Service Workshop Manual Touareg 2003 > Edition 07.2009 Service Department. Technical InformationService List of Workshop Manual Repair Groups Repair Group 00 - Technical data 45 - Anti-lock brake system 46 - Brakes - mechanism 47 - Brakes - hydraulics Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Volkswagen AG, Wolfsburg 0058961020Brake systems Touareg 2003 > @ - Edition 07.2008 00 - Technical data 45 46 1 14 12 13 2 24 22 23 3 34 32 Anti-lock brake system oarons 64 62 7 7A 72 73 8 a 82 Brakes - mechanism Contents Brake allocation via PR No. Example of a vehicle data sticker Front brakes Rear brakes (disc brakes) Technical data. . Brake master cylinder and brake servo Front brakes: Rear brakes Brake test General . cee . . Test . a cee «ancl General notes for ant-lock brake syste (ABS) Notes for repair work on the ABS. Connecting VAS 5051 and seledting functions Electricalfelectronic componehts and fiting locations Fault display via warning lamps... Assembly overview - hydraulle unt, brake servofbrake master cylinder ABS MK 25 to week 48/06 ABS MK 25 E1 from week 48/06 Removing and installing parts of ABS system on front and rear axle. Removing and installing speed sensor on front axle. Y. Removing and installing parts of ABS system on rear axle Removing and installing speed sensor on rear axle. Removing and installing parts of ESP system Removing and installing ESP sensor unit G418 Removing and installing steering angle sender G85 Repairing front brakes Repairing front brakes, FN 3 brake caliper (16°) Removing and installing brake padsdjnings Removing and installing brake caliper” Repairing front brake, Brembo 17" brake caliper (1LC) Removing and installing brake pads/inings Removing and installing brake caliper Repairing front brake, Brembo 17" brake caliper (1LE) Removing and installing brake pads/inings Removing and installing brake caliper Repairing front brake, Brembo 18" brake caliper Removing and installing brake padsiinings Removing and installing brake caliper Repairing front brake, Brembo 18" brake caliper Plus Removing and installing brake pads/inings Removing and installing brake caliper Repairing reer brakes Repairing rear brakes, brake caliper FN 44 Removing and installing brake pads/inings Removing and installing brake caliper 16, 70 78 contanis i@ 47- 24 25 26 27 28 29 2.10 211 2.12 2.13 2.14 2.15 2.16 247 3 34 32 33 34 4 44 42 5 54 52 1 14 12 13 14 2 24 22 23 24 3 4 44 42 5 54 52 6 64 62 63 7 TA 72 8 a4 Brakes - hydraulics Touareg 2003 > Brake systems - Edition 07.2009 Removing and installing brake shoes Repairing rear brakes, Brembo 17" brake caliper (1F) Removing and installing brake padsfinings Removing and installing brake caliper Removing and installing brake shoes : Repairing rear brakes, Brembo 17" brake caliper (1KQ) Removing and installing brake pads/inings Removing and installing brake caliper Removing and installing brake shoes Repairing rear brakes, 18" brake caliper Pius Removing and installing brake padsfinings Removing and installing brake caliper Removing and installing brake shoes Adjusting parking brake Assembly overview - foot-operated parking brake Parking brake pedel Transfer module Rear brake cable Removing and installing parking brake pedal Brake cables oe Removing and installing rear brake cables Removing and installing front brake cable .« Assembly overview - brake pedal (LHD). ‘Separating brake pedal from brake servo Removing and installing brake light Switch F and brake pedal suitch F47 Repairing front brake calipers”. Repairing FN 3 brake calipers Removing and installing piston for brake caliper FNS. Repairing Brembo brake calipers (17", 18" and 18” Plus) Removing and installing Brembo brake caliper piston (17, 18° and 18" Plus) Repairing rear brake calipers Repairing FN 44 brake calipers. Removing and installing piston for FN 44 brake caliper Repairing Brembo brake calipers (17"and 18" Plus). Removing and installing rear Brake caliper piston Pressurised leak test Bleeding brake system Bleeding brake system with brake filing and bieeding Unit VAS 5234 or brake filling and bleeding unit V.AG 1869 Changing brake fluid : Assembly overview - brake servoorake mbater cylinder Removing and instaling diaphragm movement potentiometer in brake servo G420, Removing and installing brake pressure sender G201 Brake servo vacuum supply ..... Overview - vacuum pump for brake servo (diesel vehicles) Assembly overview - vacuum pump for brakes V182 Checking non-return valve Removing and installing brake master cylinder Removing ceeeeeeeneee Installing Removing and installing brake servo. Removing 133 435 » 136 137 138 - 139 139 139 - 144 - 142 142 142 144 144 Contents82 of 22 Installing Repairing brake lines Assembly overview - flanging too! Work instructions: Touareg 2003 > @ Brake systems - Edition 07.2009 145 146 146 147 consents HiiTouareg 2003 > Brake systems - Edition 07.2009 IV contantswy} Technical data 1 Brake-allocation’via.PR No. The type of brake system installed in the vehiciéis indicated among’¢ther things by the corresponding PR number.on the ve- hicle data sticker. 41 Example of a vehicle data sticker In this example the vehicle is equipped with the following brakés: © Arrow 4 - Rear brakes -1KF © Arrow 2 - Front brakes -1LC ‘The vehicle data sticker can be found in the spare wheel well and in the service booklet. The following table explains the PR numbers. These are impor- tant for combining the brake caliperibrake diec/brake drum and brake pads. Allocation > Electronic Parts Catalogue (ETKA) 1.2 Front brakes Engine PR No. Front brake’ 1251-120, 128 kW TDI 1B FN3 (167) 9.1- 155, 165, TTeKW | ALOT ALE Brembo (17°) I 3.21462, 177 KW. 3.6 1-208 KW, [421-228 KW [421-257 KW 1LF Brembo (18°) 5.0 1- 230, 258 kW TOI| 601-331 KW 5.01- 258 KW TOI 4LT/1LU) _ [Brembo (18" Plus) 6.01- 331 kW ALT from week 22/2008; 1LU from week 08/2007 Country-specific brake for North America Engine PR No. Front brake 421-257 kW 4LE Brembo (17°) 3.01- 165 kW TDI 1A. Brembo (17°) 1.3 Rear brakes (disc brakes) Engine PRNo Rear brakes: 251-120, 128 kW TDI. 1KE FN 44 (16°) 3.01- 155, 165, 176 KW] 1KF/ 1kQ) Brembo (17") iol 321-162, 177 KW. 3.6 1-206 KW. 421-228 kW [421-257 kW 5.01- 230, 258 kW TDI Brake systems - Edition 07.2009 Touareg 2003 > wo zz 7L 280000481 ~™ TLAACT Touareg Basis 162KW OTTO AGS samitien AZZ Ext seam" LAW GH “Fe. 1. Brake allocation via PR No, 1Touareg 2003 > Brake systems - Edition 07.2009 601-331 KW, 5.0 1- 258 kW TDI 4KD/2ED 1) [Brembo (18" Plus) (6.01- 331 KW ) 4IKD from week 22/2008; 2ED from week 08/2007 Country-specific brake for North America: Engine PRNo. Front brakes: [3.01 - 165 KW TDI 2EE Brembo (17") 2 Rep. 1.00 - Technical dataTouareg 2003 > @ Brake systems - Edition 07.2009 2 Technical data 24 Brake master cylinder and brake servo Brake master cylinder |__@inmm 26.99 Brake servo in inch 97/10" tandem 2.2 Front brakes 2.24 Front brakes, FN 3 (16") Item_[PR No 118 1 [Brake caliper FN3 (16) a 2 [Brake pad, mm 125,95 thickness Brake pad, weer] mm 2 limit without s back plate : 3. [Brake disc [2 in mm| 308 Brake disc, mm 29.5 thickness Brake disc, mm 255 wear limit : 4 [Brake caliper [in mn] 60 piston : 2.2.2 Front brake, Brembo (17") PRNo.: 1LC 4 ltem_[PR No. 4LC. 1_[Brake caliper Brembo (17") 2 [Brake pad, mm) 10 thickness Brake pad, wear] mm a 2 limit without back plate 3 [Brakedisc _|@inmm| 330 Brake disc, mm) 32 " thickness: Brake dise, mm) 30 wear limit 4 [Brake caliper |@inmm| 2x34 al piston 2x36 = 2x38 2.Tochrical data 3@ Touareg 2003 > Brake systems - Edition 07.2009 PR No. 1LE ttem_[PR No. 4LE/4LA 1 [Brake caliper Brembo (1 2. [Brake pad, mm + thickness Brake pad, wear| tim 2 limit without back plate 3 [Brake dise [2 in mm 330 Brakedisc, mm 2 thickness Brake disc, mm 30 wear imit 4 [Brake caliper [2 inmm| 4x46 piston 2.2.3 Front brake, Brembo (18") Item_[PR No. 1LF 1 [Brake caliper Brembo (1 2 [Brake pad, mm) 10 thickness Brake'pad, wear| mm 2 rit without back plate: 3 [Brake disc ~, [in mm| 350, Brake disc, mm 34 thickness Brake disc, mm 32 wear limit 4 [Brake caliper 2 in mm] 2x30 piston 2x34 2x38 2.24 Front brake, Brembo (18" Plus) Item_[PR No. ALT /4LU 1 [Brake caliper Brembo (18" Plus) 2 [Brake peed, mam 10 thickness Brake pad, wear| mm 2 limit without back plate 3 [Brake disc [Zin mm| 368 Brake disc, mm 36 thickness Brake disc, mm 34 wear limit 4 [Brake caliper | in mm| 6x36 piston 4 Rep. cr.00 Technica dataTouareg 2003 > @ Brake systems - Edition 07.2009 2.3 Rear brakes 2.3.1 Rear brakes (16" brake disc) Item_[PR No. iKE 1_[Brake caliper FN 44 (16°) 2 [Brake pad, mm| 8 thickness: Brake pad, wear| mm 2 limit without back plate, 3 ([Brakedise _[@inmm| 34 Brake disc, mm) 22 thickness: Brake disc, mm) 18 wear limit 4 [Brake caliper [2 inmm| 44 piston 2.3.2 Rear brakes (17" brake disc) PRNo.: 1KF Item_[PR No, AKF | 26E 1_ [Brake caliper Brembo (17°) 2 [Brake pad, mm) 1 thickness: Brake pad, wear], amit 2 limit without backplate, 3 [Brakedise _[2inmm| 330) Brake disc, mm) 28 thickness. Brake disc, mm) 26 wear limit 4 [Brake caliper | inmm| 2x28 piston 2x30 2.Tochrical data 5@ Touareg 2003 > Brake systems - Edition 07.2009 PR No.: 1KQ Item_[PR.No. 41KQ 1 [Brake caliper Brembo (1 2 [Brake pad, mm) 1 thickness Brake pad, wear| mm 2 limit without back plate 3 [Brake disc [Gin mm!