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SKODA OCTAVIA

MK1
RUNNING GEAR
CHASSIS

RUNNING GEAR..........................................................................................................................................10
CHASSIS.........................................................................................................................................................10
TECHNICAL DATA......................................................................................................................................10
CHASSIS - SPECIFIED VALUES........................................................................................................................10
STEERING......................................................................................................................................................13
BRAKES.........................................................................................................................................................14
Brake variants and their assignment........................................................................................................14
Brake fluid................................................................................................................................................17
WHEELS, TYRES............................................................................................................................................18
FRONT SUSPENSION, DRIVE SHAFTS..................................................................................................21
REPAIRING FRONT WHEEL SUSPENSION.........................................................................................................21
l - Summary of components assembly carrier, anti-roll bar, track cotrol arm.........................................22
Removing and installing the track control arm........................................................................................25
Pressing out and in the bearing for the track control arm.......................................................................28
Removing and installing assembly carrier...............................................................................................31
Pressing out and in rubber-metal bearing................................................................................................34
II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake.........................35
Repairing wheel bearing housing.............................................................................................................40
Inspecting the steering joint.....................................................................................................................43
Removing and installing the steering joint...............................................................................................44
Remove and install suspension strut and wheel bearing housing............................................................45
Repairing the suspension strut.................................................................................................................49
Inspecting the shock absorber..................................................................................................................52
Disposing of the shock absorber..............................................................................................................54
Removing and installing a drive shaft......................................................................................................57
REPAIRING DRIVE SHAFT...............................................................................................................................61
Repairing drive shaft with outer and inner CV joint VL 3700.................................................................64
Inspecting outer CV joint..........................................................................................................................73
Inspecting inner CV joint..........................................................................................................................75
Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint............................................79
Disassembling and assembling the tripod joint AAR 2900......................................................................82
Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint............................................87
Disassembling and assembling the tripod joint AAR 2000......................................................................90
REAR SUSPENSION, DRIVE SHAFT.......................................................................................................94
REPAIRING REAR AXLE - DRUM BRAKE.........................................................................................................94
Removing and installing rear suspension.................................................................................................94
Summary of components of rear axle.......................................................................................................98
Replacing the rubber-metal bearing......................................................................................................102
Replacing the rubber-metal bearing - version 1..................................................................................102
Replacing the rubber-metal bearing - version 2..................................................................................111
Removing and installing shock absorber/spring....................................................................................122
Disassembling and assembling shock absorber.....................................................................................124
REPAIRING REAR AXLE - DISC BRAKE.........................................................................................................126
Removing and installing rear suspension...............................................................................................126
2

Summary of components of rear axle.....................................................................................................129


Replacing the rubber-metal bearing......................................................................................................134
Replacing the rubber-metal bearing - version 1..................................................................................134
Replacing the rubber-metal bearing - version 2..................................................................................143
Removing and installing shock absorber/spring....................................................................................154
Disassembling and assembling shock absorber.....................................................................................155
REPAIRING THE WHEEL BEARING................................................................................................................157
Repairing the wheel bearing, vehicles with front-wheel drive - drum brake.........................................157
Repairing the wheel bearing - disc brake...............................................................................................163
REPAIRING REAR AXLE (VEHICLES WITH FOUR-WHEEL DRIVE)..................................................................169
Rear axle with four-wheel drive - Overview...........................................................................................169
Coil spring and shock absorber on vehicles with four-wheel drive - Summary of components.............171
Removing and installing coil spring.......................................................................................................173
Removing and installing shock absorber...............................................................................................178
TRAILING ARM AND SUSPENSION ARM - SUMMARY OF COMPONENTS........................................................180
Pressing out and pressing in...................................................................................................................184
Removing and installing rubber-metal bearing for trailing arm...........................................................190
Removing and installing guide joint.......................................................................................................192
Removing and installing trailing arm.....................................................................................................197
Removing and installing suspension arm...............................................................................................202
SUMMARY OF COMPONENTS - ASSEMBLY CARRIER WITH FINAL DRIVE......................................................205
Removing and installing assembly carrier with final drive....................................................................207
Removing and installing rubber-metal bearing for assembly carrier....................................................212
Removing and installing rubber-metal bearing for final drive..............................................................214
REPAIRING DRIVE SHAFT.............................................................................................................................218
Removing and installing a drive shaft....................................................................................................218
Repairing drive shaft with CV joint........................................................................................................221
WHEELS, TYRES. AXLE ALIGN............................................................................................................227
VEHICLE ALIGNMENT..................................................................................................................................227
General points........................................................................................................................................227
Test conditions........................................................................................................................................228
Measurement preliminaries....................................................................................................................229
Chassis terms..........................................................................................................................................230
Nominal values for vehicle alignment....................................................................................................230
Checking the transversal inclination of the vehicle...............................................................................231
Checking the camber on the front axle, if necessary take the mean.......................................................232
Checking the camber on the rear axle....................................................................................................233
Checking the track on the rear axle, if necessary taking the mean/adjusting........................................234
Checking the track on the front axle, adjusting if necessary..................................................................235
Checking the left and right steering angle.............................................................................................236
Calculation of the misalignment on the rear axle..................................................................................237
WHEELS AND TYRES...................................................................................................................................238
General points........................................................................................................................................238
Disc wheel..............................................................................................................................................239
Light-alloy wheel....................................................................................................................................240
VEHICLES WITH TYRE REPAIR SET...............................................................................................................242
Tyre sealant.............................................................................................................................................243
3

Tyre disassembly.....................................................................................................................................244
Assembly of new tyres.............................................................................................................................245
Disposing of tyre sealant........................................................................................................................246
ABS, ADR, TCS, EDL, ESP........................................................................................................................247
ANTILOCK BRAKING SYSTEM (ABS) ITT MARK 20 IE..............................................................................247
Safety precautions, basic information on fault finding and on repairing ABS and ABS/EDL ITT Mark 20
IE............................................................................................................................................................247
Notes on repair work on ABS and ABS/EDL ITT Mark 20 IE................................................................248
Required technical information..............................................................................................................249
DISTINGUISHING FEATURES OF THE ABS ITT MARK 20 IE AND THE ABS/EDL ITT MARK 20 IE...........250
General Instructions...............................................................................................................................250
ABS ITT Mark 20 IE...............................................................................................................................251
ABS/EDL ITT Mark 20 IE......................................................................................................................252
Fitting position ABS or ABS/EDL ITT Mark 20 IE................................................................................253
SELF-DIAGNOSIS..........................................................................................................................................254
Self-diagnosis functions..........................................................................................................................254
Indication of faults by means of warning lights -K47- and -K14/33-.....................................................255
Vehicle fitted with ABS/EDL - EDL does not operate.............................................................................256
PERFORM SELF-DIAGNOSIS..........................................................................................................................257
Test requirements....................................................................................................................................257
Connecting vehicle system tester -V.A.G 1552- and selecting function..................................................258
Interrogating control unit version..........................................................................................................259
Overview of selectable functions............................................................................................................261
Interrogating fault memory....................................................................................................................262
Automatic test sequence.........................................................................................................................263
Fault table..............................................................................................................................................264
Erasing fault memory.............................................................................................................................271
Ending output.........................................................................................................................................272
Coding control unit.................................................................................................................................273
Reading measured value block...............................................................................................................275
Actuator diagnosis..................................................................................................................................278
Basic setting............................................................................................................................................283
ELECTRICAL TEST OF THE ABS AND ABS/EDL ITT MARK 20 IE.............................................................287
Test conditions........................................................................................................................................288
Multi-pin plug connection with contact assignment...............................................................................289
Overview of test steps.............................................................................................................................291
Test table.................................................................................................................................................292
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS, ABS/EDL MARK 20.....................299
Removing and installing the hydraulic control unit and the bracket.....................................................302
Repairing the hydraulic control unit......................................................................................................309
Checking/removing and installing parts of the ABS system on the front axle........................................313
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake)
- front-wheel drive..................................................................................................................................320
Removing and installing as well as adjusting brake light switch up to model year 1999......................327
Removing and installing as well as adjusting brake light switch as of model year 2000......................329
SUMMARY OF COMPONENTS OF HYDRAULIC CONTROL UNIT, BRAKE SERVO UNIT/MASTER BRAKE
CYLINDER FOR VEHICLES WITH ABS, ABS/EDL MARK 20.......................................................................330
4

