
Protected by copyright. re‐or commercial purposes, in part or in whole, is not permitted
Copying for private
placement
unless authorised by ŠKODA AUTO⇒ page 63 AUTO A. S. does not guarantee or accept any liability
A. S. ŠKODA
2 - Dust cap
lithium grease -
G 052 150 A2 - before
screwing in
❑ replace
❑ counterhold on the
guide bolt when releas‐
ing and tightening
5 - Guide bolt
❑ grease before fitting
protective cap
6 - Protective cap
❑ pull onto brake carrier
and guide bolt
7 - Brake carrier
❑ must be assembled with
sufficient grease on the
guide bolt, supplied as a
spare part
❑ fit a repair set if there is
any damage to the pro‐
tective caps or guide
bolts, use the enclosed grease packing to lubricate the guide bolts
8 - Protective cap
❑ pull with outer sealing lip onto the piston
9 - Piston with automatic adjusting device

❑ thinly coat piston with assembly paste -G 052 150 A2- before fitting
10 - Sealing ring
2.3 Removing and installing the piston of the

brake caliper C 38 / PC 38 HRA
♦ Disassembly wedge -3409 -
Removing:
Insert the resetting tool -T10165- in such a way that the collar is
resting on the piston.
– Release the piston by turning the knurled wheel of the reset‐
ting tool -T10165- to the left.
cardiagn.com
– Remove gasket ring with disassembly wedge -3409- .
Installing:
– Clean piston and gasket ring with white spirits and dry off.
– Before inserting the piston and gasket ring, thinly coat with
lithium grease -G 052 150 A2- .
– Position the new protective cap with the outer sealing lip on
the piston.
– Insert inner sealing lip of the protective cap with disassembly
wedge -3409 - in the groove of the cylinder.

To do so hold the piston in front of the brake caliper.
Caution
Use the resetting tool -T10165- to adjust the piston.

The automatic adjustment in the brake caliper is destroyed
when adjusting the piston with a resetting tool e.g. -T10165- or
by actuating the brake pedal.
Insert the resetting tool -T10165- in such a way that the collar is
resting on the brake caliper.
– Screw the piston by turning the knurled wheel of the resetting
tool -T10165- to the right into the brake caliper.
cardiagn.com
2.4 Pre-bleeding the brake caliper
Set up brake caliper for pre-bleeding as shown in the fig.
– Open vent valve -arrow A-.
– Using a commercially available ventilation reservoir pour in
brake fluid until bubble-free brake fluid drips out of the threa‐
ded bore (brake hose connection) -arrow B-.
– Close vent valve.

3 Checking the master brake cylinder

for tightness
♦ Brake system tester e. g. -V.A.G 1310 A-
♦ Adapter M 10 e.g. -V.A.G 1310/6-
Inspection requirement:
Function and tightness of the brake system (brake lines, brake
hoses, brake calipers, hydraulic unit) O.K.
– Release the vent valve on one of the front brake calipers.
Connect and bleed brake system tester e. g. - V.A.G 1310 A-
– Push down brake pedal until the pressure gauge indicates 5
MPa (50 bar). Throughout the test which lasts (45 s) the pres‐
sure loss must not exceed 0.4 MPa (4 bar). In case of high
pressure loss replace the master brake cylinder.
cardiagn.com

4 Bleeding brake system

Bleeding the brake system with the brake filling and bleeding de‐
vice ⇒ page 65
Change brake fluid ⇒ page 66
4.1 Bleeding the brake system of air with the

brake filling and bleeding device
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Brake fluid ⇒ page 2
WARNING
♦ Brake fluid is hygroscopic, i.e. it retains humidity from the

ambient air, and must therefore always be stored in airtight
containers.
♦ Brake fluid must never come into contact with fluids con‐
cardiagn.com
taining mineral oils (oil, petrol, cleaning agent). Mineral
oils damage the plugs and boots of the brake system.
♦ Drained (used) brake fluid must never be used again.
♦ Brake fluid is toxic, avoid skin contact.
♦ Because of its caustic effect brake fluid must not come into
contact
Protected with paint.
♦ Rinse anyto the
with respect brake fluid ofspills
correctness within athislot
information of water.
document. Copyright by ŠKODA AUTO A. S.��
♦ Dispose of brake fluid in compliance with the applicable

waste disposal and environmental regulations.
♦ Only use new brake fluid in accordance with the specifi‐
cation ⇒ page 2 .
A pre-pressure of 0.2 MPa (2 bar) is required to bleed the brake

system.
– Unscrew cap -1- from the brake fluid reservoir
4. Bleeding brake system 65