| 330, Brake disc, mm) 28 thickness Brake disc, mm) 26 wear limit 4 [Brake caliper |2 in mm| 2x44 piston 2.3.3 Rear brakes (18" Plus brake disc) Item_[PR No. 4KD / 2ED 1 [Brake caliper: Brembo (18" Plus) 2 [Brake pad, mm| 1 thickness Brake pad, wear| mm 2 rit without back plate 3 [Brake disc = [in mm 358) Brake disc, mm) 28 thickness Brake disc, mm) 26 wear limit 4 [Brake caliper [Z 4x30 piston 2.3.4 Parking brake (16":brake drum) Item 1 [Brake drum Bin 185 mm 2 [Brake lining, mm 30 wath Brake lining, mm 55 total thickness 6 ep. c.00 - Technica dataTouareg 2003 > @ Brake systems - Edition 07.2009 2.3.5 Parking brake (17" brake drum) Item 1 [Brake drum Bin 210 wri 2 |Brakething, mm 30, las Brake lining, mm 55 total thickness: 2.Tochrical data 7@ Touareg 2003 > Brake systems - Edition 07.2009 3 Brake test 3.1 General + The drive is provided by the roller dynamometer. + 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 + For the test, observe the specifications provided by the man- ufacturer of the roller dynamometer. i Note The brake regulation systems do not function when ignition is off 3.2 Test ‘The brake test must be performed on a regulated contra-rotating roller brake test stand, Contra-rotating means that the dynamometer rollers are driven forwards on one side and backwards on the opposite side. Regulated means that the speed of the brake test stand rollers is, 0 controlled so that there is no difference in speed during the brake test. This prevents brake forces being transferred to the drive train. The forward rotating wheel is measured during the test, which means two brake tests per axle must be performed. ‘The maximum test speed must net exceed 6 km/h ‘The test rigs authorised by Volkswagen fulfi'these requirements. 8 ep. c.00 Technica dataTouareg 2003 > Brake systems - Edition 07.2009 Anti-lock brake syste! 1 General notes for anti-lock brake sys- tem (ABS) On vehicles with ABS Mark 25, only the following version is in- stalled: ¢ ABSIEDLITCS with electronic stabilisation program (ABS! EDLITCS/ESP) ‘The ABS brake system is divided diagonally. The servo-assis. tance is effected pneumatically by the vacuum brake servo unit. Faults in the ABS influence the brake system and servo assis- tance. Achange in braking behaviour sto be reckoned with. After the ABS warning lamp comes on, the rear wheels may lock pre- maturely during braking! Models with ABS Mark 25 do not have a mechanical brake pres- sure regulator. Specially matched software in the control unit regulates the brake force distribution on the rear axle. ‘The hydraulic unit -2- and control unit -1- form one component. ‘They can be separated only when removed. Hydraulic pump -3- must not be separated from hydraulic unit. New control units from the replacement parts service are not co- ded. They must be coded once installed. > Coding control unit using VAS 5051 vie function "Guided fault finding” ABS layout in left-hand drive veticle. 1. General nots fr ant-iock brake system (ABs) 9@ Touareg 2003 > Brake systems - Edition 07.2009 2 Notes for repair work on the ABS. Before carrying out repair work on the anti-lock brake system, determine the cause of the fault using “Guided Fault Finding” ‘Guided fault finding” is carried out on the vehicle diagnosis, test- ing and information system -VAS 5051- # Before working on the anti-lock brake system, disconnect the battery earth strap. Note or request radio code on vehicles with coded radio if necessary. 4 Before carrying out welding work with an electric welding unit, note = General Information; Body Repairs, General Body Re- pairs. + When working with brake fluid, obséive the relevant safety precautions and notes = page 133 After work for which the brake system had to be opened, bleed the brake system with brake filling and bleeding equipment - VAS 5234- or -V.A.G 1869- = page 133, # During the final road test, ensure that a controlled brake test Isperformed atleast one (pulsations mus,befelat the brake pedal # Absolute cleanliness is required when working’on the anti-lock brake system, It is not permitted to use any prodycts which contain mineral oil, such as oils, greases etc. # Thoroughly clean all unions and the adjacent areas befére, loosening. Do not use aggressive cleaning agents such as brake cleanser, petrol, thinners or similer. # Place removed parts on a clean surface and cover. 4 If repairs cannot be carried out immediately, carefully cover or ‘seal open components. ( Sealing plugs -1 HO 698 311 A. should be used), Only use lint-free cloths. ‘Only unpack replacement parts immediately prior to fitting Only use genuine packed parts. When the system is open, do not work with compressed air and do not move the vehicle. Ensure that no brake fluid enters connectors, # During painting operations, the electronic control unit can be ‘exposed fo a maximum temperature of 95 °C for only a short Period, and to a maximum of 85 °C for longer periods (approx 2 hours), wees + 10 ep. 2.45 Antisock brake systemTouareg 2003 > @ Brake systems - Edition 07.2009 3 Connecting -VAS 5051- and select- ing functions Special tools and workshop equipment required + -VAS 5051- Vehicle Diagnose, Testing and Information Sys- ’ vas. Sot Diagnosis lead -VAS 5051/1- or -VAS 5051/3- L\ _ wornine During a road test, you must always secure testing and ‘measuring equioment on the back seat. * These devices may be operated onlyby apassengerwhile the vehicle is in motion. = Connect connector of diagnostic cable -VAS 5051/1- or - VAS 5051/3- to diagnostic cable -arrow.. 3. Connecting VAS 5081 and selecting functions 141Touareg 2003 > Brake systems - Edition 07.2009 = Switch on tester -arrow. ‘The tester is ready for operation when the selector buttons for the operating modes appear on the screen. = Switch on ignition = Touch on screen, = Select one after another: Brand VAS 5051 + * Type # Model year ’ ’ Body version Engine code = Confirm data entered, Wait until tester has interrogated all control units in vehicle. - Press nd select function “Function/comporiéht $8i8E°" Ac a tion’ ‘ % = Select “Running gear” on display ~ Select “Brake systems" on display. = Select “01 Selt-diagnosis capable system ...” shown on dis play. é =. Select “Anti-lock brake’system ..." shown on display = Select “Function” shgwn on display. Now all possible functions from the anti-lock brake system instal- % led'in the vehicle wil be displayed 5 = Select desired function on display. 3 12. Rep. 6.45 Antisock brake system4 Touareg 2003 > @ Brake systems - Edition 07.2009 Electrical/electronic components and fitting locations 1 - ABS hydraulic unit -N5S- Location: on right in ple- num chamber. ‘The hydraulic unit consists of the components: ABS hydraulic pump - ved a a Valve block (contains in let and outlet valves). ABS hydraulic pump - Véd- and valve block’ must not be separated from one another. From week 48/06 with brake pressure sender - G201- 2- ABS control unit J104- a a Fitting location: on the hydraulic unit on right in plenum chamber. Do not separate con- nector before success fully completing self-di- agnosis. Switch ignition off before disconnecting connector. 3. Brake pressure sender - G201- Location: to week 48/06 on brake master cyl der Removing and installing From week 48/08 in ABS hydraulic unit - N55. 4-- Brake servo pressure sensor -G294- Cr neal ony In vehicles wth petrol engiend. an autanale Yarbox Fitting location: in vacuum hose to brake servo. 0 5 = Vacuum pump for brakes -V192- Installed only in vehicles with @ petrol engine and an automatic gearbox. Fitting location: front right in engine compartment. 2 Removing and installing = page 140 6- ESP and TCS warning lamp -K185- Fitting location: in dash panel insert. Function: = page 15 7- AB: 'S warning lamp -K47- Fitting location: in dash panel insert Function: = page 15 4. Electricalloloctronic components and ting locations 13@ Touareg 2003 > Brake systems - Edition 07.2009 8 - Brake system warning lamp -K118- Fitting location: in dash panel insert Function: = page 15 9 - TCS and ESP button -£256- Fitting location: in centre console. 10 - ESP sensor unit -G419- Fitting location: under centre console, 2 Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration sender -G251- Combined in one housing, Observe installation instructions > page 34 11 - Steering angle sender -G85- Fitting location: on steering column between steering wheel and steering column switch Observe installation instructions = page 35 12.- Diagnostic connection Fitting location: driver side footwell cover. O =page 14 13 - Brake light switch -F- and brake pedal switch -F47- Removing and installing = page 112 Y Vehicles from week 48 of 2006 do not hava brake light switch 14 - Front right speed sensor -G4S- /frontleft speed sensor -G47- Renewing = pace 31 45 - Wheel hub with wheel bearing? ABS sensor ring is installéd in the whee! bearing 16 - Rear right speed sensor -G44- / rear left speed sensor -G46- Renewing = page 33. 17 - Wheel hub with wheel Bearing 8 ABS sensor ring is installed in the whee! bearing. g Diagnostic connection 14 ep. 2.45 ntisock brake systemTouareg 2003 > @ Brake systems - Edition 07.2009 5 Fault display via warning lamps Warning lamps Tem Description 1 [ESP and TCS warning lamp -K155- 2 _ [Brake pad warming lamp -K32- 3_[ABS warning lamp -K47- 4 [Brake system warning lamp -K118- ABS warning lemp -K47- © Ifthe ABS warning lamp -K47- -3- does not go out efter the ignition has been switched on and test sequence hes been completed, then the fault may be: 8 - Voltage supply is below 10 Volt b- There is a fault in the ABS, ojsyay Inthe event of an:ABS fault -b-, the anti-lock brake system re- mains switched off, but the brake system remains folly operation. al c- Sirice the last time the vehicle was started there was a tem- parery speed sensor fault In this case, ABS warning lamp -K47- will go out automatically after the engine is restarted and the vehicle exceeds a speed of 2.75 kmh (approx. 13 mph). d- The connection from dash panel insert to control unit for ABS. ‘with EDL ~J104- is interrupted. > Current flow diagrams, Electrical fault finding and Fitting locations €- The ABS warming lamp -K47- is defective. ABS warning lamp -K47- and brake system warning lamp -K118- ¢ Ifthe ABS warning lamp -K47- -3- goes out but the brake sys- tem warning lamp -K118--4-remains on then the faut may 2: a - The brake fluid level is too low. ‘Three warning tones are audible after ignition is switched on. bi There is a fault in the wiring to the brake system warning lamp -K418- = Current flow diagrams, Electrical fauit finding and Fitting locations. © Ifthe'ABS warning lamp -k47- -3- and the brake systém warn- ing lamp “K418- -4- light up, then the anti-lock brake system is defective. A’change in braking behaviours to be reckoned with, LX _ warnine After the ABS warning lamp -K47- and the brake system warn- ing amp -K1 16. have it up, 1s possible that the rear wheels will lock up earlier. 