SELF-DIAGNOSIS OF THE ABS/EDL FOR FOUR-WHEEL DRIVE VEHICLES WITH HALDEX COUPLING..........333
Interrogating control unit version..........................................................................................................334
Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling..................................335
Code ABS/EDL control unit....................................................................................................................336
Check longitudinal acceleration sender -G251-....................................................................................336
Checking the data BUS cable.................................................................................................................338
Initiating basic setting............................................................................................................................340
Switch off longitudinal acceleration sender -G251-..............................................................................340
Null balance of the longitudinal acceleration sender -G251-................................................................341
ELECTRICAL TEST OF THE ABS/EDL FOR FOUR-WHEEL DRIVE VEHICLES WITH HALDEX COUPLING........342
Test table.................................................................................................................................................343
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS (FOUR-WHEEL DRIVE).............................345
Removing and installing longitudinal acceleration sender -G251-.......................................................348
Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - four-wheel
drive........................................................................................................................................................349
ANTILOCK BRAKING SYSTEM ABS/ EDL/ESP MARK 20...........................................................................354
Safety precautions, basic information on fault finding and on repairing...............................................354
Notes on repair work on ABS/EDL/ESP Mark 20..................................................................................354
Required technical information..............................................................................................................354
DISTINGUISHING FEATURES OF THE ABS/EDL ITT MARK 20 IE AND THE ABS/EDL/ESP ITT MARK 20 IE
....................................................................................................................................................................355
General Instructions...............................................................................................................................355
ABS/EDL/ESP ITT Mark 20 IE..............................................................................................................356
Fitting position ABS/EDL/ESP ITT Mark 20 IE.....................................................................................357
SELF-DIAGNOSIS OF THE ABS/EDL/TCS/ESP MARK 20...........................................................................358
Description of the function.....................................................................................................................358
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-.......................................359
Vehicle fitted with ABS/EDL/ESP - EDL does not operate.....................................................................363
ELECTRICAL TEST OF THE ABS/EDL/ESP ITT MARK 20 IE......................................................................364
Test conditions........................................................................................................................................365
Multi-pin plug connection with contact assignment...............................................................................367
Test table.................................................................................................................................................372
Test steps 1 - 20......................................................................................................................................373
Test steps 21 - 28....................................................................................................................................384
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/ESP MARK 20.......................393
Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket.............................398
Repairing the hydraulic control unit ABS/EDL/ESP..............................................................................406
Checking/removing and installing parts of the ABS system on the front axle........................................410
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake)
- front-wheel drive..................................................................................................................................415
Removing and installing parts of the ESP system..................................................................................415
Removing and installing as well as setting the brake light switch.........................................................422
SUMMARY OF COMPONENTS OF HYDRAULIC CONTROL UNIT, BRAKE SERVO UNIT/MASTER BRAKE
CYLINDER FOR VEHICLES WITH ABS/EDL/ESP MARK 20.........................................................................423
ANTILOCK BRAKING SYSTEM (ABS) MK60...............................................................................................427
Safety precautions, basic information on fault finding and on repairing ABS and ABS/TCS/EDL MK 60
................................................................................................................................................................427
Notes on repair work on ABS and ABS/TCS/EDL MK 60......................................................................427
5

Required technical information..............................................................................................................427


General Instructions...............................................................................................................................427
ABS and ABS/TCS/EDL..........................................................................................................................427
Fitting position ABS or ABS/TCS/EDL MK 60......................................................................................427
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/TCS MARK 60......................428
Removing and installing the hydraulic control unit and the bracket.....................................................431
Repairing the hydraulic control unit......................................................................................................437
Checking/removing and installing parts of the ABS system on the front axle........................................439
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake)
- front-wheel drive..................................................................................................................................442
SUMMARY OF COMPONENTS OF HYDRAULIC CONTROL UNIT, BRAKE SERVO UNIT/MASTER BRAKE
CYLINDER ABS/EDL/TCS MARK 60.........................................................................................................443
ELECTRICAL TEST ABS/EDL/ TCS MARK 60............................................................................................445
Test requirements....................................................................................................................................446
Multi-pin plug connections with contact assignment for ABS, ABS/EDL/TCS......................................447
Test table.................................................................................................................................................450
ANTILOCK BRAKING SYSTEM ABS/ EDL/TCS/ESP MARK 60...................................................................457
Safety precautions, basic information on fault finding and on repairing...............................................457
Notes on repair work on ABS/EDL/TCS/ESP Mark 60..........................................................................457
Required technical information..............................................................................................................457
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/TCS/ESP MARK 60 MY 02
....................................................................................................................................................................458
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/TCS/ESP MARK 60 MY 02
....................................................................................................................................................................462
DISTINGUISHING FEATURES ABS/EDL/TCS MARK 60 AND ABS/EDL/TCS/ ESP MARK 60....................466
General Instructions...............................................................................................................................466
Fitting position ABS/EDL/TCS/ESP Mark 60........................................................................................466
SELF-DIAGNOSIS OF THE ABS/EDL/TCS/ESP MARK 60...........................................................................467
Description of the function.....................................................................................................................467
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-.......................................467
ELECTRICAL TEST ABS/EDL/TCS/ESP MARK 60.....................................................................................472
Test requirements....................................................................................................................................473
Multi-pin plug connection with contact assignment...............................................................................474
Test table.................................................................................................................................................478
BRAKE, BRAKE MECHANICS...............................................................................................................494
REPAIRING THE FRONT BRAKE..........................................................................................................494
Changing the brake pads of the front brake - Mounting instructions....................................................494
Repairing front brake, the floating caliper disc brake FS-III................................................................495
Removing and installing brake pads/brake caliper (FS III)...................................................................499
Repairing the front wheel brake, brake caliper FN -3...........................................................................502
REMOVING AND INSTALLING BRAKE PADS/BRAKE CALIPER FN 3..............................................................507
Removing and installing brake discs (FN 3)..........................................................................................512
REPAIRING REAR WHEEL BRAKE - FRONT WHEEL DRIVE (DRUM BRAKE)...................................................515
Replacing the brake shoes of the rear brake - Mounting instructions...................................................515
Removing and installing rear wheel brake.............................................................................................516
Resetting brake.......................................................................................................................................520
Repairing rear brake..............................................................................................................................521
6

Removing and installing brake shoes.....................................................................................................525


Setting the hand-brake (drum brake).....................................................................................................528
REPAIRING REAR WHEEL-BRAKE - FRONT-WHEEL DRIVE (DISC BRAKE).....................................................530
Changing the brake pads of the rear wheel disc brake - Mounting instructions...................................530
Removing and installing rear wheel brake.............................................................................................531
Removing and installing brake pads......................................................................................................536
Setting the hand-brake (disc brake).......................................................................................................539
REMOVING AND INSTALLING HAND-BRAKE CABLE (DRUM BRAKE)............................................................541
REMOVING AND INSTALLING HAND-BRAKE CABLE (DISC BRAKE)..............................................................543
HANDBRAKE LEVER - SUMMARY OF COMPONENTS....................................................................................545
REPAIRING REAR WHEEL-BRAKE - FOUR-WHEEL DRIVE (DISC BRAKE).......................................................547
Changing the brake pads of the rear wheel disc brake - Mounting instructions...................................547
Removing and installing rear wheel brake.............................................................................................548
Removing and installing brake pads......................................................................................................553
Setting the hand-brake............................................................................................................................557
REMOVE AND INSTALL HAND-BRAKE CABLE, FOUR-WHEEL DRIVE/DISC BRAKE........................................559
SUMMARY OF COMPONENTS OF FOOT CONTROLS, BRAKE PEDAL............................................................561
Assembly overview of the foot controls, brake pedal - LHD vehicles....................................................561
Assembly overview of the foot controls, brake pedal - RHD vehicles....................................................563
Separating the brake pedal from the brake servo unit and clipping......................................................566
Removing and installing brake pedal.....................................................................................................569
BRAKES, HYDRAULICS, REGULATOR, SERVO...............................................................................572
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITHOUT
ABS OR WITH ABS, ABS/EDL MARK 20..................................................................................................572
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with
ABS, ABS/EDL Mark 20 - LHD vehicles................................................................................................572
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with
ABS, ABS/EDL Mark 20 - RHD vehicles................................................................................................575
Removing and installing the master brake cylinder - LHD vehicles......................................................579
Removing and installing the master brake cylinder - RHD vehicles......................................................579
Check brake servo unit...........................................................................................................................579
Removing and installing the brake servo unit - LHD vehicles...............................................................579
Removing and installing the brake servo unit - RHD vehicles...............................................................579
Removing and installing the vacuum pump for the brake servo unit.....................................................579
REPAIRING THE FRONT BRAKE CALIPER, BRAKE CALIPER FS III.............................................................579
Summary of Components of Brake Caliper FS-III.................................................................................579
Removing and installing the front brake caliper piston.........................................................................579
REPAIRING THE FRONT BRAKE CALIPER, BRAKE CALIPER FN 3..................................................................579
Assembly overview of the brake caliper FN3.........................................................................................579
Removing and installing the front brake caliper piston.........................................................................579
REPAIRING THE REAR BRAKE CALIPER........................................................................................................579
Summary of components of the brake caliper........................................................................................579
Removing and installing the rear brake caliper piston..........................................................................579
Temporary filling of brake caliper......................................................................................................579
SUMMARY OF COMPONENTS OF BRAKE-POWER REGULATOR......................................................................579
INSPECTING AND ADJUSTING THE BRAKE-POWER REGULATOR...................................................................579
Adjusting values for the load-dependent brake-power regulator...........................................................579
7

