Workshop Manual Transporter 2016 10-29

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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 agen
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B80570F2F

Brake systems - Edition 09.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.3 Safety precautions when working on a high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working in vicinity of high-voltage components . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Hazard classification of high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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6.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Checking vehicles with all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Repair instructions for repair work on ABS . . . . . . . . a. g.e.n .AG . .. V.o.lk.sw. a. g.e.n A
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2 Overview of fitting locations . . . . . . . . . . . . . .d b. y.V. . . . . . . . . . . . . . . . . . . . . . . .t g. u.ar. . . . . .
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2.1 Overview of fitting locations - ABS/ESP . h. o.ri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n.te.e. . .
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3 Control unit and hydraulic unit . . . . . .ss. a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. 16
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3.1 Assembly overview - control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 17
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3.3 Separating control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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4.3 Removing and installing brake light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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4.4 Removing and installing speed sensors on front axle G45 / G47 . . . . . . . . . . . . . . . . . . . . 25
4.5 Removing and installing speed sensors on rear axle G44 / G46 . . . . . . . . . . . . . . . . . . . . 26
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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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1.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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1.5 Removing and installing brake carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Removing and installing front brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4 Removing and installing rear brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.4 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Assembly overview - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.2 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4 Removing and installing brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4 Vacuum system . . . . . . . . . . . . . G. ..V.o.lk.sw. a. g.e.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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olksw vacuum pump . . . . .es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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4.2 Assembly overviewse-dvacuum
by pump . . . . . . . . . . . . . . . u.ar.a.n . . . . . . . . . . . . . . . . . . . . . . . . 94
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4.3 Checking non-return
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ho valve . . . . . . . . . . . . . . . . . . . . . . . . . . e.e o. r. . . . . . . . . . . . . . . . . . . . . . 94
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4.4 Removing and ss installing non-return valve . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . 96
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4.5 Removing and installing brake servo pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility 103
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5.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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5.2 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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5.3 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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5.4 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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ii Contents
00 – Technical data
1 Safety information
(VRL013439; Edition 09.2019)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
⇒ “1.3 Safety precautions when working on a high-voltage sys‐
tem”, page 2
⇒ “1.4 Safety precautions when working in vicinity of high-voltage
components”, page 3
1.1 Safety measures when working on ve‐

hicles with a start/stop system
Please note the following when working on vehicles with a start/
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stop system:
WARNING
Risk of injury due to automatic start of engine in vehicles with

Start/Stop system.
♦ If the start/stop system of a vehicle is activated, the engine
can start automatically, if required.
♦ This can be identified by a message in the dash panel in‐
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switch the signition
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1. Safety information 1
1.2 Safety precautions when using testers

and measuring instruments during a
road test
Please observe the following if test and measuring equipment is
required during a road test:
WARNING
Risk of accidents due to distraction and inadequate securing

of test and measuring equipment.
♦ Operation of test and measuring equipment while driving
results in distraction.
♦ Increased risk of injury due to inadequately secured test
and measuring equipment.
♦ Test and measuring equipment must always be secured
on the rear seat.
♦ An additional person responsible for the operation of the
test and measuring equipment needs to be present in the
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vehicle.
♦ The person responsible for the operation of the test and
measuring equipment must be sitting on the rear seat.
♦ Never operate the test and measuring equipment while
sitting in the front passenger seat.
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♦ In the event of anVoaccident,
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1.3 Safety precautions when working on a high-voltage system

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Danger to life from high voltage

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The high-voltage system is under high voltage. Severe or fatal

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injury from electric shock.

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– Persons with life-preserving or other electronic medical devi‐

ces in or on their body must not perform any work on the high-
voltage system. Such medical devices include internal anal‐
gesic pumps, implanted defibrillators, pacemakers, insulin
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pumps and hearing aids.

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– The high-voltage system must be de-energised by a suitably

qualified technician.
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Risk of injury from unexpected engine/motor start

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On electric and hybrid vehicles, the operational readiness of the

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– Switch off ignition. p by
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– Always store the ignition key outside the vehicle. Prote AG.
2 Rep. gr.00 - Technical data

Risk of damage to high-voltage cables

Improper handling of high-voltage cables or high-voltage connec‐
tors may result in damage to their insulation.
– Never support yourself on high-voltage cables or high-voltage
connectors.
– Never rest tools on high-voltage cables or high-voltage con‐
nectors.
– Never kink or severely bend high-voltage cables.
– Always connect high-voltage connectors according to coding.
Risk of injury from activated stationary air conditioning

On electric and hybrid vehicles with active stationary air condi‐
tioning, the stationary air conditioning could switch on uninten‐
tionally. Risk of limbs becoming trapped or drawn in by the
radiator fan starting automatically. wage
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– Deactivate the stationary airedconditioning.
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1.4 Safety precautions when working in vicinity of high-voltage components
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Danger to life from high voltage
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The high-voltage system is under high voltage. Damage to high-
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voltage components will result in severe or fatal injury due to
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electric shock.
– Perform visual check of high-voltage components and high- t to the co
voltage cables.
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– Never use cutting or forming tools, or any other sharp-edged

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tools.
– Never use heat sources such as welding, brazing, soldering,
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hot air or thermal bonding equipment.

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1. Safety information 3
2 Identification
⇒ “2.1 Allocation of PR number - brakes”, page 4
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2.1.1 Front brakes
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The type of brake system installed in the vehicle is indicated
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among other things by the corresponding PR number on the ve‐
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– The relevant information relating to which braking system is
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notes.
The following table shows the allocation of the brake systems and
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running gear.
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Allocation ⇒ Electronic parts catalogue “ETKA” .
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Front brakes are differentiated according to running gear sizes.
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Running gear size in inches PR No. Designation of front brake
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The type of brake system installed in the vehicle is indicated cop Vo
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hicle data sticker.
– The relevant information relating to which braking system is
installed can also be called up via ELSA/vehicle-specific
notes.
16” and 17” rear brakes (hydraulic disc brakes with mechanically
actuated parking brake)

3 Repair notes
⇒ “3.1 Checking vacuum system”, page 5
3.1 Checking vacuum system

The following test instructions are intended to help you find the
causes of problems effectively and objectively in the event of
complaints about the brake servo or in the event of a so-called
»hard brake pedal«.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if included)
Measuring results will be influenced by the geographical location.
The higher the location is above sea level, the lower the air pres‐
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sure will be.
The average air pressure of the earth's atmosphere at sea level
is 1013 mbar and decreases steeply as the altitude increases
(approx. 100 mbar/1000 m altitude). Local and time fluctuations
also influence vacuum generation.
A cold engine, a switched-on air-conditioning system as well as
engine idling have an adverse influence on generation of a vac‐
uum.
Take note of the following test requirements:
♦ Inspect all vacuumehoses
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♦ Ensure
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♦ Before
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a starting work, clean engine compartment if necessary
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un
pt
an
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itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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i
or
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te
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3. Repair notes 5
4 Hazard classification of high-voltage

system
WARNING AG. Volkswagen AG d

agen oes
olksw not
V
The vehicle’s high-voltage system and the d high-voltage
by battery gu
ara
se
are dangerous and can cause burns or thoriother injuries and even nte
eo
lead to a fatal electric shock. s au ra
c
s
• Any work on the high-voltage system, or on systems which
ce
le
un
pt
could be indirectly affected by it, must only be carried out
an
d
itte
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by properly trained and qualified expert personnel.
rm
ab
pe
ility
• In the event of queries or uncertainties regarding the terms
ot
wit
, is n
“high-voltage technician” or “high-voltage expert”, or those
h re
concerning the high-voltage system, the responsible im‐
hole
spec
porter must be contacted prior to the start of any work.
es, in part or in w
t to the co
• Any repair work must be performed in accordance with
applicable laws and regulations, approved engineering
practices, any relevant accident prevention regulations (in
rrectness of i
Germany, including but not limited to the BGI/GUV-I 8686
satelettronica
– Training for work on vehicles with high-voltage systems),
l purpos
as well as this workshop manual.
nform
ercia
This vehicle is energised by ABT e-Line

m
a
com
tio
For all repair and maintenance information regarding the ABT e-
n in
r
Line conversion, consult the Electronic Service Information Sys‐

te o
thi
tem (ELSA Pro) under “Attachments and conversions”. Alterna‐
s
iva
do
r
tively, request these details from ABT e-Line.

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5 Technical
agen
data
AG. Volkswagen AG
doe
w s no
olks
⇒ “5.1 Technical
ed
by data for brakes”, page 7
V t gu
ara
ris nte
ho
5.1 Technical data for brakes
eo
aut ra
ss c
ce
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⇒ “5.1.1 Brake master cylinder and brake servo”, page 7

nl
pt
du
an
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⇒ “5.1.2 Front brakes”, page 7
y li
erm
ab
ility
⇒ “5.1.3 Rear brakes”, page 8
ot p
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5.1.1 Brake master cylinder and brake servo
h re
hole
spec
es, in part or in w
Designation Dimensions
t to the co
Brake master cylinder, diame‐ 26.99 mm (tandem)
ter
rrectness of i
Brake servo, diameter 9”/10”
l purpos
5.1.2 Front brakes
nf
ercia
Front brake, 16" (2E3)
or
satelettronica
m
m
atio
m
Item Designation Dimensions

o
n in
c
[mm]
or
thi
te
-1- Brake caliper (FN3) -

sd
iva
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cu
-2- Brake pad, thickness 12.5

o
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f
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(without backplate)
t.
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op py
-3- Brake disc, diameter 308
t. C rig
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Brake disc, thickness 29.5
op Vo
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-4- Brake caliper piston, diameter 60
Prote AG.
Front brake, 17" (2E4)

Item Designation Dimensions
[mm]
-1- Brake caliper (2FNR) -
-2- Brake pad, thickness 12
(without backplate)
-3- Brake disc, diameter 340
Brake disc, thickness 32.5
-4- Brake caliper piston, diameter 2 x 44
5. Technical data 7
5.1.3 Rear brakes

Rear brake, 16" and 17"
AG. Volkswagen AG d
agen
Item Designation Volksw Dimensions [mm] oes not
by gu
ara
-1- Brake disc orise Diameter
d
294 nte
aut
h in mm eo
ra
s c
Brake disc, s
mm 22
ce
e
nl
thickness
pt
du
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itte
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-2- Brake pad, mm 11.5
erm
ab
thickness (without
ility
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backplate)
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-3- Brake caliper Diameter 41
hole
piston in mm
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
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6 Brake test
⇒ “6.1 General information”, page 9
⇒ “6.2 Checking vehicles with front-wheel drive”, page 9
⇒ “6.3 Checking vehicles with all-wheel drive”, page 9
6.1 General information

♦ The drive is provided by the test rig.
♦ For the test, ensure for vehicles with a manual gearbox that
the gear lever is in neutral, and for vehicles with an automatic
gearbox that the selector lever is in »N«.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is off.
satelettronica
6.2 Checking vehicles with front-wheel drive
The brake test must be carried out on a single-axle roller dyna‐
mometer.
The maximum test speed is 6 km/h.
olkswagen AG
en AG. V
The test rigs authorised by Volkswagen
olks
wag fulfil these requirements.
does
no
yV t gu
db ara
6.3 thoChecking vehicles with all-wheel drive
rise nte
eo
au ra
⇒ “6.3.1 On a regulated
s roller dynamometer with counter-rotating
s c
ce
e
rollers for four-wheel drive vehicles”, page 9

nl
pt
du
an
itte
⇒ “6.3.2 Without roller dynamometer for four-wheel drive vehi‐

y li
erm
ab
cles”, page 10
ility
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6.3.1 On a regulated roller dynamometer with

, is n
h re
hole
counter-rotating rollers for four-wheel

spec
es, in part or in w
drive vehicles
t to the co
Note
rrectness of i
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The brake test must be performed on a controlled contra-rotating

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

m
m
atio
m
gle-axle roller dynamometer are driven forwards on one side and

o
n in
c
backwards on the other.

or
thi
te
sd
The rollers drive the wheels of one axle in opposite directions to

iva
o
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avoid transmitting torque to the other axle.

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“Regulated” means that the speed of the brake test stand rollers op
yi Co
is so controlled so that there is no difference in speed during the
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brake test.
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This prevents the transfer of a force through the stationary wheels
cted agen
Prote AG.
(not on the set of rollers) via the propshaft to the rotating wheels
on the rollers.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed.
6. Brake test 9
The maximum test speed is 6 km/h.

The test rigs authorised by Volkswagen fulfil these requirements.
. Volkswagen AG
gen AG
6.3.2 Without roller dynamometer ksw for four-
a does
not
y Vol gu
wheel drive vehicles db ara
ise nte
or th eo
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Note e
nl
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erm
If no test rig is available for four-wheel drive vehicles, the brake
ab
ility
test can also be carried out on a standard single-axle roller dy‐
ot p
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namometer as follows:
, is n
h re
hole
spec
– Drive vehicle forwards onto the rollers.
es, in part or in w
t to the co
– Switch off engine and wait for 2 seconds.
– Carry out front brake test.
rrectness of i
– Start engine and wait for approx. 5 seconds until sufficient
l purpos
vacuum has been built up.