– Connect the thread plug -1- of the brake filling and bleeding
device e.g. -VAS 5234- to the brake fluid reservoir.
– Provide a suitable catch pan for used brake fluid.
– Remove the dust caps of the bleeder valves at the brake cal‐
ipers.
– Switch on the brake filling and bleeding device and activate
the system with a brake fluid pressure of approx. 0.2 MPa.
– Fit the hose of the bleeding bottle -1- onto the corresponding
bleeder valve.
– Loosen bleeder valve.
– Extract as much brake fluid as possible until even the smallest
air bubbles have escaped.
– Close vent valve.
cardiagn.com
– Repeat this procedure for all brake calipers in the prescribed
sequence until the brake system is fully bled.
Bleeding sequence
1. Rear right brake caliper
2. Rear left brake caliper
3. Front right brake caliper
4. Front left brake caliper
– Inspect pedal position and idle travel at brake pedal. Idle trav‐
el: max. 1/3 of pedal travel.
– Repeat the whole procedure if necessary (several times), until
perfect bleeding is achieved.
– After bleeding close the relevant vent valve and fit dust cap.
– If necessary, correct the brake fluid level in the brake fluid res‐
ervoir.
– Disconnect the brake filling and bleeding device .
– Disconnect the brake filling and bleeding device from the
brake fluid reservoir.
– Perform a test drive. While doing so, at least one ABS adjust‐
ment must be carried out on vehicles with ABS!
4.2 Change brake fluid

⇒ Maintenance ; Booklet Octavia III

5 Brake Servo Unit/Master Brake Cyl‐

inder
Assembly overview - brake servo/brake master cylinder
⇒ page 67
Removing and installing master brake cylinder ⇒ page 68
Remove and install brake servo unit ⇒ page 72
5.1 Assembly overview - brake servo/brake master cylinder
moval
2 - Foot controls
3 - Front wall
cardiagn.com
moval
5 - Master brake cylinder
❑ cannot be repaired
❑ if there are faults re‐
place completely
⇒ page 68
Parts
6 - Brake light switch -F -
❑ Fitting location: on mas‐
ter brake cylinder
⇒ page 55
❑ check ⇒ Vehicle diag‐
nostic tester
7 - Screw, 8 Nm
❑ Master brake cylinder/
floating piston circuit to
hydraulic unit
❑ Master brake cylinder/
push rod piston circuit to hydraulic unit
10 - Plugs
❑ moisten with brake fluid, insert in the brake cylinder and press in the brake fluid reservoir
11 - Brake fluid level warning contact -F34-
12 - Brake fluid reservoir
13 - Vacuum with
hose respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
14 - Screw cap
15 - Gasket
❑ for brake servo unit
5. Brake Servo Unit/Master Brake Cylinder 67

16 - Gasket
❑ Inspect proper operation:
– With the engine off press down brake pedal repeatedly with force (this reduces the pressure already
present in the device).
– Now hold the brake pedal in brake position using a medium foot pressure and start the engine. If the
brake servo unit operates perfectly the brake pedal must yield noticeably under your foot (servo boost
takes effect).
18 - Gasket
5.2 Removing and installing master brake

cylinder
cardiagn.com
♦ Repair kit -1H0 698 311 A-
♦ Extraction bottle
Removing:
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Relevant Engine; Rep. gr. 21 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– On models fitted with a coded radio, pay attention to the cod‐
ing, determine if necessary.
– Remove connecting hose to intake manifold flap ⇒ Engine;
Rep. gr. 21 .
– Lay sufficient non-fluffing
unless authorised by ŠKODA cloths
AUTO A. around
S. ŠKODAthe AUTO engine and
A. S. does gear‐ or accept any liability
not guarantee
box. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��

– Using an extraction bottle extract as much brake fluid as pos‐

sible from the brake fluid reservoir.
For vehicles with a manual gearbox:
– Detach the return hose -B- of the clutch master cylinder from
cardiagn.com
the brake fluid reservoir and attach it slightly higher.
Continued for all vehicles:
– If present,Protected
disconnect the plug -1- from the brake light switch
-F- , the plug
unless-2- from by
authorised the vacuum
ŠKODA AUTO A. sensor
S. ŠKODA -G608-
AUTO A. and the
S. does not plug
guarantee or accept any liability
-3- from thewith
brake
respectfluid
to the level warning
correctness contact
of information in this-F34- . Copyright by ŠKODA AUTO A. S.��
document.
– Release screw -1-.