BLEED BRAKE SYSTEM, VEHICLES WITH OR WITHOUT ABS OR ABS/EDL MARK 20 AND MARK 60........579
Bleeding brake system with brake filling and bleeding device for vehicles with Mark 20....................579
Bleeding the brake system without using the brake filling and bleeding device....................................579
Bleeding brake system with brake filling and bleeding device for vehicles with ABS Mark 60.............579
CHECKING THE MASTER BRAKE CYLINDER FOR TIGHTNESS.......................................................................579
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITH
ABS/EDL/ESP MARK 20...........................................................................................................................581
Removing and installing brake pressure sender -1--G201- and brake pressure sender -2--G214-.......584
Removing and installing the master brake cylinder - LHD vehicles......................................................586
Removing and installing the master brake cylinder - RHD vehicles......................................................589
Check brake servo unit...........................................................................................................................592
Removing and installing the brake servo unit - LHD vehicles...............................................................592
Removing and installing the brake servo unit - RHD vehicles...............................................................596
Removing and installing the vacuum pump for the brake servo unit.....................................................599
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITH
ABS/EDL/TCS/ESP MARK 60...................................................................................................................599
Removing and installing brake pressure sender -1--G201-...................................................................602
Removing and installing master brake cylinder.....................................................................................602
Check brake servo unit...........................................................................................................................602
Removing and installing brake servo unit..............................................................................................602
Removing and installing brake vacuum pump -V192-...........................................................................602
Testing brake vacuum pump -V192-.......................................................................................................603
STEERING...................................................................................................................................................604
STEERING COLUMN AND STEERING WHEEL WITH AIRBAG..........................................................................604
Check the steering column for damage..................................................................................................604
Removing and installing steering column..............................................................................................605
Removing and installing the ignition lock housing with the steering column mounted.........................618
SUMMARY OF COMPONENTS OF POWER-STEERING GEAR - LHD VEHICLES................................................621
Removing and installing hydraulic oil reservoir....................................................................................624
REMOVING AND INSTALLING THE POWER-STEERING GEAR - LHD VEHICLES.............................................626
Repairing power-steering gear (ZF)......................................................................................................634
Modified track rod ends..........................................................................................................................641
Modified track rods................................................................................................................................642
Disposing of the power-steering gear....................................................................................................643
Adjusting the power-steering gear (ZF).................................................................................................644
Check the hydraulic oil level of the power-assisted steering, top up if necessary.................................645
Draining, filling and bleeding the power-assisted steering system........................................................647
Checking the power steering system for leaks........................................................................................649
Power steering noises.............................................................................................................................651
SUMMARY OF COMPONENTS OF POWER-STEERING GEAR - RHD VEHICLES...............................................652
Removing and installing hydraulic oil reservoir....................................................................................656
Removing and installing the power-assisted steering gear - RHD vehicles...........................................658
Repairing power-steering gear (ZF) - RHD vehicles.............................................................................665
SUMMARY OF COMPONENTS: VANE PUMP FOR POWER-ASSISTED STEERING..............................................668
Summary of components for the vane pump located at the top and bottom...........................................668
PAS pressure switch................................................................................................................................671
Check the feed pressure of the vane pump..............................................................................................673
8

REMOVING AND INSTALLING VANE PUMP...................................................................................................680


Vehicles with vane pump located at the top............................................................................................681
Vehicles with vane pump located at the bottom......................................................................................686
Disposing of the vane pump...................................................................................................................691

Running gear
Chassis
Technical data
Chassis - Specified values

Nominal values front axle

Chassis

Overall track -adjustableCamber4)

Max. difference of the caster angles between left and


right side

Spring strut type axle (front- and four-wheel drive)


Standard chassis Sport chassis
Rough road
1)
1)2)
suspension 3)
G06 G20 1GA
G35
G04
1GB
G12 G30 1GG
G85
G07
1GW
G13 G31 1GE
G34
G14 G32 1GH
G39
G15 G33
G40
0 10'
0 10'
0 10'
- 30' 30'
- 0 25' 30' 5)7)
- 0 28' 30' 1)
30'

- 33' 30'
30'

- 16' 30'
30'

1 30' 20'

1 31' 20'

1 27' 20'

6 35'

6 40'

6 35'

40

39 45'

40 45'

Toe difference angle on turns of 20 of inside wheel


-not adjustableToe difference angle on turns at full lock of inside
wheel -not adjustableMax. wheel lock angle -not adjustableCaster angle -not adjustable-

Max. difference between left and right side

7 40' 30' 8) 7 50' 30' 8)


7 40' +30', -60' 7 50' +30',
9)
-60' 9)
8 23' 30' 5)
6)7)
8 30'
30'
30'

7 15' 30' 8)
7 15' +30', -60' 9)
30'

Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
Not valid for Octavia 4x4
2)
Values are also valid for Octavia RS vehicles
9

3)

Values are also valid for Octavia 4x4 vehicles


It is possible to adjust the camber by shifting the assembly carrier. Note: The screws and washers of the
assembly carrier must always be replaced! After carrying out corrections of steering geometry, inspect
position of steering wheel and alter to correct position, if necessary.
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
6)
Only Service Mobil (Octavia Combi 1.9 ltr./81 kW SLX)
7)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX)
8)
up to MY 2000
9)
as of MY 2001
Specified values rear axle - front-wheel drive
Twist-beam rear axle
Standard suspension
Sport chassis 1)
Rough road suspension
Chassis

PR Nos. are not displayed on the vehicle data sticker. The allocation of the
adjusting values to the relevant running gear occurs via the PR No. of the front axle
damping.
Overall track -not
20' 10'
30' 10'
15' 10'
2)
4)
adjustable30' 15'
25' 15' 5)
6)
Camber -not adjustable- 1 36' 20'
- 1 36' 20' 6)
- 1 27' 20' 7)
- 1 27' 20' 7)
- 1 27' 20'
4)

Max. difference
between left and right
side
Max. misalignment of
the rear axle3)

- 1 43' 20' 4)
- 1 35' 20' 5)
30'

30'

30'

20'

20'

20'

Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
Values are also valid for Octavia RS vehicles
2)
The mean of the individual track values can be taken by moving the mounting brackets
3)
The mean value of the misalignment can be taken by moving the rear axle body
4)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX, Octavia Combi 1.9 ltr./81 kW SLX)
6)
up to 11.96
7)
as of 12.96
Specified values rear axle - four-wheel drive
Twist-beam rear axle

Rough road suspension


Chassis

PR Nos. are not displayed on the vehicle data sticker. The allocation of the
adjusting values to the relevant running gear occurs via the PR No. of the front
axle damping.
Overall track -not
15' 10'
adjustable-1)
Camber -not adjustable-30' 20'
10

Max. difference between


left and right side
Max. misalignment of the
rear axle2)

30'

20'

Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
The mean of the individual track values of the rear axle can be taken by moving the mounting brackets
2)
The running direction of the rear axle can be corrected by moving the mounting brackets
Nominal values rear axle
Chassis denominations with PR numbers
Different chassis are offered as additional equipment. These chassis are identified by PR numbers.
The type of chassis is identified by a chassis PR number on the vehicle data sticker.
The vehicle data sticker is located at the rear left on the luggage compartment floor and in the Service
Schedule.

Example of a vehicle data sticker


In this example the vehicle is fitted with a
standard damping running gear 1GA -arrow-.

11

Steering

Model
Type of steering
Steering gear
Steering-wheel turns from stop to stop
Steering wheel diameter (mm)
Overall ratio of the steering
Lubricant for gear racks

Filling weight (g)


Maximum clearance between pressure plate and cover (mm):
Perm. axial force for the displacement of the gear rack (N)
Rotating force of the track rods from the rest position (N)
Denomination of the hydraulic oil

Hydraulic oil amount in the system (I)

12

All
Rack and pinion type steering system
Power-steering gear
3,04
370
15,60
Fluid grease for steering gear
TL 733
N 052 733 00
Part No.: AOF 063 000 04
(e.g. DEA ORNA F6 EPO)
23 to 27
0,05 to 0,1
250
1 to 3,5
Hydraulic oil
TL 52 146
N 052 146 00
Part No.: G 002 000
(e.g. PENTOSIN CHF 11S)
0,7 ... 0.9 Itr.

Brakes
Brake variants and their assignment

Engine
S = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
Brake servo unit -

t
Front disc brake:
Front brake caliper
Front brake caliper, piston -
Front brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without
supporting plate
t
Rear disc brake:
Rear brake caliper, piston -
Rear brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without
supporting plate
t
Drum brake
Brake drum -
Brake drum - maximum diameter
Wheel-brake cylinder 1) -
Wheel-brake cylinder 2) -
Brake pad, width
Pad thickness without supporting shoe
Minimum thickness without
supporting shoe

litre/k
W

1,4/44; 1,4/55
S

1,6/55

1,6/74; 1,6/75
-

1.9/50
SDI

mm
23,81
Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''tandem

8,5
8,5

FS-III 3)
54,0
256,0
22,0
19,0
19,5
2,0

mm
mm
mm
mm
mm
mm

mm
mm
mm
mm
mm
mm

mm
mm
mm
mm
mm
mm
mm

20,64
20,64

41,0
239,0
9,0
7,0
17,0
2,0

230,0
231,0
20,64 20,64
20,64 20,64
32,0
5,5
2,5

19,05 19,05 4)
20,64 20,64

1)

Vehicles without ABS


Vehicles with ABS
3)
Not valid for Taxi vehicles (identification F4E)
4)
For Octavia Combi: 20.64
2)

Engine

litre/k
W

1,8/132

S = Manual gearbox
A = Automatic gearbox

S
13

1,9/74
-

1,9/96
-

Master brake cylinder -


Brake servo unit -

t
Front disc brake:
Front brake caliper
Front brake caliper, piston -
Front brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without supporting
plate
t
Rear disc brake:
Rear brake caliper, piston -
Rear brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without supporting
plate
t
Drum brake
Brake drum -
Brake drum - maximum diameter
Wheel-brake cylinder 1) -
Wheel-brake cylinder 2) -
Lining thickness
Pad thickness without supporting shoe
Minimum thickness without supporting
shoe
1)
2)

mm
23,81
Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''tandem
FS-III 3)
54,0
256,0
22,0
19,0
19,5
2,0

mm
mm
mm
mm
mm
mm

mm
mm
mm
mm
mm
mm

41,0
239,0
9,0
7,0
17,0
2,0

mm
mm
mm
mm
mm
mm
mm

Vehicles without ABS


Vehicles with ABS

Engine
S = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
Brake servo unit -

t
Front disc brake:
Front brake caliper
Front brake caliper, piston -
Front brake disc -
Brake disc, thickness

litre/k
W

1.9/66 TDI
S

1.9/81 TDI 1,8/92; 2,0/85 (82)