– Drive vehicle forwards until rear wheels are positioned on roll‐
satelettronica
nf
ercia
ers.
orm
m
– Switch off engine and wait for 2 seconds.
atio
om
n in
c
– Carry out rear brake test.

or
thi
te
sd
a
– Start engine and wait for approx. 5 seconds until sufficient

iv
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vacuum has been built up.
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45 – Anti-lock brake system

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

ABS
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Note
Faults in the ABS influence the brake system and servo assis‐
tance. The conventional brake system remains functional even
satelettronica
without ABS. A change in braking behaviour is to be reckoned
with. After the ABS warning lamp comes on, the rear wheels may agen AG. Volkswagen AG do
lock prematurely during braking. Vol
ksw es n
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by ua
ed ran
ris tee
The hydraulic unit -a- and control unit -b- (47-pin) formuthone com‐
o
or
ponent. They can be separated only when removed.ss a ac
ce
le
un
New control units from the replacement parts service are not co‐
pt
an
d
ded. They have to be coded after installation ⇒ Vehicle diagnostic

itte
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erm
tester.
ab
ility
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The ABS warning lamp - K47- and the ESP and TCS warning
wit
is n
lamp - K155- flash so long as the ABS control unit - J104- has not
h re
ole,
been coded.
spec
t to the co
rrectne
Layout in left-hand drive vehicles
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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Cop py
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Prote AG.
1. General information 11
Layout in right-hand drive vehicles

♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using “Guided Fault Finding”.
“Fault finding” is performed with the ⇒ Vehicle diagnostic tester.
♦ With ignition switched off, disconnect battery earth strap.
♦ Before carrying out welding work with an electric welding unit,
see ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 103 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 103
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
satelettronica
brake system. Auxiliary items containing mineral oil, e.g. oils,
greases, etc. must never be used.
♦ Thoroughly clean all unions and adjacent areas before loos‐
ening. Do not use aggressive cleaning agents such as brake
cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover them over.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing. (Use seal‐
ing plugs from repair kit 1H0 698 311 A)
♦ Only use lint-free cloths.
♦ Remove packing from replacement parts immediately prior to
installation and not before.
♦ Only use genuine packed parts. agen
AG. Volkswagen AG d
oes
olksw not
V
♦ When the system is open, do not work with compressed ed by air gu
ara
and do not move the vehicle. horis nte
eo
aut ra
♦ The valve coils in the control unit cannot be adjusted.
ss c
ce
le
un
pt
♦ The valve coils in the control unit cannot be renewed.

an
d
itte
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♦ Pressure sensor must not be changed or damaged.

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ab
pe
ility
ot
♦ The pressure sensor cannot be renewed.

wit
, is n
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♦ The sensor housing must not be exposed to mechanical

hole
spec
stress.
es, in part or in w
t to the co
♦ No measurements must be taken on contact points of control

unit.
rrectness of i
♦ No measurements must be taken on contact points of hy‐

draulic unit.
l purpos
♦ Contact pins of hydraulic unit must not be bent or damaged.

nform
ercia
♦ The contacts cannot be renewed.

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

a
com
tio
sure sensor.
n in
r
te o
thi
♦ Foreign bodies must not get between the control unit and the
s
iva
do
hydraulic unit.
r
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12
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Rep. gr.45 - Anti-lock brake system Prote
cted AG.
agen
♦ During painting operations, the electronic control unit can be

exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours). During longer periods (2 hours), the control unit can
be exposed to a maximum temperature of 85°C. Ensure that
no brake fluid enters connectors.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
satelettronica
ce
le
un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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Vo
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Prote AG.
1. General information 13
2 Overview of fitting locations

⇒ “2.1 Overview of fitting locations - ABS/ESP”, page 14
2.1 Overview of fitting locations - ABS/ESP
1 - ABS control unit - J104- agen AG. Volkswagen AG do

ksw es n
❑ with integrated ESP Vol ot g
by ua
sensor unit - G419-
ris
ed ran
tee
ho
❑ Can be checked
s aut
with or
ac
⇒ Vehicle diagnostic
s
ce
le
tester
un
pt
an
d
itte
❑ Do not separate con‐
y li
rm
ab
nector (47 pin) before
pe
ility
successfully completing
ot
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reading of fault memory.
h re
Switch ignition off be‐
hole
spec
fore separating connec‐
es, in part or in w
tor.
t to the co
❑ Removing and installing
satelettronica
⇒ page 17
rrectness of i
2 - ABS hydraulic unit - N55-
l purpos
❑ with integrated ABS re‐

turn flow pump - V39-
nform
ercia
❑ Can be checked with

m
tester
com
tion in
❑ Do not separate ABS re‐

r
te o
thi
turn flow pump - V39-

s
iva
do
and valve block

r
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⇒ page 17
Co
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3 - Brake pad warning lamp -
gh ht
pyri by
K32-
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❑ In dash panel insert
AG.

⇒ Electrical system;
Rep. gr. 90 ; Dash panel
insert; Removing and in‐
stalling dash panel in‐
sert KX2
4 - ABS warning lamp - K47-
❑ Removing and installing ⇒ Electrical system; Rep. gr. 90 ; Dash panel insert; Removing and installing
dash panel insert KX2
5 - Warning lamp for stabilisation programme - K155-
6 - Brake system warning lamp - K118-
7 - TCS and ESP button - E256-
❑ In dash panel.
14 Rep. gr.45 - Anti-lock brake system

❑ Removing and installing ⇒ Electrical system; Rep. gr. 96 ; Controls; Removing and installing special
vehicle control unit -E256-
8 - Brake light switch - F-
❑ Can be checked with ⇒ Vehicle diagnostic tester
❑ Installed on tandem brake master cylinder
❑ Removing and installing ⇒ page 24
9 - Steering angle sender - G85-
❑ Installed between steering wheel and steering column switch
❑ Removing and installing ⇒ Electrical system; Rep. gr. 94 ; Steering column switch module; Removing
and installing steering column electronics control unit J527
10 - Diagnostic connection
❑ Installed in footwell cover on driver side
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments/covers; Removing
and installing footwell cover on driver side
11 - Rear right speed sensor - G44- and rear left speed sensor - G46-
satelettronica
12 - Rear wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearings, trailing arm;
Removing and installing wheel bearing unit
13 - Front wheel bearing unit
❑ ABS sensor ring is installed in wheel l wage
ksbearing. es n
o ot g
yV ua
❑ Removing and installing ⇒ Running ed b gear, axles, steering; Rep. gr. 40
ran ; Wheel bearings; Removing and
ris
installing wheel bearing unit
uth .
o tee
o ra
sa c
14 - Front right speed sensor s- G45- and front left speed sensor - G47-
ce
le
un
pt

an
d
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ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
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Prote AG.
2. Overview of fitting locations 15

3 Control unit and hydraulic unit

⇒ “3.1 Assembly overview - control unit and hydraulic unit”, page
16
⇒ “3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 ”, page 17
⇒ “3.3 Separating control unit from hydraulic unit”, page 21
3.1 Assembly overview - control unit and hydraulic unit
1 - ABS control unit - J104-

⇒ page 17
❑ Separating ABS control olkswage es n
ot g
unit - J104- from ABS byV ua
ed ran
hydraulic unit - N55- or is tee
⇒ page 21 au
th or
a
ss c
2 - ABS hydraulic unit - N55-
ce
le
un
pt
an
d
satelettronica
itte
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⇒ page 17
erm
ab
ility
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3 - Brake line
wit
is n
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❑ Overview of brake line
ole,
connections
spec
⇒ page 17
t to the co
❑ 14 Nm
4 - Brake line
❑ Overview of brake line rrectne
connections
s
⇒ page 17
s o
cial p
❑ 14 Nm
inform
mer
5 - Brake line
atio
m

o
n
c
i
or
connections
thi
e
⇒ page 17
t
sd
iva
o
pr
❑ 14 Nm
um
r
fo
en
ng
t.
yi
6 - Brake line
Co
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connections cop Vo
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⇒ page 17 cted agen
Prote AG.
❑ 14 Nm
7 - Brake line
connections ⇒ page 17
❑ 14 Nm
8 - Brake line
❑ Overview of brake line connections ⇒ page 17
❑ 14 Nm
9 - Bolts
❑ Qty. 3
❑ Initial tightening torque: 1.5 Nm (to allow seal to settle); final tightening torque: 2.5 Nm
10 - Bracket
❑ For ABS hydraulic unit - N55- and ABS control unit - J104- .

11 - Bolts
❑ Qty. 3
❑ 9 Nm
12 - Buffer
❑ Qty. 3
13 - Battery tray
14 - Nut
❑ Qty. 3
❑ 20 Nm
15 - Bracket
3.2 Removing and installing ABS control

agen
unit
AG. V -gJ104-
olkswa en AG
doesand ABS hydraulic unit -
ksw
N55- db
y Vol not
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ar
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ris tee
tho or
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Special tools and workshop ss
equipment required
ce
e
satelettronica
nl
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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te
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Prote AG.
♦ Torque wrench - V.A.G 1331-

♦ Ring insert tool, open, AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G 1410/7-
3. Control unit and hydraulic unit 17

♦ Torque wrench - VAS 6854-

♦ Brake pedal depressor - V.A.G 1869/2-
♦ Assembly tool - V.A.G 1410/8-
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
the left in the engine compartment under the brake master cylin‐
der.
WARNING
Do not bend the brake lines in the area of the hydraulic unit!
Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
satelettronica
– Remove upper screw of trim.
– Pull out lower trim -arrow- upwards.
Vehicles with diesel engine:
– Disconnect lines -1- from coolant expansion tank -4-.
– Pull off electrical connector -2-.
– Unscrew bolts -3-.
– Lay coolant expansion tank -4- to one side, and secure it in
place.
Continued for all vehicles: agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
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– Unscrew bolt -arrow-. s aut ra
c
s
– Remove trim -1-. ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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– Unscrew bolt -arrow A-.

AG. Volkswagen AG d
– Unscrew nut -arrow B-. lksw
agen oes
not
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– Pull off trim -1- from bulkhead bracket -arrowrise B-.
d b ara
nte
tho eo
Vehicles with diesel engine: s au ra
c
s
ce
e
– Remove fuel filter ⇒ Fuel system; Rep. gr. 20 ; Fuel filter;
nl
pt
du
Removing and installing fuel filter
an
itte
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erm
ab
Vehicles with petrol engine:
ility
ot p
wit
– Disconnect fuel lines underneath brake master cylinder.
, is n
h re
hole
Continued for all vehicles:
spec
es, in part or in w
– Apply brake pedal depressor - V.A.G 1869/2- .
t to the co
– Connect bleeder bottle hose to front left brake caliper bleeder
valve and open bleeder valve.
rrectness of i
– Depress brake pedal at least 60 mm using brake pedal de‐
l purpos
pressor - V.A.G 1869/2- .

– Close front left bleeder valve.
nform
ercia
– Do not remove brake pedal depressor - V.A.G 1869/2- .
satelettronica
m
at
om
io
– Place sufficient lint-free cloths under the control unit and hy‐
n
c
in t
r
draulic unit.
o
his
ate
do
priv
c
– Remove brake lines -3- and -4-, first unscrew from brake mas‐
um
for
en
g
ter cylinder then from hydraulic unit.

n
t.
yi Co
op py
– Unscrew brake lines -2- from hydraulic unit.
t. C rig
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– Seal brake lines and threaded holes using sealing plugs - 1H0
co lksw
by
cted agen
698 311 A- . Prote AG.
– Release connector -5- and pull off in direction of -arrow- from

control unit -1-.
Note
Ensure no brake fluid gets onto contacts.
– Pull out hydraulic unit with control unit upwards from bracket.
– Separate control unit from hydraulic unit ⇒ page 21 .
Installing
Install in the reverse order of removal, observing the following:
Note
♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ If the rubber buffers -2- are pulled out of the large retainer
during removal, reinsert them into the retainer before installing
the hydraulic unit. The rubber buffers must be inserted “dry”.

– If hydraulic unit -1- has been exchanged, retainer -4- for old
hydraulic unit must be transferred to new hydraulic unit.
– Press hydraulic unit with retainer into rubber buffers.
Note
♦ The hydraulic unit must be inserted vertically (keep straight) in

the bracket as otherwise the insulation rubber will be pushed
out.
♦ Use lubricant if necessary.
satelettronica
AG. Volkswagen AG d
agen oes
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d b ara
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Connect brake lines one after other to ABS hydraulic unit -

N55- and to brake master cylinder.
1 - Brake line to brake caliper, rear left
2 - Brake line to brake caliper, front right
3 - Brake line to brake caliper, front left
4 - Brake line to brake caliper, rear right
5 - Brake line to brake master cylinder, front connection
6 - Brake line to brake master cylinder, rear connection
– Connect electrical connector.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 103 .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Note
satelettronica
Check installation position after fitting hydraulic unit. The surface
with the 4 hydraulic line unions must be horizontal. Deviations of
more than 5° are not permitted. Additionally the installation lkswage posi‐ es n
tion must not be turned by more than 5° in the vertical by V axis. When
o ot g
ua
the system is operational again a comparison o
ir swith
ed lateral accel‐ ran
tee
eration and yaw rate sensors must be performed.
au
th or
a
ss c
ce
le
– Connect ⇒ Vehicle diagnostic tester ⇒ Maintenance ; Booklet

un
pt
an
d
20.1 ; Work descriptions; Reading fault memory of all systems

itte
y li
with vehicle diagnostic tester, correcting possible faults ac‐
erm
ab
ility
cording to repair guidelines .
ot p
wit
is n
– Code ABS control unit - J104- ⇒ Vehicle diagnostic tester,
h re
ole,
Brake system , Self-diagnosis compatible systems ,
spec
Anti-lock brake system ABS/EDL/TCS/ESP , Anti-lock
t to the co
brake system functions , ABS control unit , Commis-
sioning .
rrectne
To do this, carry out basic setting of steering angle sender - G85- ,
lateral acceleration sender - G200- , longitudinal acceleration
sender - G251- and brake pressure sender - G201- .
ss o
cial p
Specified torques
inform
mer
♦ ⇒ “3.1 Assembly overview - control unit and hydraulic unit”,

atio
page 16
om
n
c
i
or
n thi
e
3.3 Separating control unit from hydraulic

t
sd
iva
o
pr
unit
um
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fo
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ng
t.
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Special tools and workshop equipment required t. Cop py
rig
gh ht
♦ ESD workplace - VAS 6613- pyri by
Vo
co lksw
by
cted agen
♦ Torx bit T25 Prote AG.
♦ If a control unit is defective, the control unit must be discon‐

nected from the hydraulic unit and only the control unit re‐
newed.
♦ If the hydraulic unit is defective, the hydraulic unit must be re‐
newed together with the control unit.
♦ To separate the control unit from the hydraulic unit, the hy‐
draulic unit must be removed first.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Transporter 2016 ➤ aut ra
c
s
Brake systems - Edition 09.2019 s
ce
le
un
pt
an
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erm
ab
WARNING
ility
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wit
is n
♦ Return flow pump must not be separated from hydraulic
h re
ole,
unit.
spec
♦ Printed circuit board becomes visible when control unit is
t to the co
removed.
♦ Neither moisture nor particles of dirt may enter the interior
rrectne
of the control unit.
♦ Avoid electrostatic charge!
ss o
cial p
f inform
This electrostatic charge can cause malfunctions if you touch
mer
electric components.
atio
om
n
c
– Before working on electric components, touch an earthed ob‐
i
or
n thi
ject, ESD workplace - VAS 6613- . Do not directly touch
te
sd
a
connector contacts or electronic components.

