Brake Systems

Service
Workshop Manual
Octavia IV 2020 ➤
Octavia IV 2021 ➤
Brake systems
Edition 10.2020
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2020 ŠKODA AUTO a. s. D4B80A03FE8

Octavia IV 2020 ➤, Octavia IV 2021 ➤
Brake systems - Edition 10.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with start-stop system. . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during road tests in which testing and measuring equipment is used . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 PR number assignment – brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Brake inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Testing vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Check the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 ABS/ESP installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Exploded view – control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Removing and installing ABS control unit J104/ABS hydraulic unit N55 . . . . . . . . . . . . . . 21
3.3 Disconnecting the control unit from the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Fitting the control unit to the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Removing and installing the sensor unit for stabilisation program G419 . . . . . . . . . . . . . . 40
4.4 Removing and installing front speed sensors G45/G47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5 Removing and installing the rear speed sensors G44/G46 . . . . . . . . . . . . . . . . . . . . . . . . 41
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.3 Removing and installing brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.5 Removing and installing heat shield for brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Removing and installing brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.4 Removing and installing brake anchor plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.5 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.6 Removing and installing heat shield for brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.2 Removing and installing control unit for electronic handbrake J540 . . . . . . . . . . . . . . . . . . 85
3.3 Removing and installing handbrake motor V282/V283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Contents i
4.1 Summary of components - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.2 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4 Clipping the brake pedal onto the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Front brake callipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Summary of components - front brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2 Removing and installing brake calliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2 Rear brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.1 Summary of components - rear brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.2 Removing and installing protective cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3 Brake servo unit and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.1 Summary of components - brake servo unit and master brake cylinder . . . . . . . . . . . . . . 111
3.2 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.3 Removing and installing master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.4 Removing and installing the warning contact for brake fluid level F34 . . . . . . . . . . . . . . . . 129
4 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.3 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.4 Testing leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
ii Contents
00 – Technical data
1 Safety instructions
(SRL001654; Edition 10.2020)
⇒ p1.1 recautions when working on vehicles with start-stop sys‐
tem.”, page 1
⇒ p1.2 recautions during road tests in which testing and meas‐
uring equipment is used”, page 1
1.1 Safety precautions when working on

vehicles with start-stop system.
When working on vehicles with start/stop system, please ob‐
serve the following instructions:
CAUTION
Risk of injury as a result of automatic engine start in vehicles
with start/stop system.
♦ In vehicles with the start/stop system activated (identifiable
by an indication in the dash panel insert) the engine can
start automatically if required.
♦ It is necessary to ensure that the start-stop system is de‐
activated when carrying out work on the vehicle (switch
ignition off and if required switch ignition on again).
1.2 Safety precautions during road tests

in which testing and measuring equip‐
ment is used
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
There is a risk of accident from deflection and insufficient
securing of testers and measuring instruments.
♦ Using testers and measuring instruments during driving
operation creates a risk of distraction.
♦ There is an increased risk of injury from unsecured testers
and measuring instruments.
♦ Always attach the testing and measurement equipment to
the rear seat.
♦ Always have the testing and measurement equipment op‐
erated by a second person.
♦ Always operate the testing and measurement equipment
from the rear seat.
♦ Do not operate the testing and measurement equipment
from the front passenger seat.
♦ Persons can be injured by the release of the passenger
airbag in the event of an accident.
1. Safety instructions 1
2 Identification
⇒ n2.1 umber assignment – brake”, page 2
2.1 PR number assignment – brake

Search brake PR numbers
The brake type information (PR number) can be found in the
ELSA system.
The brake type (PR number) is specified in the “vehicle data”
menu in the ELSA system.
Search for brake “PR numbers” in the ELSA system - “vehicle
data”
– Search for the “Family of PR numbers” in the “vehicle data”
menu -Arrow A- (front brakes - BAV family, rear brakes -
BAH family).
– -Arrow B- shows the vehicle brakes’ PR number.

This example shows a vehicle with front brake PR number 1ZA.
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
2 Rep. gr.00 - Technical data

3 Technical data
⇒ d3.1 ata for brakes”, page 3
3.1 Technical data for brakes

⇒ b3.1.1 rake cylinder and brake servo”, page 3
⇒ b3.1.2 rakes”, page 3
⇒ b3.1.3 rake”, page 5
⇒ f3.1.4 luid”, page 6
3.1.1 Master brake cylinder and brake servo

Master brake mm 23.81;
cylinder - ∅ 25.4
Brake servo Electromechanical brake booster
3.1.2 Front brakes

Explanations concerning PR Numbers ⇒ n2.1 umber assign‐
ment – brake”, page 2 .
Front brake PC 57
Posi‐ PR number 1ZE

tion
1 Brake caliper PC 57 (15")
2 Brake pad: mm 14
thickness with‐
out support
plate
Brake pad: min‐ mm 2
imum thickness
without support
plate
3 Brake disc: ∅ mm 288
3. Technical data 3
Posi‐ PR number 1ZE

tion
Brake disc: mm 25
thickness
Brake disc: min‐ mm 22
imum thickness
4 Brake calliper mm 57
piston: ∅
Front brake PC 57
Posi‐ PR number 1ZK

tion
1 Brake caliper PC 57 (16")
2 Brake pad: mm 14
thickness with‐
out support
plate
imum thickness
without support
plate
Brake disc: mm 25
thickness
imum thickness
piston: ∅
Front brake FNt57

Posi‐ PR number 1ZA

tion
1 Brake caliper FNt57 (16")
2 Brake pad: mm 14
thickness with‐
out support
plate
imum thickness
without support
plate
Brake disc: mm 26
thickness
imum thickness
piston: ∅
3.1.3 Rear brake

Explanations concerning PR Numbers ⇒ n2.1 umber assign‐
ment – brake”, page 2 .
Rear wheel brake FNtc M38
3. Technical data 5
Posi‐ PR number 1KE

tion
1 Brake caliper FNtc M38 (15”)
2 Brake pad: mm 11
thickness with‐
out support
plate
imum thickness
without support
plate
Brake disc: mm 10
thickness
imum thickness
piston: ∅
3.1.4 Brake fluid

Classification Only use new original brake fluid
N.052.766.Z0 as per US standard FMVSS
571.116, DOT 4 and VW standard 501 14
Top-up ⇒ Maintenance; Booklet Octavia IV

4 Brake inspection
⇒ p4.1 oints”, page 7
⇒ v4.2 ehicles with front-wheel drive”, page 7
⇒ v4.3 ehicles with four-wheel drive”, page 7
⇒ t4.4 he parking brake”, page 8
4.1 General points

♦ The test stand is used as drive.
♦ 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 provi‐
ded by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is

off.
4.2 Checking vehicles with front-wheel

drive
The brake test must be 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 condi‐
tions.
4.3 Testing vehicles with four-wheel drive

The brake inspection must be performed on a contra-rotative
single axle roller type test stand for vehicles with four-wheel
drive.
Contra-rotative means: The test stand rollers of the single axle
roller type test stand rotate forwards on the one side and back‐
wards on the other side.
Thus, a transfer of the braking forces in the drive train is pre‐
vented.
The wheel which rotates forwards is measured each time during
the test, this requires the need of two braking tests per axle.
The test speed must not exceed 6 km/h.
The test stands approved by Škoda comply with these condi‐
tions.
If a test stand is not available for vehicles with four-wheel drive,
the brake inspection can also be performed on a standard sin‐
gle axle roller type test stand as follows:
– Drive the vehicle forwards onto the rollers.
– Switch off engine and wait 2 seconds.
– Perform brake inspection at the front.
– Start up the engine and drive the vehicle forwards until the
rear wheels are standing on the rollers.
4. Brake inspection 7
– Switch off engine and wait 2 seconds.

– Perform brake inspection at the rear.
4.4 Check the parking brake

⇒ e4.4.1 lectromechanical parking brake, vehicles with front
drive”, page 8
⇒ e4.4.2 lectromechanical parking brake, vehicles with all-wheel
drive”, page 8
4.4.1 Check electromechanical parking

brake, vehicles with front drive
Enable »MOT mode«
• Safety belt is installed.
• Rear axle is on the 1-axle roller test stand
• Ignition is switched on.
• »Auto Hold« is switched off.
• Front wheels must be stationary.
• The rear wheels must rotate constantly between 2.5 and
9 km / h for at least 5 seconds.
Enabled »MOT mode« is signalled by the yellow Electric park‐
ing and handbrake fault lamp -K214- lighting up.
Note
The electromechanical parking brake does not fully close

in »MOT mode« when the button for the electromechanical
parking brake -E538- is pressed for the first time.
After the Button for the electromechanical parking brake -E538-

is pressed four times in succession, the parking brake fuly
locks.
Pressing thebutton for the electromechanical parking brake -
E538- leads to the electromechanical parking brake being re‐
leased.
End »MOT mode«
• Front wheels have a speed greater than 0 km / h.
• Rear wheels have a speed less than 2.5 km / h or greater
than 9 km / h.
• Ignition is switched off.
4.4.2 Check electromechanical parking

brake, vehicles with all-wheel drive
Enable »MOT mode«
• Safety belt is installed.
• Rear axle is on the 1-axle roller test stand
• Ignition is switched on.
• »Auto Hold« is switched off.
• Front wheels must be stationary.
• The rear wheels must rotate constantly between 2.5 and
9 km / h for at least 5 seconds.

Enabled »MOT mode« is signalled by the yellow Electric park‐

ing and handbrake fault lamp -K214- lighting up.
Note
The electromechanical parking brake does not fully close

in »MOT mode« when the button for the electromechanical
parking brake -E538- is pressed for the first time.
After the Button for the electromechanical parking brake -E538-

is pressed four times in succession, the parking brake fuly
locks.
Pressing thebutton for the electromechanical parking brake -
E538- leads to the electromechanical parking brake being re‐
leased.
– Start engine and wait approx. 5 seconds until adequate vac‐
uum has built up.
End »MOT mode«
• Front wheels have a speed greater than 0 km / h.
• Rear wheels have a speed less than 2.5 km / h or greater
than 9 km / h.
• Ignition is switched off.
4. Brake inspection 9
45 – Anti-lock brake system

1 General points
⇒ i1.1 nstructions for repair work on ABS”, page 10
1.1 Repair instructions for repair work on

ABS
The ABS brake system is split diagonally. The brake boosting is
pneumatically performed by the electromechanical brake servo.
Specifically matched software in the ABS control unit -J104-
regulates the brake pressure distribution on the rear axle.
Note
♦ If the ABS hydraulic unit -N55- is damaged, the ABS control

unit -J104- and the ABS hydraulic unit -N55- must be fully
replaced.
♦ The ABS control unit -J104- can be separated from the ABS
hydraulic unit -N55- ⇒ t3.3 he control unit from the hydraulic
unit”, page 32 .
♦ The hydraulic pump and the ABS hydraulic unit -N55- must
not be separated from each other.
♦ Faults in the ABS do not influence the brake system and
servo assistance. The conventional braking system remains
fully functional even without ABS. There will be a change in
braking behaviour. After the ABS warning lamp comes on,
the rear wheels may lock prematurely during braking.
Arrangement of the ABS, left-hand drive vehicle
1 - ABS hydraulic unit -N55- with ABS control unit -J104-

2 - Brake servo
10 Rep. gr.45 - Anti-lock brake system

Arrangement of the ABS in right-hand drive vehicles
1 - Brake servo
2 - ABS hydraulic unit -N55- with ABS control unit -J104-
The ABS control unit -J104- -1- and the ABS hydraulic unit
-N55- -2- form a single unit. They can only be separated after
the complete unit is removed. The ABS control unit -J104- can
be separated from the ABS hydraulic unit -N55- ⇒ t3.3 he con‐
trol unit from the hydraulic unit”, page 32 . The hydraulic pump
-3- must not be separated from the ABS hydraulic unit -N55-
-2-.
New control units supplied by the spare parts area are not co‐
ded. They must be coded after installation ⇒ Vehicle diagnostic
tester.
♦ Before starting work on anti-lock brake systems, query the
event memory to check for complaints and conduct guided
fault finding ⇒ Vehicle diagnostic tester.
♦ Do not separate plug connections unless the ignition is
switched off.
♦ Before working on anti-lock braking systems, switch off the
ignition and disconnect the ground strap from the battery
⇒ Electrical system; Rep. gr. 27; Battery; Disconnect and
connect battery.
♦ If the battery earth strap is disconnected and connected, car‐
ry out additional operations ⇒ Electrical System; Rep. gr. 27;
Battery.
♦ Welding work using electric welding equipment may affect
the ABS system.
♦ Do the following before commencing welding work using
electrical welding tool:
– Disconnect the earth strap from the negative terminal of the
battery and cover the negative terminal.
1. General points 11
– Connect the earth connection of the electric welding tool

directly to the part to be welded. There must not be any
electrically 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 painting operations, the ABS control unit -J104- may
be exposed to a max. temperature of 95 °C for only a short
period, and to a max. of 85 °C for longer periods (approx.
2 hours).
♦ Do not drive the vehicle if the connector is unplugged from
the ABS control unit -J104-.
♦ 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 close opened components if the repair
is not completed immediately (use plugs from the repair kit
-1H0 698 311A-).
♦ Only use lint-free cloths.
♦ Do not remove spare parts from their wrappings until imme‐
diately before installation.
♦ Use only genuine wrapped parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ The valve coils in the ABS control unit -J104- must not be
calibrated.
♦ The valve coils in the ABS control unit -J104- cannot be
replaced.
♦ The pressure sensor must not be modified or damaged.
♦ The pressure sensor cannot be replaced.
♦ The sensor housing must not be subjected to mechanical
load.
♦ No measurements must be carried out at the contact points
of the ABS control unit -J104-.
♦ No measurements must be carried out at the contact points
of the ABS hydraulic unit -N55-.
♦ The valve domes of the ABS hydraulic unit -N55- must not
be damaged or bent.
♦ The contacts on the ABS control unit -J104- and the ABS
hydraulic unit -N55- cannot be replaced.
♦ Do not use contact spray.
♦ No contamination or foreign object may located between
ABS control unit -J104- and ABS hydraulic unit -N55-.
♦ Ensure that no brake fluid enters connectors.
♦ Observe the relevant instructions when handling brake fluid.
♦ After completing work which involved opening the brake
system, bleed the brake system with the brake filling and

bleeding device -VAS 5234- or -VAS 6860-, ⇒ h5.2 ydraulic

system following standard procedure”, page 136 .
♦ During the subsequent road test, ensure that at least one
controlled brake application is performed (pulsing must be
felt on the brake pedal).
1. General points 13
2 Installation location overview

⇒ i2.1 nstallation location overview”, page 14
2.1 ABS/ESP installation location overview
Note
♦ If the ABS hydraulic unit -N55- is damaged, the ABS control unit -J104- must be fully replaced with the
ABS hydraulic unit -N55-.
♦ The ABS control unit -J104- can be separated from the ABS hydraulic unit -N55- ⇒ t3.3 he control unit
from the hydraulic unit”, page 32 .
♦ The hydraulic pump and the ABS hydraulic unit -N55- must not be separated from each other.