5. Fault dispay vie waming lamps 15@ Touareg 2003 > Brake systems - Edition 07.2009 ESP and TCS warning lamp -K155- % Ifthe ESP and TCS warming lamp -K155--1- does not go out after the ignition has been switched on and the test sequence has been completed, then the fault may be: ‘A fault in the system affecting only the TCS/ESP. The ABS/EDL and EBD safety systems on the vehicle remain fully functional > Interrogate fault memory. a - Short circuit to positive in TCS and ESP button -E256- 'b - Short circuit to earth in wire controlling ESP and TCS warning lamp -K185- ¢- Open circuit in connection from dash panel insert to contact 31 of ABS control unit J104- d- The TCS/ESP system has been switched off by the TCS and ESP button -£256- If the ESP and TCS warning lamp -K155- flashes during travel, the TCS or ESP system is regulating the system, Ifthe ESP and TCS warning lamp -K155- -1- does not light up during the self-test, the fault may be: ~The ESP and TCS warning lamp -K155- is defective = perform electrical check. ABS warning lamp -K47- and ESP and TCS warning lamp -k155- Ifthe ABS waming lamp -K47- -3- and the ESP and TCS warning lamp -K185- -1- do not go out after: the ignition has been switched on and after the test sequence has been com- pleted, then the fault may be: a - Voltage supply for anti-lock brake" system (ABS) is below 10 volts and vehicle speed is less than 12 km/h = Performing electrical test. bb - Short circuit to earth in wire‘controlling ESP end TCS warning lamp -K185- = Short circuit to positive in FCS and ESP button -E256- ‘ABS warning lamp -K47-, brake system warning lamp-K118- and ESP and TCS waming lamp -K155- 4+ the ABS warning lamp -K47- 3, the ESP and TCS waming lamp -K 158-1 anc the brake system weming lamp -K118- ~4- do not go out, then the fault may be: a - Voltage supply for anti-lock brake system (ABS) is below 10 volts and vehicle speed ig less than 12 km/h = Performing electrical test. b- There is a fault in the hydraulic control unit; the anti-lock brake system (ABS) is not operational, A change in braking behaviour is to be reckoned with. The rear Wheels can lock early when braking! ¢-Adynamic speed sensor fauit was present during the last driv- en period In this case, the warning lamps go out automaticéily after the ve~ hicle is restarted and @ speed of 2.75 km/h is exceeded. The prerequisite is thet the fault on the apeed sensor no longer occurs after fault rectification and repeating check. 16 op. 2.45 - Antisock brake systemBrake system warning lamp -K118- ¢ Ifthe brake system warning lamp -K118- -4- does not go out after the ignition has been switched on, the fault may be: a - The foot-operated parking brake is applied = The switch for the brake system wating lamp "K18xis, defec- tive or incorrectly adjusted. 2 = There is a wiring fault > Performing electrical test ‘The parking braké contact switch also informs the ABS control Unit -J104- as,to whether the foot-operated parking brake is ap- plied or released. When the foot-operated parking brake is ap- plied, ESP control is negatively influenced. Brake pad warning lamp -K32- ¢ Ifthe brake pad warning lamp -K32--2- does not go out 3 sec- ‘onds after the ignition is switched on, or it if comes on during vehicle operation, the fault may be: a- The brake padsilinings are worn. Check brake pads/linings on front and rear axles. Renew worn brake padsilinings. b- There is a wiring fault. = Current flow diagrams, Electrical fault finding and Fitting locations. Touareg 2003 > @ Brake systems - Edition 07.2009 5. Fault dispay vie waming lamps 17Touareg 2003 > Brake systems - Edition 07.2009 6 Assembly overview - hydraulic unit; brake servo/brake master cylinder 61 ABS MK 25 to week 48/06: 1 ABS control unit -J104- Removing and installing 2- ABS hydraulic unit -NS5- 2 Removing and installing > page 24 3 - Brake line D_From primary piston cir- cuit of brake master cyl- inder to hydraulic unit Marked on hydraulic unit with -DK- 4 - Brake line 0 From secondary piston circuit of brake master cylinder to hydraulic unit, Q Marked on hydraulic unit with -Sk- 5 - Brake line 1D Torearleft caliper viain- termediate piece. O Marked on hydraulic unit with -HL- 6 - Brake line @ To front right brake cali- per vie intermediate piece, Marked on hydraulic unit with -VRe 7 Brake line To front left brake cali- ber NS0345, Marked on hydraulic unit with -VL- 8 - Brake line To rear right caliper via intermediate piece. Marked on hydraulic unit with -HR- 9 - Intermediate piece 10- Bracket 1 Allocation = Electronic Parts Catalogue (ETKA) 11 - Hexagon flange bolt, 5 Nm 12- Hexagon bolt, 8 Nm 13- Buffer 14- Seal O For brake servo. 18 op. 6.45 Antisock brake systemTouareg 2003 > @ Brake systems - Edition 07.2009 15- Tandem brake servo Including brake pressure solenoid trip switch -F84- and brake pressure solenoid valve -N247- (cannot be renewed) On petrol engines, the required vacuum is taken from the intake manifold. Vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump, Diesel engines are fitted with @ vacuum pump to create the required vacuum, Functional check: With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit. ouoog — Nowstep on and hold brake pedal with medium pressure and start engine. Ifthe brake servo is functioning properly, the brake pedal wil be felt to go down as the servo takes effect. If faulty renew complete (check all vacuum lines first) Removing and installing = page 144 16 - Sealing ring 17 - Potentiometer for brake servo diaphragm travel-G420! Removing and installing = page 137) Discontinued from week 48/06: 18 Snap ring 19 Sealing plug Connection for vacuum hose 20 - Vacuum hose Fit in brake servo 21-Sealingring = 22 Hexagon nut, self locking, 25 Nm Always renew after removing 23 - Brake pressure sender -G201- 3 2. Removing and installing = page 138 From week 48/06 in ESP unit 24 Bracket 25 - Brake master cylinder Cannot be repaired: f faulty, renew complete 2. Removing and installing = page 142 26 - Sealing plug 2. Moisten with brake fluid ancpress into brake fluid reservoir. 27 - Brake fluid reservoir 28- Cap 29 - Torx bolt, 4 Nm 6. Assembly overvow- hydraulic unt, brake servafbrake master cyinder 19@ Touareg 2003 > Brake systems - Edition 07.2009 Connecting brake lines from brake master cylinder to hydraulic unit (On brake master cylinder: (On hydraulic unit: A.- From hydraulic unit to primary piston circuit of brake master cylinder. ~ Marked on hydraulic unit with -DK-. B - From hydraulic unit to secondary piston circuit of brake master oylinder. ~ Marked on hydraulic unit with -SK-, 1. From hydraulic unit to front left brake caliper. - Marked on hydraulic unit yith-Vu 2 Hydraulic unit to rohit right brake caliper vie interniédiate piece. ~ Marked on hydraulic unit with -VR- 3 - Hydraulic unit to rear right brake caliper via intermediate piece + Markéd on hydraulic unit with -HR- 4-- Hydraulic unit to rear left brake caliper via intermediate piece. - Marked on hydraulic unit with -HL- 20 ep. 2.45 Antisock brake systemTouareg 2003 > @ Brake systems - Edition 07.2009 6.1.1 Removing and installing control unit and hydraulic unit Special tools and work- shop equipment re- quired Torque wrench - VAG 1410- ¢ Brake pedal depres- sor -V.A.G 1869/2- Sealing’plugs repair kit, Part.No. 1HO 698 311 A The transport protection for the contact pins must ‘always be placed on the hydraulic unit after the control unit has been dis- connected from the hy- draulic unit No warranty can be as- sumed for hydraulic units ‘without transport protec- tion, 4 - Transport protection for contact pins (foam) 2 Sealing plug M 10 3 Sealing plug M12 Fitting location: ‘THé.control unit is bolted to the hydraulic unit and is located on right in ple- num cherhber. VAG 1410 VAG 1869/2 Ae 6. Assembly overvow- hydraulic unt, brake servarorake master cyinder 21@ Touareg 2003 > Brake systems - Edition 07.2009 ZX veanine Do not bend the brake ines in the area of the ‘ydhraulic unit! 6.1.2 Removing control unit and hydraulic unit — Note or request radio code on vehicles with coded radio if necessary, = Disconnect baitery = Electrical system; Rep. Gr. 27 ; Dis- connecting ané.reconnecting battery = Remove plenum chamber cover > General body repairs, ex- terior: Rep. Gr. 64 : Flush bonded windows; Removing and installing plenum chamber cover = Remove engine control unit — Unbolt earth wire frormbody behind bracket for engine control unit. = Unclip wiring harness and iy, jt to side, ~ Remove bracket for engine contféhunt — Remove intake duct > Heating, air concitidiiing system; Ried) Gr. 87 ; Dismantling and assembling air conditioner unit . = Release control unit connector in direction of arrow-1-and pull off (arrow -2-). Connect bleeder bottle hose to front left brake caliper bleeder valve and open bleeder valve. = Apply brake pedal depressor -V.A.G 1869/2- = Close front left blesder vaive = Place sufficient lint-free cloths under the control unit and hy- Brake systems - Edition 07.2009 — Remove external Torx screws -arrows- — Without canting it, pull control unit off from hydraulic unit -arrow, A WARNING # Nomoisturs or particles oft may enter contol unit. ° Pyerelenumo mustrtzessnarteatom nut = Cover control unit solenoids with a neal th ‘After separating control unit and hydraulié Ln, use transport pro= tection for contact pins 6.1.4 Installing new control unit A WARNING é Severe shocks (e.g. dropping. impact) may destroy contro! 