S

1,8/110
S A

mm
23,81
Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''tandem
FS-III 3)5)
54,0
280,0
22,0

mm
mm
mm
14

FN 3 4)
54,0
288,0
25,0

Brake disc, minimum thickness


Pad thickness with supporting plate
Minimum thickness without supporting
plate
t
Rear disc brake:
Rear brake caliper, piston -

mm
mm
mm

Rear brake disc -

mm

Brake disc, thickness


Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without supporting
plate
t
Drum brake
Brake drum -
Brake drum - maximum diameter
Wheel-brake cylinder 1) -
Wheel-brake cylinder 2) -
Brake pad, width
Pad thickness without supporting shoe
Minimum thickness without supporting
shoe

mm
mm
mm
mm

19,0
19,5
2,0

38,0 8)
41,0 9)

mm

mm
mm
mm
mm
mm
mm
mm

23,0
19,5
2,0

232,0 6)
239,0 7)

232,0
239,0 7)
9,0
7,0
17,0
2,0

230,0
231,0
20,64
20,64 20,64
32,0
5,5
2,5

1)

Vehicles without ABS


Vehicles with ABS
3)
Not valid for Taxi vehicles (identification F4E)
4)
For Taxi vehicles (F4E) also 1.9/66; 2.0/85; 1.9/81
5)
For Taxi vehicles (F4E) also 1.4/44; 1.4/55; 1.6/55; 1.6/74; 1.6/75; 1.9/50
6)
Vehicles with ESP
7)
vehicles with four-wheel drive
8)
up to 07.98
9)
as of 08.98
2)

15

Brake fluid

Classification
Capacity of brake fluid

Change brake fluid

N 052 766 ZO (USA standard FMVSS 571.116 DOT 4)


VW 501 14
l 0.49 Vehicles with rear drum brakes, without ABS
0.53 Vehicles with rear drum brakes, with ABS
0.57 Vehicles with rear disc brakes, with ABS
every 2 years

Wheels, Tyres

Wheel rims:
t
Bolt hole circle diameter: 100 mm
t
Centre hole diameter: 57 mm
t
5-hole fixing
t Tyre inflation pressures BookletOctavia I as well as sticker on the fuel-tank cap
Note

t
t
t
t
t
t
t
t
t

Only tyres of the same size and type may be fitted to the vehicle, however the same brand and tread
pattern must always be fitted to wheels on the same axle. It is exceptionally allowed to use a different
tyre temporarily in the event of breakdown. Take into account a change in driving and braking behaviour.
Use wheel bolts with spherical collar and a thread of M14 x 1.5 - tightening torque: 120 Nm.
Only use authorised rims on the relevant vehicle.
When replacing rims always use wheel bolts that belong to these rims (different length and spherical cap
shape).
Also observe the national legislation.
If winter tyres are used with a lower speed rating than the maximum permissible driving speed, it has to
be pointed out with a sticker providing an additional note which must be fixed in the field of vision of
the driver.
The information given on the sticker determines the maximum permissible driving speed for the winter
tyres fitted, which must not be exceeded during the operation of the vehicle.
The note on the sticker can be replaced with the system installed in the vehicle for life (for example the
onboard computer) Operating instructions.
On vehicles with the tyre pressure inspection system, it must be adapted again after changing one or
several wheels Operating instructions.
Caution

Tyres that are more than 6 years old must only be used in case of emergency and while driving very
carefully.
Engine

1.4 ltr./44kW
1.4 ltr./55kW
1.6 ltr./55 kW
1.9 ltr./50 kW

Wheel size 1)

Light-alloy rim Steel rim Offset (mm) Snow chains permitted


yes
no
175/80 R14 88 T, H
6J x 14 H2
38
X
195/65 R15 91 T, H, V
6J x 15 H2 6J x 15 H2
38
X
43
X
205/60 R15 91 H
6.5J x 15 H2
205/55 R16 91 H

6.5J x 16 H2
16

42

1.6ltr./74 kW
1.6 ltr./75 kW

2.0 ltr./85 kW

1,8 Itr./92 kW

1.8 ltr./110 kW

1.8 ltr./132 kW

1.9 ltr./66 kW TDI

1.9 Itr./74 kW PDi

1.9 ltr./81 kW TDI

1.9 Itr./96 kW PDi

1)
2)

205/55 R16 91 W
175/80 R14 88 H
195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
195/65 R15 91 H, V
205/60 R15 91 H, V
205/55 R16 91 H, V, W
205/55 R16 91 W
195/65 R15 91 V
205/55 R16 91 V, W
205/60 R15 91 V
205/55 R16 91 W
205/55 R16 91 W
205/55 R16 91 W
205/50R17 89W2)
195/65 R15 91 T, H, V
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
195/65 R15 91 V
205/60 R15 91 V
205/55 R16 91 V
205/55 R16 91 W
195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H, V, W
205/55 R16 91 W
195/65 R15 91 V
205/60 R15 91 V
205/55 R16 91 V, W
205/55 R16 91 W

5,5J x 16 H2
6J x 15 H2
6.5J x 15 H2
6.5J x 16 H2
5,5J x 16 H2
6J x 15 H2
6.5J x 15 H2
6.5J x 16 H2
5,5J x 16 H2
6J x15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 16H2
6.5J x 15H2
5,5J x 16H2
6.5J x 16H2
5,5J x 16H2
7J x 17 H2
6J x15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2

6J x 14 H2
6J x 15 H2
6J x 15 H2
6Jx15 H2
6Jx15 H2
6.5Jx16H2
6Jx15 H2
6Jx15 H2
6Jx15 H2
6Jx15 H2
-

36
38
38
43
42
36
38
43
42
36
38
43
42
36
38
42
43
36
42
36
38
38
43
42
36
38
43
42
36
38
43
42
36
38
43
42
36

Tyre inflation pressures BookletOctavia


Not valid for Octavia Combi RS

Load rating-indexes (Load index):

88 = 560 kg 91 = 615 kg
89 = 580 kg
T =190km/h H = 210km/h
V = 240 km/h W = 270 km/h

Speed symbols:

17

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-

Tyre legend
Marking e.g. 175/80 R14 88 T
175/80
R
14
88
T
Production date
DOT...394
DOT...0300

Meaning
Tyre width (mm) section ratio between height - width (%)
Tyre type (radial)
Rim diameter (inch)
Load rating-index
Speed symbol
Manufactured during week 39 of 1994
( = denomination of the decade 1990...1999)
Manufactured during week 3 of 2000
+ 03 = 3rd calendar week, 00 = year 2000)

18

Front suspension, drive shafts


Repairing front wheel suspension

I - Removing and installing assembly carrier, anti-roll bar, track control arm Chapter
II - Removing and installing wheel bearing, suspension strut, drive shaft, brake Chapter

l - Summary of components assembly carrier, anti-roll bar, track control arm

Note
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing and wheel control components of the
t
wheel suspension.
t
Self-locking nuts must always be replaced.
t Always replace corroded self-locking nuts and screws.
t

19

1t
t
23t
t
4t
5t
t
t
t
6t
7t
89-

track control arm


removing and installing Chapter
Oblong holes are not intended for camber adjustment!
15 Nm + 90
Coupling rod
coupling rods of the same version must be present on one axle
Assignment Electronic Catalogue of Original Parts
15 Nm + 90
replace after each removal
Coupling rod
only for anti-roll bars with a diameter of 23 mm
replace with steel version
coupling rods of the same version must be present on one axle
Assignment Electronic Catalogue of Original Parts
Front bearing for track control arm
pressing in and pressing out Chapter
70 Nm + 90
replace after each removal
Pendulum support
40 Nm + 90
20

t
replace after each removal
10 40 Nm + 90
t
replace after each removal
11 20 Nm + 90
t
replace after each removal
12 Assembly carrier
t
removing and installing Chapter
t The repair of the thread for the screwed connection of the front track control arm is not permissible!
13 Self-locking nut
t
replace after each removal
t
M10 - 15 Nm + 90
t
M12 - 90 Nm
14 Anti-roll bar
t
to remove and install lower assembly carrier
15 Rubber bearing
16 25 Nm
17 Clamp
18 Coupling rod
t mount the spherical head with the long joint stub -A- (top) to the spring cap
t mount the spherical head with the short joint stub -B- (bottom) to the anti-roll bar
t Assignment Electronic Catalogue of Original Parts
19 Nut, 90 Nm
t
replace after each removal
20 Rubber-metal bearing
t
pressing in and pressing out Chapter
21 Self-locking nut
t
replace after each removal
22 100 Nm + 90
t
replace after each removal
23 Rear bearing for track control arm
t
Fitting position Anchor
t
pressing in and pressing out Anchor
24 100 Nm + 90
t
replace after each removal
25 70 Nm + 90
t
replace after each removal
26 Lock washer
t
replace after each removal
27 20 Nm + 90
t
replace after each removal
28 Steering joint
t
check Chapter
t Inspect rubber bellows for damage, if necessary replace
t removing and installing only in combination with the wheel bearing housing Chapter
mark fitting position before removal, set in the middle of the oblong hole when replacing the track control
t
arm and check track
29 20 Nm + 90
t
replace after each removal

21

Removing and installing the track control arm

Special tools and workshop equipment required


t
Extractor -MP 6-425t
Supporting device -MP 9-200t
Torque wrench, e.g. -V.A.G 1756Removing
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

Raise the vehicle until the front axle is free of stress.