– Pull the brake fluid reservoir -2- out of the plugs.
5. Brake Servo Unit/Master Brake Cylinder 69

– Unscrew the brake lines -1- at the master brake cylinder, close
the brake lines with the screw plugs from the repair kit -1H0
698 311 A- .
– Unscrew nuts -2- from brake master cylinder.
– If present, remove the protection plate.
– Carefully remove brake master cylinder from brake servo.
Installing:
When installing, pay particular attention to the following points:
Note
If the battery earth strap is disconnected and connected, carry out

certain additional operations ⇒ Electrical System; Rep. gr. 27 .
– When installing the master brake cylinder with the brake servo
unit pay attention to the correct positioning of the pressure rod
in the master brake cylinder.
cardiagn.com
– Bleeding brake system ⇒ page 65 .
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .

Tightening torques:
Master brake cylinder to brake servo unit 23 Nm
♦ Use new nuts!
Brake lines to master brake cylinder 14 Nm
cardiagn.com
71
5.3 Removing and installing brake servo

unit
♦ Repair kit -1H0 698 311 A-
♦ Extraction bottle
– Remove master brake cylinder ⇒ page 68 .
– Separating the brake pedal from the brake servo unit
⇒ page 52 .
– Release the nut -1- and carefully pull off the foot mat -2-
-in direction of arrow-.
cardiagn.com
– Release the nuts -3- and -4-.
– Carefully remove the brake servo unit from the vehicle.
Installing: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Note
♦ If the battery earth strap is disconnected and connected, carry

out certain additional operations ⇒ Electrical System; Rep. gr.
27 .
♦ The gasket between the brake servo unit and the front wall is
only fitted in the series. After removing the brake servo unit, it
must no longer be replaced.
After installing, it is necessary to:

– Bleeding brake system ⇒ page 65 .
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .
72
Tightening torques:
Brake servo to pedal cluster/bulkhead 25 Nm
♦ Use new nuts!
Master brake cylinder to brake servo unit 23 Nm

♦ Use new nuts!
Brake lines to master brake cylinder 14 Nm
cardiagn.com
73
6 Brake line
Repairing brake lines ⇒ page 74 .
Flaring tool - Summary of components ⇒ page 76 .
Work instruction ⇒ page 76 .
6.1 Repairing brake lines

Using the brake line flaring tool -VAS 6056- , the brake lines can
be crimped with a pipe outside diameter of 5 mm, without dam‐
aging the coating. So that in certain cases parts of the brake lines
can be replaced cheaply.
Note
♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict the cross-section
of the line to an impermissible degree.
♦ Preferably separate brake lines at underbody.
cardiagn.com
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle, clean only with methylated spirits.

♦ Brake line flaring tool -VAS 6056-
♦ Brake filling and bleedingunless
device - VAS
authorised 5234-AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by ŠKODA
List of individual tools:
74
1 - Flaring tool -VAS 6056/1-

❑ in the flaring tool -VAS
6056/1- the flaring
chucks -VAS 6056/6-
are included
2 - Pipe cutter -VAS 6056/2-
3 - Brake line-peeler -VAS
6056/3 -
❑ The grub screws (in the
shank and sideways)
are adjusted and must
not be altered!
4 - Gripping pliers with plastic
chuck jaws -VAS 6056/4 -
5 - Tube bending tool -VAS
6056/5-
6 - Offset screwdriver SW6
7 - Flaring chucks -VAS
6056/7-
cardiagn.com
6. Brake line 75
6.2 Flaring tool - summary of components
1 - Flaring tool top part

❑ unscrew for changing
the flaring chucks
2 - Attachment for door handle
❑ must be unscrewed to
access securing bolt for
upper part
3 - Fixing screw
❑ for flaring tool top part
4 - Center the grub screws for
flaring chucks
❑ and hold the flaring
chucks
❑ 2 mm hexagon socket
5 - Flaring chucks
cardiagn.com
❑ different
❑ Mounting instruction
⇒ page 76
Mounting instruction of flaring chucks:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (bright) for green brake lines
Note
The arrow, on the rounded side of the flaring chucks, must point
to the housing edge and the straight side of the flaring chucks
must be installed to the spindle, otherwise the flaring head is not
properly formed.
6.3 Work instruction