1 - Dash panel insert

❑ includes:
♦ Brake pad warning light -
K32-
♦ ABS warning light -K47-
♦ ESP and TCS warning
lamp -K155-
♦ Brake system warning light
-K118-
2 - Steering angle sender -
G85-
❑ Installation location: in
the steering gear
❑ the steering angle
sender -G85- cannot be
changed separately
3 - Brake servo
❑ Summary of compo‐
nents ⇒ o3.1 f compo‐
nents - brake servo unit
and master brake cylin‐
der”, page 111
❑ Removing and instal‐
ling ⇒ a3.2 nd installing
brake servo”, page 115
4 - Brake line
5 - Screw
❑ Tightening torque ⇒
o4.2 verview - speed
sensor on rear axle”,
page 40
6 - Rear right and left wheel
speed sensors -G44-/-G46-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ a4.5 nd installing the rear speed sensors G44/G46”, page 41
7 - Wheel hub with wheel bearing
❑ for front axle
❑ Sensor ring for ABS is built into the wheel hub
❑ for front axle
9 - Screw
❑ Tightening torque ⇒ o4.1 verview - speed sensor on front axle”, page 39
10 - Front right and left wheel speed sensors -G45-/-G47-
❑ Removing and installing ⇒ a4.4 nd installing front speed sensors G45/G47”, page 41
11 - ABS control unit -J104- with ABS hydraulic unit -N55-
❑ Installation location: in the engine compartment on the front passenger's side
❑ do not disconnect the plug connection before the self-diagnosis is complete; switch off the ignition
before disconnecting the plug connection
The following components are integrated in the ABS control unit -J104-:
2. Installation location overview 15

♦ Sensor unit for ESP -G419-

♦ Control unit for electronic handbrake -J540-
♦ Lateral acceleration sender -G200-
♦ Yaw rate sender -G202-
♦ Longitudinal acceleration sender -G251- (depending on equipment fitted)
♦ The components cannot be changed individually.
❑ Summary of components ⇒ v3.1 iew – control unit and hydraulic unit”, page 17
❑ Removing and installing the ABS control unit -J104- with the ABS hydraulic unit -N55- ⇒ a3.2 nd
installing ABS control unitJ104/ABS hydraulic unitN55”, page 21
❑ Disconnecting the control unit from the hydraulic unit ⇒ t3.3 he control unit from the hydraulic unit”,
page 32
❑ Fitting the control unit to the hydraulic unit ⇒ t3.4 he control unit to the hydraulic unit”, page 34

3 Control unit and hydraulic unit

⇒ v3.1 iew – control unit and hydraulic unit”, page 17
⇒ a3.2 nd installing ABS control unitJ104/ABS hydraulic
unitN55”, page 21
⇒ t3.3 he control unit from the hydraulic unit”, page 32
⇒ t3.4 he control unit to the hydraulic unit”, page 34
⇒ b3.5 rake lines to hydraulic unit”, page 36
3.1 Exploded view – control unit and hy‐

draulic unit
⇒ v3.1.1 iew – control unit and hydraulic unit, left-hand drive
vehicle”, page 17
⇒ v3.1.2 iew – control unit and hydraulic unit, right-hand drive
vehicle”, page 19
3.1.1 Exploded view – control unit and hydraulic unit, left-hand drive vehicle
Note
♦ Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after
removal.
3. Control unit and hydraulic unit 17

1 - ABS control unit -J104-

with ABS hydraulic unit -N55-
ling ⇒ a3.2 nd in‐
stalling ABS control
unitJ104/ABS hydraulic
unitN55”, page 21
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit ⇒ t3.3 he
control unit from the hy‐
draulic unit”, page 32
❑ Fitting the control unit
to the hydraulic unit
⇒ t3.4 he control unit
to the hydraulic unit”,
page 34
❑ Tightening torques of
the fixing screws for the
ABS control unit -J104-
page 34
2 - Brake line
❑ to rear right brake cal‐
liper
❑ Distinguishing feature:
∅ 5.25 mm and pipe
screw with long thread
M10 x 1
❑ 14 Nm
3 - Brake line
❑ to front left brake callip‐
er
∅ 5.25 mm and pipe
screw with long thread M10 x 1
❑ 14 Nm
4 - Brake line
❑ to front right brake calliper
❑ Distinguishing feature: ∅ 5.25 mm and pipe screw with long thread M10 x 1
❑ 14 Nm
5 - Brake line
❑ to rear left brake calliper
❑ 14 Nm
6 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit -N55-
❑ Distinguishing feature: ∅ 6 mm and pipe screw with long thread M12 x 1
❑ 14 Nm
7 - Brake line
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit -N55-
❑ 14 Nm

8 - Brake servo
❑ if there are faults replace completely
❑ Removing and installing ⇒ a3.2.1 nd installing brake servo unit, left-hand drive vehicles”, page 115
9 - Brake line
❑ 14 Nm
10 - Brake line
❑ 14 Nm
11 - Heat shield
❑ Assignment ⇒ Electronic Catalogue of Original Parts
12 - Nut
❑ 20 Nm
13 - Mounting bracket
14 - Threaded bores
15 - Rubber shock absorber bushing
16 - Screw
❑ 8 Nm
3.1.2 Exploded view – control unit and hydraulic unit, right-hand drive vehicle
Note
removal.

1 - ABS hydraulic unit -N55-

with ABS control unit -J104-
ling ⇒ a3.2 nd in‐
stalling ABS control
unitJ104/ABS hydraulic
unitN55”, page 21
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit ⇒ t3.3 he
control unit from the hy‐
draulic unit”, page 32
❑ Fitting the control unit
to the hydraulic unit
page 34
❑ Tightening torques of
the fixing screws for the
ABS control unit -J104-
page 34
2 - Brake line
❑ from master brake cyl‐
inder (floating piston
circuit) to ABS hydraul‐
ic unit
∅ 6 mm and pipe
screw with long thread
M12 x 1
❑ 14 Nm
3 - Brake line
❑ from master brake cyl‐
inder (push rod piston
circuit) to ABS hydraul‐
ic unit
❑ 14 Nm
4 - Brake line
❑ to rear right brake calliper
❑ 14 Nm
5 - Brake line
❑ to front left brake calliper
❑ 14 Nm
6 - Brake line
❑ to front right brake calliper
❑ 14 Nm
7 - Brake line
❑ to rear left brake calliper

❑ 14 Nm
9 - Threaded bores
11 - Nut
❑ 20 Nm
12 - Rubber shock absorber bushing
13 - Screw
❑ 8 Nm
14 - Brake servo
❑ Removing and installing ⇒ a3.2.2 nd installing brake servo unit - right-hand drive”, page 117
15 - Brake line
❑ 14 Nm
16 - Brake line
❑ 14 Nm
3.2 Removing and installing ABS control

unit -J104-/ABS hydraulic unit -N55-
⇒ a3.2.1 nd installing the ABS control unitJ104/ABS hydraulic
unitN55, left-hand drive and petrol engine”, page 21
⇒ a3.2.2 nd installing the ABS control unitJ104/ABS hydraulic
unitN55, left-hand drive and diesel engine”, page 24
⇒ a3.2.3 nd installing ABS control unitJ104/ABS hydraulic
unitN55, right-hand drive vehicles”, page 29
3.2.1 Removing and installing the ABS con‐

trol unit -J104-/ABS hydraulic unit -
N55-, left-hand drive and petrol engine
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 ABS control unit -J104- is bolted to the ABS hydraulic unit
-N55- and is located in the engine compartment on the right
side.
Note
Do not bend the brake lines in the area of the hydraulic unit.

– Read out and note the actual control unit coding.

– Disconnect battery earth strap ⇒ Electrical system; Rep.
gr. 27; Battery; Disconnecting and connecting battery.
– If present, remove the engine cover.
– Release catch -arrow A- and remove protective cover -1-
-in the direction of arrow B- (if present).
– Release the fuse plug -1- -in the direction of arrow A-

and pull it off the ABS control unit -J104-
-in the direction of arrow B-.
– Fit the brake pedal depressor.

– Attach the bleeder hose of the bleeding bottle onto the vent
valves of the front left and rear left brake calliper and open
vent valves.
– Press down the brake pedal with the brake pedal depressor
at least 60 mm.
– Close front left and rear left bleeder valves.
– Do not remove the brake pedal depressor.
– Place a sufficient non-fluffing cloths under and around the
ABS control unit -J104- and the ABS hydraulic unit -N55-.
NOTICE
Make sure that no brake fluid gets onto the contacts of the
ABS control unit -J104-.
– Mark both brake lines -5- and -6- from the master brake
cylinder and unscrew from the ABS hydraulic unit -N55-.
– Close the brake lines and threaded holes immediately with

plugs from the repair kit -1H0 698 311A-.
– Mark the brake lines (for brake calliper) -1- to -4-, unscrew
and close with plugs from the repair kit -1H0 698 311A-.
– Remove lambda probe upsteam of the catalytic converter
⇒ Engine; Rep. gr. 24; Lambda probe; overview of compo‐
nents - Lambda probe.
– Pull the ABS hydraulic unit -N55- and the ABS control unit
-J104- upwards and out of the shock absorbers.
Note

unit -J104- must be fully replaced with the ABS hydraulic unit
-N55-.
unit”, page 32 .
Installing
Installation is carried out in the reverse order. When installing,
observe the following:

Note
♦ Only remove plugs from the new ABS hydraulic unit -N55- if
the relevant brake line is installed.
♦ If the plugs were already removed from the ABS hydraulic
unit -N55-, 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 for tight fight, otherwise failure may be caused by a
malfunction of the ABS hydraulic unit -N55-.
– Observe the tightening sequence of the brake lines ⇒ Fig.

““Tightening sequence of the brake lines”“, page 24 .
– Remove the brake pedal depressor.
– Bleed brake system ⇒ h5.2 ydraulic system following stand‐
ard procedure”, page 136 .
– 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 pres‐
sure sender 1 -G201- and the longitudinal acceleration sender
-G251- must be performed ⇒ Vehicle diagnostic tester.
Tightening sequence of the brake lines
Tightening torques - summaries of components
Note
Replace bolts / nuts that are tightened at an angle of rotation,

as well as replacement components after removal.
♦ ⇒ v3.1.1 iew – control unit and hydraulic unit, left-hand drive

vehicle”, page 17
♦ Lambda probe ⇒ Engine; Rep. gr. 24; Lambda probe; Over‐
view of components - Lambda probe
3.2.2 Removing and installing the ABS con‐

trol unit -J104-/ABS hydraulic unit -
N55-, left-hand drive and diesel engine

♦ Repair kit -1H0 698 311A-

♦ Engine support bracket -T10533-
Removing
Fitting location:
-N55- and is located in the engine compartment on the right
side.
Note

– If present, remove the engine cover.
– Remove the coupling rod ⇒ Engine; Rep. gr. 10; Powertrain
mounting; removing and installing the coupling rod.
– Removing the sound damper ⇒ External body repairs; Rep.
gr. 66; Sound damper; removing and installing sound damp‐
er.
– Remove the exhaust front pipe ⇒ Engine; Rep. gr. 26; Ex‐
haust gas cleaning system; overview of components - ex‐
haust gas cleaning.
For vehicles with four-wheel drive
– Remove propshaft from front gearbox and place to one side
⇒ Rep. gr. 39; Propshaft; Disconnecting and connecting
propshaft.
Continued for all vehicles
– Press the engine with the engine support bracket -T10533-
forwards.
– Release catch -arrow A- and remove protective cover -1-

-in the direction of arrow B- (if present).

– Unclip cable guide.

vent valves.
at least 60 mm.


NOTICE
Make sure that no brake fluid gets onto the contacts of the
ABS control unit -J104-.
– Detach the top section of the heat-protection matting on the

front wall and shift to side.
– Clip the brake lines off the two mounting brackets.
– Mark both brake lines -5- and -6- from the master brake

and close with plugs from the repair kit -1H0 698 311 A-.
-J104- -1- in the -direction of the arrow- and out of the shock
absorbers.
– Lay the ABS hydraulic unit -N55- with the ABS control unit
-J104- facing downwards in the engine compartment.
– Raise vehicle.
– Remove mounting bracket -arrows- in the vehicle from the

– Remove the ABS hydraulic unit -N55- and the ABS control
unit -J104- at the bottom from the vehicle.
Note

-N55-.
unit”, page 32 .
Installing
Note


Note

♦ ⇒ v3.1.1 iew – control unit and hydraulic unit, left-hand drive

vehicle”, page 17
♦ Sound damper ⇒ External body repairs; Rep. gr. 66; Sound
damper; removing and installing sound damper
♦ Pendulum support ⇒ Engine; Rep. gr. 10; Unit carrier; over‐
view of components - unit carrier
♦ Exhaust front pipe ⇒ Engine; Rep. gr. 26; Exhaust gas
cleaning system; overview of components - exhaust gas
cleaning
♦ Propshaft ⇒ Rep. gr. 39; Propshaft; Summary of compo‐
nents - propshaft
3.2.3 Removing and installing ABS control

unit -J104-/ABS hydraulic unit -N55-,
right-hand drive vehicles
Removing:
Fitting location:
-N55- and is located in the engine compartment on the left side.
Note

– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.