3 unit. The control unit must not then be used. + Clean surfaces before assembling. = Without canting it, place contrél unit onto hydraulle unit 3 ~ Bolt hydraulic unit and control unit with enclosed, new Torx a socket head bolts. [Bnet * . ? [tis not possible fo ft a new contro! unit are than twice fo an 2 instaled hycraule unit to ensure tht the fexioe seals fee c of leaks. a, © Acontrol unit which has already been operated in a Vehicle, ows ‘must not be installed @ second time 6.1.5 Installing control unit and hydraulic unit ¢ Remove sealing plugs from new hydraulic unit only when the corresponding brake line is going to be fitted. ¢ If sealing plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaran- teed that the unit can be suficiently filled and bled. 6. Assembly overvow- hydraulic unt, brake servafbrake master cyinder 23@ Touareg 2003 > Brake systems - Edition 07.2009 = Install in reverse order. — Remove brake pedal depressor -V.A.G 1869/2- — Bleed brake system > page 133 = Code radio. = Code ABS control unit -J104- with = Vehicle diagnosis, testing {and information system VAS 5051 in “Guided fault finding’. — Basic setting must additionally be performed when ABS con- trol unit ~J104-is replaced, Torque settings Control unit to hydraulic unit max. 4Nm Hexagon bolt of hydraulic unit to bracket 8Nm Brake lines to ABS unit: Thread M 10x14 44Nm Thread M 12x14 14.Nm 6.2 ABS MK 25 E1 from week 48/06 1 ABS control unit -J104- Removing and installing 2- ABS hydraulic unit -NSS- 2 Removing and installing = page 27 3 - Brake line From primary piston cir- cuit of brake master cyl- inder to hydraulic unit Marked on hydraulic unit with -DK 4 Brake line To front right brake cali per via intermediate, piece. Q Marked on hydraulic unit with -VR 5 - Brake line To front left brake cali- per Marked 6n hydraulic unit with -VL= 6 - Brake line = From secondary piston circuit of brake master cylinder to hydraulic unit, Marked on hydraulic unit with «SK 7 = Brake line 1D Torear left Caliper via in- termediate piece. Marked on hyciraulic unit with -HL- 8 - Brake line @ To rear right caliper vig intermediate piece. 24 ep. 2:45 Antisock brake systemTouareg 2003 > @ Brake systems - Edition 07.2009 2 Marked on hydraulic unit with -HR- 9- Intermediate piece 10- Bracket 2 Allocation = Electronic Parts Catalogue (ETKA) 11- Bolt, 8 Nm. 12 - Hexagon flange bolt, 9 Nm 13 - Rubber damper 14- Bracket 2 Allocation = Electronic Parts Catalogue (ETKA) 18 - Seal For brake servo. 16 - Tandem brake servo Including brake pressure solenoid trip switch -F84- and brake pressure solenoid valve -N247- (cannot be renewed) (On petrol engines, the required vacuum is taken from the intake manifold. Vehicles with petrol engine and an automatic gearbox are equipped with a brake vacuum pump. Diesel engines are fitted with @ vacuum pump to create the required vacuum. Functional check: With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit. oocog ~ Nowstep on and hold brake pedal with medium pressure and start engine. Ifthe brake servo is functioning properly, the brake pedal wil be felt to go down as the servo takes effect If faulty renew complete (check all vacuum lines first) 2 Removing and installing = page 144 17- Sealing plug Connection for vacuum hose 18 - Vacuum hose! a FitjA'brake servo 419 - Sealing ring 20 - Self-locking hexagon nut, 25 Nm Always renew after removing 21 - Bracket 22 - Brake master cylinder Cannot be repaired. If fauity, renew as a complete unit Removing and installing + page 142 23 - Self-locking hexagon nut, 25 Nm Always renew after removing 24 - Sealing plug I. Moisten with brake fluid and press into brake fluid reservoir. 25 - Brake fluid reservoir 26-Cap 27 - Torx bolt, 2+0.8 Nm Without canting, tighten in stages using diagonal sequence. 6. Assembly overvow- hydraulic unt, brake servaforake master cyinder 25@ Touareg 2003 > Brake systems - Edition 07.2009 Connecting brake lines from brake master cylinder to hydraulic unit (On brake master cylinder: (On hydraulic unit: A.- From hydraulic unit to primary piston circuit of brake master cylinder. ~ Marked on hydraulic unit with -DK-. B - From hydraulic unit to secondary piston circuit of brake master oylinder. ~ Marked on hydraulic unit with SK- 41 - From hydraulic unit to front left brake caliper. - Marked on hydraulic unit with -VL- 2.- Hydraulic unit to front right brake caliper via intermediate piece. ~ Marked on hydraulic unit with -VR- 3-Hydraulic unit to rear right brake caliper via intermediate piece. ~ Marked on hydraulic unit with -HR- 4 Hydraulic unit to rear left brake caliper via intermediate piece. - Marked on hydraulic unit with -HL- 26 op. 2.45 Antisock brake systemTouareg 2003 > @ Brake systems - Edition 07.2009 6.2.1 Removing and installing control unitand hydraiulic unit Special tools ahd work- shop equipment re- quired Torque wrench - VAG 1410- VAG 1410 qo) © Brake:pedal depres- sor-V.A.G 1869/2. V.AG 1869/2 Ae Sealing plugs repair kit, Part No. 1HO 698 311 A The transport protection for the contact pins must always be placed on the hydraulic unit after the control unit has been dis- connected from the hy- draulic unit. No warranty can be as- sumed for hydraulic units without transport protec- tion, 1- Transport protection for contact pins (foam) 2- Sealing plug M10 3- Sealing plug M12, Location: The control unit is bolted to the hydraulic unit and is located on right in ple- num chamber. 6. Assembly overvow- hydraulic unt, brake servafbrake master cyinder 27@ Touareg 2003 > Brake systems - Edition 07.2009 ZX veanine Do not bend the brake lines in the area of the ‘hydraulic unit! 6.2.2 Removing control unit and hydraulic unit — Note or request radio code on vehicles with coded radio if, necessary, = Disconnect battery = Electrical system; Rep. Gr. 2? Dis- connecting and reconnecting battery = Remove plenum chamber cover = General body repairs, ex- terior, Rep. Gr. 64 : Flush bonded windows; Removing and installing plenum chamber cover = Remove engine control unit — Unbolt earth wire from body behind bracket for engine control unit. ~ Unelip wiring hamess and lay itto side. = Remove bracket for engine control unit. Remove intake duct > Heating, air concitisning system; Rep. Gr. 87 ; Dismantling and assembling air conditioner unit . = Release control unit connector in direction of arrow-1-and pull off (arrow -2-). Connect bleeder bottle hose to front left brake caliper bleeder valve and open bleeder valve. = Apply brake pedal depressor -V.A.G 1869/2- = Close front left blesder vaive = Place sufficient lint-free cloths under the control unit and hy. @ Brake systems - Edition 07.2009 Unbolting control-unitfrom hydraulic unit A WARNING ¢ Printed circuit board becomes visible when control unit is removed. No moisture or particles of dirt may enter control unit. ¢ Avoid electrostatic charge! = Gover control unit solencids with a lint-free cloth. ‘After s@parating control unit and hydraulic unit, use transport pfo- tection fo contact pins. 6.2.4 Installing new control unit A WARNING Severe shooks (e.g. dropping, impact) may destroy contol init Control uni must not inen be used. — Push all seals -A- over contact pins slightly. — Without canting it, place control unit onto hydraulic unt The seals are thus moved to end position. Tighten hydraulic unit and control unit diagonally in stages to specified torque with enclosed new Torx bolts. Clean surfaces before assembling fa) Note ¢ Anew control unit may be mounted on an existing hydraulic unit max. twice fo guarantee impermeability of the elastic seal. ¢ control unit which has already been operated in a vehicle ‘must not be installed @ second time. 6. Assembly overvow- hydraulic unt, brake servaforake master cyinder 29@ Touareg 2003 > Brake systems - Edition 07.2009 6.2.5 Installing control unit and hydraulic unit i Note # Remove sealing plugs from new hydraulic unit only when the corresponding brake line is going to be fitted. 4 /f seating plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaran- teed that the unt can be sufficiently filed and bled. = Install in reverse order. — Before installing bracket for ABS hydraulic unit -N5S- in ple- ‘num chamber, spray rubber dampers with silicone lubricant D 007 000 A2'to make installation, easier: ZX weaning Ensure that rubber dampers are not pressed out of bracket when installing. After installing, check hydraulic unit with con- trol unit for proper seating, otherwise malfunctions can occur. Remove brake pedal depressor -V.A.G 1869/2- — Bleed brake system = page 133 = Code radio. Coffe ABS control unit -J104- with = Vehicle diagnosis, testing and information system VAS 5051 in “Guided fault finding’ ~ Basic setting must additionally be performed when ABS con- trofunit -J104- is replaced, Specifigd torques: Control Unit to hydraulic unit 2Nm+08 # Use new bolts! Nm: Bolt for braket on hydraulic unit 8Nm Brake lines t6ABS unit, Thread M10 x 1 14Nm Thread M12 x 4 44Nm 30 Rep. 6x45 - Anttock brake systomTouareg 2003 > @ Brake systems - Edition 07.2009 7 1 - ABS speed sensor a a 2=Hexagon socket head bolt, 8Nm 3- Wheel hub with wheel bear- ing = a 4 Drive shatt, 7.1 7.44 < Removing and installing parts of ABS system on front and rear axle Before inserting sensor, clean fitting hole inner surface and coat with olycarbamide grease - 6052 142.2- Removing and installing ‘ABS sensor ring is in- stalled in the wheel beacing, NAB-0887 Removing and installing speed sensor on front axle Removing = Raise vehicle. 7. Removing and insaling parts af ABS system on front andrearaxte 31@ Touareg 2003 > Brake systems - Edition 07.2009 Separate connector -1- from speed sensor wire and from ‘speed sensor. = Remove bolt -2- from wheel bearing housing. — Pull ABS speed sensor out of wheel bearing housing. TAQ Installing = Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with polycarbamide grease -G 052 142 A2-. =. Insert speed sensor into hole in wheel bearing housing ang tighten bolt to 8 Nm. ° wagen a — Connect speed sensor to speed sensoriire.. 72 Removing and installing parts of ABS system on rear axle 1 - ABS speed sensor Before inserting sensct, clean fiting hole inner Surface and coat with polvearbamice grease - 6052 142 A2- Removing ae intting => page 3. 