Slacken twelve-point nut.

Raise vehicle and remove wheel.

Release twelve-point nut.


Removing noise insulation Engine - Mechanics; Rep. gr.10
Only for vehicles with automatic gearbox:

Insert supporting device -MP 9-200- and


support engine/gearbox in this position.
For all vehicles:
Note

Mark installation position of bolts -1-, otherwise


the steering geometry must be checked.

Release screws -1-.

22

Push out the drive shaft. To do so position the


tool as shown in the fig.
Note

While pushing out the drive shaft make sure there


is sufficient clearance.

Unscrew screws -3-, if present, at the track


control arm.
Screw out screws -1- and -2-.
Remove the track control arm.
Only for vehicles with autom. gearbox
Release screws -4- for pendulum support.
Unscrew screws -5- and -6- for assembly

carrier.
Note

Release the screw -1- downwards by slightly


pressing the assembly carrier and take out the
wheel-bearing housing.
Install
(Valid for vehicles with manual and automatic
gearbox).
Remove possible corrosion in the thread/serration
of the outer joint.
Insert track control arm and secure.
Secure assembly carrier.
Moisten the serration of the wheel hub with oil.
Insert outer joint as far as possible into the

serration of the wheel hub.


Screw the steering joint and track control arm

with the new screws in the former positions.


Screw the pendulum support to the gearbox.
If necessary, screw the coupling rod with the

track control arm or with the suspension strut.


Moisten the contact surface of the twelve-point
nut as well as the serration and the thread of the
outer joint with oil and screw on new twelvepoint nut as far as possible.
Insert the outer joint into the wheel hub until

the outer joint rests in the wheel bearing.


Install noise insulation Engine,

Mechanics; Rep. gr.10.


23

Attach the wheel.


Lower vehicle, when doing so, ensure that the

wheels do not yet touch the ground.


Use new screws!
If the wheel bearings are loaded through the
vehicle's own weight, the wheel bearing will be
initially damaged. This shortens the life of the
wheel bearing.
Depress brake pedal (assistance of second

mechanic required).
Tighten new twelve-point nut to 225 Nm and

release by 1/2 a turn.


Torque wheel hub a further min. 90.
Tighten twelve-point nut:
Tightening torque:
50 Nm + 60.
Note

The torque wrench is recommended e.g. for


tightening the twelve-point nut -V.A.G 1756-.

Tightening torques:
Assembly carrier to body
t
Use new screws!
Steering joint to track control arm
t Use new screws and new lock washer!
Pendulum support to gearbox
t
Use new screws!
Coupling rod to track control arm
t
Use new screws!

100 Nm + 90
20 Nm + 90
40 Nm + 90
15 Nm + 90

Pressing out and in the bearing for the track control arm

Special tools and workshop equipment required


t
Pressure plate -MP 3-406t
Pressure plate -MP 3-407t
Pipe section -MP 3-41424

t
t
t
t
t
t
t
t
t

Pipe section -MP 3-429Pressure washer -MP 3-456Assembly device -MP 5-402Assembly device -MP 6-401Pressure spindle -MP 6-405Base -MP 6-407Pressure pipe -MP 6-408Workshop press, e.g. -V.A.G 1290 Aacid-free lubricant, e.g. -G 294 421-

Press off front bearing for track control arm

Press in front bearing for track control arm


Insert bearing into pipe section -MP 3-414-.
Note
Use acid-free lubricant, e.g. -G 294 421-, when
pressing in the bearing. Under no circumstances
use grease or detergent.

25

Fitting position of rear bearing for track control


arm
One of the embossed arrows points to the
impression in the track control arm, the kidneyshaped recess (-arrow A-) in the bearing points to
the centre of the vehicle.

Pressing out and in the rear bearing for the track


control arm
Pay attention to the fitting position when pressing
in Anchor.

Removing and installing assembly carrier

Special tools and workshop equipment required


t
Extractor -MP 6-425t Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2Removing
Remove wheel trim caps of the front wheels, for light-alloy wheels remove the caps (pull-off hook in

tool kit).

Raise the vehicle until the front axle is free of stress.

Slacken left and right twelve-point nut.


26

Raise vehicle and remove wheel.


Unscrew left and right twelve-point nut.
Remove noise insulation Engine - Mechanics; Rep. gr.10.
Note

Mark installation position of bolts -1-, otherwise the steering geometry must be checked.

Release screws -1-.

Press out left and right drive shaft. To do so


position the tool as shown in the fig.
Note

While pushing out the drive shaft make sure there


is sufficient clearance.
Separate left and right track control arm from

steering joint.
Swivel out the wheel-bearing housing with the

steering joint and support.

Release screws -1- and -2- and remove


pendulum support.
Release screws for power-steering gear -5-.
Unscrew nut -7- for coupling rod from anti-roll
bar.
Unscrew screws -6- for exhaust system.
Position the gearbox jack with adapter, e.g.
-V.A.G 1383/A- with -V.A.G. 1359/2-, under
the assembly carrier.
Unscrew screws -3- and -4- for assembly
carrier.
Lower assembly carrier with gearbox jack.
Note

27

Ensure that the steering gear loosens from the


assembly carrier.
Support steering gear, if necessary clamp with

tensioning strap to the top.


Install
Before inserting the screws for the assembly
carrier, position the steering gear on the assembly
carrier and insert the screws for the steering gear.

The threaded bush -1- must fit in the hole of the


assembly carrier.
Further installation occurs in reverse order.
Tightening torques Chapter.
Once the steering gear has been installed it is then
important to check the position of the steering
wheel during a test drive.
If the vehicle drifts, a chassis alignment must be
performed.

Pressing out and in rubber-metal bearing

Special tools and workshop equipment required


t
Pressure plate -MP 3-407t
Pressure spindle -MP 3-448t
Counterholder -MP 6-410t
Extractor -MP 6-425t
Assembly device -MP 6-430t
Workshop press, e.g. -V.A.G. 1290At Gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G 1359/2t
acid-free lubricant, e.g. -G 294 421 A1-.
Pressing out and in the rubber-metal bearings is only possible after removing the assembly carrier.
Removing and installing assembly carrier Chapter.

28

Pressing out the rubber-metal bearing

Pressing in rubber-metal bearing


Note
Coat rubber-metal bearing and assembly carrier
with acid-free lubricant before pressing them in,
e.g. -G 294 421 A1-. Under no circumstances use
grease or detergent.

II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake

Note
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing and wheel control components of the front
t
wheel suspension.
t
Always replace self-locking nuts.
t Always replace corroded self-locking nuts and screws.
t

29

1Self-locking nut, 60 Nm
t
replace after each removal
2Stop
3Suspension strut
t
removing and installing Chapter
t
repairing Chapter
t Assignment Electronic Catalogue of Original Parts
4Drive shaft with inner CV joint
t
removing and installing Chapter
t
repairing Chapter
5Shim
6Fillister head screw with internal serrations
t
replace after each removal
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 180
M10 = 50 Nm + 45
t Assignment Electronic Catalogue of Original Parts
7Drive shaft with inner tripod joint
t
removing and installing Chapter
t
repairing Chapter
30

8Fillister head screw with internal serrations


t
replace after each removal
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 90
M10 = 50 Nm + 45
t Assignment Electronic Catalogue of Original Parts
9Brake disc (FS-III)
t
without marking for axial run-out
t
with a fixing hole for the wheel hub
t Assignment Electronic Catalogue of Original Parts
10 Wheel screw, 120 Nm
11 Self-locking twelve-point nut
t
slacken and tighten Chapter
t
replace after each removal
12 4 Nm
13 Brake discs (FS-III)
t
removing and installing Chapter
14 Brake caliper (FS-III)
Including for vehicles with engine up to 92 kW.
t do not release brake hose when working on the front wheel suspension
t
tie up with wire or anything similar
t
repairing Chapter
15 Guide bolt (FS-III), 30 Nm
t
removing and installing Chapter
16 Cap (FS-III)
17 Brake disc (FN 3)
t
with marking for maximum axial run-out
t
with 5 fixing holes for the wheel hub
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
18 Wheel hub with pulse rotor for wheel speed sensor
t
with marking for minimum axial run-out
t
only on vehicles with ABS
t
pressing out Chapter
t
installing Chapter
t
Pull off the inner ring of the bearing Chapter
t
Check axial run-out of pulse rotor Chapter
t Assignment Electronic Catalogue of Original Parts
19 Brake discs (FN-3)
t
removing and installing Chapter
20 Retaining spring (FN-3)
21 Brake carrier (FN-3)
22 Brake caliper (FN-3)
Including for vehicles with engine as of 96 kW.
t do not release brake hose when working on the front wheel suspension
t
tie up with wire or anything similar
t
Removing and installing brake pads Chapter
t
repairing Chapter
23 Guide bolt (FN-3), 30 Nm
t
removing and installing Chapter
31