Note
The illustration shows the hydraulic unit for ABS -N55- with
control unit for ABS/ESC -J104- for left-hand drives.
vent valves.
at least 60 mm.

– Mark both brake lines -A- and -B- from the master brake

and close with plugs from the repair kit -1H0 698 311 A-.
-J104- -1- in the -direction of the arrow- and out of the shock
absorbers.
– Remove the ABS control unit -J104- and the ABS hydraulic
unit -N55- from the vehicle.
Note

-N55-.
unit”, page 32 .
Installing

Note

Note

♦ ⇒ v3.1.2 iew – control unit and hydraulic unit, right-hand

drive vehicle”, page 19
♦ Battery tray ⇒ Electrical system; Rep. gr. 27; Battery; Re‐
moving and installing battery tray
3.3 Disconnecting the control unit from the

hydraulic unit
♦ ESD workstation -VAS 6613-

♦ In the case of a malfunction of the ABS control unit -J104-,

the control unit must be disconnected from the ABS hydraul‐
ic unit -N55- and replaced individually.
♦ In the event of a malfunction in the ABS hydraulic unit -N55-,
the ABS hydraulic unit -N55- must be fully replaced, along
with the ABS control unit -J104-.
Note
♦ The hydraulic pump -V64- and ABS hydraulic unit -N55-

must not be separated from each other.
♦ On a disconnected ABS control unit -J104-, the printed cir‐
cuit board is exposed.
♦ No moisture and no dirt particles must penetrate into the
interior of the ABS control unit -J104-.
♦ Electrostatic charge can cause malfunctions of the ABS con‐
trol unit -J104-.
♦ Before handling the ABS control unit -J104-, the technician
must discharge himself electrostatically. The electrostatic
discharge is achieved by touching earthed metal parts. Do
not grab directly at the plug contacts or electronic compo‐
nents.
– Remove the ABS hydraulic unit -N55- with the ABS control
unit -J104- ⇒ a3.2 nd installing ABS control unitJ104/ABS
hydraulic unitN55”, page 21 .
– Lay the ABS hydraulic unit -N55- with the ABS control unit
-J104- on a clean flat surface facing upwards.
– Unscrew the fixing screws -arrows- of the ABS control unit
-J104- and place to one side immediately (danger of mixing
with new screws).
– Separate the ABS control unit -J104- from the ABS hydraulic
unit -N55- in the -direction of arrow-.

Note
The ABS control unit -J104- may not tilt when it is pulled off
from the ABS hydraulic unit -N55-.
– Cover the solenoid coils of the ABS control unit -J104- with a
non-fluffing cloth.
After separating from the ABS control unit -J104- and the
ABS hydraulic unit -N55-, use the transport protection for valve
domes.
– Check the sealing surface of the ABS hydraulic unit -N55-
for cleanliness. If necessary clean with white spirits and a
non-fluffing cloth.
Note
♦ The sealing surface of the ABS control unit -J104- may not
be repaired using a file, metal scraper or similar.
♦ If the sealing surface is damaged, replace the sealing sur‐
face of the ABS control unit -J104-.
♦ The seal of the ABS control unit -J104- must not be dam‐
aged.
♦ The seal is not designed as spare part, so it is part of the
new ABS control unit -J104-.
3.4 Fitting the control unit to the hydraulic

unit
♦ ESD workstation -VAS 6613-

Note
Strong vibrations (e.g. fall, knock) can destroy the ABS control
unit -J104-. The ABS control unit -J104- must no longer be
used.
• The contact surfaces must be cleaned before assembling.

• The seal of the ABS control unit -J104- must not be dam‐
aged.
– Position the ABS control unit -J104- without tilting it onto the
– Start by bolting the ABS control unit -J104- to the ABS hy‐
draulic unit -N55- by hand using new screws -arrows-.
Note
♦ A new ABS control unit -J104- may only be installed on

the remaining ABD hydraulic unit -N55- a maximum of three
times in order to ensure leak-tightness of the elastic seal.
♦ If the ABS control unit -J104- has already been installed and
used in the vehicle, it must not be installed a second time.
♦ The threads in the ABS hydraulic unit -N55- must not be
repaired or recut.
♦ If the thread is damaged, the ABS hydraulic unit -N55- must
be replaced.
– Tighten the screws in two stages:

Note

♦ 1st level: Preliminary tightening torque: 1 Nm to 1.5 Nm (to

fit the seal)
♦ 2nd level: final tightening torque: 2.5 Nm

3.5 Connecting brake lines to hydraulic

unit
⇒ t3.5.1 he brake lines to the hydraulic unit, left-hand drive
vehicle”, page 36
⇒ t3.5.2 he brake lines to the hydraulic unit, right-hand drive
vehicle”, page 37
3.5.1 Connect the brake lines to the hydraul‐

ic unit, left-hand drive vehicle
On the ABS hydraulic unit -N55-
1 - from the ABS hydraulic unit -N55- to the rear right brake
caliper
- Distingushing feature: ∅ 5.25 mm and pipe screw with short
thread M 12 x 1
2 - from the ABS hydraulic unit -N55- to the front left brake
calliper
- Distinguishing feature: ∅ 5.25 mm and pipe screw with thread
M 10 x 1
3 - from the ABS hydraulic unit -N55- to the front right brake
calliper
thread M 12 x 1
4 - from the ABS hydraulic unit -N55- to the rear left brake
caliper
M 10 x 1
5 - Secondary piston circuit of brake master cylinder to ABS
hydraulic unit -N55-
- Distinguishing feature: ∅ 6 mm and pipe screw with thread M
12 x 1
6 - Primary piston circuit of brake master cylinder to ABS hy‐
draulic unit -N55-
12 x 1

At brake master cylinder

12 x 1
2 - Brake servo with brake master cylinder
draulic unit -N55-
12 x 1
obrázek nahoře - Octavia IV
obrázek dole - ignore
3.5.2 Connect the brake lines to the hydraul‐

ic unit, right-hand drive vehicle
On the ABS hydraulic unit -N55-
A - Primary piston circuit of brake master cylinder to ABS hy‐

draulic unit -N55-
12 x 1
B - Secondary piston circuit of brake master cylinder to ABS


12 x 1
1 - from the ABS hydraulic unit -N55- to the rear left brake
caliper
M 10 x 1
2 - from the ABS hydraulic unit -N55- to the front right brake
calliper
thread M 12 x 1
3 - from the ABS hydraulic unit -N55- to the front left brake
calliper
M 10 x 1
4 - from the ABS hydraulic unit -N55- to the rear right brake
caliper
thread M 12 x 1
At brake master cylinder
1 - Brake servo with brake master cylinder

draulic unit -N55-
12 x 1
12 x 1

4 Sensors
⇒ o4.1 verview - speed sensor on front axle”, page 39
⇒ o4.2 verview - speed sensor on rear axle”, page 40
⇒ a4.3 nd installing the sensor unit for stabilisation pro‐
gramG419”, page 40
⇒ a4.4 nd installing front speed sensors G45/G47”, page 41
⇒ a4.5 nd installing the rear speed sensors G44/G46”, page
41
4.1 Assembly overview - speed sensor on front axle
Note
Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after
removal.
1 - Assembly overview -
speed sensor on front axle -
G45-/-G47-
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ clean the inner surface
of the hole before in‐
serting the sensor and
brush over with a hot
bolt paste -G 052 112
A3-.
ling ⇒ a4.4 nd instal‐
ling front speed sen‐
sors G45/G47”, page
41
2 - Screw
❑ 8 Nm
3 - Drive shaft
4. Sensors 39
4.2 Assembly overview - speed sensor on rear axle
Note
removal.
1 - Wheel hub with wheel

bearing
❑ Sensor ring for ABS is
built into the wheel hub
2 - Axle stud
3 - Assembly overview -
speed sensor on rear suspen‐
sion -G44-/-G46-
Parts
❑ clean the inner surface
of the hole before in‐
serting the sensor and
brush over with a hot
bolt paste -G 052 112
A3-.
the rear speed sensors
G44/G46”, page 41
4 - Screw
❑ 8 Nm
4.3 Removing and installing the sensor

unit for stabilisation program -G419-
The ESP sensor unit -G419- is integrated in the ABS control
unit -J104-.
Sensor unit for ESP -G419- includes: Lateral acceleration en‐
coder -G200-, yaw rate encoder -G202- and longitudinal accel‐
eration encoder -G251-.
The sensor unit for ESP -G419- cannot be replaced separately,
only the removal of the ABS control unit -J104- is possible ⇒
a3.2 nd installing ABS control unitJ104/ABS hydraulic unitN55”,
page 21 .

4.4 Removing and installing front speed

sensors -G45-/-G47-
Removing
– Raise vehicle.
– Disconnect plug -3- on the front wheel speed sensor -G45-/-
G47-.
– Remove screw -2-.

– Pull front speed sensor -G45-/-G47- -1- out of the wheel
bearing housing.
Installing
– Installation is carried out in the reverse order. When instal‐
ling, observe the following:
– Clean the inner surface of the hole before inserting the
speed sensor and brush over the front speed sensor -G45-/-
G47- with hot screw paste -G 052 112 A3-.
Note

♦ ⇒ o4.1 verview - speed sensor on front axle”, page 39
4.5 Removing and installing the rear speed

sensors -G44-/-G46-
Note
The procedure for removal and installation of the ABS speed

sensor is the same for the torsion beam axle as well as for the
multi-link suspension.
4. Sensors 41
Removing
– Raise vehicle.
– Disconnect plug -2- on the rear speed sensor -G44-/-G46-.

– Pull rear speed sensor -G44-/-G46- out of the axle.
Installing
– Installation is carried out in the reverse order. When instal‐
ling, observe the following:
– Clean the inner surface of the hole before inserting the
speed sensor and brush over the rear speed sensor -G44-/-
G46- with hot screw paste -G 052 112 A3-.
Note

♦ ⇒ o4.2 verview - speed sensor on rear axle”, page 40

46 – Brakes - mechanism
1 Front brakes
⇒ o1.1 verview - front brakes”, page 43
⇒ a1.2 nd installing brake pads”, page 47
⇒ a1.3 nd installing brake calliper”, page 56
⇒ a1.4 nd installing brake disc”, page 64
⇒ a1.5 nd installing heat shield for brake”, page 65
1.1 Assembly overview - front brakes

⇒ o1.1.1 f components - front brake PC57”, page 43
⇒ o1.1.2 f components - front brake FNt57”, page 45
1.1.1 Summary of components - front brake PC57
Note
♦ Observe the instructions for changing the pad ⇒ t1.2.1 he brake pads of the front brake - Mounting
instructions”, page 47
♦ Brake inspection ⇒ i4 nspection”, page 7 .
♦ 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 -VAS 5234- or -VAS 6860-, to drain the brake fluid from the
brake fluid reservoir.
♦ Use brake pedal loader, e.g. -V.A.G 1869/2- before removing a brake calliper or separating a brake hose
from the brake calliper
removal.
1. Front brakes 43
1 - Screw
❑ clean when using again
❑ 200 Nm
2 - Wheel bearing housing
Parts
3 - Brake hose
❑ with banjo union and
hollow screw
❑ pay attention to correct
installation position
❑ 35 Nm
4 - Buckle
6 - Screw
❑ 8 Nm
7 - Heat shield for brake
heat shield for brake”,
page 65
Parts
8 - Screw
❑ 12 Nm
9 - Brake disc
❑ internally ventilated
❑ always replace axle-
wise
❑ Dimensions and wear limit ⇒ d3.1 ata for brakes”, page 3
❑ Removing and installing ⇒ a1.4 nd installing brake disc”, page 64
❑ Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent; as you
could otherwise damage the brake discs.
10 - Screw
❑ 8 Nm
11 - Brake carrier
❑ screwed onto the wheel-bearing housing
12 - External brake pad
❑ do not unscrew the brake hose when replacing the brake pad
❑ always replace axle-wise
❑ Removing and installing ⇒ a1.2.2 nd installing brake pads, brake calliper PC57”, page 48
❑ Installation position of the brake pads ⇒ page 50
❑ Observe the instructions for changing the pad ⇒ t1.2.1 he brake pads of the front brake - Mounting
❑ Installation position of the clips for brake pads in the brake carrier ⇒ Fig. ““Installation position of the
clips for brake pads in the brake carrier”“, page 50
44 Rep. gr.46 - Brakes - mechanism

13 - Internal brake pad
❑ Removing and installing ⇒ a1.2.2 nd installing brake pads, brake calliper PC57”, page 48
❑ Installation position of the brake pads ⇒ page 50
❑ Installation position of the clips for brake pads in the brake carrier ⇒ Fig. ““Installation position of the
clips for brake pads in the brake carrier”“, page 50
14 - Brake caliper
❑ Removing and installing ⇒ a1.3.1 nd installing brake calliper PC57”, page 56
❑ Summary of components ⇒ o1.1.1 f components - Front brake caliper PC57”, page 100
15 - Screw
❑ self-locking
❑ Replace after disassembly
❑ 35 Nm
1.1.2 Summary of components - front brake FNt57
Note
♦ Observe the instructions for changing the pad ⇒ t1.2.1 he brake pads of the front brake - Mounting
removal.
1. Front brakes 45
1 - Screw
❑ clean when using again
❑ 200 Nm
2 - Wheel bearing housing
Parts
3 - Brake hose
hollow screw
❑ 35 Nm
4 - Buckle
6 - Screw
❑ 8 Nm
heat shield for brake”,
page 65
Parts
8 - Screw
❑ 12 Nm
9 - Brake disc
❑ internally ventilated
❑ always replace axle-
wise
10 - Screw
❑ 8 Nm
11 - Brake carrier
❑ screwed onto the wheel-bearing housing
12 - Buckle
13 - External brake pad
❑ Removing and installing ⇒ a1.2.3 nd installing brake pads, brake calliper FNt57”, page 52
❑ Installation position of the brake pads ⇒ Fig. ““Installation position of the brake linings”“, page 54