5 2 - Hexagon socket head bot, 8m 3- Wheel hub with wheetbear- ing ABS sensor ring is'in- stalled in the wheel bearing, 4 Drive shaft 32 Rop. 6x45 - Antock brake systomTouareg 2003 > @ Brake systems - Edition 07.2009 73 Removing and installing speed sensor on rear axle 7.3.1 Removing Raise vehicle. Separate connector -1- from speed sensor wire and from speed sensor. Remove bolt -2- from wheel bearing housing. Pull ABS speed sensor out of wheel bearing housing, 7.3.2 Installing = Before inserting speed sensor, clean halé inner surface and coat speed sensor all-round with polycarbamide grease -G. 052 142.A2-. Insert speed sensor into hole in whéel bearing housing and tighten bolt to 8 Nm é = Connect speed sensor to speed sensor wire, 7. Removing and instaling parts of ABS systom on font andrearaxte 3S@ Touareg 2003 > Brake systems - Edition 07.2009 8 Removing and installing parts of ESP system 8.1 Removing and installing ESP sensor unit -G419- ‘The lateral acceleration serider -G200- , the yaw rate sender - G202- and the longitudinal acceleration sender -G251- are in- stalled in a housing beyteath the centre console. After exchanging the ESP sensor unit -G419-, perform basic set- ting for lateral acceleration sender -G200- and the longitudinal acceleration sender'-G251- A WARNING ‘Shocks or jolts'can destroy the Jateral acceleration sender - G200-, the yaw rate sensor -G202- and the longitudinal ac- celeration sénder -G257- 8.1.1 Removing Remove centre console > General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trims; Removing and in- stalling centre console ZX warns When working on the Airbag control unit -J234- . please follow the general safety procedures for werking on the airbag, belt tensioner and battery isolation units (pyrotechnical units) =. General body repairs, interior; Rep. Gr. 69. = Disconnect battery = Electrical system; Rep. Gr. 27 ; Dis- connecting and reconnecting battery = Unscrew airbag control unit and move clear forwards > Gen- eral body repairs, interior; Rep. Gr. 69 ; Airbag; Removing and installing airbag control unit (J234) = Pull connector -1- off ESP sensor unit -G419- — Remove the two securing nuts -arrows-. = Remove ESP sensor unit -G419- 8.1.2 Installing = Install in reverse order. When installing the ES? sensor unit, make sure it is correctly seated in its bracket and is free of stress. 34 kop. G45 - Antock brake systomTouareg 2003 > @ Brake systems - Edition 07.2009 Do not use the securing nuts to forcibly position ESP sensor unit. — Tighten securing nuts to 8 Nm. — Carry out basic settings for lateral acceleration sender -G200- and longitudinal acceleration sender -G251- Conneeting -VAS 5051- and selecting) functions = pace 11 82 Removing and installing steering-angle sender -G85- ‘The steeriig angle sender -G85- is located between the steering wheel and steering column switch, 8.2.4 Removing and installing = Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - ex- teffor, Steering column switch = Then perform basic setting of steering angle sender -G85- Gonnecting -VAS 5051- and selecting functions = pace 11 8 Removing nd insaling pats of ESP syst 3D,Touareg 2003 > Brake systems - Edition 07.2009 [5H <= em == MST) 1 Repairing front brakes 14 Repairing front brakes, FN 3 brake cali- per (16") [Eno #5 Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. 6 After work for which the brake system had to be opened, bleed the brake system with brake filing and bleeding unit - VAS 5234- or extraction unit -V.A.G 1869/4- + “Fit brake pedal depressor-V.A.G 1869/2- before removing a brake caliver or disconnecting a brake hose (release pressure in-system). 1. Braké'dise Ventilated brake disc: & 308 mmr Brake disc'thickness: 285mm D Wear limit: 25.5 mm. Always renew on both sides of an axle. Remove brake caliper andbrake carrier prior to removing. 2- Fitted bolt, 15 Nm Brake disc to wheel hub 3 - Brake pads Thickness: 11.5 mm without backpiate Pad wear limit: 2 mm without backplate With break pad wear in- dicator (When wear reaches a predetermined limit (ap- prox. 4 mm) the warning lamp in the dash panel insert comes on. Checking thickness = Maintenance ; Book- let 17.1 ; Work sequen- ces; Front and rear brake padsllinings: Checking thickness. Always renew on both sides of an axle. Removing and installing Na 10085 3620p. 646 - Brakes - mechanismTouareg 2003 > @ Brake systems - Edition 07.2009 = page 37 4- Retaining spring Press under brake carrier and insert into both holes in brake caliper housing. 5 - Brake caliper Do not disconnect brake hose when changing brake pads or brake discs. 2 Removing and installing = page 41 Repairing = page 114 6 - Guide pin, 30 Nm 7 = Cover cap 8 - Retainer for brake pad wear indicator line 9- Bolt, 10 Nm 10- Brake carrier Bolt to wheel bearing housing 11 - Hexagon bolt, 270 Nm 2 Always renew after removing 12- Bracket 13 - Hexagon socket head bolt, 9 Nm 14- Brake hose, 14Nm Do not unscrew when changing brake pads or brake discs. 1.2 Removing and installing brake pads/lin- ings ‘Special tools and workshop equipment requiréd © Torque wrench -V.AG 1331- V.A.G 1331 Piston resetting tool -T10145- 1. Repating font brakes 37Touareg 2003 > Brake systems - Edition 07.2009 1.2.1 Removing Mark brake pads when removing if they are fo be reused. Fit in ‘same position when installing, or braking will be uneven. — Remove wheels, = Press retaining spring in direction of -arrow A- until it can be pressed out of hole in direction of -arrow B-. — Tum retaining spring -1- clockwise -arrow- until it can be re- moved from the upper hole, — Disconnect connector -1- for brake, pad wear indicator. Pull off dust cap -2- and lift offittake pad weer indicator wire. ~ Remove brake pad wear indicator wire from brake caliper housing retainer = = Remove caps -arrows- 3820p. 6:46 - Brakes - mechanism= Unscrew both guide pins -arrows- from brake caliper and re- move. = Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose. — Remove brake pads Cleaning: LX _ wornine Do not blow out brake system with compressed air; the result- ing dust constitutes a health hazard! ~ Thoroughly clean brake carrier and contact surfaces for brake pads and remove corrosion. — Clean brake caliper (remove adhesive remains), the adhesive surface must be clean and dry. Use only methylatéd spirits for cleaning the brake caliper housing. 1.2.2 “Installing Before pressing piston back into cylinder with piston resetting tool, draw off brake fluid from brake fiuid reservoir. Otherwise, partic- ulalyiireseroirhas been topped up hid wll overfiowand cause jamage. ~ Piss pistons back with piston resetting tool -T10145. [H] Note The inner brake pad (piston side) is rotation sensitive and is therefore marked. Directional brake-pads 1 Right-hand piston’ ide brake pad 2 Left-hand piston side brake, pad When installed, the arrow -A- on thé brake pad Backplate must point downwards (in direction of brake disc rotation), Touareg 2003 > @ Brake systems - Edition 07.2009 1. Repating font brakes, 3QTouareg 2003 > Brake systems - Edition 07.2009 — Insert brake pad with retaining spring into the piston “arrows = Pull protective foil off outer brake pad backplate. correctly, a\ a ~ Fit outer brake pad -A- to brake carrier. DROZ YI When positioning the brake caliper, ensure that the brake ped WN. VY does not stick to the brake caliper housing befere itis positioned \ \g | fi — Bolt brake caliper to brake carrier with both guide pins “arrows. = Fitboth cover caps, een RV — Reconiect brake wear indicator connector -1-to connector on bracket on wheel bearing housing, — Secufe the brake wear indicator wire with the dust cap -2- on bleed-valve and retainer -3- on brake caliper. 40 0p. 2r-46- Brakes -mochanismTouareg 2003 > Brake systems - Edition 07.2009 © = Fit retaining spring into upper hole -arrow- and turn anti-clock- ‘wise -direction of arrow. = Seat retaining spring into lower section of brake carrier. First press retaining spring in -direction of arrow A-, and then simultaneously into hole in brake caliper direction of arrow B- = Fit wheels. Specifies torque of whee! bots = Running gear, xls, stering Rep. Gr. 44 Specified torques of wheelibolts [Fe ; © Every time after changing pads, depress brake pedal fimmly ‘several tines with vehicle stationary, so that brake pads are properly seated in their normal operating position. ¢ Check brake fluid level after changing brake pads. Specified tofgue ‘Brake caliper to brake carer ~*~ 3 4.3 - Removing and installing brake caliper g Special tools and workshop equipment required Torque virench -V.A.G 1331- V.A.G 1331 1. Repairing front bakes 441Touareg 2003 > Brake systems - Edition 07.2009 4 Brake pedal depressor -V.A.G 1869/2- VAG 18692 1.3.1 Removing This procedure applies only'to exchanging or the following repair work on the brake caliper, ~ Remove wheels. Press retaining spting in direction of -arrow A- until it ean be pressed out of hgle in direction of -arrow B-. ‘Tum retaining spring’=1- clockwise -arrow- until it can be re- moved from the upper hole. = Disconnect connector -1- for brake pad wear indicator. = Pull off dust cap -2- and lift off brake pad weer indicator wire. - Remove brake pad wear indicator wire from brake caliper housing retainer -3- = Connect bleeder bottle hose to brake caliper bleeder valve and open bleeder valve. = Apply brake pedal depressor -V.A.G 1869/2- — Close bleeder valve and remove bleeder bottle. = Disconnect brake hose. 42 Rep. 2:46- Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 - Remove caps -arrows- Unscrey) and remove both guide pins -arrows- from brake cal- iper. 3 Pull brake caliper off brake cartier. Remove brake pads from brake caliper. 