– Unscrew the affected brake line on the brake caliper or wheel-
brake cylinder, while doing so collect escaping brake fluid and
dispose according to the specifications.
76
– Cut through the brake line in a suitable location (straight, freely

accessible piece) with the pipe cutter -2-.
– Remove the removable part.
– Degrease the surface of the brake line.
– Clamp the brake line in the gripping pliers -4- tight enough, so
that it protrudes approx. 50 mm out of the plastic chuck jaws.
– Tension the peeler -3- in a boring machine and place it onto
the brake line.
– Peel off the coating of the brake line using the slower speed
of the boring machine and by exerting a slight pressure against
the brake line.
cardiagn.com
The length of the peeling is determined by the stop in the peeler.
– Separate the peeler from the brake line and remove peel res‐
idues.
– Remove the gripping pliers and push the pipe screw -D- onto
the brake line.
– Push the brake line -B- against the stop -A- in the flaring tool.
Note
When tightening the Allen screws the brake line must lie against
the stop, otherwise the flaring head does not function properly.
– Pre-tension the brake line in the flaring tool so that the brake
line can no longer be moved. Fold up the stop -A- and then
tighten the Allen screws crosswise completely with the offset
screwdriver -C-.
6. Brake line 77
– Turn the spindle in the flaring tool up to the stop.

– Turn back the spindle once again.
– Loosen the Allan screws crosswise.
– Take the brake line out of the flaring tool, clean and check the
brake line as well as the flaring head.
Briefly rinse the part of the brake line remaining in the the vehicle:
– Connect the brake filling and bleeding device -VAS 5234- , fit
the hose of the bleeding bottle onto the flaring head of the
brake line and allow the brake filling and bleeding device -VAS
5234- to run briefly until some brake fluid has passed through.
– Blow through the newly inserted brake line with compressed
air.
– Assemble the brake lines together with the connecting piece

-E-.
– Mount brake line.
– Bleeding Brake System ⇒ page 65
cardiagn.com
78

Brake System

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Brake System

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2013 ŠKODA AUTO a. s. D4B802B4AD9

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Repairing brake caliper C 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.1 Brake variants and their assignment

Front brake caliper (type denomina‐ PC 57 PC 57 PC 57 PC 57

Rear brake caliper (type denomina‐ C 38 C 38 C 38 PC 38 HRA

Engine 1.6 ltr./77 kW TDI CR 2.0 ltr./110 kW TDI

Engine 1.6 ltr./77 kW TDI CR 2.0 ltr./110 kW TDI

Front brake caliper (type denomination) PC 57 PC 57

1.2 Brake fluid

1.3 Brake inspection

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

2 Rep. gr.00 - Technical data

Test, vehicles with front-wheel-drive

45 – Anti-lock brake system

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

1.1 Distinguishing features of the ABS sys‐

1.2 Instructions for repair work on ABS

♦ If the battery earth strap is disconnected and connected, carry

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

2 Fitting location overview

2.1 Summary of components - ABS/ESC

1 - ABS/ESC control unit -

The hydraulic unit consists of

2. Fitting location overview 7

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

3 Hydraulic unit, brake servo unit

1 - ABS/ESC control unit -

3. Hydraulic unit, brake servo unit 9

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

3.3 Removing and installing control unit and

– Read out and note the actual control unit coding.

3. Hydraulic unit, brake servo unit 11

– Remove protective cover -1-.

– Close front left and rear left bleeder valves.

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

– Installation is carried out in the reverse order.

Tightening sequence of the brake lines:

G85- , the lateral acceleration sender -G200- , the brake pressure

3. Hydraulic unit, brake servo unit 13

3.4 Removing and installing control unit and

– Read out and note the actual control unit coding.

– Position brake pedal load , e.g. -V.A.G 1869/2- .

– Installation is carried out in the reverse order.

Tightening sequence of the brake lines:

3.5 Removing and installing bracket for hy‐

1 - ABS wheel speed sensor

4.1.1 Removing and installing the ABS speed

– Separate plug connection -1- wheel speed sensor/wheel

1 - ABS wheel speed sensor

4.2.1 Removing and installing the ABS speed

– Separate plug connection -1- wheel speed sensor/wheel

4.3 Sensor unit for ESP -G419-

4.4 Steering angle sender -G85-

1.1 Changing the brake pads of the front

1. Repairing front wheel brake 27

1.2 Repairing front wheel brake, brake caliper PC 57

♦ Observe the instructions for changing the pad ⇒ page 27

28 Rep. gr.46 - Brakes - mechanism

1.3 Removing and installing the brake pads