14 - Internal brake pad

❑ Removing and installing ⇒ a1.2.3 nd installing brake pads, brake calliper FNt57”, page 52
❑ Installation position of the brake pads ⇒ Fig. ““Installation position of the brake linings”“, page 54
15 - Brake caliper
❑ Removing and installing ⇒ a1.3.2 nd installing brake calliper FNt57”, page 60
❑ Summary of components ⇒ o1.1.2 f components - front brake FNt57”, page 45
16 - Guide bolt
❑ 30 Nm
17 - Cap
1.2 Removing and installing brake pads

⇒ t1.2.1 he brake pads of the front brake - Mounting instruc‐
tions”, page 47
⇒ a1.2.2 nd installing brake pads, brake calliper PC57”, page
48
⇒ a1.2.3 nd installing brake pads, brake calliper FNt57”, page
52
1.2.1 Changing the brake pads of the front

brake - Mounting instructions
When changing the pads, pay attention to the following points:
– Check protective collar of brake calliper piston.
Replace protective cap if damaged.
When replacing the protective cap:
– Check the contact surfaces of the brake piston and the
brake calliper for any dirt (oxidation).
Carefully clean the piston as well as the brake calliper if dirty
and replace the sealing cap.
– Check the brake piston and the brake calliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake calliper completely if damaged.
For brake calliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake
calliper.
If the piston cannot be slightly pressed into the brake calliper:
– Check and clean the brake piston as well as the brake callip‐
er, replace sealing sleeve and protective cap.
Replace the brake calliper completely if damaged.
1. Front brakes 47
1.2.2 Removing and installing brake pads,

brake calliper PC57
♦ Piston jig -T10145-
Note
♦ Observe the instructions for changing the pad ⇒ t1.2.1 he

brake pads of the front brake - Mounting instructions”, page
47 .
♦ When removing mark the brake pads (inner, outer) you in‐
tend to keep using. Fit in same position when installing, or
braking will be uneven!
♦ Do not unscrew the brake hose when replacing the brake
pad.
Removing
– Remove wheel.
– If present, disconnect the connector -1- for the brake pad
wear indicator.
– Remove the mounting screws -1-, counterhold the guide

bolts -2- as you do so.
Note
Do not unscrew the brake hose -5-.

– Remove the brake caliper -3- from the carrier -4- and secure
with wire in such a way that the weight of the brake caliper
does not burden or damage the brake hose.
– Tilt out the brake pads -1- in the direction of the front
-arrows- from the brake carrier -2-.
– Remove the brake pads -1- from the brake carrier -2-.
Clean
NOTICE
Do not flush the brake system with compressed air. The dust
that is generated is hazardous to health!
– Thoroughly clean guiding surface for brake pads on brake

carrier and remove corrosion.
– Clean brake calliper.
Note
Use spirits only to clean the brake calliper housing.
Installing
Note

47 .
♦ The adhesive for the brake pads must be free from glue
residues and grease.
♦ Drain the brake fluid from the brake fluid reservoir using a
ventilation bottle before resetting the piston. Otherwise, par‐
ticularly if reservoir has been topped up, fluid will overflow
and cause damage.
♦ When resetting the piston with a piston resetting device the
automatic reset in the brake calliper is destroyed.
CAUTION
Brake fluid is toxic and must never be sucked up by mouth!
– Press the piston into the brake caliper using the piston reset‐
ting jig -T10145- -A-.
1. Front brakes 49
Installation position of the clips for brake pads in the brake

carrier
– Slightly grease the pad guide surface on the brake calliper

with lithium grease -G 052 150 A2-.
Installation position of the brake linings
1- Internal brake pad with recess

2- Outer brake pad
– The recess in the back plate -arrow- must point upwards.
NOTICE
If the internal brake linings are incorrectly installed, uneven
wear of the brake discs occurs.
– Insert the brake pads -1- in the rear into the upper -arrow A-
and lower -arrow B- springs in the recess in the brake carrier
-2-.

– Clip the brake pads -1- into the brake carrier -2- opposite to
the direction of the -arrow-.
– Carefully fit the brake caliper -3- to the brake carrier -4-.
– Attach the brake caliper onto the brake carrier with new
self-locking screws -1-, while counterholding the guide bolts
-2-.
– If available, connect plug connection -1- for the brake pad
wear indicator.
– Attach the wheel.
Note
♦ After each brake pad replacement, forcefully apply the brake

pedal repeatedly to ensure the brake pads go into their nor‐
mal operating position.
♦ Check brake fluid level after changing brake pads.
1. Front brakes 51
Note

♦ ⇒ o1.1.1 f components - front brake PC57”, page 43

♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44;
Wheels, tyres; Specified torque for wheel bolts.
1.2.3 Removing and installing brake pads,

brake calliper FNt57
Note

47 .
pad.
Removing
– Remove wheel.
wear indicator.
– Push out the buckle in -arrow direction A- from the brake

caliper and in -arrow direction B-.

– Remove the sealing caps -1- for the brake caliper guide
bolts -2-.
– Remove the guide bolts -arrows-, remove the brake caliper

-1- and secure with wire in such a way that the weight of
the brake caliper does not burden or damage the brake hose
-2-.
Note
Do not unscrew the brake hose -2-.
– Take out the brake pads.

Clean
NOTICE
1. Front brakes 53

Note
Installing
Note

47 .
and cause damage.
CAUTION

1- Internal brake pad with spring

2- Outer brake pad
– Insert the internal brake pad with spring into the brake cali‐
per.
– Insert the external brake lining into the brake carrier.
– Insert the brake caliper -1- into the brake carrier -2- and
secure it with a clip.
– Install the guide bolts -arrows-.
– Install the sealing caps -1- for the caliper guide bolts -2-.

wear indicator.
1. Front brakes 55
Note

Note

♦ ⇒ o1.1.2 f components - front brake FNt57”, page 45

1.3 Removing and installing brake calliper

⇒ a1.3.1 nd installing brake calliper PC57”, page 56
⇒ a1.3.2 nd installing brake calliper FNt57”, page 60
1.3.1 Removing and installing brake calliper

PC57
Note

47 .
pad.
♦ This procedure applies only to exchanging or the following
repair work on the brake calliper.

Removing
– Remove wheel.
– Disconnect the plug connection -1- for the brake pad wear
indicator.
at least 60 mm.
– Tighten the drain plug.
– Remove the brake hose -5- from the brake caliper -3-.
– Remove the mounting screws -1-, counterhold the guide

bolts -2- as you do so.
– Remove the caliper -3- from the carrier -4-.
1. Front brakes 57
Clean
NOTICE

Note
Installing
Note

47 .
and cause damage.
CAUTION
– Lightly grease guiding surface for brake pads on brake carri‐

er with grease from the repair kit.

Note
Do not interchange the inside and outside brake pads. Note

installation position ⇒ page 50 .
– Insert the brake pads -1- in the rear into the upper -arrow A-
and lower -arrow B- springs in the recess in the brake carrier
-2-.
– Clip the brake pads -1- into the brake carrier -2- opposite to
the direction of the -arrow-.
– Carefully fit the brake caliper -3- to the brake carrier -4-.
– Attach the brake caliper onto the brake carrier with new
self-locking screws -1-, while counterholding the guide bolts
-2-.
wear indicator.
– Insert brake hose -5-.
1. Front brakes 59

Note

47 .
♦ Firmly depress brake pedal several times with vehicle sta‐
tionary so that the brake pads are properly seated in their
normal operating position.
♦ Check brake fluid level.
Note


1.3.2 Removing and installing brake calliper

FNt57
Note

47 .
pad.
Removing
– Remove wheel.
wear indicator.

– Push out the buckle in -arrow direction A- from the brake

caliper and in -arrow direction B-.
– Remove the sealing caps -1- for the brake caliper guide
bolts -2-.
– Remove the brake hose -2- from the brake caliper -1-.
– Remove the guide pins -arrows-, remove the caliper -1- from
the carrier.
1. Front brakes 61
– Take out the brake pads.

Clean
NOTICE

Note
Installing
Note

47 .
and cause damage.
CAUTION

1- Internal brake pad with spring

2- Outer brake pad
– Insert the internal brake pad with spring into the brake cali‐
per.
– Insert the external brake lining into the brake carrier.
– Insert the brake caliper -1- into the brake carrier -2- and
secure it with a clip.
– Install the guide bolts -arrows-.
– Install the sealing caps -1- for the caliper guide bolts -2-.
1. Front brakes 63

wear indicator.
Note

Note

♦ ⇒ o1.1.2 f components - front brake FNt57”, page 45

1.4 Removing and installing brake disc

Removing
– Remove wheel.
– Remove the brake pads ⇒ a1.2 nd installing brake pads”,
page 47 .
– Remove screws for brake carrier ⇒ o1.1.1 f components -
front brake PC57”, page 43 and brakes.

– Remove the screw -arrow- and take off the brake disc.
Installing
– Clean the surfaces for the brake disc and wheel hub.
Note


1.5 Removing and installing heat shield for

brake
Removing
– Remove wheel.
– Remove brake disc ⇒ a1.4 nd installing brake disc”, page
64 .
– Unscrew screws -arrows-.
– Remove the cover plate -1- from the wheel bearing housing.
Installing
1. Front brakes 65
– Clean the contact surfaces for the cover plate and the wheel
bearing housing.
WARNING
Note



2 Rear brakes
⇒ o2.1 verview - rear brakes”, page 67
⇒ a2.2 nd installing brake pads”, page 69
⇒ a2.3 nd installing brake calliper”, page 75
⇒ a2.4 nd installing brake anchor plate”, page 80
⇒ a2.5 nd installing brake disc”, page 81
⇒ a2.6 nd installing heat shield for brake”, page 82
2.1 Assembly overview - rear brakes
Note
♦ Observe the instructions for changing the pad ⇒ t2.2.1 he brake pads of the rear brake - Mounting
removal.
2. Rear brakes 67
1 - Buckle
2 - Brake hose
hollow screw
❑ To the brake calliper:
35 Nm
❑ To the brake line: 14
Nm
3 - Brake line
❑ 14 Nm
4 - Handbrake motor -V282-/-
V283-
handbrake motor V282/
V283”, page 86
5 - Screw
o3.1 verview - parking
brake”, page 84
6 - Cap
7 - Guide bolt
❑ 35 Nm
8 - Spring
❑ Only on inner brake
pad
❑ Check fitting position
9 - Sheet metal buckle
10 - Brake pad
❑ Dimensions and wear
limit ⇒ d3.1 ata for
brakes”, page 3
❑ Removing and installing ⇒ a2.2 nd installing brake pads”, page 69
❑ Observe the instructions for changing the pad ⇒ t2.2.1 he brake pads of the rear brake - Mounting
11 - Rear axle
12 - Screw
❑ 90 Nm + 90°.
13 - Screw
❑ Tightening torque ⇒ o4.2 verview - speed sensor on rear axle”, page 40
14 - Assembly overview - speed sensor on rear suspension -G44-/-G46-
❑ Removing and installing ⇒ a4.5 nd installing the rear speed sensors G44/G46”, page 41
15 - Axle stud
❑ Removing and installing ⇒ a2.6.2 nd installing heat shield for brake, multi-link rear suspension”, page
83

17 - Screw
❑ 30 Nm + 90°
❑ Removing and installing ⇒ Chassis, axles, steering; Rep. gr. 42; Wheel bearing, trailing arm; Remov‐
ing and installing the wheel bearing unit
19 - Screw
❑ Tightening torque ⇒ Chassis, axles, steering; Rep. gr. 42; Wheel bearing, trailing arm; Removing and
installing wheel bearing unit.
20 - Brake disc
❑ unscrew the brake calliper before removing
21 - Screw
❑ 8 Nm
22 - Cap
23 - Brake caliper
❑ Removing and installing ⇒ a2.3 nd installing brake calliper”, page 75
❑ Observe the instructions for changing the pad ⇒ t2.2.1 he brake pads of the rear brake - Mounting
❑ After repair or replacement, carry out “basic setting” with the ⇒ Vehicle diagnostic tester
24 - Spring
25 - Brake carrier
❑ Removing and installing ⇒ a2.4 nd installing brake anchor plate”, page 80
2.2 Removing and installing brake pads

⇒ t2.2.1 he brake pads of the rear brake - Mounting instruc‐
tions”, page 69
⇒ a2.2.2 nd installing brake pads”, page 70
2.2.1 Changing the brake pads of the rear

brake - Mounting instructions
When changing the pads, pay attention to the following points:
– Check protective collar of brake calliper piston.
Replace protective cap if damaged.
When replacing the protective cap:
– Check the contact surfaces of the brake piston and the
brake calliper for any dirt (oxidation).
2. Rear brakes 69
Carefully clean the piston as well as the brake calliper if dirty

and replace the sealing cap.
– Check the brake piston and the brake calliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake calliper completely if damaged.
For brake calliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake
calliper.
If the piston cannot be slightly pressed into the brake calliper:
– Check and clean the brake piston as well as the brake callip‐
er, replace sealing sleeve and protective cap.
Replace the brake calliper completely if damaged.
2.2.2 Removing and installing brake pads

♦ Vehicle diagnosis, measurement and information system
♦ Bit 7 mm -T10503-
Removing
Note

47 .
♦ When removing mark the brake pads (inner and outer) you
intend to keep using. Fit in same position when installing, or
♦ Do not disconnect the connectors of the handbrake motor.
and cause damage.
pad.
♦ Do not operate the handbrake for any reason! If the hand‐
brake is operated, the brake caliper is permanently dam‐
aged.
CAUTION
• Electronic handbrake not actuated.