1.3.2 % Installing Piston ipressed back Outer braké pad is seated on brake carrier Inset nner bre pad wih retsning spring Into bake clipe (Piston) (BH) Note The inner brake pad (piston side) is rotation sensitive and is therefore marked. Directional brake pads 1 - Right-hand piston side brake pad 2- Left-hand piston side brake pad ‘When installed, the arrow -A- on the brake pad backplate must point downwards (in direction of brake disc rotation). ‘When positioning the brake caliper, ensure that the brake pad does not stick to the brake caliper Rousing before its positioned correctly. Do not damage adhesive surface, Bolt brake caliper to brake carrier with both guide pins. Fit both cover caps. Bolt brake hose to brake caliper. Remove brake pedal depressor -V.AG 1869/2- 1. Repating font brakes, 43@ Touareg 2003 > Brake systems - Edition 07.2009 Fitretaining spring into upper hole -arrow- and turn anti-clock- wise -direction of arrow ‘Seat retaining spring into lower section of brake carrier. First press retaining spring in -direction of @rrow A, and then simultaneously into hole in brake caliper “direction of arrow B- Bleed brake system = page 133° - Fit wheels. . Specified torque of wheel bolts Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts (B) woe ‘+ Firmly depress brake pedel several times with venice station- ary, 30 thal the brake pads are properly seated n their normal operating positon. © Check brake fluid level Specified torques: Guide pin to brake carrier 30. Nm, Brake hose to brake caliper 14Nm 14 Repairing front braké, Brembo 17" brake caliper (1LC) Period of use: to week 32 of 2005 (B) noe + Everytime after changing pads, depress brake pedal frm Soveral hss wth vohCb statnaly, 20 tha brake pas are properly seated m their norma operating positon @ After work for which the brake system had to be opened, bleed the brake system with brake filing and bleeding unit - VAS 5234- or extraction unit -VA.G 1869/4- Fit brake pedal depressor-V.A.G 1869/2- before removing a brake caper or clecamecting@ brake heee(releeee pressure in system). 44 6p. 2.46 Brakes -mochanism1 - Brake disc a oo ooo 2.- Fitted bolt, 15 Nm a 3- Brake caliper a a a 4+ Hexagon bolt, 270 Nm a 5 - Brake line, 14 Nm a 6 - Spring clip Touareg 2003 > @ Brake systems - Edition 07.2009 Ventilated brake disc: 2 330 mm Brake disc thickness: 32 mm Weer limit: 30 mm Always renew on both sides of an axle. Different designs on left and right. Unscrew brake celiper prior to removing, do not disconnect brake line but remove bracket = Item 7 (page 45) Brake disc to wheel hub Do not disconnect brake line when changing, brake viges Removing ardinstaing = page $8 Repairing > page 117 Always renew after re- moving Do not disconnect brake line when changing brake discs, 7 - Bracket a Bolt to wheel bearing housing 8 - Hexagon socket head bolt, 9 Nm 9- Brake hose a Ensure that lugs are properly seated in grooves in bracket. 10- Hexagon bolt, 30 Nm 14 - Retaining pin 12- Retaining spring 13- Brake pads oo © oouoo Thickness: 10 mm not including backplate Pad wear limit: 2 mm without backplate With break pad wear indicator When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert comes on Checking thickness + Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads|linings: Checking thickness Always renew on both sides of an axle Removing and installing = page 46. 14- Brake pad wear indicator wire 1. Repaiing font brakes, 45@ Touareg 2003 > Brake systems - Edition 07.2009 15 Removing and installing brake pads/lin- ings Special tools and workshop equipment required 4 Torque wrench -V.AG 1331- V.A.G 1991 4 Piston resetting tool -T10145- 1.5.1 Removing ‘Mark brake pads when removing if they’dre fo be reused. Fit in ‘same position when installing, or braking will be uneven, = Remove wheels = Disconnect connector -1for brake pad wear indicator. — Pull off dust cap -2- andlift off brake pad wear indicator wire. 6 op. 2r-46- Brakes -mochanism= Remove bot = Press retaining spring inwards -arrow- whilst pulling out re- taining pin -4. — Pull brake Gad wear indicator -arrows- wire out of brake caliper housing and-out of retaining spring -1-. — Remove retaining spring. Before pressing back brake pads, draw off brake fluid from res- ervoir. Otherwise, particularly if reservoir hes been topped up, fluid will overfiow and cause damage. Push brake pads off brake disc and remove from brake caliver. — Ifthe brake pads are to be renewed, carefully remove sensor ‘with wire for brake pad wear indicator from the brake pads and check for damage. ‘Sensors end wires which are not damaged can be used again. Cleaning: LX _ wornine Do not blow out brake system with comoressed air; the result ing dust constitutes a health hazard! - Clean brake caliper. Use only methylated spirits for cleaning the brake caliper housing. 1.5.2 Installing Before pressing piston back nto cylinder with piston resetting too, draw off brake fluid from brake fluid reservoir. Otherwise, partic- Touareg 2003 > @ Brake systems - Edition 07.2009 1. Repating font brakes, 47Touareg 2003 > Brake systems - Edition 07.2009 ularly ifreservoir has been topped up, fluid will overflowand cause damage. = Press pistons back, — Carefully ingertthe sensors of the wire for the braké'pad wear indicator into the new brake pads, ~ Inserttbrake pads into brake caliper. = Fit retaining spring -1- ‘= Insert brake wear indicator wire under the retainer in the re- taining spring and into brake caliper housing -arrows-. = Press retaining spring inwards -arrow- and drive retaining pin f= n onto limit stop. Ensure that the flat edge of the retaining pin seats correctly into brake caliper housing (preventing it from turning). = Tighten bott 4B 0p. 2:46 Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 = Reconnect brake wear indicator connector -1- to connector on bracket on wheel bearing housing. = Secure brake wear indicator wire on bleed valve with the dust cap -2. — Fit wheels. ‘Specified torque of wheel bolts > Running gear, axles, steering: Rep. Gr. 44 ; Specified torques of wheel bolts fa) Note © Every time after changing pads, depress brake\padal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. © Check brake fluid level after changing brake pads. Specified torque Hexagon bolt to retaining pin 30Nm. 16 Removing and installing brake caliper Special tools and workshop equipment required © Torque wrench -V.A.G 1410: VAG 1410 eS @ Torque wrench -V.A.G 1576- V.A.G 1576 1. Repating font brakes, 4Q@ Touareg 2003 > Brake systems - Edition 07.2009 # Brake pedal depressor -V.A.G 1869/2- 1.6.1 Removing This procedure applies only to exchanging or the following repair work on the brake caliper. ~ Remove wheels. — Connect bleeder bottle hose to a bleeder valve on brake cali- per and open bieeder valve. ~ Apply brake pedal depressor -V.A.G 1869/2-. = Close bleeder valve and remove bleeder Bottle, — Disconnect brake line from brake caliper. — Disconnect bracket = Item 7 (page 45) from wheel bearing housing, - Remove brake pads = page 46 = Unbolt brake caliper from wheel bearing housing. 1.6.2 Installing = Bolt brake caliper to wheel bearing housing = Install brake pads > page 46 = Reconnect brake line to brake caliper. — Bolt bracket = Item 7 (page 45) to wheel bearing housing, = Remove brake pedal depressor -V.A.G 1869/2- = Bleed brake system > page 133 ~ Fit wheels. ‘Specified torque of wheel bolts > Running gear, axles, steering; Rep. Gr. 44 : Specified torques of wheel Bolts (Ene + Firmly depress brake pedal several times with vehicle station- ary, $0 that the brake pads are properly seated in their normal operating position. % Check brake fluid level. cified torques: Hexagon bolt to wheel bearing housing 270 Nm # Use new bolts! Brake line to brake caliper 44.Nm Bolt for bracket to wheel bearing housing 9Nm VAG.t9692 50 200. 6:46 - Brakes - mechanismTouareg 2003 > @ Brake systems - Edition 07.2009 17 Repairing front brake, Brembo 17" brake caliper (1LE) Period of use: from week 32 of 2005 (F) ne © Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads, are properiy seated in their normal operating position. After work for which the brake system had to be opened, bleed the brake system with brake filing and bleeding unit - VAS 5234- or extraction unit-VA.G 1869/4 Fit brake pedal depressot -V.A.G 1869/2- before removing 9 brake caliper or discomecting a brake hose (release pressure in system). 1 - Brake dise Ventilated brake disc: 2 330 mm Brake disc thickness: 32 mm Weer limit: 39 mm Always renew on both sides of an axle. Different designs on left and right. Unscrew brake ésliper prior to removing, do not disconnect brake line but remove bracket > Item 7 (page 51) 2.- Fitted bolt, 15 Nm 2 Brake disc to whee! hub oo ooo 3- Brake caliper Do not disconnect brake line when changing brake discs. Removing and installing = page 54 OD Repairing = page 117 4 - Hexagon bolt, 270 Nm 2 Always renew after re- moving 5 Brake line, 14.Nm 2. Donotdisconnect brake line when changing brake discs. 6 Spring clip 7 - Retainer Bolt to wheel bearing housing 1. Repairing ont bakes 51@ Touareg 2003 > Brake systems - Edition 07.2009 8 - Hexagon socket head bolt, 9 Nm 9- Brake hose Ensure that lugs are properly seated in grooves in bracket. 10 - Pad retaining pins 11 - Retaining spring 12- Brake pads Thickness: 11 mm without backplate Pad wear limit: 2 mm without backplate With break pad wear indicator comes on. Checking thickness Always renew on both sides of an ake, Removing and installing = paeS2 13 - Brake pad wear indicator wire oo © oooo 1.8 Removing and installing brake pads/lin- ings ‘Special tools and workshop equipment required @ Piston resetting tool -T10145~ 1.8.1 Removing ‘Mark brake pads when removing if they are fo be reused. Fit in ‘same position when installing, or braking will be uneven. = Remove wheels. = Disconnect connector -1- for brake pad wear indicator. = Pull off dust cap -2- and lift off brake pad wear indicator wire. When wear reaches a predetermined limit (approx'4'ffi) the warning lantf‘in.the dash panel insert Checking thickness = Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings: 52 op. 646 - Brakes - mechanism- Drive out brake pad retaining pins -arrows- — Pullbrake pad wear indicator -arrows- wire out of brake caliper housing and out of retaining spring -1-. - Remove retaining spring. Before pressing back brake pads, draw off brake fluid from res- etvoir. Otherwise, particularly if reservoir hes been topped up, fluid will overflow and cause damage. — Push brake pads off brake disc and remove from brake caliper. = Ifthe breke pads are to be renewed, carefully remove seAder with wire for brake pad wear indicator from the braké pads and check for damage. Sensors and wires which are not damaged can be used again. Cleaning: ZX wernine Do not blow out brake system with compressed air; the result- ing dust constitutes a health hazard! = Clean brake caliper. Use only methylated spirits for cleaning the brake caliper housing. 