iv
o
pr
cum
r
fo
– Lay down hydraulic unit together with control unit on ESD
en
ng
t.
yi
workplace - VAS 6613- .
Co
Cop py
t. rig
satelettronica
gh
– Unscrew Torx bolts -arrows- from control unit and lay them
ht
pyri by
Vo
o
aside immediately (to avoid interchanging with new Torx by c lksw
cted agen
bolts). Prote AG.
– Carefully pull off control unit from hydraulic unit, making sure
that it is not canted.
Specified torques
♦ ⇒ “3.1 Assembly overview - control unit and hydraulic unit”,
page 16

AG. Volkswagen AG d
agen oes
olksw not
by
V gTransporter
ua 2016 ➤
ed ran
thoris Brake systems - tEdition
ee
or
09.2019
au ac
ss
ce
e
4 Sensors
nl
pt
du
an
itte
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erm
ab
⇒ “4.1 Assembly overview - speed sensor on front axle”,
ility
ot p
page 23
wit
, is n
h re
⇒ “4.2 Assembly overview - speed sensor on rear axle”,
hole
page 24
spec
es, in part or in w
⇒ “4.3 Removing and installing brake light sensor”, page 24
t to the co
⇒ “4.4 Removing and installing speed sensors on front axle G45 /
G47 ”, page 25
rrectness of i
⇒ “4.5 Removing and installing speed sensors on rear axle G44 /
l purpos
G46 ”, page 26
4.1 Assembly overview - speed sensor on front axle
nf
ercia
orm
m
atio
om
1 - Speed sensor
n in
or c
thi
❑ Front right speed sensor
te
sd
iva
- G45- / front left speed
o
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rp
cu
sensor - G47-
o
m
f
en
ng
satelettronica
t.
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op
⇒ page 25
C py
t. rig
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yri
❑ Clean inside surface of
p by
o Vo
by c lksw
hole before inserting Prote
cted AG.
agen
sender.
❑ Coat hole with polycar‐
bamide grease - G 052
142 A2- ⇒ Electronic
Parts Catalogue (ETKA)
2 - Bolt
❑ 8 Nm
3 - Drive shaft
4 - Wheel bearing unit
❑ ABS sensor ring is inte‐
grated into wheel bear‐
ing.
5 - Brake disc
6 - Wheel bearing housing
4. Sensors 23
4.2 Assembly overview - speed sensor on rear axle
1 - Speed sensor agen

AG. Volkswagen AG d
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❑ Rear left speed sensor - d by
Vo gu
ara
G46- / rear right speed orise nte
sensor - G44- aut
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❑ Removing and installings
ce
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nl
⇒ page 26
pt
du
an
itte
❑ Clean inside surface of
y li
erm
ab
hole before inserting
ility
ot p
sender.
wit
, is n
❑ Coat hole with polycar‐
h re
hole
bamide grease - G 052
spec
142 A2- ⇒ Electronic
es, in part or in w
t to the co
Parts Catalogue (ET‐
KA) .
2 - Bolt
rrectness of i
❑ 8 Nm
l purpos
3 - Brake disc
satelettronica
nform
ercia

❑ ABS sensor ring is inte‐
m
at
om
i
grated into wheel bear‐
on
c
ing.
in t
or
his
ate
5 - Suspension link
do
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cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
4.3 Removing and installing brake light sen‐

sor
Removing
Vehicles with diesel engine:
– Unclip vacuum lines from air intake hose.
– Open clips -1- and -2-.
– Remove air intake hose.

Vehicles with petrol engine:

– Open clips -2- and -3-.
– Remove air ducting hose -1-.
Continued for all vehicles:

– Release and pull off electrical connector -2- from brake light
switch - F- -1-.
– Unscrew bolt for brake light sensor -3-.
Installing
– Install in reverse order. The following should be observed:
satelettronica
AG. Volkswagen AG d
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byV gu
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ed
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ility
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wit
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spec
– Ensure that brake light sensor -1- sits properly on edge
es, in part or in w
t to the co
-arrow- of brake master cylinder.
Specified torque
rrectness of i
♦ ⇒ “3.1 Assembly overview - brake servo/brake master cylin‐
der”, page 84
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.4 Removing and installing speed sensors

on front axle -G45- / -G47-
Special tools and workshop equipment required
4. Sensors 25
Brake systems - Edition 09.2019 AG. Volkswagen AG d
agen oes
olksw not
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♦ Torque wrench - V.A.G 1410- d b ara
rise nte
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pt
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Raise vehicle.
– Disconnect connector -1- from speed sensor.
nf
ercia
orm
– Unscrew bolt -2- and pull out speed sender from wheel bearing
m
atio
m
housing.
o
n in
or c
thi
Installing
e
satelettronica
t
sd
iva
o
r

rp
cu
o
m
f
en
ng
– Clean inner surface of hole and coat with polycarbamide

t.
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op
grease - G 052 142 A2- ⇒ Electronic Parts Catalogue (ETKA) . C py
t. rig
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yri by
Specified torques cop Vo
by lksw
cted agen
Prote
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page
AG.
23
4.5 Removing and installing speed sensors

on rear axle -G44- / -G46-
Removing
– Raise vehicle.

– Disconnect connector -1- from speed sensor.

– Unscrew bolt -2- and pull out speed sender from wheel bearing
housing.
Installing
– Clean inner surface of hole and coat with polycarbamide
grease - G 052 142 A2- ⇒ Electronic Parts Catalogue (ETKA) .
Specified torques
♦ ⇒ “4.2 Assembly overview - speed sensor on rear axle”, page
24
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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au ra
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satelettronica
erm
ab
ility
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spec
t to the co
rrectness o
cial p
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mer
atio
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c
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Cop py
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Prote AG.
4. Sensors 27
46 – Brakes - mechanism
1 Front brakes
⇒ “1.1.1 Assembly overview - front brake, floating caliper disc
brake FN3”, page 28
brake 2FNR”, page 31
Volkswa
⇒ “1.2 Removing and installing brakespads/linings”,
wage
n AG. page 32does
gen AG
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⇒ “1.3 Removing and installing by
dbrake caliper”, page 40 ara
se ri nte
ho eo
⇒ “1.4 Removing and installing
au
t brake disc”, page 49 ra
c
ss
⇒ “1.5 Removing and installing brake carrier”, page 50
ce
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1.1 Assembly overview - front brakes
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1.1.1 Assembly overview - front brake, floating caliper disc brake FN3
ole,
spec
satelettronica
t to the co
Note
rrectne
♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the pads
are properly seated in their normal operating position.
s
♦ Use brake filling and bleeding equipment -VAS 5234- to draw off brake fluid from brake fluid reservoir.
s o
cial p
f in
♦ Fit brake pedal actuator -V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose. form
mer
atio
om
n
c
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te
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Cop py
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Prote AG.
28 Rep. gr.46 - Brakes - mechanism


2 - Bolt
❑ 8 Nm
3 - ABS speed sensor
❑ Clean inner surface of
hole, and coat with pol‐
ycarbamide grease ⇒
Electronic Parts Cata‐
logue (ETKA)
4 - Cover plate
5 - Bolt
❑ 10 Nm
7 - Brake disc
Vehicles with 16'' wheels, 2E3.
♦ Ventilated brake disc: ∅
308 mm
satelettronica
♦ Brake disc thickness:
29.5 mm.
♦ Wear limit: 26.5 mm
♦ Ventilated brake disc: ∅
AG. Volkswagen AG d
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♦ Brake disc thickness: ised b ara
nte
32.5 mm. ut
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♦ Wear limit: 29.5 mm s
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pt
❑ When worn, always re‐
an
d
itte
new on both sides of
y li
rm
ab
axle.
pe
ility
ot
❑ Never remove brake
wit
, is n
discs from wheel hub by
h re
hole
force. If necessary use penetrating fluid, because otherwise brake discs can be damaged.
spec
es, in part or in w

t to the co
8 - Bolt
❑ 15 Nm
rrectness of i
9 - Connector
l purpos
❑ When changing pads, remove from bracket ⇒ Item 18 (page 30) .

10 - Brake pads
nform
ercia

m
a
com
ti
♦ Brake pad thickness: 12.5 mm not including backplate

on in
r
te o
thi
♦ Wear limit: 2 mm excluding backing plate.

s
iva
do
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rp
cum
fo
♦ Brake pad thickness: 11 mm not including backplate

en
ng
t.
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op
♦ Wear limit: 2 mm excluding backing plate.
C py
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rig ht
❑ Always replace on both sides py by
co Vo
by lksw
cted
❑ The inner pad on the left side of the vehicle has a wear indicator.
agen
Prote AG.
❑ When wear reaches a predetermined limit (approx 2-3 mm), a warning lamp in dash panel insert comes
on.
❑ Check thickness ⇒ Maintenance ; Booklet 19.1 .
1. Front brakes 29
11 - Retaining spring
12 - Brake carrier
❑ Bolt to wheel bearing housing.
13 - Brake caliper
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Do not disconnect brake hose when changing pads.
14 - Guide pin
❑ 30 Nm n AG. Volkswagen AG do
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15 - Cover d byV
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ran
ir se tee
16 - Brake hose/brake line utho
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❑ Screw into brake caliper ss
ce
e
nl
❑ Do not disconnect brake hose when changing brake pads.
pt
du
an
itte
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❑ Observe fitting instructions ⇒ page 30 .
erm
ab
satelettronica
❑ 15 Nm
ility
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17 - Bracket
h re
hole
spec
18 - Bracket
es, in part or in w
t to the co
19 - Bolt
❑ 10 Nm
rrectness of i
20 - Bolt
l purpos
❑ Renew after removal

❑ 180 Nm +45°
nform
mercia
at
om
Fitting instructions for brake hose ion

c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
♦ Once the front brake hose has been installed, there must be
yi Co
op
a minimum of 40 mm ± 10 mm clearance -a- between the cou‐
C py
t. rig
gh
pling rod and the brake hose.
ht
pyri by
Vo
co lksw
by
♦ Clearance must be measured in rebound condition. Wheels
cted agen
Prote AG.
must be in straight-ahead position.

1.1.2 Assembly overview - front brake, floating caliper disc brake 2FNR

2 - Bolt
❑ 8 Nm
3 - ABS speed sensor
❑ Clean inner surface of lkswage es n
hole, and coat with pol‐ d byV
o ot g
ua
ycarbamide grease ⇒ o
ir se
ran
tee
Electronic Parts Cata‐ auth or
ac
logue (ETKA) ss
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un
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4 - Cover plate
an
d
itte
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5 - Bolt
rm
ab
pe
ility
❑ 10 Nm
ot
wit
, is n
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hole
spec
7 - Brake disc
es, in part or in w
t to the co
❑ Ventilated brake disc: ∅
satelettronica
340 mm
❑ Brake disc thickness:
rrectness of i
32.5 mm.
l purpos
❑ Wear limit: 29.5 mm

❑ When worn, always re‐
nform
ercia
new on both sides of

axle.
m
a
com
ti
❑ Never remove brake
on in
discs from wheel hub by
r
te o
thi
force. If necessary use
s
iva
do
penetrating fluid, be‐
r
rp
cum
cause otherwise brake
fo
en
ng
discs can be damaged.

t.
yi Co
Cop py
t. rig
gh ht
yri
⇒ page 49 p by
co Vo
by lksw
cted agen
8 - Bolt Prote AG.
❑ 20 Nm
9 - Brake carrier
❑ Bolted to wheel bearing housing.
10 - Brake pads
❑ Brake pad thickness: 12 mm not including backplate.
❑ Pad wear limit: 2 mm excluding backing plate.
❑ Always replace on both sides
❑ The inner brake pad on the left side of the vehicle has a wear indicator.
❑ When wear reaches a predetermined limit, the brake pad warning lamp - K32- in the dash panel insert
lights up.
11 - Connector
❑ When changing brake pads, remove from bracket ⇒ Item 17 (page 32) .
❑ Ensure correct seating
13 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
1. Front brakes 31
14 - Guide pin
❑ Use tool 9 mm socket - T50036 - .
❑ 60 Nm
15 - Caps
❑ Cover caps for guide pins.
olkswagen AG
en AG. V
16 - Brake hose/brake line olks
wag does
not
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❑ Screw into brake caliper ise
d b ara
nte
or
❑ Do not disconnect brake hose when changing
au
th brake pads. eo
ra
ss c
❑ 15 Nm
ce
le
un
pt
17 - Bracket
an
d
itte
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erm
❑ Retainer for electric brake pad wear indicator connector.
ab
ility
ot p
❑ Lock electric connector in bracket and ensure it is seated correctly.
wit
is n
h re
18 - Bolt
ole,
spec
❑ 10 Nm
t to the co
19 - Bolt
satelettronica
❑ Threaded connection, brake carrier to wheel bearing housing.
rrectne
❑ 180 Nm +45°
ss o
cial p
f inform
mer
1.2 Removing and installing brake pads/lin‐
atio
m
ings
o
n
c
i
or
n thi
e
⇒ “1.2.1 Removing and installing brake pads, floating caliper disc

t
sd
va

i
o
pr
cum
r
fo
en
ng
⇒ “1.2.2 Removing and installing brake pads, floating caliper disc

t.
yi Co
brake 2FNR 44”, page 35 Cop py
t. rig
gh ht
yri
1.2.1 Removing and installing brake pads,
p by
co Vo
by lksw
cted agen
floating caliper disc brake FN3
Prote AG.