Summary of components - brake calliper, torsion beam axle

1 - Brake caliper
A - Torsion beam axle
Summary of components - brake calliper, multi-link axle
1 - Brake caliper
B - Multi-link rear suspension
Note
Drain the brake fluid from the brake fluid reservoir using a venti‐
lation bottle before resetting the parking brake piston.
– Remove wheels.
– Reset the pistons for the electronic handbrake ⇒ Vehicle
diagnostic tester.
Note
You must set back the pistons with the ⇒ Vehicle diagnostic
testerin all cases! The compressor nut in the piston has a
sleeve bearing, so that the piston can only be pushed out and
cannot be pulled back. Only the spindle is driven back with the
compressor nut.
NOTICE
Do not operate the handbrake for any reason! If the hand‐
brake is operated, the brake caliper is permanently damaged.
– Pry out the springs -2- e.g. with a screwdriver from the cali‐
per -1-.
2. Rear brakes 71
– Remove the sealing caps -arrows-.
– Remove the two guide pins from the caliper e.g. with Bit 7
mm -T10503-.
– Remove brake calliper and secure with wire so that weight of
brake calliper does not strain or damage brake hose.
Note
Do not disconnect the brake line.
NOTICE
Do not operate the handbrake for any reason! If the hand‐
brake is operated, the brake caliper is permanently damaged.
– Remove the brake pads -1- and -2- from the brake carrier
-3-.

Clean
WARNING

Note
Installing
Note

brake pads of the rear brake - Mounting instructions”, page
69 .
and cause damage.
aged.
CAUTION
– Lightly grease guiding surface for brake pads on brake carri‐

er with lubricating grease G 052 150 A2.
– Insert the internal -1- and external -2- brake pad into the
metal buckles -arrows-.
2. Rear brakes 73
– Insert the internal -1- and external -2- brake pad into the
brake carrier -3-.
– Fit the brake caliper and guide pin e.g. with the bit 7 mm
-T10503- onto the brake carrier.
– Insert the sealing caps -arrows-.
– Insert the spring -2- into the brake caliper -1-.

Note
Pay attention to the correct position of the retaining spring in the

brake caliper.
– Bring the brake system to basic position ⇒ Vehicle diagnos‐

tic tester.
– Attach the wheels.
Note
Check brake fluid level, if necessary top up with brake fluid.
Note

♦ ⇒ o2.1 verview - rear brakes”, page 67


♦ Vehicle diagnosis, measurement and information system
♦ Brake filling and bleeding device -VAS 5234- or -VAS 6860-
♦ Bit 7 mm -T10503-
♦ Bleeding bottle (commercially available)
♦ Braking fluid ⇒ Electronic Catalogue of Original Parts
2. Rear brakes 75
Removing
Note
♦ This procedure applies only to exchanging or the following

repair work on the brake calliper.
47 .
♦ When removing mark the brake pads (inner and outer) you
intend to keep using. Fit in same position when installing, or
♦ Do not disconnect the connectors of the handbrake motor.
and cause damage.
pad.
aged.
CAUTION
• Electronic handbrake not actuated.
Note
Drain the brake fluid from the brake fluid reservoir using a venti‐
lation bottle before resetting the parking brake piston.
– Remove wheels.
– Reset the pistons for the electronic handbrake ⇒ Vehicle
diagnostic tester.
– Remove handbrake motor ⇒ a3.3 nd installing handbrake
motor V282/V283”, page 86 .
– Fit the bleeder hose of the bleeding bottle -1- onto the bleed‐
er valve and release bleeder valve.

at least 60 mm.
– Tighten the bleeder valve and remove the hose of the bleed‐
ing bottle.
– Remove screw -Arrow- and pull off the brake hose -1- from
the brake calliper -2-.
– Pry out the springs -2- e.g. with a screwdriver from the cali‐
per -1-.
2. Rear brakes 77
– Remove the sealing caps -arrows-.
– Remove the guide pins -arrows- e.g. with Bit 7 mm -T10503-

and remove the caliper -1- from the brake carrier -2-.
Clean
WARNING

Note

Installing
Note

69 .
and cause damage.
aged.
CAUTION

– Perform basic setting of the brake system with the ⇒ Vehicle
diagnostic tester.
– Attach the wheels.
Note
Check brake fluid level, if necessary top up with brake fluid.
Note


♦ ⇒ o2.1 f components - rear brake calliper”, page 107
2. Rear brakes 79
2.4 Removing and installing brake anchor

plate
Note
♦ When removing the brake carrier, do not unscrew the brake
hose.
Removing
– Remove wheel.
– Remove brake pads and calliper, but do not disconnect the
brake hose and hang the brake calliper with wire so that the
calliper weight does not stress or damage the brake hose ⇒
a2.3 nd installing brake calliper”, page 75 ,
– Remove screws -arrows- and brake carrier -1- from the axle.
Clean
WARNING
Health hazard due to toxic dust from the brake system.
There is a risk of irreversible deposition of dust particles in the
lungs, which can then have a negative effect on breathing.
Do not flush the brake system with compressed air!
– Thoroughly clean the contact surfaces for the brake pads on

brake carrier and remove corrosion.
Note
Installing

Note

69 .
♦ If brake linings are reused, they must be reinstalled at the
same point, otherwise there will be an uneven braking effect!
♦ Check brake fluid level after replacing the brake pads, if
necessary top up with brake fluid.
Note


2.5 Removing and installing brake disc

Removing
– Remove brake carrier ⇒ a2.4 nd installing brake anchor
plate”, page 80 .
– Unscrew screw -arrow-.
– Remove brake disc -1-.

Installing
– Clean the surfaces for the brake disc and wheel hub.
2. Rear brakes 81
Note


2.6 Removing and installing heat shield for

brake
⇒ a2.6.1 nd installing heat shield for brake, torsion beam axle”,
page 82
⇒ a2.6.2 nd installing heat shield for brake, multi-link rear sus‐
pension”, page 83
2.6.1 Removing and installing heat shield for

brake, torsion beam axle
Removing
– Remove wheel.
81 .
– Removing wheel hub ⇒ Chassis, axles, steering; Rep.
gr. 42; Wheel bearing, trailing arm; Removing and installing
wheel bearing unit.
– Remove the cover plate -1- and the axle stud housing -2-.
Installing
bearing housing.
Note



♦ Wheel hub ⇒ Chassis, axles, steering; Rep. gr. 42; Wheel
bearing, trailing arm; Summary of components - wheel bear‐
ing
2.6.2 Removing and installing heat shield for

brake, multi-link rear suspension
Removing
81 .
For vehicles with sealed heat shield
– Removing wheel hub ⇒ Chassis, axles, steering; Rep.
gr. 42; Wheel bearing, trailing arm; Removing and installing
wheel bearing unit.
– Remove cover plate -1-.

Installing
bearing housing.
Note

♦ Wheel hub ⇒ Chassis, axles, steering; Rep. gr. 42; Wheel

bearing, trailing arm; Summary of components - wheel bear‐
ing
Component Tightening torque
Heat shield for brake 12 Nm
2. Rear brakes 83
3 Handbrake
⇒ o3.1 verview - parking brake”, page 84
⇒ a3.2 nd installing control unit for electronic handbrakeJ540”,
page 85
⇒ a3.3 nd installing handbrake motor V282/V283”, page 86
3.1 Assembly overview - parking brake

1 - Dash panel insert

❑ with fault lamp
for electronic park‐
ing/handbrake -K214-
❑ with brake system
warning light -K118-
❑ with acoustic signal
2 - Switch unit
❑ Fitting location: in the
centre console
❑ includes:
♦ Button for AUTO HOLD -
E540-
♦ Control light for AUTO
HOLD -K237-
♦ Indicator light for electro-
mechanical parking brake
-K213-
♦ Button for electro-mechan‐
ical parking brake -E538-
ling ⇒ Electrical sys‐
tem; Rep. gr. 96;
Controls; Removing
and installing buttons
for electro-mechanical
handbrake -E538-/But‐
tons for AUTO HOLD -
E540-
3 - Brake caliper
4 - Sealing ring
❑ Replace after disas‐
sembly
5 - Handbrake motor
❑ Installation location: on rear brake caliper
❑ Removing and installing ⇒ a3.3 nd installing handbrake motor V282/V283”, page 86
❑ Basic braking system setting ⇒ Vehicle diagnostic tester
6 - Screw
❑ 8 Nm
7 - Control unit for electronic handbrake -J540-
❑ integrated into the ABS control unit -J104- and cannot be replaced separately
❑ Removing and installing ABS control unit -J104- ⇒ a3.2 nd installing ABS control unitJ104/ABS hy‐
draulic unitN55”, page 21
❑ Separate the ABS control unit -J104- from the ABS hydraulic unit -N55- ⇒ t3.3 he control unit from the
hydraulic unit”, page 32
3.2 Removing and installing control unit for

electronic handbrake -J540-
It is not possible to remove these parts separately.
Control unit for electronic handbrake -J540- integrated into the
ABS control unit -J104- ⇒ v3.1 iew – control unit and hydraulic
unit”, page 17 .
3. Handbrake 85
3.3 Removing and installing handbrake

motor -V282-/-V283-
♦ Vehicle diagnosis tester
Removing
Note
The ignition must be switched off for at least 30 seconds before

disconnecting the connector.
– Pull connector -1- off the handbrake motor.
– Remove screws -arrows- of the handbrake motor.

– Pull the handbrake motor off the brake caliper, turning the
handbrake motor back and forth slightly as you do so.
– Remove the sealing ring -1- from the groove in the brake
calliper -2-.
Note
Make sure that the annular groove of the sealing ring and the
contact surface of the handbrake motor are not damaged.
– Clean the annular groove and the contact surface of the

handbrake motor.
Installing
– Lightly grease the new sealing ring -1- and install it, ensuring
that the sealing ring is kept straight and not damaged.

– Fully grease the drive shaft of the handbrake motor.
Note
The sealing ring must not be twisted out while assembling the
handbrake motor!
– Carefully slide the handbrake motor onto the brake caliper,

while ensuring that the sealing ring is seated correctly.
Note
If necessary, drive back the drive shaft slightly with an E11

Torx insert -A- so that you can position the handbrake motor
correctly.
– Twist the handbrake motor until the screw holes and thread
are aligned.
Note
Make sure the handbrake motor is in contact with the brake

caliper. Do not tighten the screws if the handbrake motor is not
in contact with the brake caliper.
– Screw in the screws -arrow-.
3. Handbrake 87
– Reconnect connector -1-.

– Bring the brake system to basic position ⇒ Vehicle diagnos‐
tic tester.
Note

♦ ⇒ o3.1 verview - parking brake”, page 84

4 Brake pedal
⇒ o4.1 f components - brake pedal”, page 89
⇒ a4.2 nd installing bearing bracket”, page 93
⇒ b4.3 rake pedal from brake servo”, page 95
⇒ t4.4 he brake pedal onto the brake servo unit”, page 96
⇒ a4.5 nd installing brake pedal”, page 97
4.1 Summary of components - brake pedal

⇒ o4.1.1 f components - brake pedal, left-hand drive”, page 89
⇒ o4.1.2 f components - brake pedal, right-hand drive”, page
91
4.1.1 Summary of components - brake pedal, left-hand drive

WARNING
The brake pedal travel must not be restricted by additional
floor coverings.
Do not oil or grease the bearing bolt The bearing bolt must
remain dry.
Note
removal.
4. Brake pedal 89
1 - guide bushing
2 - Threaded bores
3 - guide bushing
4 - guide bushing
5 - Bearing bracket
ling ⇒ a4.2.1 nd instal‐
ling bushing, left-hand
drive vehicles”, page
93
6 - Nut
❑ self-locking
sembly
❑ Tightening sequence ⇒
Fig. ““order of tighten‐
ing”“, page 90
❑ 25 Nm
7 - Retaining clip
8 - Cap
9 - Brake pedal
ling ⇒ a4.5.1 nd in‐
stalling the brake ped‐
al, left-hand drive vehi‐
cles”, page 97
❑ separate from the
brake servo unit ⇒
b4.3 rake pedal from
❑ insert with brake servo
unit ⇒ t4.4 he brake
pedal onto the brake
servo unit”, page 96
10 - Bushing
❑ pay attention to correct installation position
11 - Bearing shell
12 - Support
❑ for ball head of pressure rod of brake servo unit
13 - Bearing shaft
Note
Do not oil or grease the bearing

bolt The bearing bolt must remain
dry.
14 - Threaded bores
order of tightening

4.1.2 Summary of components - brake pedal, right-hand drive

WARNING
The brake pedal travel must not be restricted by additional
floor coverings.
Do not oil or grease the bearing bolt The bearing bolt must
remain dry.
Note
removal.
4. Brake pedal 91
1 - Screw
❑ 20 Nm
2 - Threaded bores
3 - guide bushing
4 - Bearing bracket
stalling bearing brack‐
et, right-hand drive ve‐
hicles”, page 94
5 - Threaded insert
6 - Retaining clip
7 - Retaining clip
8 - Nut
❑ 25 Nm
9 - Bushing
10 - Brake pedal
stalling the brake ped‐
al, right-hand drive ve‐
hicles”, page 98
❑ separate from the
brake servo unit ⇒
b4.3 rake pedal from
❑ insert with brake servo
unit ⇒ t4.4 he brake
pedal onto the brake
servo unit”, page 96
11 - Cap
12 - Support
❑ for ball head of pressure rod of brake servo unit
13 - Bearing shaft
Note
Do not oil or grease the bearing

bolt The bearing bolt must remain
dry.
14 - Threaded bores
15 - guide bushing
16 - guide bushing

4.2 Removing and installing bearing brack‐

et
⇒ a4.2.1 nd installing bushing, left-hand drive vehicles”, page
93
⇒ a4.2.2 nd installing bearing bracket, right-hand drive vehi‐
cles”, page 94
4.2.1 Removing and installing bushing, left-

hand drive vehicles
Removing
– Remove brake pedal ⇒ a4.5.1 nd installing the brake pedal,
left-hand drive vehicles”, page 97 .
– Disconnect the plug connections -arrows- and expose the
electrical cable.
– Remove accelerator pedal module -GX2- ⇒ Rep. gr. 20;

Throttle control; removing and installing accelerator pedal
module -GX2-.
– Remove diagnostic interface for data bus -J533- ⇒ Electrical
system; Rep. gr. 97; Control units; removing and installing
diagnostic interface for data bus -J533- and unclip its holder
from the bracket (fastened to the bracket with 2 expanding
rivets).
– Release the nuts -1- to -4-.
– Remove bearing bracket from the vehicle.