1.8.2 Installing Before pressing piston back into cylinder with piston resetting tool draw off brake fluid from brake fiuid-reservorr. Otherwise, partic- Ulary if reservoir has been topped up;fuid will overflowand cause damage. = Press pistons back. — Carefully insert the sensors of the wire for the brake pad wear indicator into the new brake pads, Touareg 2003 > @ Brake systems - Edition 07.2009 1. Repating font brakes, 5STouareg 2003 > Brake systems - Edition 07.2009 = Insert brake pads into brake caliper. = Fitretaining spring -1- = Insert brake wear indicator wire under the retainer in the re- taining spring and into brake caliper housing -arrows-. = Press retaining spring down and insert brake pad retaining pins in brake caliper. — Drive brakeBad retaining pins into brake caliper to stop, ~ Reconnect brake wear indicator connector -1-to connector on. bracket on wheel bearing housing, ~ Secure brake wear indicator wire on bleed valve with the dust cap=2- - Fitwheels. ‘Specified torque of wheel bolts > Running gear, axles, steering; Rep. Gr. 44 {Specified torques of wheel bolts fw Note + Everytime after changing pas) dapress brake peda Mmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. % Check brake fluid level after changing brake pads. 19 Removing and installing brake caliper ‘Special tools and workshop equipment required 54 op. 646 - Brakes - mechanismTouareg 2003 > @ Brake systems - Edition 07.2009 @ Torque wrench -V.A.G 1410- vac 14i0 © Torque wrench -V.A.G 1576- V.A.G 1876 Brake pedal depressor -V.A.G 1869/2- VAG 1889/2 1.9.1 Removing This procedure applies only to exchanging or the following repair ‘work on the brake caliper. - Remove wheels, = Connect bleeder bottle hose to a bleeder valve on brake cali- per and open bleeder valve. — Apply brake pedal depressor -V.A.G 1869/2- — Close bleeder valve and remove bleeder bottle. = Disconnect brake line from brake caliper. = Disconnect bracket = Item 7 (page 51) from wheel bearing housing, — Remove brake pads = page 52 = Unbolt brake caliper from wheel bearing housing 1.9.2 Installing — Bolt brake caliper to wheel bearing housing, 1. Repating font brakes, 5S@ Touareg 2003 > Brake systems - Edition 07.2009 = Install brake pads, — Reconnect brake line to brake caliper. — Bolt bracket = Item 7 (page 51) to wheel bearing housing - Remove brake pedal depressor -V.A.G 1869/2. ~ Bleed brake system = page 133 ~ Fit wheels. ‘Specified torque of wheel bolts > Running gear, axles, steering; Rep. Gr. 44 : Specified torques of wheel bolts i) Note Firmly depress brake pedal several times with vehicle station- ary, So that the brake pads are properly seated in their normal ‘operating position. % Check brake fluid level Specified torques: Hexagon bolt to wheel bearing housing 270 Nm # Use new bolts! Brake line to brake caliper 14m Bolt for bracket to wheel bearing housing, Nm 1.10 Repairing front brake, Brembo 18" brake caliper (Fre # Every time aftecchanging pads, depress brake pedal firmly several times.ivith vehicle stationary, so that brake pads are properly seated in their normal operating position After work for which the brake system had fo be opened, bleed the brake system with brake filing and bleeding unit - VAS 5284- or extraction untt -V.A.G 1869/4- 4 Fit prake pedal depressor-V.A.G 1869/2. before removing a brake calper or disconnecting a brake hose (release pressure in system). 56 ep. 2-46 Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 1 - Brake disc Ventilated brake disc: 360 mm Brake disc thickness: 34 mm Weer limit: 32 mm. Always renew on both sides of an axle. Different designs on left and right. Unscrew brake celiper prior to removing, do not disconnect brake line but remove bracket = Item 7 (page 57) 2.- Fitted bolt, 15 Nm Brake disc to wheel hub oo ooo 3- Brake caliper Donot disconnect brake line when changing brake discs. Removing and instaling = page 6 Repairing = page 117 4+ Hexagon bolt, 270 Nm Always renew after re- moving 5 - Brake line, 14 Nm Do not disconnect brake line when changing brake discs, 6 - Spring clip 7 - Retainer Bolt to wheel bearing housing 8 - Hexagon socket head bolt, 9 Nm 9- Brake hose Ensure that lugs are properly seated in grooves in bracket. 10- Hexagon bolt, 30 Nm 14 - Retaining pin 12- Retaining spring 13- Brake pads Thickness: 10 mm not including backplate Pad wear limit: 2 mm without backplate With break pad weer indicator When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert comes on Checking thickness + Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads|linings: Checking thickness Always renew on both sides of an axle Removing and installing = page 58 14- Brake pad wear indicator wire oo © oouoo 1. Repating font brakes, ST@ Touareg 2003 > Brake systems - Edition 07.2009 1.11 Removing and installing brake.pads/lin- ings ‘Special tools and workshop équipment required # Torque wrench -V.AG 1331- V.AG 1331 4 Piston regetting tool -T10145- 1.11.1 Removing ‘Mark brake pads/linings when removing if they are to be reused. Fit in same position when installing, or braking will be uneven. = Remove wheels = Disconnect connector -1- for brake pad wear indicator. = Pull off dust cap -2- and lift off brake pad wear indicator wire. 5820p. 646 - Brakes - mechanism= Remove bot = Press retaining spring inwards -arrow- whilst pulling out re- taining pin -1-. Pull brake pad wear indicator -arrows- wire out of brake caliper housing and out of retaining spring -1-. ~ pRemove retaining spring. Before pressing back brake pads, draw off brake fluid from res« ervoir. Otherwise, particularly if reservoir has been topped up, fluid will overflow and cause damage. Push brake pads off brake disc and remove from brake caliver. — Ifthe brake pads are to be renewed, carefully remove sensor ‘with wire for brake pad wear indicator from the brake pads and check for damage ‘Sensors end wires which are not damaged can be used again. Cleaning: LX _ wernine Do not blew out brake system with compressed air;the result ing dust constitutes a health hazard! - Clean brake caliper. Use only methylated spirits for cleaning the brake caliper housing. 1.11.2 Installing Before pressing piston back nto cylinder with piston resetting too, draw off brake fluid from brake fluid reservoir. Otherwise, partic- Touareg 2003 > @ Brake systems - Edition 07.2009 1. Repating font brakes, SQTouareg 2003 > Brake systems - Edition 07.2009 ularly ifreservoir has been topped up, fluid will overflowand cause damage. = Press pistons back. — Carefully insert the sensors of the wire for the brake pad wear indicator into the new brake pads. ~_ Insert brake pads into brake caliper. = Fitretaining spring -1- — Insert brake wear indicator wire under the retaineyin.the re- taining spring and into brake caliper housing -arrows-. = Press retaining Spring inwards -arrow- and drive retaining pin A= in onto limit stop. Ensure that the fiat edge of the retaining pin seats correctly into brake caliper housing (preventing it from turning). = Tighten bott 60 ep. 2-46 Brakes -mochanism= Reconnect brake wear indicator connector -1- to connector on bracket on wheel bearing housing. = Secure brake wear indicator wire on bleed valve with the dust cap -2. — Fit wheels. ‘Specified torque of wheel bolts »\'Rnning gear, axles, steetingy Rep. Gr. 44 ; Specified torques of wheel bolts fa) Note © Every time after changing pads, depress brake pedal firmly ‘several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. © Check btBke fluid level after changing brake pads. Specified torque Hexagon bolt fo retaining pin 30 Nm 1.12, Removing and installing brake caliper Special tools and workshop equipment required @ Torque wrench -V.A.G 1410- @ Torque wrench -V.A.G 1576- Touareg 2003 > @ Brake systems - Edition 07.2009 VAG 1410 =O V.A.G 1576 1. Repairing ont bakes 641@ Touareg 2003 > Brake systems - Edition 07.2009 4 Brake pedal depressor -V.A.G 1869/2. VAG 18692 1.12.1 Removing This procedure applies only to exchanging or the following repair work on the brake caliper. ~ Remove wheels. — Connect bleeder bottle hose to a bléeder valve on brake call- per and open bieeder valve. Apply brake pedal depressor -V.A.G 1868/2, = Close bleeder valve and remove bleeder botti¢: — Disconnect brake line from brake caliper. — Disconnect bracket = Item 7 (page 57) from wheel bearing housing, - Remove brake pads = page 58 = Unbolt brake caliper from wheel bearing housing. 1.12.2 Installing = Bolt brake caliper to wheel bearing housing = Install brake pads > page 58 = Reconnect brake line to brake caliper. — Bolt bracket = Item 7 (page $7) to wheel bearing housing. = Remove brake pedal depressor -V.A.G 1869/2- = Bleed brake system > page 133 ~ Fit wheels. ‘Specified torque of wheel bolts > Running gear, axles, steering; Rep. Gr. 44 : Specified torques of wheel Bolts (Ene + Firmly depress brake pedal several times with vehicle station- ary, $0 that the brake pads are properly seated in their normal operating position. % Check brake fluid level. cified torques: Hexagon bolt to wheel bearing housing 270 Nm # Use new bolts! Brake line to brake caliper 44.Nm Bolt for bracket to wheel bearing housing 9Nm 62 Rep. 6r-46- Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 1.13 Repairing front brake, Brembo 18" brake caliper Plus fa Note ¢ Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. ¢ After work for which the brake system had to be opened, bleed the brake system with brake filing and bleeding unit - VAS 5234- or extraction unit -VAG 1869/4- © Fit brake pedal depressor -V.A.G 1869/2- betare removing a brake caliper or disconnecting a brake hase (release pressure in system). 