♦ Piston resetting appliance - T10145-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Transporter a2016
ran ➤
ise
r tee
tho Brake systems - Edition 09.2019 o
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nf
ercia
orm
Mark brake pads or linings when removing if they are to be
m
atio
m
reused. Fit in same position when installing, or braking will be

o
n in
c
uneven.
or
thi
te
sd
a
– Remove wheels.
iv
o
r
rp
cu
o
m
f
– Press retaining spring in direction of -arrow A- until it can be
en
ng
t.
yi
satelettronica
pressed out of hole in direction of -arrow B-.
Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from upper hole.
– Remove cover caps -1-.

– Push connector -2- in direction of -arrow- out of retainer on
brake caliper.
– Separate electrical connector -2-.
– Remove cable from retainer -3-.
1. Front brakes 33
– Unscrew and remove both guide pins -arrows- from brake cal‐
iper.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Remove brake pads.
Use only methylated spirits for cleaning the brake caliper housing.
Installing
Before inserting new brake pads, press piston back into the cyl‐
inder using piston resetting tool - T10145- . Before pressing the n AG. Volkswagen AG do
swage es n
piston back, draw off brake fluid from the reservoir with a bleeder by Volk ot g
ua
bottle. Otherwise, fluid can overflow and cause damage, particu‐ ir se
d ran
tee
larly if reservoir has been topped up. utho
or
a ac
ss
ce
– Press piston back. le
un
pt
an
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itte
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1- Piston resetting appliance - T10145-
rm
ab
pe
ility
16” brakes:
ot
satelettronica
wit
, is n
h re
♦ Clean brake caliper (remove adhesive remains), the adhesive
hole
surface must be clean and dry.
spec
es, in part or in w
♦ Pull protective covering off backplate of pad.
t to the co
rrectness of i
l purpos
– Insert brake pad with retaining springs into pistons -arrows-.
nform
ercia
– Fit outer brake pad to brake carrier.

m
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Bolt brake caliper to brake carrier with both guide pins

-arrows-.
– Fit both protective caps.
– Insert wire of brake pad wear indicator into bracket on brake
caliper.
– Reconnect connector, and push it into bracket on brake cali‐
per.

– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
– Position retaining spring at bottom of brake carrier.
– First press retaining spring in direction of -arrow A-, and then

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♦ After changing brake pads/linings, check brake fluid level.
t to the co
Specified torques
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♦ ⇒ “1.1.1 Assembly overview - front brake, floating caliper disc
l purpos
1.2.2 Removing and installing brake pads,
nf
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or
floating caliper disc brake 2FNR 44
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1. Front brakes 35
♦ Socket, 9 mm - T50036 -
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Removing
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Note
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Mark brake pads when removing if they are to be reused. Reinstall
brake pads in same position, or braking may be uneven.
rrectne
– Remove front wheels.

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– Use a screwdriver -2- to lever retaining spring -1- off brake

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caliper in direction of -arrow-.

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– Release and disconnect connector of brake pad wear indicator

-3-.
– Remove mating part of connector from bracket -2-.
– Remove protective caps -1-.
– Unscrew guide pins using socket 9 mm - T50036 - .
– Remove brake caliper -1- in direction of -arrow- from brake
satelettronica
carrier.
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– Remove outer brake pad -4- from brake carrier -3- in direction
es, in part or in w
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of -arrow A-.
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1. Front brakes 37
Brake systems - Edition 09.2019 agen
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– Position piston resetting appliance - T10145- -1- risedbetween in‐ nte
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♦ Before pressing brake pistons back, draw off some brake fluid
from the brake fluid reservoir. Otherwise there is a risk of brake
fluid spilling out of the reservoir and causing damage to the
rrectne
vehicle when the brake pistons are being pressed back.
♦ Use only methylated spirits for cleaning the brake caliper.
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– Push inner brake pad in direction of -arrow- into pressed-back

brake pistons.

– Insert outer brake pad -3- into brake carrier -2-.

– Fit brake caliper -1- onto brake carrier -2-.
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– Insert both guide pins -1- into brake caliper, and tighten them.
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– Insert protective caps of both guide pins.
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– Push mating part of connector -2- into bracket on brake caliper
-arrow-.
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part of connector.
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– Position retaining spring in direction of -arrow A- at bottom of

brake carrier.
– Use a screwdriver to lever in upper metal tab of retaining
spring on upper brake carrier in direction of -arrow B-.
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
Note
♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, to ensure that the brake
pads are properly seated in their normal operating position.
♦ Check brake fluid level in the brake fluid reservoir every time
after brake pads have been changed.
Specified torques
1. Front brakes 39
1.3 Removing and installing brake caliper

⇒ “1.3.1 Removing and installing brake caliper, floating caliper
disc brake FN3”, page 40
⇒ “1.3.2 Removing and installing brake caliper, floating caliper
disc brake 2FNR 44”, page 44
1.3.1 Removing and installing brake caliper,

floating caliper disc brake FN3
Removing and installing brake caliper without opening in hydraul‐
ic circuit ⇒ page 40
Removing and installing brake caliper with opening in hydraulic
circuit ⇒ page 41
ic circuit
satelettronica
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Removing
– Remove wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
rrectne
Wheels, tyres; Wheel change .

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40
AG.
Rep. gr.46 - Brakes - mechanism
– Remove brake caliper -1- with brake lines still attached in di‐
rection of -arrow-.
– Suspend brake caliper with wire in area of body so that brake
lines are relieved of load. wage
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– Press brake piston of brake caliper a few millimetres back us‐
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ing piston resetting appliance - T10145- .
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– Install brake caliper, ensuring that no foreign bodies are loca‐ erm
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ted between brake pads and brake disc.
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vehicle stationary.
spec
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– Check the brake fluid level in the brake fluid reservoir.
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Specified torques
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Removing
1. Front brakes 41
– Press retaining spring in direction of -arrow A- until it can be

pressed out of hole in direction of -arrow B-.
– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from the upper hole.
satelettronica
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– Remove caps -1-.

– Push connector -2- in -direction of arrow- out of retainer on
brake caliper.
– Separate connector -2- and remove cable from retainer -3-.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper off brake carrier.
– Remove brake pads from brake caliper.
Installing
• The piston is pressed back.
satelettronica
• Outer brake pad is seated on brake carrier.
– Insert inner brake pad with retaining spring in brake caliper
(piston).
When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly. AG. Volkswagen AG d
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– Bolt brake caliper to brake carrier with both guide pins.
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– Fit both protective caps. s
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– Connect brake hose to brake caliper. When doing this, ob‐
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serve fitting instructions. ⇒ page 30
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– Fit both protective caps.
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– Insert wire for brake pad wear display into retainer on brake
hole
caliper, join connector and push into bracket on brake caliper.
spec
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– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
rrectness of i
– Seat retaining spring into lower section of brake carrier.
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1. Front brakes 43
– First press retaining spring in -direction of arrow A-, and then

simultaneously into hole in brake caliper
-direction of arrow B-.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads/linings are properly seated in their
normal operating position.
♦ Check brake fluid level.
Specified torques
satelettronica
1.3.2 Removing and installing brake caliper,
floating caliper disc brake 2FNR 44
ic circuit ⇒ page 44
circuit ⇒ page 45
Removing and installing brake caliper without
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Removing
– Remove brake caliper -1- with brake lines still attached in di‐
rection of -arrow-.
– Suspend brake caliper with wire in area of body so that brake
lines are relieved of load. gen AG
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– Press brake piston of brake caliper a few millimetres back us‐ s
ce
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ing piston resetting appliance - T10145- .

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– Install brake caliper, ensuring that no foreign bodies are loca‐
rm
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ted between brake pads and brake disc.
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– After assembly, firmly depress brake pedal several times with
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hole
spec
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– Check the brake fluid level in the brake fluid reservoir.
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Specified torques
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circuit
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1. Front brakes 45
♦ Socket, 9 mm - T50036 -
satelettronica
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The procedure described below applies only to the exchange or
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spec
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– Use a screwdriver -2- to lever retaining spring -1- off brake
caliper in direction of -arrow-.
rrectness of i
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– Release and separate electric connector for brake pad wear

indicator -6-.
– Remove mating part of electric connector -4- from bracket
-5-.
– Connect bleeder bottle hose to brake caliper bleeder valve
-3- and open bleeder valve.
– Close bleeder valve -3- and remove bleeder bottle with bleed‐
er hose.
– Separate brake hose -1- at transition point to body.
– Unscrew brake hose -1- from brake caliper.
– Remove protective caps -2-, unscrew guide pins beneath with
satelettronica
9 mm socket - T50036 - and remove from brake caliper.
– Remove brake caliper -1- from brake carrier in direction of
-arrow-.
– Remove inner brake pad out of brake piston. AG. Volkswagen AG d
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Install in the reverse order of removal, observing
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• The brake pistons are pressed back. s
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• Outer brake pad is seated on brake carrier.
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– Screw brake hose hand-tight into brake caliper.
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1. Front brakes 47
– Guide electrical cable of brake pad wear indicator -1- through

brake caliper -2-.
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– Press inner brake pad into pressed-back brake piston in s
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-direction of arrow-.
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– Position brake caliper -1- onto brake carrier -2-.
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– Insert both guide pins -2- into brake caliper and tighten.
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– Connect electric wiring harness for brake pad wear indicator
-6- to mating part and audibly lock connector.
– Screw brake hose into transition point at body.

– Tighten brake hose -1- on brake caliper.

– Position retaining spring on bottom of brake carrier in
-direction of arrow A-.
– Use a screwdriver to lever upper metal tab of retaining spring
in on upper brake carrier in -direction of arrow B-.
– Mount front wheel ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres
Note
♦ Depress brake pedal firmly several times with vehicle station‐

ary, so that brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level in brake fluid reservoir.
Specified torques
satelettronica
1.4 Removing and installing brake disc

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Removing
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– Remove brake caliper without opening in hydraulic circuit
⇒ page 40 . rrectness of i
– Unscrew bolt -1-.
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– Remove brake disc -2-.

nform
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Note
m
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ion
Do not use force to separate the brake disc from the wheel hub.
c
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or
Brake disc damage may otherwise occur on reuse. Use penetra‐

his
ate
tion spray.
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1. Front brakes 49
olkswagen AG
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Specified torques aut
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♦ Vehicles with floating caliper disc brake FN3
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♦ Vehicles with floating caliper disc brake 2FNR
ility
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1.5 Removing and installing brake carrier

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Removing
– Remove brake caliper ⇒ page 40 .
– Remove backplate -2-.
Installing
Specified torques
♦ Vehicles with floating caliper disc brake FN3
♦ Vehicles with floating caliper disc brake 2FNR

2 Rear brakes
⇒ “2.1 Assembly overview - rear brakes”, page 51
⇒ “2.2 Removing and installing brake pads/linings”, page 52
⇒ “2.3 Removing and installing brake caliper”, page 55
2.1 Assembly overview - rear brakes
Note
♦ Every time after changing the brake pads, depress the brake pedal firmly several times with the vehicle
stationary so that the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Brake pedal actuator - V.A.G 1869/2- must be inserted before removing a brake caliper or separating a
brake hose.
1 - Suspension link
satelettronica
⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Suspension link, track
rod; Assembly overview
- transverse link
2 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Clean inner surface of
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❑ Can be checked with s
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❑ Removing and installing ab

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⇒ page 26 wit
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3 - Bolt
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spec
❑ 8 Nm
es, in part or in w
t to the co
4 - Bolts
❑ Qty. 2
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❑ Bolts of brake carrier to

wheel bearing housing
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❑ 165 Nm
nf
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5 - Bolts
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2. Rear brakes 51
7 - Brake caliper . Volkswagen AG

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❑ Removing and installing ⇒ page 55Volkswa not
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8 - Brake hose/brake line ris
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❑ Do not disconnect brake hose when changing brake pads.
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9 - Brake pads
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❑ Wear limit: 2 mm excluding backing plate.
hole
spec
❑ Always replace on both sides
es, in part or in w
t to the co
❑ The inner pad on the right side of the vehicle has a wear indicator.
❑ When wear reaches a predetermined limit (approx 2-3 mm), a warning lamp in dash panel insert comes
on.
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10 - Brake carrier
nform
ercia
❑ Bolt to wheel bearing housing.

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at
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11 - Bolt
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❑ 20 Nm
at
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12 - Brake disc
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❑ Ventilated brake disc: ∅ 294 mm.