Installing
– Clip the brake pedal onto the brake servo ⇒ t4.4 he brake
pedal onto the brake servo unit”, page 96 .
4. Brake pedal 93
– Observe tightening sequence ⇒ Fig. ““order of tightening”“,

page 90 .
Note

♦ Bearing bracket ⇒ o4.1.1 f components - brake pedal, left-

hand drive”, page 89
♦ Accelerator pedal module -GX2- ⇒ Rep. gr. 20; Throttle con‐
trol; Overview of components - accelerator pedal module
4.2.2 Removing and installing bearing brack‐

et, right-hand drive vehicles
Removing
– Remove windscreen wiper motor with linkage ⇒ Electrical
system; Rep. gr. 92; Windscreen wiper system; Removing
and installing windscreen wiper motor -V-.
– Remove brake pedal ⇒ a4.5.1 nd installing the brake pedal,

left-hand drive vehicles”, page 97 .
– Disconnect the plug connections -arrows- and expose the
electrical cable.
– Remove accelerator pedal module -GX2- ⇒ Rep. gr. 20;

Throttle control; removing and installing accelerator pedal
module -GX2-.
– Remove diagnostic interface for data bus -J533- ⇒ Electrical
system; Rep. gr. 97; Control units; removing and installing
diagnostic interface for data bus -J533- and unclip its holder

from the bracket (fastened to the bracket with 2 expanding

rivets).
– Remove the nuts -arrows- and remove the bearing block -1-
from the vehicle.
Installing
Note

♦ Bearing bracket ⇒ o4.1.2 f components - brake pedal, right-

hand drive”, page 91
♦ Accelerator pedal module -GX2- ⇒ Rep. gr. 20; Throttle con‐
trol; Overview of components - accelerator pedal module
♦ Wiper motor with linkage ⇒ Electrical system; Rep. gr. 92;
Windscreen wiper system; Summary of components - wind‐
screen wiper system
4.3 Separating brake pedal from brake ser‐

vo
♦ Release tool -T10159A- or -T10159B-
– Press the brake pedal towards the brake servo unit and hold
it in position.
4. Brake pedal 95
2 - Plunger rod
3 - Retaining lugs
– Insert the release tool and pull in direction of the driver seat.
When doing this, counter-hold on brake pedal. (At this stage
the brake pedal must not be allowed to move backwards).
This pushes the retaining lugs -3- of the mount off the ball
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.
– Pull the release tool and brake pedal together towards the
driver seat. (This causes the brake pedal to be drawn off the
ball head of the push rod).
4.4 Clipping the brake pedal onto the

brake servo unit
– Hold ball head of push rod in front of mount and push brake
pedal in direction of brake servo, so that the ball head clicks
into place.
– Check that it is correctly locked in place by briefly pulling on

the brake pedal.

4.5 Removing and installing brake pedal

⇒ a4.5.1 nd installing the brake pedal, left-hand drive vehicles”,
page 97
⇒ a4.5.2 nd installing the brake pedal, right-hand drive vehi‐
cles”, page 98
4.5.1 Removing and installing the brake ped‐

al, left-hand drive vehicles
Removing
– Remove screw -1- and open the footwell covering -2- in
-direction of arrow-.
– Remove knee airbag ⇒ Interior body work; Rep. gr. 69; Knee
airbags; removing and installing knee airbag with ignition.
– Remove the driver side footwell vent ⇒ Heating system, air
conditioning system; Rep. gr. 87; Air duct; Remove and in‐
stall driver side footwell vent.
– Loosen the crash strut (impact absorber) fixing screw so that
it can be moved a little ⇒ Interior body work; Rep. gr. 70;
Crossmember panel; removing and installing crash strut (im‐
pact absorber).
– Remove bolt -1- from universal coupling -2- and pull off uni‐
versal joint in -direction of arrow-.
– Separating the brake pedal from the brake servo unit ⇒

b4.3 rake pedal from brake servo”, page 95 .
– Remove retaining clips -1-.
4. Brake pedal 97
– Remove the bearing bolt -3- to the left

-in the direction of the arrow-.
– Take the brake pedal out of the bearing bracket.
Installing
Installation is carried out in the reverse order.
Note

♦ Steering column universal joint ⇒ Chassis, axles, steering;

Rep. gr. 48; Steering column; Summary of components -
steering column
♦ Remove the crash strut (impact absorber) ⇒ General body
repairs, interior; Rep. gr. 70; Dashboard crossmember; Re‐
moving and installing impact absorbers
♦ Knee airbag ⇒ General body repairs, interior; Rep. gr. 69;
Knee airbags; Removing and installing knee airbag with ig‐
niter
4.5.2 Removing and installing the brake ped‐

al, right-hand drive vehicles
Removing
– Removing the driver side glove compartment ⇒ General
body repairs, interior; Rep. gr. 68; Compartments/covers;
Removing and installing glove compartment.
– Remove footrest for driver and push floor covering back‐
wards.
– Remove knee airbag ⇒ Interior body work; Rep. gr. 69; Knee
airbags; removing and installing knee airbag with ignition.
– Remove the driver side footwell vent ⇒ Heating system, air
conditioning system; Rep. gr. 87; Air duct; Remove and in‐
stall driver side footwell vent.
– Loosen the crash strut (impact absorber) fixing screw so that
it can be moved a little ⇒ Interior body work; Rep. gr. 70;
Crossmember panel; removing and installing crash strut (im‐
pact absorber).
– Remove bolt -1- from universal coupling -2- and pull off uni‐
versal joint in -direction of arrow-.

– Separating the brake pedal from the brake servo unit ⇒

b4.3 rake pedal from brake servo”, page 95 .
– Remove retaining clips -1-.
– Remove the bearing bolt -3- to the left

-in the direction of the arrow-.
– Take the brake pedal out of the bearing bracket.
Installing
Note

♦ Steering column universal joint ⇒ Chassis, axles, steering;

Rep. gr. 48; Steering column; Summary of components -
steering column
♦ Remove the crash strut (impact absorber) ⇒ General body
repairs, interior; Rep. gr. 70; Dashboard crossmember; Re‐
moving and installing impact absorbers
♦ Knee airbag ⇒ General body repairs, interior; Rep. gr. 69;
Knee airbags; Removing and installing knee airbag with ig‐
niter
4. Brake pedal 99
47 – Brakes - hydraulics
1 Front brake callipers
⇒ o1.1 f components - front brake calliper”, page 100
⇒ a1.2 nd installing brake calliper piston”, page 103
1.1 Summary of components - front brake

calliper
⇒ o1.1.1 f components - Front brake caliper PC57”, page 100
⇒ o1.1.2 f components - Front brake caliper FNt57”, page 102
1.1.1 Overview of components - Front brake caliper PC57
Note
♦ Install the complete repair set when undertaking repairs.

♦ Use only methylated spirit for cleaning.
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease -G 052 150 A2-.
removal.
100 Rep. gr.47 - Brakes - hydraulics

1 - Brake caliper
stalling brake calliper
PC57”, page 56
2 - Screw
sembly
❑ 35 Nm
3 - Vent valve
❑ thinly coat thread with
lithium grease -G 052
150 A2- before screw‐
ing in
❑ 10 Nm
4 - Dust cap
5 - Sealing ring
❑ not interchangeable, no
spare part
6 - Hollow screw
❑ not interchangeable, no
spare part
❑ 35 Nm
7 - Brake hose
8 - Brake pads
brake pads”, page 47
9 - Guide bolt
10 - 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
11 - Brake carrier
❑ is supplied as replacement part assembled with guide pin and protective caps as well as adequate
quantity of grease on guide pins
❑ if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed grease
packing to lubricate the guide bolts)
12 - Sheet metal buckle
13 - Boot
❑ Removing and installing ⇒ a1.2 nd installing brake calliper piston”, page 103
❑ do not damage when inserting the piston
14 - Piston
❑ before installing, thinly coat piston with lithium grease -G 052 150 A2-
15 - Sealing ring
1. Front brake callipers 101

1.1.2 Overview of components - Front brake caliper FNt57
Note

removal.

1 - Cap
2 - Guide bolt
o1.1.2 f components
- front brake FNt57”,
page 45
3 - Bushing
4 - Brake caliper
stalling brake calliper
FNt57”, page 60
5 - Brake carrier
❑ 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 protective caps
or guide bolts fit a re‐
pair set (use the en‐
closed grease packing
to lubricate the guide
bolts)
6 - Boot
brake calliper piston”,
page 103
❑ do not damage when
inserting the piston
7 - Piston
ling ⇒ a1.2 nd installing brake calliper piston”, page 103
❑ before installing, thinly coat piston with lithium grease -G 052 150 A2-
8 - Sealing ring
9 - Vent valve
❑ thinly coat thread with lithium grease -G 052 150 A2- before screwing in
❑ 10 Nm
10 - Dust cap

piston
♦ Disassembly wedge -3409-
♦ Lithium grease -G 052 150 A2-

Removing
– Remove brake caliper ⇒ a1.3.1 nd installing brake calliper
PC57”, page 56 .
Insert a wooden plate -A- in the brake caliper to avoid damag‐
ing the piston as it is being pressed out.
– Press the piston out of the brake caliper using compressed

air -arrow-.
Note
Make sure that the cylinder surface is not damaged when re‐
moving the gasket ring.
– Remove the sealing ring -2- using the disassembly wedge

-3409- -1-.
Installing
Note
♦ Always install the complete repair kit when repairing the

brake calliper.
♦ Use only methylated spirits for cleaning the brake.
♦ New brake callipers are filled with brake fluid and are pre-
bled.
♦ It is absolutely necessary, if repairs are being undertaken,
to pre-bleed the brake callipers before installing them in the
vehicle (without brake pads) ⇒ page 106 .
– Clean piston and gasket ring with white spirits and dry off.

– Before installing the piston and sealing ring in the brake

calliper, thinly coat with lithium grease -G 052 150 A2-.
– Insert new gasket ring in the groove of the brake calliper.
– Position the protective cap with the outer sealing lip on the
piston.
– Insert inner sealing lip of the protective cap with disassembly

wedge -3409- -A- in the groove of the cylinder.
To do so hold the piston with the hand.

Note
The outer sealing lip of the protective cap will clip into the piston
groove.
– Install brake caliper ⇒ a1.3.1 nd installing brake calliper

PC57”, page 56 .

Pre-bleeding the brake calliper

Set up brake calliper 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.

2 Rear brake calliper

⇒ o2.1 f components - rear brake calliper”, page 107
⇒ a2.2 nd installing protective cover”, page 108
2.1 Summary of components - rear brake calliper
Note

removal.
2. Rear brake calliper 107

1 - Brake caliper housing

❑ replace brake calliper
housing if the lever for
the handbrake cable is
not sealed
2 - Damping sleeve
3 - Guide bolt
o2.1 verview - rear
brakes”, page 67
4 - Cap
5 - Screw
o2.1 verview - rear
brakes”, page 67
6 - Handbrake control motor
handbrake motor V282/
V283”, page 86
7 - Sealing ring
sembly
8 - Compressor nut
❑ Cannot be removed
9 - Sealing ring
10 - Piston
11 - Boot
ling ⇒ a2.2 nd installing protective cover”, page 108
12 - Vent valve
❑ thinly coat thread with lithium grease -G 052 150 A2- before screwing in
❑ 10 Nm
13 - Dust cap
2.2 Removing and installing protective cov‐

er
♦ Assembly tool -T10146-
♦ Disassembly wedge -3409-
Removing
Only the protective cover always has to be replaced.

Note
If the protective cover is replaced, the brake caliper does not

have to be removed or the brake hose unscrewed.
• The piston is pushed back.

• Handbrake control motor has been removed.
NOTICE
♦ When the piston and compressor nut are removed, the
thread is destroyed.
♦ Never completely unscrew the compressor nuts and pis‐
ton!
– Unscrew the piston in -direction of arrow- by maximum of

20 mm -a-.
– Use the disassembly wedge -3409- to remove the protective

cover from the brake caliper.
Installing
Note
Use only methylated spirits for cleaning the brake.
– The piston surfaces and brake caliper must be cleaned with

spirit and then left to dry.
– Fit protective cover into the groove -arrow- on the piston.
2. Rear brake calliper 109

– Screw in piston in -direction of arrow-.
– Press the protective cover with the piston resetting tool

-T10145- -1- and assembly device -T10146/5- -2- onto the
brake caliper so that it is in contact around the circumfer‐
ence of the brake caliper.