24 Cap (FN-3)
25 Screw with securing collar (FN-3), 124 Nm
t
Clean ribbing on the underside
26 Wheel-bearing housing
Including for vehicles with engine as of 96 kW.
t
removing and installing Chapter
t
repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing
t
evenly with -G 052 723 A227 Cover plate
28 Self-locking nut, 50 Nm
t
replace after each removal
29 Steering joint
t
check Chapter
t Inspect rubber bellows for damage, if necessary replace
t
removing and installing Chapter
30 Wheel-bearing housing
Including for vehicles with engine up to 92 kW.
t
removing and installing Chapter
t
repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing
t
evenly with -G 052 723 A231 Self-locking nut, 20 Nm + 90
t
replace after each removal
32 Screw
t
replace after each removal
33 8 Nm
34 ABS wheel speed sensor
t
only on vehicles with ABS
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
35 Self-locking nut
t
up to 05.98: 50 Nm + 90
t
as of 06.98: 60 Nm + 90
t
replace after each removal
36 Track rod with track rod end
t
removing and installing Chapter
37 10 Nm
38 Wheel bearing
t
press out Chapter
t
replace, is damaged when pressing out
t
installing Chapter
The spare part is only delivered as a set wheel bearing with mounting parts (Pos. 11, 39, 38, 28, 31 and
t
35)
39 Circlip
t
pay attention to correct position Chapter
t
replace after each removal
40 Wheel hub without pulse rotor
t
only on vehicles without ABS
t Assignment Electronic Catalogue of Original Parts
41 Wheel hub with pulse rotor for wheel speed sensor
32

t
t
t
t
t
t
t

without marking for minimum axial run-out


only on vehicles with ABS
press out Chapter
installing Chapter
Pull off the inner ring of the bearing Chapter
Check axial run-out of pulse rotor Chapter
Assignment Electronic Catalogue of Original Parts

Repairing wheel bearing housing

Special tools and workshop equipment required


t
Pressure plate -MP 3-406t
Pressure plate -MP 3-407t
Pressure spindle -MP 3-408t
Pipe section -MP 3-4012t
Pipe section -MP 3-450t
Thrust plate -MP 3-467t
Ring spanner SW 46 -MP 6-413t
Assembly device -MP 6-414/1t
Washer -MP 6-415t
Washer -MP 6-416t
Thrust piece -MP 6-418t
Pipe -MP 6-419t
Pressure pipe -MP 6-420t
Extractor -MP 6-425t
Socket wrench insert SW 21 -MP 6-427t
Spreader -VAS 3424t
Puller Kukko -V 176t
Workshop press, e.g. -V.A.G 1290 At
Torque wrench, e.g. -V.A.G 1756t
Cross member Kukko 18-0
t
Grease -G 052 723 A2- (molykote grease)
It is only possible to repair the wheel-bearing housing, by pressing out and in the wheel hub and the wheel
bearing, after removing the suspension strut and the wheel-bearing housing.
Remove and install suspension strut and wheel bearing housing Chapter.

33

Press the wheel hub out of the wheel bearing

Removing and installing circlip


Remove or replace circlip with commercially

available circlip pliers.


Note
t

Replace.
When inserting, pay attention to the correct
t
position of the circlip.

Press the wheel bearing out of the wheel bearing


housing

34

Pull the inner ring of the bearing off the wheel


hub
Insert washer -MP 6-416- as shown.
Screw cross member Kukko 18-0 into washer

-MP 6-416-.
Position thrust plate -MP 3-467- onto wheel
hub and pull off the inner ring of the bearing by
turning the threaded spindle.

Press the wheel bearing into the wheel bearing


housing
-A- Wheel bearing
Before pressing in the wheel bearing, coat the
entire wheel bearing seat in the wheel bearing
housing evenly with -G 052 723 A2-.
Note
After pressing in the wheel bearing, the circlip
must be inserted Anchor.

Press the wheel hub into the wheel bearing


Note
When pressing in the wheel hub, ensure that the
t washer -MP 6-415- rests against the inner ring
of the bearing.
For wheel bearing housing and wheel hub on
vehicles including with engine as of 110 kW
t (brake FN-3) observe the assignment of the
wheel hub electronic catalogue of original
parts.
Wheel hubs with a 3 mm wide ink-jet marking
for marking the minimum axial run-out can also
be combined with brake discs without marking
t
of the maximum axial run-out. Then the
reduction of the overall axial run-out of the
brake FN 3 is not effective.

Inspecting the steering joint


35

Inspecting axial play

Pull the track control arm down with force and


push up again.
Inspecting radial play

Forcefully push the wheel


at the bottom towards the
inside and the outside.
Note
For these two tests no
t play may be felt or be
visible.
Observe the steering
t
joint during the tests.
Take into account
possible wheel bearing
t play or play in top
suspension strut
bearing.
Inspect rubber bellows
t for damage, if
necessary replace.

Removing and installing the steering joint

Special tools and workshop equipment required


t
Socket wrench insert SW 19 -MP 6-423t
Extractor -MP 6-425t
Socket wrench insert SW 21 -MP 6-427t
Spreader -VAS 3424t
Extractor Matra -V176Removing
It is only possible to remove the steering joint after removing the suspension strut and the wheel bearing
36

housing.
Remove and install suspension strut and wheel bearing housing Chapter.

Position the special tools as shown in the fig.


and slacken the hexagon nut.
-A- Torx screw -T 30

Place the extractor as shown in the fig. and


push out the steering joint.
Install
Installation is carried out in the reverse order.
Note

Replace hexagon collar nut.

Tightening torques:
Steering joint to wheel-bearing housing

20 Nm + 90

Remove and install suspension strut and wheel bearing housing

Special tools and workshop equipment required


t
Extractor -MP 6-425t
Socket wrench insert SW 21 -MP 6-427t
Spreader -VAS 3424t
Torque wrench, e.g. -V.A.G 1756t
Extractor Matra -V176Removing
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

Raise the vehicle until the front axle is free of stress.

Slacken twelve-point nut.

Remove wheel and raise vehicle.


37

Note
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.

Release screws -1-.

Push out the drive shaft. To do so position the


tool as shown in the fig.
Note

While pushing out the drive shaft make sure there


is sufficient clearance.

Press the track rod off the steering arm using


the extractor Matra -V176- (commercially
available).
Disconnect the plug -1- of the ABS wheel

speed sensor.
Remove the ABS wheel speed sensor cable

from the ties -arrows-.

38

Remove caps -2- and unscrew brake caliper.


Secure brake carrier with wire to body.
Remove the brake disc (the brake disc is

secured with a screw to the wheel hub).


If necessary, unscrew the coupling rod from the

suspension strut.

Unscrew the suspension strut on the body with


socket wrench insert -MP 6-427-.
Take out the suspension strut with the wheel

bearing housing.

Separate the suspension strut from the wheel


bearing housing
Insert the spreader -VAS 3424- as shown and

spread open the wheel bearing housing.


Remove the suspension strut.
Install
- Remove possible corrosion in the
thread/serration of the outer joint.
Insert the suspension strut with the wheel
bearing housing and secure it to the suspension
strut dome.
If necessary, secure the coupling rod to the

suspension strut.
Moisten the serration of the wheel hub with oil.
Insert outer joint as far as possible into the

serration of the wheel hub.


Screw the steering joint and track control arm

with the new screws in the former positions.


Secure the brake caliper housing to the wheel

bearing housing.
39

Note
Tighten the FN-3 brakes at the wheel bearing
housing to 124 Nm.
Insert the cable of the ABS wheel speed sensor

into the brackets.


Mount the plug of the ABS wheel speed sensor.
- Moisten the contact surface of the twelve-point
nut as well as the serration and the thread of the
outer joint with oil and screw on new twelvepoint nut as far as possible.
Insert the outer joint into the wheel hub until

the outer joint rests in the wheel bearing.

Attach the wheel.


Lower vehicle, when doing so, ensure that the

wheels do not yet touch the ground.


If the wheel bearings are loaded through the
vehicle's own weight, the wheel bearing will be
initially damaged. This shortens the life of the
wheel bearing.
Depress brake pedal (assistance of second

mechanic required).
Tighten new twelve-point nut to 225 Nm and

release by 1/2 a turn.


Torque wheel hub a further min. 90.
Tighten twelve-point nut:
Tightening torque:
50 Nm + 60
Note

A torque wrench is recommended for tightening


the twelve-point nut -V.A.G 1756-.

Tightening torques:
Suspension strut to suspension strut dome
Coupling rod to suspension strut
t
Use new nuts!
Steering joint to track control arm

60 Nm
90 Nm
20 Nm + 90
40

t
Use new nuts!
Brake caliper housing to wheel bearing housing
t Use new screws and new lock washer!

30 Nm

Repairing the suspension strut

Special tools and workshop equipment required


t
Socket wrench insert SW 21 -MP 6-427t Spring tensioning device, e.g. -S 505 501 V- or -V.A.G 1752/1t
Suspension strut support, e.g. -V.A.G 1752/2t Spring holder with protective lining, e.g. -V.A.G 1752/4-

1Shock absorber with spring cap


t
must be replaced completely
t Assignment Electronic Catalogue of Original Parts
t
can be replaced individually
t
Inspecting the shock absorber Chapter
t
disposing of Chapter
2Stop buffer
3Boot
4Coil spring
t
removing Fig.
t
installing Fig.
t Assignment Electronic Catalogue of Original Parts
41

t
check colour coding
t The surface of the spring coil must not be damaged
t
replace on both sides of the axle
t
per axle only use coil springs of the same make
5Spring cap
6Bush
Only present on vehicles with rough road suspension (PR No. 1GB). This PR No. can be found on the
t
vehicle data sticker in the luggage compartment or in the Service Schedule Chapter
7Axial grooved ball bearing
8Suspension strut bearing
9Collar nut, 60 Nm
t
replace after each removal
t
loosen and tighten
10 Spring cap
11 Collar nut, self-locking, 60 Nm
t
replace after each removal Fig.