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❑ Wear limit: 19.9 mm
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❑ When worn, always renew on both sides of axle. Prote AG.
❑ Never remove brake discs from wheel hub by force. If necessary use penetrating fluid, because otherwise
brake discs can be damaged.
❑ Fitting location: on rear suspension link ⇒ Item 1 (page 51)
❑ ABS sensor ring is integrated into wheel bearing.
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearings, trailing arm;
Removing and installing wheel bearing unit
14 - Bolts
❑ Qty. 3
❑ 9.5 Nm
15 - Cover plate
16 - Rear handbrake cable
❑ Adjusting ⇒ page 59
2.2 Removing and installing brake pads/lin‐

ings

♦ Piston compressing tool - T10165-
AG. Volkswagen AG d
agen oes
olksw not
♦ Torque wrench - V.A.G 1331- d byV gu
ara
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aut ra
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nl
pt
du
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erm
ab
ility
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satelettronica
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.
nf
ercia
orm
WARNING
m
atio
om
n in
c
It is only permissible to change the position of the brake piston

or
thi
e
with the piston compressing tool - T10165- .

t
sd
iva
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f
en
ng
t.
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– Remove wheels.
Co
Cop py
ht. rig
– Turn connector for break wear display (only on right side of rig ht
py by
Vo
vehicle) 90° and pull out of metal retainer.
co lksw
by
cted agen
Prote AG.
– Disconnect connector for brake pad wear indicator.
2. Rear brakes 53
– Unhook handbrake cable -1- from retainer on brake caliper.

– Remove securing bolts -arrows- for brake caliper.
– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Remove brake pads.
– Remove pad retainers.
AG. Volkswagen AG d
Cleaning ksw
agen oes
not
Vol
by gu
d ara
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WARNING hor eo
aut ra
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Do not blow out brake system with compressed air as the re‐
ce
le
un
pt
sulting dust is dangerous to health!
an
d
itte
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erm
ab
ility
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wit
is n
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Note
ole,
spec
Use only methylated spirits for cleaning the brake caliper housing.
satelettronica
t to the co
– Thoroughly clean contact surfaces for brake pads on brake
rrectne
carrier and remove corrosion.
Installing
ss o
cial p
f inform
mer
WARNING
atio
om
n
c
i
or
n
Before pressing pistons back, draw off some brake fluid from
thi
te
sd
the brake fluid reservoir. Use a bleeder bottle or a plastic bottle
iva
o
r
which is used exclusively for brake fluid. Brake fluid is poison‐

p
cum
r
fo
ous and must on no account be sucked out by mouth using a

en
ng
t.
yi
hose!
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Apply piston compressing tool - T10165- so that collar -arrow- of
AG.
tool rests on brake caliper.

– Screw in piston by turning knurled wheel clockwise, taking
care not to damage protective cap.
– Insert brake pads with pad retainers.
If existing brake pads are to be re-used, re-install the marked
brake pads at the same position.
With new brake pads, use the pad retainers included in the repair
kit.

– Ensure that brake pads are seated correctly in anti-rattle

springs -arrows-.
– Check guide pins on brake carrier for ease of movement.
– Install brake caliper and secure with new self-locking bolts

-arrows-.
The repair kit includes 4 self-locking hexagon bolts which must
always be installed.
– Attach handbrake cable -1-.
– Join connector for brake pad wear indicator (only on right side
of vehicle), insert in metal retainer and turn 90°.
satelettronica
– Fit wheels. ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres
Note
♦ After changing brake pads, firmly depress brake pedal several

times with vehicle stationary, so that. the
Volksbrake
wage pads are prop‐
gen AG position.n AG doe
erly seated in their normallkoperating
swa sn o ot g
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♦ After changing brake
ris
edpads/linings, check brake fluid level. ran
b a
t ee
ho
aut or
ac
Specified torquesss
ce
e
nl
pt
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 51

du
an
itte
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erm
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ;

ab
ility
Wheels, tyres; Specified torque for wheel bolts .

ot p
wit
, is n
h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Rear brakes 55

equipment required
AG. Volkswagen AG d
agen oes
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satelettronica
nl
pt
du
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
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n in
or c

thi
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iva

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t.
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op py
. C rig
ht ht
rig by
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♦ Brake pedal depressor - V.A.G 1869/2- by c lksw
cted agen
Prote AG.
Removing
– Remove wheels.


– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Close bleeder screw and remove bleeder bottle.
– Unscrew brake line from brake caliper.
– Remove securing bolts -arrows- for brake caliper.
– Pull brake caliper from brake carrier.
Installing AG. Volkswagen AG d
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ol ksw not
yV gu
Install in the reverse order of removal, observing
ed b the following: ara
nte
ris
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• The piston is pressed back. aut ra
c
ss
• The brake pads are seated in the retaining springs on the
ce
e
nl
pt
du
brake carrier.
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itte
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erm
ab
– Secure brake caliper to brake carrier with new self-locking
ility
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bolts.
wit
, is n
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– Screw brake line to brake caliper.
satelettronica
hole
spec
es, in part or in w
t to the co
– Adjust handbrake ⇒ page 59 .
– Fit wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
rrectness of i
Wheels, tyres
l purpos
Note
nform
ercia
♦ Firmly depress brake pedal several times with vehicle station‐

m
at
ary so that the brake pads/linings are properly seated in their
om
ion
normal operating position.
c
in t
or
his
te
♦ Check brake fluid level.

a
do
priv
cum
for
en
g
Specified torques
n
t.
yi Co
Cop py
♦ ⇒ “2.1 Assembly overview - rear brakes”, page 51 ht. rig
rig ht
py by
o Vo
♦ Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ; by c lksw
cted agen
Wheels, tyres; Specified torque for wheel bolts . Prote AG.
2. Rear brakes 57
3 Parking brake
The repair instructions provided here may no longer be applicable
on account of the ABT e-Line conversion or may need to be sup‐
plemented by repair instructions from ABT e-Line.
The necessary repair instructions relating to the ABT e-Line are
stored in the Electronic Service Information System (ELSA Pro)
under “Attachments and conversions”.
Alternatively, these can also be requested from ABT e-Line.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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ut
⇒ “3.1 Assembly overview - sparking
s a brake”, page 58 ra
c
ce
e
⇒ “3.2 Adjusting parking brake”, page 59

nl
pt
du
an
itte
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⇒ “3.3 Removing and installing front brake cable”, page 59
erm
ab
ility
ot p
⇒ “3.4 Removing and installing rear brake cable”, page 62
wit
satelettronica
, is n
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3.1 Assembly overview - parking brake
hole
spec
es, in part or in w
t to the co
1 - Push-button
2 - Handbrake lever trim
rrectness of i
❑ Press down locking lug
underneath handle and
l purpos
pull off forwards.
nform
ercia
3 - Bracket trim
m
4 - Nut
at
om
ion
❑ For adjusting hand‐

c
in t
or
brake ⇒ page 59 .
his
ate
do
riv
5 - Nut
p
cum
for
en
❑ Qty. 2
ng
t.
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op
❑ 20 Nm
C py
ht. rig
rig ht
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6 - Pull cable co Vo
by lksw
cted agen
Prote
7 - Handbrake lever
AG.
8 - Console
9 - Handbrake cable
10 - Bracket
11 - Return spring
12 - Spring retainer
13 - Adjustment nut
14 - Compensation element

3.2 Adjusting parking brake

plemented by repair instructions from ABT e-Line. AG. Volkswagen
n AG do
lks ABT e-Line are wage es n
The necessary repair instructions relating to Vothe ot g
by ua
stored in the Electronic Service Information
ris
ed System (ELSA Pro) ran
tee
under “Attachments and conversions”. ut
ho or
sa ac
Alternatively, these can also be requested
s
from ABT e-Line.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
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Adjustment of the handbrake is necessary if the handbrake ca‐
h re
bles, brake calipers, brake pads or brake discs are renewed or
hole
spec
the cables are sagging.
es, in part or in w
t to the co
– Depress foot brake hard at least 3 times.
– Pull handbrake on three times and then release again.
rrectness of i
satelettronica
Below the first notch, the handbrake lever must return to its re‐
leased position.
l purpos
• Handbrake lever in rest position.
nform
ercia
– Raise vehicle.
m
a
com
t
– Tighten adjusting nut -arrow- until levers on brake calipers lift
ion in
off stop.
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– The total of distances -a- between levers and stops on both

sides must not exceed 2 mm.
– Make sure that the wheels are free to turn.
3.3 Removing and installing front brake cable

3. Parking brake 59
The necessary repair instructions relating to the ABT ge-Line

AG. Vare
olkswagen AG
stored in the Electronic Service Information System a en does
olksw(ELSA Pro) not
under “Attachments and conversions”. byV gu
ara
ed is nte
or
Alternatively, these can also be requested
au
th from ABT e-Line. eo
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
Removing
ot
wit
, is n
– Apply handbrake.
h re
hole
spec
– Using a screwdriver, carefully press retaining tab -arrow- for
es, in part or in w
handbrake level trim outwards.
t to the co
– Pull trim forwards off handbrake lever.
rrectness of i
– Release handbrake.
l purpos
nform
mercia
satelettronica
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Pull off bracket trim -1-.
um
fo
en
ng
t.
yi
– Unscrew adjuster nut -arrow- from cable.
Co
Cop py
ht. rig
– Raise vehicle. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Detach return spring -arrow- from underbody and from spring

retainer -1-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut Transporter 2016 ra ➤
c
s
s Brake systems - Edition 09.2019
ce
e
nl
pt
du
an
itte
– Unscrew spring retainer -1-.
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unscrew nut -arrow- from cable.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
satelettronica
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press pull cable -1- out of bracket -2-.

– Pull pull cable -1- forwards out of bracket -3- and then pull out
of underbody.
Installing
– Guide pull cable through underbody into interior.
– Insert cable -1- into retainer -3-.

– Insert cable -1- into retainer -2-.
– Attach pull cable to hand brake lever using adjusting nut.
3. Parking brake 61
– Screw nut -arrow- onto cable.
– Screw on spring retainer -1-. n AG. Volkswagen AG do

lkswage es n
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satelettronica
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Attach return spring -arrow- to underbody and to spring re‐
tainer -1-.
rrectness of i
– Insert bracket trim.
l purpos

– Attach handbrake lever trim.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op py
3.4 Removing and installing rear brake cable
t. C rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
Removing
– Release handbrake.
– Raise vehicle.

– Detach return spring -arrow- from underbody and from spring

retainer -1-.
– Unscrew spring retainer -1-.
satelettronica
– Unscrew nut -arrow- from cable.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
– Pull compensator off cable.

y li
erm
ab
ility
– Detach handbrake cable -1- from compensator -2-.

ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Parking brake 63
– Unhook handbrake cable from retainers on transverse link

-arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
ce
le
satelettronica
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Press together lugs on handbrake cable -arrows-, and push
es, in part or in w
handbrake cable towards rear and out of cable support brack‐
t to the co
et.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
– Detach handbrake cable -1- from compensator -2-.

rp
cum
fo
en
ng
Installing
t.
yi Co
Cop py
. rig
– Guide handbrake cable through cable support bracket and at‐
t
gh ht
yri by
tach to compensator. cop Vo
by lksw
cted agen
Prote AG.

– Engage handbrake cable properly in underbody -arrow-.
– Attach handbrake cable in retainers -arrows- on suspension

link.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Attach handbrake cable -1- to brake caliper. s ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Attach handbrake cable -1- to compensator -2-.

o
cial p
f inform
– Fit compensator onto cable.

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Parking brake 65
AG. Volkswagen AG d
agen oes
Transporter 2016 ➤ olksw not
byV gu
ara
Brake systems - Edition 09.2019 ris ed
nte
ho eo
aut ra
– Screw on cable nut -arrow-. ss c
ce
e
nl
pt
– Screw spring retainer onto cable.
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Attach return spring -arrow- to underbody and to spring re‐

tainer -1-.
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
satelettronica
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 67
⇒ “4.2 Removing and installing brake light switch”, page 68
⇒ “4.3 Separating brake pedal from brake servo”, page 68
⇒ “4.4 Connecting brake pedal to brake servo”, page 69
⇒ “4.5 Removing and installing brake pedal”, page 69
4.1 Assembly overview - brake pedal
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
Lubricate all bearing points and contact surfaces using grease -

G 000 450 02- .
satelettronica
lkswage es n
o ot g
1 - Brake pedal mounting d byV ua
ran
bracket o
ir se tee
th or
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2 - Nut ss
a ac
ce
le
❑ Qty. 1
un
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❑ 20 Nm
ility
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3 - Nut
h re
ole,
❑ Qty. 1
spec
❑ 25 Nm
t to the co
4 - Nut
❑ Qty. 4
rrectne
❑ 25 Nm
s
5 - Nut
s o
cial p
❑ Qty. 1 f inform
❑ 25 Nm
mer
atio
m
6 - Brake pedal
o
n
c
i
or
❑ Separating brake pedal

thi
te
sd
a
from brake servo

iv
o
pr
⇒ page 68
cum
r
fo
en
ng
❑ Connect brake pedal to

t.
yi Co
op
brake servo C py
t. rig
⇒ page 69 gh ht
pyri by
Vo
o
c by lksw
cted agen
⇒ page 69
Prote AG.
7 - Bearing shell
8 - Support
❑ For ball head of brake
servo plunger rod.
9 - Nut
❑ Qty. 1
❑ 9 Nm
4. Brake pedal 67
10 - Angled retainer
11 - Fitted bolt
12 - Bulkhead
4.2 Removing and installing brake light

switch
The brake light switch is no longer installed on the brake pedal.
Instead, it is installed on the brake master cylinder as a brake light AG. Volkswagen AG d
sensor. lksw
agen oes
not
o
yV gu
– Removing and installing brake light sensor ⇒ page 24 .rised b ara
nt ee
tho or
Removing: s au ac
s
ce
4.3 Separating brake pedal from brake ser‐ e
nl
pt
du
an
itte
vo
y li
erm
ab
ility
ot p
wit
, is n
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♦ Release tool - T10159-
satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Remove footwell cover on driver side ⇒ General body repairs,

iv
o
r
rp
cu
interior; Rep. gr. 68 ; Compartments/covers .
o
m
f
en
ng
t.
yi
– Remove brake light switch ⇒ page 68 .
Co
Cop py
ht. rig
– First press brake pedal in direction of brake servo and hold.
rig ht
py by
co Vo
by lksw
cted
1- Brake pedal
agen
Prote AG.
2- Push bar
3- Retaining lugs
– Insert release tool - T10159- and pull in direction of driver seat
while counter-holding on brake pedal -1-. (At this moment,
brake pedal must not be allowed to move towards front of ve‐
hicle). This action will press retaining lugs -3- of mounting off
ball head of plunger rod -2-.
For clarity, separation of brake pedal from brake servo is shown
with pedal cluster removed.
– Pull release tool - T10159- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).