3 Brake servo unit and master brake

cylinder
⇒ o3.1 f components - brake servo unit and master brake cylin‐
der”, page 111
⇒ a3.2 nd installing brake servo”, page 115
⇒ a3.3 nd installing master brake cylinder”, page 119
⇒ a3.4 nd installing the warning contact for brake fluid lev‐
elF34”, page 129
3.1 Summary of components - brake servo

unit and master brake cylinder
⇒ o3.1.1 f components - brake servo unit/master brake cylinder,
left-hand drive vehicles”, page 111
⇒ o3.1.2 f components - brake servo unit/master brake cylinder,
right-hand drive vehicles”, page 113
3.1.1 Summary of components - brake servo unit/master brake cylinder, left-

hand drive vehicles
Note
removal.
3. Brake servo unit and master brake cylinder 111

1 - Brake fluid level warning

contact -F34-
the warning contact for
brake fluid levelF34”,
page 129
2 - Cover
3 - Brake fluid reservoir
4 - Body-bound rivet
5 - Supply hose
❑ Only for vehicles with
manual gearbox
6 - Seal
sembly
7 - Bearing bracket
❑ Summary of compo‐
nents ⇒ o4.1.1 f com‐
ponents - brake pedal,
left-hand drive”, page
89
8 - Nut
❑ self-locking
sembly
o4.1.1 f components -
brake pedal, left-hand
drive”, page 89
9 - Brake servo
ling brake servo unit, left-hand drive vehicles”, page 115
The following components are integrated in the brake servo:
♦ Brake pedal position sender -G100-
♦ Brake pedal position sender 2 -G836-
♦ Voltage supply sender 1 -G730-
♦ Voltage supply sender 2 -G731-
♦ Brake servo current sender -G822-
♦ Brake servo temperature sender 1 -G838-
♦ Motor position sender for brake servo -G840-
♦ Brake servo control unit -J539-
♦ Electromechanical brake servo motor -V548-
❑ Check function ⇒ Vehicle diagnostic tester.
10 - Sealing ring

11 - Brake line
❑ Tightening torque ⇒ v3.1.1 iew – control unit and hydraulic unit, left-hand drive vehicle”, page 17
12 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ Removing and installing ⇒ a3.3.1 nd installing master brake cylinder, left-hand drive vehicles”, page
119
13 - Nut
❑ 22 Nm
14 - Plugs
❑ moisten with brake fluid, insert in the brake cylinder and press in the brake fluid reservoir
15 - Brake line
❑ Tightening torque ⇒ v3.1.1 iew – control unit and hydraulic unit, left-hand drive vehicle”, page 17
3.1.2 Summary of components - brake servo unit/master brake cylinder, right-

hand drive vehicles
Note
removal.

1 - Brake fluid level warning

contact -F34-
the warning contact for
brake fluid levelF34”,
page 129
2 - Cover
3 - Brake fluid reservoir
4 - Body-bound rivet
5 - Supply hose
❑ Only for vehicles with
manual gearbox
6 - Brake servo
ling brake servo unit -
right-hand drive”, page
117
The following components are
integrated in the brake servo:
♦ Brake pedal position send‐
er -G100-
♦ Brake pedal position send‐
er 2 -G836-
♦ Voltage supply sender 1 -
G730-
♦ Voltage supply sender 2 -
G731-
♦ Brake servo current send‐
er -G822-
♦ Brake servo temperature
sender 1 -G838-
♦ Motor position sender for brake servo -G840-
♦ Brake servo control unit -J539-
♦ Electromechanical brake servo motor -V548-
❑ Check function ⇒ Vehicle diagnostic tester.
7 - Seal
8 - Bearing bracket
❑ Summary of components ⇒ o4.1.2 f components - brake pedal, right-hand drive”, page 91
9 - Nut
❑ self-locking
❑ Tightening torque ⇒ o4.1.2 f components - brake pedal, right-hand drive”, page 91
10 - Sealing ring

11 - Screw
❑ 8 Nm
12 - Heat shield
13 - Brake line
❑ Tightening torque ⇒ v3.1.2 iew – control unit and hydraulic unit, right-hand drive vehicle”, page 19
14 - Nut
❑ 22 Nm
15 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ Removing and installing ⇒ a3.3.2 nd installing master brake cylinder, right-hand drive vehicles”, page
123
16 - Brake line
❑ Tightening torque ⇒ v3.1.2 iew – control unit and hydraulic unit, right-hand drive vehicle”, page 19
17 - Plugs
❑ moisten with brake fluid, insert in the brake cylinder and press in the brake fluid reservoir
3.2 Removing and installing brake servo

⇒ a3.2.1 nd installing brake servo unit, left-hand drive vehicles”,
page 115
⇒ a3.2.2 nd installing brake servo unit - right-hand drive”, page
117
3.2.1 Removing and installing brake servo

unit, left-hand drive vehicles
♦ Extraction bottle (commercially available)
♦ Repair kit -1H0 698 311 A-
♦ Hot air blower e.g. -V.A.G 1416-
Removing
– Remove master brake cylinder ⇒ a3.3.1 nd installing master
brake cylinder, left-hand drive vehicles”, page 119 .
Vehicles with diesel engine
– Remove air duct ⇒ Rep. gr. 21; Charge air system; removing
and installing air duct pipe.
Vehicles with automatic transmission
– Remove gearshift mechanism from gearbox ⇒ Rep. gr. 34;
Gearshift mechanism; Assembly overview – Gearshift opera‐
tion.
– Disconnect brake servo from brake pedal ⇒ b4.3 rake pedal
from brake servo”, page 95 .
– Release the nuts -3- and -4-.

– Carefully detach the brake servo from the front wall and
remove it from the vehicle.
NOTICE
Risk of damaging the front wall when detaching the brake
servo.
When detaching the brake servo from the front wall, do not
use a lever tool between the brake servo and the front wall.
– Lightly warm the adhesive residues -arrows- and remove

from the front wall -1- and the brake servo -2-.
– Thoroughly clean the contact surfaces.

Installing
– Replace the seal for the brake servo on the front wall ⇒
o3.1.1 f components - brake servo unit/master brake cylin‐
der, left-hand drive vehicles”, page 111 .
Note
When gluing a new seal to the brake booster, it must be held

pressed down for at least 1 second.

– Insert the brake servo and lightly tighten the fastening nuts
by hand.
– Check that the brake servo seal ⇒ Item 10 (page 112) is
correctly positioned.
– Fill up with new brake fluid.
– Code the brake servo control unit -J539- ⇒ Vehicle diagnos‐
tic tester.
– Perform basic adjustment of the electromechanical brake
servo ⇒ Vehicle diagnostic tester.
Vehicles fitted with a manual gearbox
– Bleed the clutch ⇒ Rep. gr. 30; Clutch mechanism; Bleed the
clutch mechanism.
Note

♦ ⇒ o3.1.1 f components - brake servo unit/master brake cylin‐

der, left-hand drive vehicles”, page 111
♦ ⇒ o4.1.1 f components - brake pedal, left-hand drive”, page
89
♦ Gearshift mechanism ⇒ Rep. gr. 34; Shift mechanism; Sum‐
mary of components - shift mechanism
♦ Air guide pipe ⇒ Rep. gr. 21; Charge air system; Summary
of components - charge air system.
3.2.2 Removing and installing brake servo

unit - right-hand drive
♦ Hot air blower e.g. -V.A.G 1416-
Removing
Vehicles with exhaust gas cleaning module
– Remove the exhaust gas cleaning module ⇒ Engine; Rep.
gr. 26; Exhaust gas cleaning module; overview of compo‐
nents - exhaust gas cleaning.
Vehicles with particle filter
– Remove the particle filter ⇒ Rep. gr. 26; Exhaust gas clean‐
ing; removing and installing particle filter.
Vehicles with independent auxiliary heating
– Remove coolant hoses on the front wall ⇒ Auxiliary heating;
Rep. gr. 82; Coolant circuit with auxiliary heating.

Vehicles with catalytic converter

– Remove catalytic converter ⇒ Rep. gr. 26; Exhaust gas
cleaning; removing and installing catalytic converter.
– Disconnect brake servo from brake pedal ⇒ b4.3 rake pedal
from brake servo”, page 95 .
– Remove master brake cylinder ⇒ a3.3.2 nd installing master
brake cylinder, right-hand drive vehicles”, page 123 .
– Release fixing nuts -arrows-.
– Carefully detach the brake servo from the front wall and
remove it from the vehicle in a downward direction.
NOTICE
Risk of damaging the front wall when detaching the brake
servo.
When detaching the brake servo from the front wall, do not
use a lever tool between the brake servo and the front wall.
– Lightly warm the adhesive residues -arrows- and remove

from the front wall -1- and the brake servo -2-.
– Thoroughly clean the contact surfaces.

Installing
– Replace the seal for the brake servo on the front wall ⇒
o3.1.2 f components - brake servo unit/master brake cylin‐
der, right-hand drive vehicles”, page 113 .
Note
When gluing a new seal to the brake booster, it must be held

pressed down for at least 1 second.
– Insert the brake servo and lightly tighten the fastening nuts
by hand.
– Check that the brake servo seal ⇒ Item 7 (page 114) is
correctly positioned.
– Code the brake servo control unit -J539- ⇒ Vehicle diagnos‐
tic tester.
clutch mechanism.
Note


der, right-hand drive vehicles”, page 113
♦ ⇒ o4.1.2 f components - brake pedal, right-hand drive”, page
91
♦ Exhaust gas cleaning ⇒ Engine; Rep. gr. 26; Exhaust gas
cleaning; Overview of components - Exhaust gas cleaning
3.3 Removing and installing master brake

cylinder
⇒ a3.3.1 nd installing master brake cylinder, left-hand drive ve‐
hicles”, page 119
⇒ a3.3.2 nd installing master brake cylinder, right-hand drive
vehicles”, page 123
3.3.1 Removing and installing master brake

cylinder, left-hand drive vehicles


♦ Repair kit -1H0 698 311 A-
Removing
– Remove the engine cover panel ⇒ Rep. gr. 10; Engine cover
panel; removing and installing engine cover panel.
– Remove air filter housing:
♦ Petrol engines ⇒ Rep. gr. 24; Air filter; Removing and instal‐
ling air filter housing
♦ Diesel engines ⇒ Rep. gr. 23; Air filter; Removing and instal‐
ling air filter housing
– Remove connecting hose to intake manifold flap ⇒ Rep.
gr. 21; Charge air system; Summary of components - charge
air system.
– Remove the connecting piece for the exhaust turbocharger
⇒ Rep. gr. 21; Turbocharger; Removing and installing con‐
necting piece for exhaust turbocharger.
– Release cable -3- and place to the side.
– Place the NOx transmitter control unit -J583- to the side.

– Unclip the holder for electrical cable -4-.
– Release screw -2- and remove air tube -1-.
– Lay sufficient non-fluffing cloths around the engine and gear‐
box.
– Use brake filling and bleeding device-A-, to extract as much
brake fluid as possible with the extraction bottle from the
brake fluid reservoir -1-.


– Detach the return hose of the clutch master cylinder -4- from
the brake fluid reservoir -1- and attach it slightly higher.

– Disconnect plug -4- from the brake fluid level warning con‐
tact -F34-.

– Disconnect plug -2- for electric brake servo and plug -6- for
brake light switch -F-.
– Unclip the electrical cable -8- from the master brake cylinder
-1- and place to the side.
– Remove the brake lines -3- and -5- from the master brake
cylinder -1-.
plugs from the repair kit -1H0 698 311 A-.
– Unscrew the nuts -7-.
– Remove master brake cylinder -1- from the vehicle.
Installing
– When installing the master brake cylinder with the brake
servo unit pay attention to the correct positioning of the pres‐
sure rod in the master brake cylinder.
servo, pay attention to the correct positioning of the sealing
ring ⇒ Item 10 (page 112) .
– Check the seals - 2 - for damage and replace if necessary.

– Fit the trailing hose of the clutch master cylinder -4- on the
– Check that the seal is fitted correctly -2-.
clutch mechanism.
Note


der, left-hand drive vehicles”, page 111
3.3.2 Removing and installing master brake

cylinder, right-hand drive vehicles
Removing
– Remove the engine cover panel ⇒ Rep. gr. 10; Engine cover
panel; removing and installing engine cover panel.


– Remove the line for the injection valve for reduction agent
-N474- from the toothed belt guard in an upward direction
⇒ Rep. gr. 15; Toothed belt drive; Removing and installing
toothed belt guard.
– Remove the injection valve for reducing agent -N474- and
put it to one side with the cable connected ⇒ Engine; Rep.
gr. 26; SCR system (Selective Catalytic Reduction); summa‐
ry of components - Injection valve for reducing agent.
– Remove the differential pressure transmitter -G505- ⇒ En‐
gine; Rep. gr. 15; Cylinder head; overview of components -
Cylinder head cover.
– Remove the exhaust gas temperature encoder 1 -G235-
⇒ Engine; Rep. gr. 26; Exhaust gas temperature control sys‐
tem; removing and installing the exhaust gas temperature
encoder 1 -G235-.
– Remove the exhaust gas temperature encoder 3 -G495-
⇒ Engine; Rep. gr. 26; Exhaust gas temperature control sys‐
tem; removing and installing the exhaust gas temperature
encoder 3 -G495-.
– Remove fuel filter and put it to one side with the lines con‐
nected ⇒ Fuel system - Diesel engines; Rep. gr. 20; Fuel
filter; Removing and installing the fuel filter.
– Separate electrical plug connection -1-.
– Carefully release the locks with a screwdriver -arrow-.

– Place coolant expansion tank to one side.
– Remove the fuel lines -1- and -2- and place to the side.
– Separate quick couplings ⇒ Rep. gr. 20; Quick couplings;

separating quick couplings.

CAUTION
The fuel system is under pressure.
Risk of injury from ejected fuel.
– Wear safety goggles.
– Wear protective gloves.
– Relieve the pressure: place clean cloths around the con‐
nection point and carefully open the connecting point.
– Disconnect the refrigerant lines ⇒ Heating, Air conditioning;

Rep. gr. 87; Refrigerant circuit; system overview - refrigerant
circuit
– Open the holder -arrows- and disconnect the refrigerant line

-1- on the longitudinal member towards the front.
– Disconnect plug -3- from the brake fluid level warning con‐
tact -F34-.
– Disconnect plug -5- for electric brake servo and plug -2- for
brake light switch -F-.
– Unclip the electrical cable -4- from the master brake cylinder
-1- and place to the side.
Vehicles with heat shield
– Remove screw -4- and unhook heat shield -3- from the con‐
tainer -1- and remove it from the vehicle.