Removing the coil spring


Clamp the suspension strut support, e.g. -V.A.G

1752/2-, in the vice.


Clamp the suspension strut to the shock

absorber pipe in the suspension strut support.


Preload the coil spring with spring tensioning
device, e.g. -V.A.G 1752/1-, until the top spring
cap is released.

Removing the coil spring


Pay attention to the correct seating of the coil
spring in the adapter, e.g. -V.A.G 1752/4-arrow-.

42

Removing the coil spring


Unscrew the collar nut from the piston rod
using the socket wrench insert -MP 6-427-, to
do so counterhold with Allen key.
Remove individual parts of the suspension strut
and the preloaded coil spring using the spring
tensioning device, e.g. -V.A.G 1752/1-.

Installing the coil spring


Position the preloaded coil spring with spring
tensioning device, e.g. -V.A.G 1752/1-, on the
bottom spring washer, to do so the spring coil
end must lie against the stop -arrow-.

Inspecting the shock absorber

43

Leaks on the shock absorbers


Minor oil leakage (sweating) on the piston rod
seal does not entail the replacement of the shock
absorber.
If an oil leak is visible (but blunt, dull, possibly
dried by dust) and does not propagate any further
than from the top shock-absorber plug (piston rod
seal) to the bottom spring cap -arrow-, the shock
absorber is deemed to be O.K.
Note
A slight oil leak is beneficial as the gasket is
lubricated and this increases the life time. This
applies for shock absorbers on the front as well as
the rear axle.
Noises on the shock absorbers
Attention must be drawn to the fact that in the
event of complaints about noise, the shock
absorbers are very often regarded as being the
source of noise.
Note
In the event of complaints about noises
interpreted as knocking or cracking noises,
always first perform a test drive with the
customer to determine where, when and how
these noises occur (preferably on a bumpy dry
road).
Inspect shock absorber without gas pressure
Defective shock absorbers become noticeable
while driving because of the knocking noises caused by wheel hopping - more specifically on
poor road and they must be replaced. The failure
is mainly caused by the loss of oil. The shock
absorber then compresses and/or expands in jolts.
It has an "idle travel" before taking effect.
Note
Shock absorbers are maintenance-free. It is not
possible to top up the shock absorber oil.
Inspect shock absorber with gas pressure
Defective shock absorbers with gas pressure are
also noticeable because of loud knocking noises
caused by wheel hopping and externally usually
exhibit considerable oil leakage.
Manual testing, as described below, can
determine if the shock absorber is damaged or
not:
Compress the shock absorber by hand.
While doing so, the piston rod can be moved
during the entire stroke time with a uniform
resistance and without jerking.
44

Release the piston rod. On sufficiently


pressurized shock absorbers it will
automatically return to its original position.
If this is not the case, the shock absorber need
not necessarily be replaced, as it will still
operate as a conventional shock absorber (see
instructions below).
Note
The absorbing function is still fully present
without gas pressure as long as the oil leakage
is not too important. However, the noise
t
intensity can deteriorate. On older vehicles it is
possible to continue using an operational yet
pressureless shock absorber without problem.
The spring shock absorbers with gas pressure
t
are only installed on the rear axle.
The gas pressure in the shock absorber
t improves the noise behaviour and the function
when driving over poor road surfaces.
Disposing of the shock absorber

Special tools and workshop equipment required


t
Pipe cutter, e.g. Stahlwille Express -150/3t
Protective goggles
t
Oil catching pan
WARNING
Cover the opening during degassing (gas pressure in as-new condition up to 2.5 MPa) and wear protective
googles.
Note
Defective shock absorbers with gas pressure are also noticeable because of loud knocking noises caused
by wheel hopping and externally usually exhibit considerable oil leakage.
The oils used in the shock absorbers do not contain any harmful substances. These oils can be disposed
t
of together with drained engine and gearbox oil.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral hydraulic
t oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or
thinners, chemicals etc.
t After "draining" the used parts must be allowed to drip adequately.
Drain front shock absorber
t

45

Clamp shock absorber in a vice.


Lever off protective cap with assembly lever or

anything similar and remove protective tube.


The protective cap and the protective tube are
only present on caulked shock absorbers.
Position a pipe cutter, e.g. Stahlwille Express

-150/3-, and cut through the outer pipe.


Pull the piston rod upwards and while doing so
grip the inner pipe with pipe pliers and press it
down in such a way that it remains in the outer
pipe when the piston rod is slowly pulled out.
Pull the piston rod out of the inner pipe.

Drain shock absorber.


Drain rear shock absorber (shock absorber with
gas pressure)
Clamp shock absorber vertically with the

piston rod pointing downwards in a vice.

Drill a hole in the outer pipe 3 mm -arrow


A-.
WARNING

Wear safety goggles.


Note
Gas will escape during drilling of the first pipe
wall (only for pressurized shock absorbers).
Drill further until the inner pipe has also been

drilled through (approx. 25 mm deep).

46

Drill a second hole (-arrow B-) 6 mm


through the inner pipe.
Hold the shock absorber over an oil catching
pan, move the piston rod several times up and

down over its entire stroke until no more oil


escapes.
Note

The shock absorber can also be opened with a


pipe cutter Anchor. First the shock absorber
must be depressurized by center drilling the outer
pipe (-arrow A-) previous fig. Anchor.

Removing and installing a drive shaft

Special tools and workshop equipment required


t
Extractor -MP 6-425t
Torque wrench, e.g. -V.A.G 1756Removing
Note
t The wheel bearing must not be loaded when the twelve-point nut is loose. At full load the wheel bearing
47

is initially damaged through the vehicle's own weight, thus shortening the life of the wheel bearing.
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
t
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Assignment of the drive shaft and marking electronic catalogue of original parts.
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

Raise the vehicle until the front axle is free of stress.

Slacken twelve-point nut.

Remove wheel and raise vehicle.


Remove noise insulation Engine - Mechanics; Rep. gr.10.
Unscrew the drive shaft from the flange shaft/gearbox.
Note
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.

Release screws -1-.

Push out the drive shaft. To do so position the


tool as shown in the fig.
Note

While pushing out the drive shaft make sure


there is sufficient clearance.
The drive shaft must not hang down while
t being pressed out. Otherwise overstretching
will cause damage to the inner joint.
Remove the drive shaft.
Note
t

The following working step must only be


performed on vehicles with automatic gearbox.

48

Slacken screws of gearbox-pendulum support


-arrow- at assembly carrier.

Lever out the engine/gearbox assembly with a


tyre iron in direction of travel, at the same time
the drive shaft with tripod can be removed.
The -arrow- shows the direction of travel.
Install (vehicles with manual and automatic
gearbox)
- Remove possible corrosion in the
thread/serration of the outer joint.
Moisten the serration of the wheel hub with oil.

Insert drive shaft.


Insert outer joint as far as possible into the

serration of the wheel hub.


Screw the steering joint and track control arm

with the new screws in the former positions.


Screw drive shaft onto flange shaft.
Screw the pendulum support to the assembly

carrier.
- Moisten the contact surface of the twelve-point
nut as well as the serration and the thread of the
outer joint with oil and screw on new twelvepoint nut as far as possible.
Insert the outer joint into the wheel hub until

the outer joint rests in the wheel bearing.


Install noise insulation Engine,

Mechanics; Rep. gr.10.

Attach the wheel.


Lower vehicle, when doing so, ensure that the

wheels do not yet touch the ground.


If the wheel bearings are loaded through the
vehicle's own weight, the wheel bearing will be
initially damaged. This shortens the life of the
wheel bearing.
Depress brake pedal (assistance of second

mechanic required).
Tighten new twelve-point nut to 225 Nm and

release by 1/2 a turn.


Torque wheel hub a further min. 90.
49

Tighten twelve-point nut:


Tightening torque:
50 Nm + 60.
Note

The torque wrench is recommended e.g. for


tightening the twelve-point nut -V.A.G 1756-.

Tightening torques:
Steering joint to track control arm
t Use new screws and new lock washer!
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
Screw M8 x 18
Screw M8 x 48
t
Use new screws!
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)

20 Nm + 90

I.
2nd
10 Nm 20 Nm + 90
10 Nm 20Nm + 180

I.
2nd
10 Nm 50 Nm + 45

Screw M10
t
Use new screws!
Pendulum support to assembly carrier
t
Use new screws!

20 Nm + 90

Repairing drive shaft

Repairing drive shaft with outer and inner CV joint


Special tools and workshop equipment required
t
Circlip pliers, e.g. -VW 161 At
Pressure plate -MP 3-406t
Pressure plate -MP 3-407t
Pressure spindle -MP 3-448t
Strutting bushing -MP 6-428t
Tensioner -MP 6-429t
Workshop press, e.g. -V.A.G 1290 A50

t
t

Tensioning pliers, e.g. -V.A.G 1682Sealant -D 454 300 A2Note

t Assignment of the drive shafts Electronic Catalogue of Original Parts.


t Grease joint if necessary, when replacing the joint boot.
t Spread the grease mass evenly in the joint boot - only on the side of the joint.