4.4 Connecting brake pedal to brake servo

– Hold push rod ball head -2- in front of mounting and push
-arrow- brake pedal -1- in direction of brake servo so that ball
head audibly engages.
– Check engagement by pulling briefly on brake pedal.
The remaining installation steps are carried out in the reverse or‐
der of removal.
satelettronica
4.5 Removing and installing brake pedal
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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un
pt
an
d
itte
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Removing
erm
ab
ility
ot p
– Separate brake pedal from brake servo ⇒ page 68 .

wit
is n
h re
– Remove nuts from brake servo -arrows-.

ole,
spec
– Working from engine compartment, pull off brake servo ap‐

t to the co
prox. 1 cm from plenum chamber bulkhead.

rrectne
Note
Ensure that the brake lines are not damaged.

ss o
cial p
f in
– Remove nut -1- and push out brake pedal pin

form
mer
-in direction of arrow-.

atio
om
– Remove brake pedal.

n
c
i
or
n thi
e
Ensure that brake servo piston rod always remains straight.

t
sd
iva
o
pr
cum
If necessary, have a second mechanic pull brake servo into en‐

r
fo
en
ng
gine compartment in order to remove brake pedal.

t.
yi Co
Cop py
Installing
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Brake pedal 69
– Insert brake pedal in pedal bracket. Insert pin from left in op‐
posite direction of -arrow-.
– Renew nut -1- and screw on.
Ensure that brake servo piston rod always remains straight.
If necessary, have a second mechanic push brake servo against
plenum chamber bulkhead in order to install brake pedal.
– Secure brake servo with nuts -arrows-.

– Clip brake pedal to brake servo ⇒ page 69 .
The remaining installation steps are carried out in the reverse or‐
der of removal.
Specified torques
♦ ⇒ “4.1 Assembly overview - brake pedal”, page 67
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - front brake caliper”, page 71
⇒ “1.2 Removing and installing brake caliper piston”, page 74
1.1 Assembly overview - front brake caliper

⇒ “1.1.1 Assembly overview - front brake caliper, floating caliper
disc brake FN3”, page 71
⇒ “1.1.2 Assembly overview - frontVbrake caliper, floating caliper
. olkswagen AG
disc brake 2FNR”, page 73
swagen AG does
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1.1.1 Assembly overview - front brake caliper, floating caliper disc brake FN3
ris
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Note
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♦ When conducting repairs on the brake caliper, always install the complete repair kit.
rm
ab
satelettronica
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♦ Use only methylated spirits to clean the brake.
wit
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♦ New brake calipers are filled with brake fluid and are pre-bled.
hole
spec
es, in part or in w
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake cylinder, piston and seal.
♦ When repairs are performed, it is essential to appropriately pre-bleed the brake calipers (without brake pads) t to the co
before installing them in the vehicle ⇒ page 81 . rrectness of i
l purpos
nform
mercia
a
com
tion in
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te o
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Prote AG.
1. Front brake caliper 71

1 - Dust cap
❑ Fit onto bleeder valve.
❑ Secures brake pad wear
indicator wiring.
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread
❑ 17 Nm
3 - Caps
❑ Insert into mounting
bush.
4 - Guide pin
❑ 30 Nm
5 - Bearing bush
❑ Insert into brake caliper.
6 - Brake caliper
satelettronica
7 - Brake carrier
❑ Bolt onto brake caliper.
❑ Insert with both ends in
holes in brake caliper.
9 - Seal
⇒ page 74
AG. Volkswagen AG d
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10 - Piston olksw not
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❑ Removing and installing orise nte
⇒ page 74 auth eo
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ss c
11 - Protective cap
ce
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❑ Do not damage when inserting piston.

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erm
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es, in part or in w
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c
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do
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by
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Prote AG.
72 Rep. gr.47 - Brakes - hydraulics

1.1.2 Assembly overview - front brake caliper, floating caliper disc brake 2FNR
Note
♦ When conducting repairs on the brake caliper, always install the complete repair kit.
♦ When repairs are performed, it is essential to appropriately pre-bleed the brake calipers (without brake pads)
before installing them in the vehicle ⇒ page 81 .
1 - Brake carrier
❑ Bolt to brake caliper
housing.
2 - Guide pin
❑ Guide pin with Allen
satelettronica
head, AF 9 mm.
❑ 60 Nm
3 - Caps
❑ Cover caps for guide
pins.
4 - Dust cap
❑ Fit onto bleeder valve.
5 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of assembly swage
es n
paste - G 052 150 A2- to byV
olk ot g
ua
thread ir se
d ran
tee
o
❑ 17 Nm auth or
ac
ss
6 - Bearing bush
ce
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❑ Insert into brake caliper
itte
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housing.
erm
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7 - Brake caliper
wit
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hole
⇒ page 50
spec
es, in part or in w
t to the co
❑ Ensure correct seating

rrectness of i
⇒ page 32
l purpos
9 - Protective caps
❑ Take care not to dam‐
nform
ercia
age when inserting pis‐

ton.
m
at
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io
❑ Apply a thin coat of lithium grease.

n
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or
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10 - Brake piston
at
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❑ ∅ 2 x 44 mm.
p
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en
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❑ Apply a thin coat of lithium grease onto pistons before installing.

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❑ Removing and installing brake caliper piston ⇒ page 76
C py
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Prote AG.

11 - Oil seals
❑ Before installing in, coat with assembly paste.

piston
⇒ “1.2.1 Removing and installing brake caliper piston, floating
caliper disc brake FN3”, page 74
⇒ “1.2.2 Removing and installing brake caliper piston, floating
caliper disc brake 2FNR”, page 76
1.2.1 Removing and installing brake caliper

piston, floating caliper disc brake FN3
♦ Removal wedge - 3409-
satelettronica
AG. Volkswagen AG d
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spec
♦ Assembly tool for protective caps - T10146/1-

t to the co
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cial p
f inform
mer
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n
c
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Removing
um
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• Front brake caliper is removed
Co
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74
agen
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Rep. gr.47 - Brakes - hydraulics
AG. Volkswagen AG d
– Press piston out of brake caliper using compressed
wage
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Place a piece of wood in the recessut to prevent
ho damage to the eo
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piston. ss
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spec
t to the co
– Lever off protective cap from brake caliper using removal
wedge - 3409- .
rrectne
A - Vice clamps
ss o
cial p
f inform
mer
atio
om
satelettronica
n
c
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or
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Cop py
.
– Remove seal using removal wedge - 3409- .
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When removing ensure that the surface of the cylinder is not
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damaged.
AG.
Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of assembly paste - G 052 150 A2- to piston
and seal before installing.
– Insert seal in brake caliper.
– Fit protective cap -A- in assembly tool - T10146/1- -1-.

– Push protective cap onto brake caliper using assembly tool -

T10146/1- -1- and piston resetting appliance - T10145- -2- in
such a way that protective cap lies against brake caliper all
around its circumference.
Check seat of protective cap:
– At this stage it should not be possible to remove protective cap

from brake caliper by hand.
satelettronica
– Press piston lightly onto protective cap and lock it in this po‐
sition using e.g. removal wedge - 3409- -2-.
Do not cant piston to prevent damage to sealing collar.
– Blow out protective cap using compressed air (max 3 bar)
-1-. Protective cap will spring over the piston.
A - Vice clamps
AG. Volkswagen AG d
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– Press piston into brake caliper using piston resetting tool -

nl
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T10145- -1-.
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The outer sealing lip of the protective cap will then lock in the
ility
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groove of the piston.

wit
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Specified torques
hole
spec
es, in part or in w
♦ ⇒ “1.1.1 Assembly overview - front brake caliper, floating cal‐

t to the co
iper disc brake FN3”, page 71

rrectness of i
l purpos
1.2.2 Removing and installing brake caliper

nform
ercia
piston, floating caliper disc brake 2FNR

m
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ate
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76
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Rep. gr.47 - Brakes - hydraulics Prote AG.

AG. Volkswagen AG d
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satelettronica
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spec
t to the co
♦ Assembly tool for protective caps - T10145/3-

Removing
rrectne
Note
ss o
cial p
Removal and installation of brake pistons are described for one

inform
of the two brake pistons only. Proceed in the same way when
mer
removing and installing the second brake piston.

atio
om
n
c
i
or
• Front brake caliper is removed

thi
te
sd
iva
– Position piston resetting appliance - T10145- -1- on one of the

pr
cum
r
fo
two brake pistons.

en
ng
t.
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op
– Place a piece of wood in brake caliper shaft in front of other
C py
t. rig
brake piston to prevent it from being damaged when pressing
gh ht
pyri by
out.
o Vo
by c lksw
cted agen
Prote AG.

– Press out brake piston from brake caliper housing using com‐
pressed air.
– Lever off protective cap from brake caliper using removal
wedge - 3409- -1-.
lkswage es n
o ot g
byV ua
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ir se tee
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ab
– Remove piston resetting appliance - T10145- -1- from brake
ility
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caliper.
wit
is n
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– Remove seal from brake caliper housing using removal wedge
ole,
spec
- 3409- -2-.
t to the co
Note
rrectne
satelettronica
When removing, ensure that the surface of the brake piston is not
damaged.
ss o
cial p
f
Installing
inform
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
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pr
cum
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The surfaces of the piston and oil seals must be cleaned only with
en
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Cop py
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– Apply thin coat of assembly paste to brake piston and seal cop Vo
by lksw
before installing. cted agen
Prote AG.
– Insert seal into groove of brake caliper housing.

– Press protective cap into brake caliper housing using piston

resetting appliance - T10145- -2- and assembly tool for pro‐
tective caps - T10145/3- -1-.
– Push protective cap onto brake caliper housing so that it
comes into contact all around housing -arrow-.
Check seat of protective cap:

– Make sure that protective cap -1- can no longer be pulled off
brake caliper housing -2- by hand.
satelettronica
– Apply thin coat of assembly paste to brake piston and seal
before installing.
– Position piston resetting appliance - T10145- -3- on second
brake piston and preload tool.
AG. Volkswagen AG d
agen o
– Press brake piston lightly ontoVoprotective
lksw cap e.g. using aes not g
commercially available extension
d by -1-. When doing this, do not uaran
ise
cant piston (keep straight)
ho
r to prevent damage to protective tee
cap. aut or
ac
s s
ce
le
– Inflate protective cap with compressed air (maximum 3 bar)

un
pt
-2-. The protective cap will then locate around the brake piston.
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
– Slowly press brake piston into brake caliper housing by hand.

h re
hole
spec
es, in part or in w
t to the co
Note
The inner sealing lip on the protective cap -1- will then slip into
rrectness of i
the brake piston groove -2-.

l purpos
– Install brake caliper ⇒ page 40 .

nform
Specified torques
mercia
♦ ⇒ “1.1.2 Assembly overview - front brake caliper, floating cal‐

a
com
tio
iper disc brake 2FNR”, page 73

n in
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te o
thi
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t.
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Cop py
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gh ht
pyri by
Vo
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by
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Prote AG.

2 Rear brake caliper

⇒ “2.1 Assembly overview - rear brake caliper”, page 80
⇒ “2.2 Removing and installing brake caliper piston”, page 81
2.1 Assembly overview - rear brake caliper
Note
♦ When conducting repairs, use complete repair kit.

♦ When repairs are performed, it is essential to appropriately pre-bleed the brake calipers (without brake pads)
before installing them in the vehicle ⇒ page 81 .
satelettronica
1 - Bolt
❑ Renew after removal agen
AG. Volkswagen AG d
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❑ When loosening and d byV
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tightening, counter hold orise nte
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on guide pin. aut
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❑ 35 Nm s
ce
e
nl
pt
du
2 - Seal
an
itte
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erm

ab
ility
⇒ page 81
ot p
wit
, is n
3 - Piston with automatic ad‐

h re
hole
justment
spec
es, in part or in w

t to the co
⇒ page 81
4 - Protective cap
rrectness of i
❑ Pull on so that outer

sealing lip goes over
l purpos
piston.
5 - Dust cap
nform
ercia
6 - Bleeder valve
m
at
om
io
❑ 12 Nm
n
c
in t
or
his
e
7 - Brake caliper with hand‐

at
do
riv
brake cable lever

p
cum
for
❑ If there is a leak at hand‐

en
ng
t.
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brake cable lever, re‐
Co
Cop py
new brake caliper. ht. rig
rig ht
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❑ Following repair work,
co Vo
by lksw
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pre-bleed brake caliper
agen
Prote AG.
⇒ page 81 .
8 - Guide pin
❑ Grease before fitting
protective cap.
9 - Protective cap
❑ Fit onto brake carrier and guide pin.
10 - Brake carrier with guide pin(s) and protective cap
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.

❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.

piston
♦ Piston compressing tool - T10165-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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un
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an
d

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rm
ab
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
a
com
tion in
r
te o
WARNING
thi
s
iva
do
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rp
It is only permissible to change the position of the brake piston

um
fo
en
g
with the piston compressing tool - T10165- .

n
t.
yi Co
Cop py
ht. rig
rig ht
py by
• Rear brake caliper removed
co Vo
by lksw
cted agen
Prote AG.
– Apply piston resetting appliance - T10165- so that collar
-arrow- is in front of piston.
– Screw piston out of brake caliper by turning thumb wheel anti-
clockwise. Do not damage protective cap.
– If pistons are difficult to move, a 13 mm open-end spanner can
be used on intended flats -arrow A-.
2. Rear brake caliper 81

– Remove seal using removal wedge - 3409- .

Installing
Note
♦ When conducting repairs on the brake caliper, always install

the complete repair kit.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake
cylinder, piston and seal.
olkswagen AG
en AG. V
♦ When repairs are performed, it oislksessential
wag to appropriately
does
no
pre-bleed the brake calipers d b(without brake pads) before in‐
yV t gu
ara
stalling them in the vehicle
ho
rise ⇒ page 81 . nte
eo
t
au ra
♦ ss c
ce
le
un
pt
satelettronica
an
d
– The surfaces of the piston and seal must be cleaned only with
itte
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rm
ab
pe
ility
– Insert seal into groove.
ot
wit
, is n
h re
– Apply thin coat of assembly paste - G 052 150 A2- to piston
hole
spec
and seal before installing.
es, in part or in w
t to the co
– Place protective cap with outer sealing lip on piston.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐ C py
t. rig
gh
inder groove.
ht
pyri by
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o
by c lksw
When doing this, hold piston in front of brake caliper. cted agen
Prote AG.

Apply piston compressing tool - T10165- so that collar -arrow- of

tool rests on brake caliper.
– Screw in piston by turning knurled wheel of piston resetting
appliance - T10165- clockwise; do not damage protective cap
when doing this.
Pre-bleeding brake caliper n AG. Volkswagen AG do

lkswage es n
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– Position brake caliper as illustrated tosepre-bleed.
d b ua
ran
ir tee
ho
– Open bleeder valve -arrow A- and, au using a commercially avail‐
t or
ac
able bleeder bottle, fill with brake fluid until bubble-free brake
ss
ce
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fluid flows out of threaded hole of brake hose connection

nl
pt
du
-arrow B-. Then close bleeder screw.
an
itte
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erm
ab
Specified torques
satelettronica
ility
ot p
wit
♦ ⇒ “2.1 Assembly overview - rear brake caliper”, page 80
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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or c
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by
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Prote AG.
2. Rear brake caliper 83

3 Brake servo and brake master cylin‐

der
⇒ “3.1 Assembly overview - brake servo/brake master cylinder”,
page 84
⇒ “3.2 Removing and installing brake servo”, page 86
⇒ “3.3 Removing and installing brake master cylinder”,
page 87
⇒ “3.4 Removing and installing brake fluid reservoir”, page 90
3.1 Assembly overview - brake servo/brake master cylinder
WARNING
♦ Never allow brake fluid to come into contact with fluids

containing mineral oil (oil, petrol, cleaning agents) as
these damage the brake system's plugs and sleeves.
♦ Brake fluid is poisonous and must never be sucked out by
satelettronica
mouth through a hose.
♦ Due to its corrosive effect brake fluid must not come into
contact with paintwork.
♦ Observe applicable regulations for disposal.
♦ Only use brake fluid conforming to VW standard
(VW 501 14).
AG. Volkswagen AG d
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nl
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
84
by lksw
cted agen
Rep. gr.47 - Brakes - hydraulics Prote AG.
1 - Brake servo
❑ Operation check:
❑ If faulty renew complete
⇒ page 86
2 - Brake fluid reservoir
⇒ page 90
3 - Cap
4 - Sealing plug
❑ Moisten with propylene
glycol - 294440- assem‐
bly fluid from outside
and press into brake
master cylinder
❑ Moisten with propylene
glycol - 294440- from in‐
side and press into
brake fluid reservoir
satelettronica
5 - Hexagon nut
❑ Qty. 2
❑ 25 ± 4 Nm
6 - Securing pin
❑ Secures brake fluid res‐
ervoir on tandem brake
master cylinder
7 - Tandem brake master cyl‐
inder
❑ Cannot be repaired, re‐ gen AG. Volkswagen AG
does
new completely when olks
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faulty. byV gu
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ris nte
❑ Removing and
ut installing ⇒ page 87
ho eo
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8 - Brake line s
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e
nl
pt
❑ Brake master cylinder/secondary piston circuit to ABS hydraulic unit - N55- .

du
an
itte
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❑ 14 Nm
erm
ab
ility
ot p
9 - Brake line
wit
, is n
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❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .
hole
spec
❑ 14 Nm
es, in part or in w
t to the co
10 - Brake light switch

11 - Bolt
rrectness of i
❑ Qty. 1
l purpos
❑ 8 Nm
12 - Vacuum hose
nform
ercia
❑ With non-return valve

m
❑ Press in brake servo with propylene glycol - 294440- assembly fluid axially onto rubber plug as far as it
at
om
io
will go
n
c
in t
or
his
e
13 - Sealing plug
at
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❑ Connection for vacuum hose.

p
cum
for
en
ng
14 - Seal
t.
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Cop py
❑ Oil seal between brake servo and brake master cylinder. ht. rig
rig ht
py by
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by lksw
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Prote AG.
3. Brake servo and brake master cylinder 85

15 - Seal
❑ For brake servo
16 - Brake pedal with mounting bracket
AG. Volkswagen AG d
agen oes
17 - Nut olksw not
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ara
❑ Renew after removal rised
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❑ 25 Nm s aut ra
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un
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3.2 Removing and installing brake servo
erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
rrectness
satelettronica
o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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♦ Brake filling and bleeding equipment - VAS 5234-
pr
cum
r
fo
en
ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Remove bolt -arrow- and remove cover -1- to left of battery.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray.

– Remove trim -1-.

– For vehicles with brake assist system, pull off connector -2-.
AG. Volkswagen AG d
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– Detach supply hose of clutch master cylinder -1- from retainer
h re
ole,
-2-.
spec
– Raise bracket -2- slightly at rear tab and pull off brake servo
t to the co
in -direction of arrow-.
– Unbolt cooling system expansion tank and lay to side without
rrectne
opening cooling system.
– Remove fuel filter ⇒ Fuel system; Rep. gr. 20 ; Fuel filter;
satelettronica
s
Removing and installing fuel filter
o
cial p
f inform
– Disconnect vacuum hose from brake servo.
mer
atio
om
n
c
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or
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e
– On vehicles with brake assist system, pull off electrical con‐

t
sd
va
nector -1- from brake servo.

i
o
pr
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– Remove brake master cylinder ⇒ page 87 .

t.
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– Separate brake pedal from brake servo ⇒ page 68 .
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– Remove nuts from brake servo -arrows-.

– Carefully remove brake servo from the vehicle.
Installing
– Install brake master cylinder ⇒ page 87 .
– Clip brake pedal to brake servo ⇒ page 68 .
– Install and adjusting brake light switch ⇒ page 68 .
– Code radio.
After bleeding brake system, perform basic settings for brake
pressure sender -1- - G201- ⇒ Vehicle diagnostic tester.
Specified torques
der”, page 84
3.3 Removing and installing brake master cylinder


equipment required
AG. Volkswagen AG d
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Removing
WARNING

these damage the brake system's plugs and sleeves.
(VW 501 14).
– Note or request radio code on vehicles

agen
AG. with coded
Volksw radio
agen AG
does if
necessary. Volksw not
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– Disconnect battery ⇒horElectrical
ise system; Rep. gr. 27 ; Battery; ntee
satelettronica
Disconnecting andaureconnecting
t battery . or
ac
s s
– Place sufficient lint-free cloths in area of control unit and hy‐
ce
le
un
pt
draulic unit.
an
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– Draw off as much brake fluid as possible from brake fluid res‐
ility
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ervoir using brake filling and bleeding equipment - VAS 5234- .
wit
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– Pull clutch master cylinder supply hose off brake fluid reservoir
ole,
and tie in place.

spec
– Pull connector off brake fluid level warning contact - F34- .

t to the co
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– Unhook wire -1- from bracket -2-.

– Unscrew brake lines -3- from brake master cylinder.
– Seal brake lines with sealing plugs - 1H0 698 311 A- .
– Unscrew both nuts securing brake master cylinder to brake
servo.
– Carefully take brake master cylinder out of brake servo.
Installing
Note
♦ When assembling brake master cylinder with brake servo,

make sure plunger rod is properly positioned in brake master
cylinder.
♦ Ensure that the seal between the brake master cylinder and
the brake servo is properly installed.
satelettronica
– On vehicles with manual gearbox, bleed clutch master cylinder
⇒ Rep. gr. 30 ; Clutch mechanism; Bleeding clutch mecha‐
nism .
– Code radio.
After bleeding brake system, perform basic settings for brake
pressure sender -1- - G201- ⇒ Vehicle diagnostic tester.
Specified torques
der”, page 84
3.4 Removing and ageninstalling brake

AG. Volkswagen AG d fluid res‐
oes
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ervoired by Vol not
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Special tools and
au workshop equipment required
th ra
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es, in part or in w
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Rep. gr.47 - Brakes - hydraulics
Removing
WARNING
AG. Volkswagen AG d
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♦ Never allow brake fluidbto y V come into contact with fluids t gua
ol no
containing mineral oil ris
ed(oil, petrol, cleaning agents) as ran
tee
these damage the uthobrake system's plugs and sleeves. or
a ac
ss
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un
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an
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erm
ab
ility
ot p
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spec
(VW 501 14).
t to the co
– Remove upper battery cover.
rrectne
– Remove bolt -arrow-. Remove “large” side cover -1- and
“small” side cover from battery.
ss
satelettronica
o
cial p
f inform
mer
atio
om
n
c
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or
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t.
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Cop py
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– Open cap of brake fluid reservoir -1-.
p by
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– As protection against escaping brake fluid, place a sufficient
Prote AG.
number of lint-free cloths in area beneath brake master cylin‐

der.
– Extract as much brake fluid as possible -5- from brake fluid
reservoir using brake filling and bleeding equipment - VAS
5234- .
– Separate electrical connector from brake fluid level warning
contact - F34- -2-.
– Pull off return hose -3- for clutch master cylinder from brake
fluid reservoir -5-.
– Pull out locking pin -4- in direction of -arrow A- from brake fluid
reservoir.
– Remove brake fluid reservoir -5- from brake master cylinder in
direction of -arrow B-.
Installing

– Coat sealing plug on brake master cylinder -1- with propylene

glycol - 294440- assembly fluid.
– Insert brake fluid reservoir in sealing plug -1-.
– Push locking pin -4- through brake fluid reservoir -5-.

– Attach electrical connector to brake fluid level warning contact
- F34- -2-.
– Fit supply hose -3- on brake fluid reservoir -5-.
– Bleed brake system ⇒ page 103 . AG. Volkswagen AG d
agen oes
olksw not
V gu
– On vehicles with manual gearbox, bleed d b clutch master cylinder
y ara
satelettronica
ise nte
⇒ Rep. gr. 30 ; Clutch mechanism;thor Bleeding clutch mecha‐ eo
nism . s au ra
c
s
ce
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– Install battery cladding.

nl
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du
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4 Vacuum system
AG . Volkswagen AG
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⇒ “4.1 Assembly overview - electric vacuum pump”, page 93 e
nl
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⇒ “4.2 Assembly overview - vacuum pump”, page 94
erm
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⇒ “4.3 Checking non-return valve”, page 94
wit
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⇒ “4.4 Removing and installing non-return valve”, page 96
hole
satelettronica
spec
⇒ “4.5 Removing and installing brake servo pressure sensor”,
es, in part or in w
t to the co
page 97
⇒ “4.6 Checking vacuum system”, page 98
rrectness of i
4.1 Assembly overview - electric vacuum pump
l purpos

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4. Vacuum system 93
1 - Vacuum pump for brakes -

V192-
2 - Vacuum line
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
3 - Bolt
❑ 8 Nm
❑ Qty. 2
4 - Bracket
5 - Rubber damper
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Qty. 3
❑ Do not push rubber
damping elements out
of the bracket during in‐
stallation
6 - Bracket
satelettronica
7 - Bolt
❑ 25 Nm
AG. Volkswagen AG d
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4.2 Assembly overview - vacuum pump
rrectness of i
Petrol engine ⇒ Rep. gr. 15 ; Cylinder head; Assembly overview
- cylinder head
l purpos
Diesel engine ⇒ Lubrication; Rep. gr. 17 ; Oil sump/oil pump;

Assembly overview - oil sump/oil pump nf
ercia
orm
4.3 Checking non-return valve

m
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The necessary repair instructions relating to the ABT e-Line are t. C rig
gh ht
stored in the Electronic Service Information System (ELSA Pro) pyri by
Vo
co
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⇒ “4.3.1 Checking mechanical non-return valve”, page 95

⇒ “4.3.2 Checking non-return valve with pressure sensor”,
page 95
4.3.1 Checking mechanical non-return valve

– Carefully pull non-return valve with vacuum line -1- out of

brake servo.
satelettronica
– Blow a little air through non-return valve, first in one direction
and then in other.
• Air must pass through non-return valve -1- in direction of
-arrow A-.
n AG. Volkswagen A
• Non-return valve -1- must remain closed olks
wagein opposite direction
G do
es n
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of -arrow B-. If this is not the case,
d by renew non-return valve or,
V ua
ran
if necessary, complete vacuum or
ise line. tee
th or
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Note
un
pt
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rm
When installing the vacuum line with non-return valve, make sure
ab
pe
ility
that the installation position is correct.