– Use brake filling and bleeding device-A-, to extract as much
brake fluid as possible with the extraction bottle from the

– Detach the return hose of the clutch master cylinder -4- from
the brake fluid reservoir -1- and attach it slightly higher.
– Remove the brake lines -1- and -3- from the master brake
cylinder -2-.

plugs from the repair kit -1H0 698 311 A-.
– Unscrew the nuts -2-.

– Remove master brake cylinder -1- from the vehicle.

Installing
servo unit pay attention to the correct positioning of the pres‐
sure rod in the master brake cylinder.
servo, pay attention to the correct positioning of the sealing
ring ⇒ Item 10 (page 112) .
– Check the seals - 2 - for damage and replace if necessary.
– Fit the trailing hose of the clutch master cylinder -4- on the
– Check that the seal is fitted correctly -2-.
clutch mechanism.


Note


der, right-hand drive vehicles”, page 113
♦ Line for injection valve for reduction agent -N474- on the
toothed belt guard at the top ⇒ Rep. gr. 15; Toothed belt
drive; Summary of components - toothed belt guard,
♦ Injection valve for reduction agent -N474- ⇒ Engine; Rep.
gr. 26; SCR system (Selective Catalytic Reduction); Summa‐
ry of components - injection valve for reduction agent.
♦ Exhaust gas temperature encoder 1 -G235- ⇒ Engine; Rep.
gr. 26; Exhaust gas temperature encoder; Removing and
installing exhaust gas temperature encoder 1 -G235-.
♦ Exhaust gas temperature encoder 3 -G495- ⇒ Engine; Rep.
gr. 26; Exhaust gas temperature encoder; Removing and
installing exhaust gas temperature encoder 3 -G495-.
♦ Differential pressure encoder -G505- ⇒ Engine; Rep. gr. 15;
Cylinder head; overview of components - Cylinder head cov‐
er
♦ Fuel filter with the lines connected ⇒ Fuel system - Diesel
engines; Rep. gr. 20; Fuel filter; Removing and installing the
fuel filter
3.4 Removing and installing the warning

contact for brake fluid level -F34-
Removing
– Press together the retaining tabs -2- and remove the warn‐
ing contact for brake fluid level -F34- from the brake fluid
reservoir -in the direction of the arrow-.
Installing

4 Brake lines
⇒ b4.1 rake lines”, page 130
4.1 Repairing brake lines

⇒ o4.1.1 verview - Flaring tool”, page 130
⇒ i4.1.2 nstruction”, page 132
4.1.1 Assembly overview - Flaring tool

List of individual tools
1 - Flaring tool -VAS 6056/1-

❑ The flaring chucks -
VAS 6056/6- are inclu‐
ded in the flaring tool
-VAS 6056/1-
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 - Pipe bending tool -VAS
6056/5-
6 - Screwdriver SW6
❑ Short
7 - Flaring chucks -VAS
6056/7-
Assembly overview - Flaring tool

1 - Flaring tool upper part

❑ unscrew for changing
the flaring chucks
2 - Attachment for door han‐
dle
❑ must be unscrewed to
access securing bolt for
upper part
3 - Fixing screw
❑ For flanging tool upper
part
4 - Grub screws for flaring
chucks
❑ For centring and hold‐
ing the flaring chucks
❑ 2 mm hexagon socket
5 - Flaring chucks
❑ Various
❑ Assembly instructions
⇒ Fig. ““Mounting in‐
struction for flaring
chucks:”“, page 131
Mounting instruction for flaring chucks:
♦ VAS 6056/6 (dark) for black brake lines

♦ VAS 6056/7 (bright) for green brake lines
4. Brake lines 131

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.
4.1.2 Work instruction

♦ Brake line flaring tool -VAS 6056-
NOTICE
♦ Brake fluid must never come into contact with fluids con‐
taining mineral oils (oil, petrol, cleaning agent, because the
fluids damage the sealing rings and boots of the brake
system.
♦ Because of its caustic effect, the brake fluid must not come
into contact with paint.
♦ Observe the applicable disposal instructions.
♦ Only use new brake fluid.
CAUTION
Note
♦ Brake lines must only be bent max. 90°, otherwise they kink
or present deformations, which constrain the line cross-sec‐
tion in an unauthorized manner.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle and only clean with methylated spirits.
♦ The arrow, on the rounded side of the flaring chucks, must
point to the housing edge. The straight sides of the flaring
chucks must be installed facing the spindle, otherwise the
flaring head is not correctly positioned.
Using the brake line flaring tool -VAS 6056-, the brake lines
can be crimped with a pipe outside diameter of 5 mm, without
damaging the coating. So that in certain cases parts of the
brake lines can be replaced cheaply.
Disconnect
– Unscrew the affected brake line on the brake calliper or
wheel-brake cylinder, while doing so collect escaping brake
fluid and dispose according to the specifications.
– Cut through the brake line in a suitable location (straight,
freely accessible piece) with the pipe cutter -2-.

– Remove the part to be replaced.

– 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.
The length of the peeling is determined by the stop in the peel‐
er.
– Separate the peeler from the brake line and remove peel
residues.
– Remove gripping pliers.
Crimping
– Slide pipe screw -D- onto the brake line.
4. Brake lines 133

– 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-.
– 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 flush the part of the brake line still in the vehicle:
– Connect the brake filling and bleeding device, fit the hose of
the bleeding bottle onto the flaring head of the brake line and
allow the brake filling and bleeding device to run briefly until
some brake fluid has passed through.
– Purge the brake line that you will be fitting with compressed
air.
– Assemble the brake lines together with the connecting piece
-E-.

– Install brake line.

– Bleeding Brake System ⇒ h5.2 ydraulic system following
standard procedure”, page 136
4. Brake lines 135

5 Hydraulic system
⇒ n5.1 otes on brake fluid”, page 136
⇒ h5.2 ydraulic system following standard procedure”, page 136
⇒ b5.3 leeding of hydraulic system”, page 141
⇒ l5.4 eak-tightness”, page 141
5.1 General notes on brake fluid

♦ The brake fluid is hygroscopic, i.e. it retains humidity from
the ambient air, and must therefore always be stored in air‐
tight containers.
♦ Brake fluid must never come into contact with fluids contain‐
ing mineral oils (oil, petrol, cleaning agent). Mineral oils dam‐
age the plugs and boots of the brake system.
♦ Drained (used) brake fluid must never be used again.
♦ The brake fluid is toxic, avoid skin contact.
♦ Because of its caustic effect, the brake fluid must not come
into contact with paint.
♦ Rinse off spilled brake fluid using plenty of water.
♦ Dispose of brake fluid in compliance with the applicable
waste disposal and environmental regulations.
♦ Only use new brake fluid in accordance with the specifica‐
tion ⇒ f3.1.4 luid”, page 6 .
5.2 Bleeding hydraulic system following

standard procedure
⇒ h5.2.1 ydraulic system following standard procedure”, page
136
⇒ p5.2.2 ump of hydraulic unit for ABS in the usual way”, page
138
⇒ t5.2.3 he electro-mechanical brake booster in the usual way”,
page 139
5.2.1 Bleeding hydraulic system following

standard procedure
♦ Tool kit for bleeding brakes, e.g. -VAS 6564-
♦ Brake fluid
– Note the general instructions on brake fluid ⇒ n5.1 otes on
brake fluid”, page 136 .
A pre-pressure of 0,2 MPa (2 bar) is required to bleed the brake
system.
– Unscrew cap -1- from the brake fluid reservoir

– Connect the thread plug -1- of the brake filling and bleeding
device 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
callipers.
– 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 small‐
est air bubbles have escaped.
5. Hydraulic system 137

Bleeding sequence
1. Front right brake calliper
2. Front left brake calliper
3. Rear right brake calliper
4. Rear left brake calliper
– Close vent valve.
– Repeat this procedure in the prescribed sequence until the
brake system is fully bled.
– Inspect pedal position and idle travel at brake pedal. Idle
travel: 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
reservoir.
– Disconnect the brake filling and bleeding device.
– Disconnect the brake filling and bleeding device from the
– Perform a test drive While doing so perform at least one
ABS adjustment!
If the system could not be vented in the usual way, the sys‐
tem can be vented by means of ⇒ t5.2.3 he electro-mechani‐
cal brake booster in the usual way”, page 139 (for example,
removal of the Control unit for ABS -J104-/of the Hydraulic unit
for ABS -N55-) ⇒ p5.2.2 ump of hydraulic unit for ABS in the
usual way”, page 138 or (e.g. when removing the master cylin‐
der/brake booster).
If the brake pedal travels too far, or if it is a so-called »soft
brake pedal«, a subsequent bleeding must be carried out ⇒
b5.3 leeding of hydraulic system”, page 141 .
5.2.2 Bleed pump of hydraulic unit for ABS in

the usual way
♦ Brake fluid
Note
If the system cannot be vented in the usual way, the following

procedure can be performed.

system.


callipers.
– Connect vehicle diagnosis tester and select the following:
1- “0003 - Brake electronics”
2- “0003 - Basic setting”
3- “0003- Brake system”
– Follow the instructions on the vehicle diagnosis tester ⇒ Ve‐
hicle diagnostic tester.
ABS adjustment!
brake pedal«, a subsequent bleeding must be carried out ⇒
5.2.3 Bleed the electro-mechanical brake

booster in the usual way
♦ Brake fluid

Note
If the system cannot be vented in the usual way, the following

procedure can be performed.

system.

callipers.
– Connect vehicle diagnosis tester and select the following:
1- “0023 - Brake booster Gen2”
2- “0023 - Brake booster function”
3- “0023 - Basic setting”
4- “0023 - Bleeding the brake system”
– Follow the instructions on the vehicle diagnosis tester ⇒ Ve‐
hicle diagnostic tester.
ABS adjustment!


brake pedal«, a subsequent bleeding must also be carried out ⇒
5.3 Subsequent bleeding of hydraulic sys‐

tem
♦ Brake fluid
Subsequent bleeding must be performed if the brake pedal trav‐
els too far or if the »brake pedal "feels" soft«.
Note
A second mechanic is needed for this task.
– Firmly push the brake pedal to the floor and keep it held
down.
– Connect the bleeder bottle.
– Open the bleeder screw on the brake calliper.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
– Release brake pedal slowly.
– Repeat this operation on all callipers in the prescribed se‐
quence at least 5 times.
Bleeding sequence
1. Front right brake calliper
2. Front left brake calliper
3. Rear right brake calliper
4. Rear left brake calliper
ABS adjustment!
5.4 Testing leak-tightness

♦ Brake system tester e. g. -V.A.G 1310A-
♦ Adapter M 10 e.g. -V.A.G 1310/6-
Test requirements:
• Function and tightness of the brake system (brake lines,
brake hoses, brake callipers, hydraulic unit) O.K.
– Unscrew and remove the bleeder screw on one of the front
brake callipers.
– Connect the brake system tester e.g. to the brake caliper
and bleed.
– Push down brake pedal until the pressure gauge indicates
5 MPa (50 bar). Throughout the test which lasts 45 s the

pressure loss must not exceed 0.4 MPa (4 bar). If the loss of
pressure is higher, replace the master brake cylinder.
– Disconnect the brake system tester.
– Screw the bleeder screw into the calliper and bleed the
brake calliper.

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Copyright © 2020 ŠKODA AUTO a. s. D4B80A03FE8

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

4.1 Summary of components - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1.1 Safety precautions when working on

1.2 Safety precautions during road tests

2.1 PR number assignment – brake

– -Arrow B- shows the vehicle brakes’ PR number.

2 Rep. gr.00 - Technical data

3.1 Technical data for brakes

3.1.1 Master brake cylinder and brake servo

3.1.2 Front brakes

Posi‐ PR number 1ZE

Posi‐ PR number 1ZE

Posi‐ PR number 1ZK

4 Rep. gr.00 - Technical data

Posi‐ PR number 1ZA

3.1.3 Rear brake

Posi‐ PR number 1KE

3.1.4 Brake fluid

6 Rep. gr.00 - Technical data

4.1 General points

The brake regulation systems do not function when ignition is

4.2 Checking vehicles with front-wheel

4.3 Testing vehicles with four-wheel drive

– Switch off engine and wait 2 seconds.

4.4 Check the parking brake

4.4.1 Check electromechanical parking

The electromechanical parking brake does not fully close

After the Button for the electromechanical parking brake -E538-

4.4.2 Check electromechanical parking

8 Rep. gr.00 - Technical data

Enabled »MOT mode« is signalled by the yellow Electric park‐

The electromechanical parking brake does not fully close

After the Button for the electromechanical parking brake -E538-

45 – Anti-lock brake system

1.1 Repair instructions for repair work on

♦ If the ABS hydraulic unit -N55- is damaged, the ABS control

Arrangement of the ABS, left-hand drive vehicle

1 - ABS hydraulic unit -N55- with ABS control unit -J104-

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

Arrangement of the ABS in right-hand drive vehicles

– Connect the earth connection of the electric welding tool

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

bleeding device -VAS 5234- or -VAS 6860-, ⇒ h5.2 ydraulic

2 Installation location overview

2.1 ABS/ESP installation location overview

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

1 - Dash panel insert

2. Installation location overview 15

♦ Sensor unit for ESP -G419-

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

3 Control unit and hydraulic unit

3.1 Exploded view – control unit and hy‐

3. Control unit and hydraulic unit 17

1 - ABS control unit -J104-

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

3. Control unit and hydraulic unit 19

1 - ABS hydraulic unit -N55-

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