1 - Brake disc Ventilated brake disc: 368 mm Brake disc thickness: 26. mm) Weer limit: 34 mm Always renew on both sides of an axle, Different designe on left and right. For removal, first unbolt brake caliper. Do not disconnect brake hose. 2.- Fitted bolt, 15 Nm Brake disc to whee! hub 3 - Breke pad weer indicator wire 4 Brake caliper 2. Donot disconnect brake hose when changing brake pads or brake disc. 2 Removing an instaling = page 6 Q Repairing = page 117 5 - Hexagon bolt, 270 Nm Always renew after re- moving 6 - Retaining spring For brake pads oooog 7 - Retaining spring For brake pad wear in- dicator wire 8 - Brake pads Thickness: 10 mm not including backplate Wear limit: 2 mm not including backplate With break pad wear indicator 1. Repating font brakes, 6STouareg 2003 > Brake systems - Edition 07.2009 When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert comes on. Checking thickness = Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings: Checking thickness ‘Always renew on both sides of an axle, Removing and installing > pace 64 9-Cilip For brake pad wear indicator wire 40- Brake hose, 14m 11 - Hexagon bolt, 20 Nm 12 Bracket Bolt to whee! bearing housing a a a a 1.14 Removing and installing brake pads/lin- ings ‘Special tools and workshop equipment required 4 Torque wrench -V.AG 1576- VAG 1576 4 Piston resetting tool -T10145- l 1.14.1 Removing ‘Mark brake pads/linings when removing if they are to be reused. Fit in same position when installing, or braking will be uneven. = Remove wheels — Separate connector for brake pad wear indicator. ~ Remove brake pad wear indicator wire from clip and take it out of retaining spring = Pull brake hose out of retainer on wheel bearing housing, 64 ep. 2r-46- Brakes -mochanismTouareg 2003 > @ tems - Edition 07.2009 Before pressing back brake pads, draw off brake fluid from res- ervoir. Otherwise, particularly if reservoir hes been topped up, fluid will overfiow and cause damage. = Push brake pads off brake disc. Carefully remove sensor with brake pad wear indicator wire from brake pads and check for damage. ‘Sensors and wires which are not damaged can be used again. = Unbolt brake caliper -errows- from wheel bearing housing, AY owen Never unbolt brake caliper trom adapter plate. Do not loosen radially bolted muttipoint bolts. — Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose. ~2 Lever brake pads with a commercially available screwdriver ‘out of brake caliper -arrows-, being careful not to damage dust, caps. = Take brake pads out of retaining springs. Cleaning: A WARNING Do not biow out brake system with compressed air; the result. ing dust constitutes @ health hazard! = Clean brake caliper. Usé.only methylated spirits for cleaning the brake caliper housing. 1.14.24, Installing Before presdingpiston beck nto cyinder with piston resets too), draw off brake fluid. from brake fiuid reservoir. Otherwise, partic~ ual ifeservoirnas Bean opped up hid wll everiowancause lamage. Press pistons back. +The retaining springs are correctly seated in the brake caliper. + The long part of the retaining springs faces towards the middle of the brake caliper. — Pull protective foil off brake pad backplate. 1. Repating font brakes, 6S@ Touareg 2003 > Brake systems - Edition 07.2009 = Insert brake pads into brake caliper and push onto 4 pad re- taining pins -arrows-. L\ warns The brake pads must be correctly seated in the brake pad re- taining springs and on the retaining pins. — Set brake pads onto 4 contact surfaces of brake pad retaining springs -arrows- = Carefully set brake caliper over brake disc. Bolt brake caliper -arrows- to wheel bearing housing. Push brake hose into retainer on wheel bearing housing. Carefully insert sensors of brake pad wear indicator wire into new brake pads. Insert brake pad wear indicator wire under retainers in retain- ing spring and into clip. — Reconnect connector for brake pad wear indicator. ~ Fit wheels. ‘Specified torque of wheel bolts > Running gear, axles, steering; Rep. Gr. 44 : Specified torques of wheel Bolts (Fn # Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position, # Check brake fluid level after changing brake pads. cified torques: Hexagon bolt to wheel bearing housing 270 Nm # Use new bolts! 1.15 Removing and installing brake caliper ‘Special tools and workshop equipment required 66 ep. 2r-46- Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 VAG 1576 @ Torque wrench -V.A.G 1576+ ¢ Brake pedal depressor -V.A.G 1869/2- VAG 1869/2 1.15.1. Removing This procedure applies only to exchanging or the following repair ‘work on the brake caliper. = Remove wheels, — Connect bleeder bottle hose to a bleeder valve on brake cali- Per and open bleeder valve, - Apply brake pedal depressor -V.AG 1869/2- = Close bleeder valve and remove bleeder bottle. — Separate connector for brake pad wear indicator = Disconnect brake hose from brake caliper. = Unbolt brake caliper from wheel bearing housing — Remove brake pads > page 64 1.15.2 Installing = Install brake pads > page 64 = Bolt brake caliper to wheel bearing housing, = Reconnect brake hose to brake caliper. = Carefully insert sensors of brake pad weer indicator wire into new brake pads. = Insert brake pad wear indicator wire under retainers in retain- ing spring and into clip. = Reconnect connector for brake pad wear indicator. - Remove brake pedal depressor -V.AG 1869/2- = Bleed brake system => page 133 — Fit wheels. 1. Repating font brakes 67@ Touareg 2003 > Brake systems - Edition 07.2009 ‘Specified torque of wheel bolts + Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts ff Note + Firmly depress brake pedal several times with vehicle station- ary, So that the brake pads are properly seated in their normal operating position. 4% Check brake fuid level. Specified torques: Hexagon bolt to wheel bearing housing 270 Nm + Brake hose to brake calip. 44.Nm 68 ep. 2r-46- Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 2 Repairing rear brakes 24 Repairing rear brakes, brake caliper FN 44 (B) note ‘¢ Every time after changing pads, depress brake pedal firmly ‘several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. ¢ After work for which the brake system had to be opened, bleed the brake system with brake filing and bleeding unit - VAS 5234- or extraction unit VAG 18694- Fit brake pedal depressor -V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose (release pressure in system). 1 - Brake disc/drum’ Ventilated brake disc: 314 mim Brake disc thickness: 22 am, Weer limit: 18 mm. F Brake drum: 2 185 mm, A Pad wear limit: 188 mm Always renew on both sides of an axle. 5 D Remove brake caliper and brake carrier priorto removing but to not open brake line. 2- Fitted bolt, 20 Nm 2 Brake disc to whee! hub 3 “Brake carrier Bolt to wheel bearing housing 4 Hexagon bolt, 200 Nm 5 - Brake pads Thickness: 13 mm with- ut backplate: Pad wear limit: 2m, without backplate a 2 With break pad wear in- a dicator When wear reaches a predetermined limit (ap- prox 4mm) the warring lamp in the dash panel insert comes on Checking thickness > Maintenance ; Booklet 17.1 ; Work sequences: Front and rear brake padsilinings: Checking thickness Always renew on both sides of en axle 2. Ropating warbrakes OQ@ Touareg 2003 > Brake systems - Edition 07.2009 Removing and installing > page,Z0: 6 - Retaining spring 7 - Brake caliper Do not disconnect‘brake hose when changing brake pads or brake discs Removing angiinstalling = pace 75 Repairing =.pane 123 8 - Secures braké pad wear indicator wiring. 9- Bolt, 10.Nm 10 - Guide pin:30 Nm 11 - Cover cab 12 - Hexagon socket head bolt, 8 Nm 13- Retainer 44 - Brake hose with banjo union and banjo bolt, 38 Nm Do not unserew when changing brake pads or brake discs. 15 - Hold-down pin 416 - Compression Spring 17 - Extension spring Fitting location: ofthe adjustment nut Identifying the springs, tem 18 (page 70 larger number of spring coils can be bent easily by hand 18 - Extension spring 1 Fitting location: on expander Identifying the spring = Item 17 (page 70) smaller number of spring coils ‘ cannot be bent easily by hand 19 - Brake shoe Removing and installing = page 86 Minimal thickness of brake lining: 41mm Check thickness. 20 - Expander 24 - Adjustment nut Adjusting parking brake = page 101 22 - Brake backplate 23 - Rear brake cable 22 Removing and installing brake pads/lin- ings ‘Special tools and workshop equipment required 70 Rep. 6r-46- Brakes -mochanismTouareg 2003 > @ Brake systems - Edition 07.2009 V.A.G 1331 @ Torque wrench -V.A.G 1331- Piston resetting tool -T10145- 2.2.1 Removing Mark brake pads when removing if they are to be reused. Fit in same position when installing, of braking willbe uneven. = Remove wheels, , Press staining spring in -direction of arrow A- until it Can be pregsed out of hole in -direction of arrow B- — Tum retaining spring -1- clockwise -arrow- until it can be re- moved from the upper hole. 2. Repating war brakes 71@ Touareg 2003 > Brake systems - Edition 07.2009 = Disconnect connector -1- for brake pad wear indicator. — Remove brake pad wear indicator wire from brake caliper housing retainer -2- — Remove brake wear indicator lower connector -3- and speed sensor wire -4- from bracket on brake caliper - Remove caps -arrows- ~ Unscrew both guide pins -arrowss.ftom,brake caliper and re- move. ou = Remove brake'Galiper and secure with wire so thal Weight of brake caliper does not strain or damage brake hose. = Remoie brake pads. Cleaning: ZX wean ‘Do not blow out brake system with compressed air; the result- jing dust constitutes a health hazard! == Thoroughly clean brake carrier and contact surfaces for brake pads and remove corrosion, = Clean brake caliper. ‘Use only methylated spirits for cleaning the brake caliper housing, 72. Rep. 6r:46- Brakes - mechanism