ot
wit
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es, in part or in w
t to the co
4.3.2 Checking non-return valve with pressure sensor

rrectness of i

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nform
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Prote AG.
4. Vacuum system 95
– Carefully pull out non-return valve with pressure sensor and

vacuum line -1- from brake servo.
– Blow a little air through non-return valve, first in one direction
and then in other.
• Air must pass through non-return valve -1- in
-direction of arrow-.
• The non-return valve -1- must remain closed in the opposite
-direction of arrow-. If this is not the case, renew non-return
valve or, if necessary, complete vacuum line.
Note
When installing the vacuum line with non-return valve, make sure
that the installation position is correct.
4.4 Removing and installing non-return valve
satelettronica
AG. Volkswagen AG d
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4.4.1 Removing and installing mechanical non-return valve
V gu
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This vehicle is energised
aut by ABT e-Line ra
ss c
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– Carefully pull non-return valve with vacuum line -1- out of

brake servo.
– Pull off vacuum hose in direction of -arrow- from non-return
valve.
4.4.2 Removing and installing non-return valve with pressure sensor

The necessary repair instructionsagenrelating to theAABT
AG. Volkswagen G d e-Line are
oes
satelettronica
ksw Information System (ELSA
stored in the Electronic Service gu Pro)
ol not
yV
under “Attachments isand
ed b conversions”. ara
n r tee
ho
Alternatively, these
sa
ut can also be requested from ABT e-Line. or
ac
s ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
– Carefully pull out non-return valve with pressure sensor and

wit
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vacuum line -1- from brake servo.

h re
hole
– Pull off connector -2- in direction of -arrow A-

spec
es, in part or in w
t to the co
– Carefully pull off non-return valve with pressure sensor and

vacuum line -1- from vacuum pump suction pipe in direction
of -arrow B-.
rrectness of i
l purpos
nf
ercia
orm
m
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4.5 Removing and installing brake servo
lksw
cted agen
Prote AG.
pressure sensor
Note
The vacuum sender - G608- is only installed in selected petrol

engines.
4. Vacuum system 97
Removing
– Disconnect connector -3- from vacuum sender - G608- -1-.
– Unclip vacuum sender - G608- -1- from vacuum line -2-.
Do not damage plastic locking mechanisms.
Installing
Note
♦ Make sure to check the seal for damage before installing the
vacuum sender - G608- .
♦ If the seal is damaged, the vacuum sender must be renewed.
4.6 Checking vacuum system
satelettronica
. Volkswagen AG
gen AG does
Alternatively, these can also be requested from ABT
Vol
kswe-Line.
a
not
y gu
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rise nte
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nl
pt
⇒ “4.6.1 Connecting brake servo tester VAS 6721 ”, page 98

du
an
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⇒ “4.6.2 Checking vacuum generation”, page 100

erm
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ility
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⇒ “4.6.3 Checking for leaks”, page 100

wit
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⇒ “4.6.4 Vacuum generation with manual vacuum pump VAS

hole
spec
6213 ”, page 102

es, in part or in w
t to the co
4.6.1 Connecting brake servo tester - VAS 6721-

rrectness of i

l purpos

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ercia

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om

on
c
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or

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ate
do
priv
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AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
d
rise Brake systemsnte - Edition 09.2019
tho eo
s au ra
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♦ Vacuum gauge for brake servo - VAS 6721- s
ce
e
nl
pt
du
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erm
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ility
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es, in part or in w
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rrectness of i
l purpos
Observe the notes before performing any tests ⇒ page 11 .
nform
ercia
– Pull vacuum hose out of brake servo.

m
at
om
i
First press the brake pedal several times in order to facilitate re‐
on
c
in t
moval of the vacuum hose.
or
his
ate
– Place brake servo tester - VAS 6721- in between
do
priv
c
-see following illustrations-.
um
for
en
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Item Component Explanation

A Cut-off valve In direction of vacuum hose, non-return valve and, if fitted, vacuum pump
B Cut-off valve ♦ Open to facilitate removal of brake servo tester - VAS 6721-
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS 6213-
C Cut-off valve In direction of brake servo
4. Vacuum system 99
AG. Volkswagen AG d
agen oes
olksw not
V
Transporter 2016 ➤ d by gu
ara
ise nte
Brake systems - Edition 09.2019 thor eo
au ra
ss c
– Fit hose -A- of brake servo tester - VAS 6721- on vacuum hose
ce
le
un
pt
and press adapter -C- into brake servo.
an
d
itte
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ility
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t to the co
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4.6.2 Checking vacuum generation
cial p
f inform
mer
atio
om
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c
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satelettronica
t.
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op
C py
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Alternatively, these can also be requested from ABT e-Line. cop Vo
by lksw
cted agen
Prote AG.
Observe the notes before performing any tests on the vacuum

system.
– Connect brake servo tester - VAS 6721- ⇒ page 98 .
– Open cut-off valve -A-.
– Close shut-off valves -B- and -C-.
– Start warm engine (>60°C), press accelerator briefly (engine
speed above 2000 rpm).
– Read indicated measured value.
Normally, the vacuum that is generated should be between 600
and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions have been met, the vacuum system must first be checked
for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213- ⇒ page 102 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.6.3 Checking for leaks


Brake
en AGsystems
. Volksw age-nEdition
AG 09.2019
ag does
ksw not
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au ra
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system ⇒ page 5 .
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– Connect brake servo tester - VAS 6721- ⇒ page 98 .
ility
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– Open cut-off valve -A-.
, is n
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hole
– Close shut-off valves -B- and -C-.
spec
es, in part or in w
– Start warm engine (>60°C), press accelerator briefly (engine
t to the co
speed above 2000 rpm).
Normally, the vacuum that is generated should be between 600
rrectness of i
and 950 mbar (depending on engine size).
l purpos
nform
mercia
at
om
ion
c
in t
or
satelettronica
his
ate
do
riv
– Open cut-off valve -C- to evacuate brake servo.

p
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for
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– Switch off engine.

n
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– Read and make a note of measured value shown.
t. C rig
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A vacuum decrease of 400 mbar in 12 hours is permissible. by c lksw
cted agen
Prote AG.
If the vacuum decrease is greater, check for leaks in the vicinity
of
1- Brake servo
or
2- non-return valve, vacuum hoses with push-on connections
and vacuum pump/intake manifold
if the leak can be found there.
If there are large leaks, the vacuum decreases steeply within a
few seconds.
Vacuum check in vicinity of brake servo:
– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake manifold:
4. Vacuum system 101

– After generating a vacuum, close shut-off valve -C- in order to

check vacuum system from brake servo tester - VAS 6721- to
intake pipe or to vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.
4.6.4 Vacuum generation with manual vacuum

. Volkswage
pump - VAS 6213-
AG n AG d
agen oes
This vehicle is energised by ABT e-Line olksw not
yV gu
db ara
The repair instructions provided here may riseno longer be applicable nte
tho eo
on account of the ABT e-Line conversion
s au or may need to be sup‐ ra
c
plemented by repair instructions from
s ABT e-Line.
ce
le
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pt
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d
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satelettronica
rm
ab
pe
ility
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spec
es, in part or in w
t to the co
system ⇒ page 5 .
rrectness of i
Instead of vacuum generation by means of engine or vacuum
l purpos
pump, the vacuum can be generated with the manual vacuum

pump - VAS 6213- in certain cases.
nform
ercia
– To do this, connect hand vacuum pump - VAS 6213- to vac‐

m
uum hose from connection -B- on brake servo tester - VAS

com
tio
6721- .
n in
r
te o
thi
– Open cut-off valve -B-.

s
iva
do
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rp
– Generate vacuum with hand vacuum pump - VAS 6213- until

um
fo
en
g
between 600 and 950 mbar is shown on brake servo vacuum

n
t.
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gauge - VAS 6721- . Cop py
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– Then, carry out the corresponding checks. p by
o Vo
by c lksw
cted agen
Prote AG.

5 Hydraulic system
⇒ “5.1 General notes on brake fluid”, page 103
⇒ “5.2 Bleeding hydraulic system following standard procedure”,
page 103
⇒ “5.3 Subsequent bleeding of hydraulic system”, page 104
⇒ “5.4 Testing for leaks”, page 105
5.1 General notes on brake fluid
WARNING

these damage the seals, boots and sleeves of the brake
system and clutch mechanism.
satelettronica
♦ Always observe the relevant regulations for disposal.
♦ Only use new brake fluid conforming to VW standard
(VW 501 14).
AG. Volkswagen AG d
agen oes
olksw not
Note d by
V gu
ara
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♦ ut poisonous. Also due to its corrosive effect brake
Brake fluids ais ra
c
fluid must not come into contact with paintwork.
s
ce
e
nl
pt
du
♦ Brake fluid is hygroscopic, which means it absorbs moisture

an
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from the ambient air and should therefore always be stored in

erm
ab
air-tight containers.
ility
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♦ Rinse off spilled brake fluid using plenty of water.

h re
hole
spec
5.2 Bleeding hydraulic system following

es, in part or in w
t to the co
standard procedure
rrectness of i
♦ Brake filling and bleeding unit - VAS 5234-

l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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en
ng
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Cop py
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Prote AG.
5. Hydraulic system 103

♦ Tool set for brake bleeding - VAS 6564-
Strictly adhere to procedure when bleeding brake system.

– Connect brake filling and bleeding equipment - VAS 5234- and
switch on.
A pre-pressure of 2 bar must be maintained to bleed the hydraulic
system.
– Open bleeder valves in specified order and bleed brake cali‐
satelettronica
pers.
1. Front right brake caliper
2. Front left brake caliper
3. Rear right brake caliper
4. Rear left brake caliper
Note
olkswagen AG
en AG. V
Make sure to use a suitable bleeder hose. It must sit tightly on the Volkswag does
not
bleeder valve so that no air can enter the brake system. ed
by gu
ara
ris nte
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ut ra
– Leave bleeder valve of each brake caliper open withssbleeder
a c
hose fitted until brake fluid discharges free of air bubbles.
ce
e
nl
pt
du
an
5.3 Subsequent bleeding of hydraulic sys‐
itte
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ab
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ility
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Note
es, in part or in w
t to the co
♦ This bleed sequence must be carried out 5 times per brake

caliper.
rrectness of i
♦ After bleeding, a road test must be carried out, during which

at least one ABS intervention must be triggered.
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Repeat bleeding is carried out in connection with excessive brake

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pedal travel or so-called »spongy« brakes.

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This requires the assistance of a second mechanic:

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– Depress brake pedal firmly and hold.

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– Open bleeder valve on brake caliper. Observe bleeding se‐

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– Fully depress brake pedal. . Cop py
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– Close bleeder valve with pedal held down.
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– Release brake pedal slowly.
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Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
– Carry out road test.
5.4 Testing for leaks

♦ Tester for brake pressure regulator - V.A.G 1310 A-
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♦ Adapter M10 - V.A.G 1310/6-
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Prerequisites for testing:
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• Brake system (hydraulic unit, brake hoses, brake lines and
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brake calipers) operating properly and free of leaks.
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Checking
– Remove bleeder valve at one of front brake calipers.
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– Connect tester for brake pressure regulator - V.A.G 1310 A-
and bleed.
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– Apply pressure to brake pedal until gauge indicates a pressure

of 50 bar.
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The pressure must not drop by more than 4 bar during the test
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period of 45 seconds. Renew brake master cylinder if drop in

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pressure exceeds specification.

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5. Hydraulic system 105

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Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B80570F2F

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

3.3 Separating control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.3 Removing and installing brake light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.5 Removing and installing brake carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.5 Removing and installing brake servo pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

5.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.2 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.3 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.4 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.1 Safety measures when working on ve‐

Risk of injury due to automatic start of engine in vehicles with

1.2 Safety precautions when using testers

Risk of accidents due to distraction and inadequate securing

1.3 Safety precautions when working on a high-voltage system

Danger to life from high voltage

The high-voltage system is under high voltage. Severe or fatal

injury from electric shock.

– Persons with life-preserving or other electronic medical devi‐

pumps and hearing aids.

– The high-voltage system must be de-energised by a suitably

Risk of injury from unexpected engine/motor start

On electric and hybrid vehicles, the operational readiness of the

vehicle is difficult to detect. There is a risk of parts of the body

2 Rep. gr.00 - Technical data

Risk of damage to high-voltage cables

Risk of injury from activated stationary air conditioning

1.4 Safety precautions when working in vicinity of high-voltage components

Danger to life from high voltage

– Never use cutting or forming tools, or any other sharp-edged

hot air or thermal bonding equipment.

installed can also be called up via ELSA/vehicle-specific

Allocation ⇒ Electronic parts catalogue “ETKA” .

4 Rep. gr.00 - Technical data

3.1 Checking vacuum system

4 Hazard classification of high-voltage

WARNING AG. Volkswagen AG d

“high-voltage technician” or “high-voltage expert”, or those

as well as this workshop manual.

This vehicle is energised by ABT e-Line

Line conversion, consult the Electronic Service Information Sys‐

tively, request these details from ABT e-Line.

6 Rep. gr.00 - Technical data

⇒ “5.1.1 Brake master cylinder and brake servo”, page 7

⇒ “5.1.2 Front brakes”, page 7

5.1.1 Brake master cylinder and brake servo

5.1.2 Front brakes

Front brake, 16" (2E3)

Item Designation Dimensions

-1- Brake caliper (FN3) -

-2- Brake pad, thickness 12.5

Front brake, 17" (2E4)

5.1.3 Rear brakes

8 Rep. gr.00 - Technical data