1Right joint boot (tubular shaft)


t Assignment Electronic Catalogue of Original Parts
2Fillister head screw with internal serrations
t
replace after each removal
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
t Assignment Electronic Catalogue of Original Parts
3Shim
t Assignment Electronic Catalogue of Original Parts
4Open warm-type clamp
t
replace
t
tensioning Fig.
5Joint boot for inner CV joint, 94 mm
t
inspect for tears and chafing points
t
remove from CV joint with drift
The fitting position of the joint boot for the inner CV joint for the right shaft is the same as the fitting
t
position of the joint boot for the outer CV joint 84mm Fig.
t before installation coat the inside of the cap with sealant -D 454 300 A2t Assignment Electronic Catalogue of Original Parts
51

6Joint boot for inner CV joint, 100 mm


t
inspect for tears and chafing points
t
remove from CV joint with drift
t
Fitting position for the left shaft Fig.
t
Fitting position for the right shaft Fig.
t before installation coat the inside of the cap with sealant -D 454 300 A2t Assignment Electronic Catalogue of Original Parts
7Disc spring
t
Fitting position Fig.
8Inner CV joint
t
must be replaced completely
t
pressing out Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
t Assignment Electronic Catalogue of Original Parts
9Gasket
t The adherend on the inner CV joint must be free of grease and oil!
t
replace
t Remove the protective foil from the gasket and stick it into the inner joint
t Assignment Electronic Catalogue of Original Parts
10 Circlip
t
replace
t
remove with circlip pliers, e.g. -VW 161 A-,
t Assignment Electronic Catalogue of Original Parts
11 Left drive shaft (solid shaft)
t Assignment Electronic Catalogue of Original Parts
12 Open warm-type clamp
t
replace
t
tensioning Fig.
13 Joint boot for outer CV joint
t
inspect for tears and chafing points
t Assignment Electronic Catalogue of Original Parts
t pay attention to different version: 84 mm, 90 mm
t The fitting position of the joint boot for the outer CV joint 90 mm for the left shaft Fig.
The fitting position of the joint boot for the outer CV joint 90 mm for the right shaft is determined by
t
the fitting position on the shaft, identical as Fig.
t The fitting position of the joint boot for the outer CV joint 84 mm for the left shaft Fig.
t The fitting position of the joint boot for the outer CV joint 84 mm for the right shaft Fig.
14 Open warm-type clamp
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
15 Disc spring
t
Fitting position Fig.
16 Thrust ring
t
Fitting position Fig.
17 Circlip
t
replace
t
insert into the groove at the shaft
18 Outer CV joint
52

t
must be replaced completely
t
removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t
grease Anchor
t
check Chapter
19 22 Nm
20 M8 = 20 Nm, M10 = 33 Nm
21 Protective housing

Repairing drive shaft with outer and inner CV joint VL 3700

Special tools and workshop equipment required


t
Chapter
Note
t
t

Assignment Electronic Catalogue of Original Parts


Grease joint if necessary, when replacing the joint boot.

1Outer CV joint
t
must be replaced completely
t
removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t
grease Anchor
t
check Chapter
2Circlip
t
replace
53

t
insert into the groove at the shaft
3Thrust ring
t
Fitting position Fig.
4Disc spring
t
Fitting position Fig.
5Open warm-type clamp
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
6Joint boot for outer CV joint
t
Material: Hytrel (Polyelastomere)
t
inspect for tears and chafing points
t
Fitting position for the left shaft Fig.
t
Fitting position for the right shaft Fig.
t Assignment Electronic Catalogue of Original Parts
7Open warm-type clamp
t
replace
t
tensioning Fig.
8Drive shaft
t Assignment Electronic Catalogue of Original Parts
9Joint boot for inner CV joint
t
Material: Arnitel (Polyelastomere)
t
inspect for tears and chafing points
t
Fitting position for the left shaft Fig.
t
Fitting position for the right shaft Fig.
t Assignment Electronic Catalogue of Original Parts
10 Open warm-type clamp
t
replace
11 Cover
t
remove from CV joint with drift
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2t The sealing surface must be free of oil and grease!
12 Inner CV joint
t
must be replaced completely
t
pressing out Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
t Assignment Electronic Catalogue of Original Parts
13 Circlip
t
replace
t
remove with circlip pliers, e.g. -VW 161A-,
14 Fillister head screw with internal serrations
t
replace after each removal
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
t Assignment Electronic Catalogue of Original Parts
15 Shim
t Assignment Electronic Catalogue of Original Parts
16 Gasket
54

t The adherend on the inner CV joint must be free of grease and oil!
t
replace
t Remove the protective foil from the gasket and stick it into the inner joint
t Assignment Electronic Catalogue of Original Parts
17 Cover
t
remove from CV joint with drift
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2t The sealing surface must be free of oil and grease!
Grease quality and grease quantity
Note
The outer joints of the drive shaft are filled with:
Grease for operating at normal temperatures part no.: -G 052 738 A2
Grease from the relevant repair kit
High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3The inner joints of the drive shaft must only be filled with high temperature grease from the relevant
t repair kit or with grease part no.: -G 052 133 A2-, or part no.: -G 052 133 A3- electronic catalogue of
original parts
Grease quantity Anchor

Removing outer CV joint


Drive off joint boot with a drift.
Drive off the drive shaft with a strong blow of

a plastic hammer.

Pressing out the inner CV joint


Note
Support ball hub

55

Fitting position of the disc spring on the outer


joint (gearbox side)
-1- Disc spring

Fitting position of the disc spring and thrust ring


on the outer joint
-1- Disc spring
-2- Thrust ring

Pressing in the inner CV joint


Press the joint up to the stop.

Insert the circlip.


Note
Chamfer on inner diameter of the ball hub
(serration) must point towards the bearing collar
of the drive shaft.

56

Fitting position of the joint boot for the inner CV


joint 100 mm on the left shaft
Dimension -a- = 17 mm
Note
Mark the dimension -a- before installing the joint
boot on the drive shaft, e.g. using colour or
adhesive tape. Under no circumstances the
paintwork must be damaged with a sharp object.

Fitting position of the joint boot for the inner CV


joint 100 mm on the right shaft
The ventilation chamber -A- must be located on
the large pipe diameter.
-B- Ventilation hole.

Tighten the open warmtype clamp on the outer


joint (at the large
diameter)
Note

t
t
t

In view of the hard


material (as opposed to
rubber) of the joint
boot, which requires
the use of a stainless
steel open warm-type
clamp, the latter can
only be correctly
tightened with
tensioning pliers, e.g.
-V.A.G 1682-.
Tightening torque: 25
Nm.
Use a torque wrench.
Make sure the thread of
spindle -A- of the
57

tensioning pliers is
smooth. If necessary
grease with grease, e.g.
molykote MoS2.
If it is not smooth, e.g.
if the thread is dirty, the
necessary clamping
t force of the open
warm-type clamp is not
reached at the given
torque.
Position the tensioning
pliers, e.g. -V.A.G
1682-, as shown in the
fig. Make sure the

cutting edges of the


pliers are positioned in
the corners (-arrows B-)
of the open warm-type
clamp.
Tighten the open warmtype clamp by turning
the spindle with a
torque wrench (do not
tilt the pliers during this
process).
-A- Spindle of tensioning
pliers
-B- Cutting edges of
tensioning pliers
Tighten the open warm-type clamp on the outer
joint (small diameter)
Position the tensioning pliers, e.g. -V.A.G
1682-, as shown in the fig. Make sure the

cutting edges of the pliers are positioned in the


corners (-arrows B-) of the open warm-type
clamp.
Tighten the open warm-type clamp by turning
the spindle with a torque wrench (do not tilt the
pliers during this process).
-A- Spindle of tensioning pliers
-B- Cutting edges of tensioning pliers
-C- Torque wrench

58

Tighten the open warm-type clamp on the inner


joint
Position the tensioning pliers, e.g. -V.A.G
1682-, as shown in the fig. Make sure the

cutting edges of the pliers are positioned in the


corners (-arrows B-) of the open warm-type
clamp.
Tighten the open warm-type clamp by turning
the spindle with a torque wrench (do not tilt the
pliers during this process).
-A- Spindle of tensioning pliers
-B- Cutting edges of tensioning pliers
-C- Torque wrench

Fitting position of the joint boot for the outer CV


joint 90 mm on the left shaft
The sealing surface of the joint boot must rest up
to the stop on the shoulder of the shaft

Fitting position of the joint boot for the outer CV


joint 84 mm on the left and right shaft
On the drive shaft, 1 to 1 1/2 groove must be
visible
Note
The condition mentioned above regarding the
fitting position is also valid for the joint boot for
the inner CV joint 94 mm.

59

Fitting position of the joint boot for the inner CV


joint at the left and right shaft

Fitting position of the joint boot for the outer CV


joint at the left shaft

Fitting position of the joint boot for the outer CV


joint at the right shaft

Inspecting outer CV joint

Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected
60

for wear and damage.


Removing

With an electric stylus or rubstone mark the


position of the ball hub relatively to the ball
cage and housing before disassembling -arrow-.
Rotate the ball hub and ball cage.
Remove the balls one after the other.

Turn the cage until the two rectangular cage


windows (-arrow-) rest on the joint part.
Remove cage with hub.

Turn the hub segment in the rectangular


window of the cage.
Swivel the hub out of the cage.
Note

The 6 balls of each joint belong to a tolerance


group. Inspect the axle studs, hub, cage and
balls for small depressions (pitting = point
erosion) and seizing marks. Load alteration
t
shocks indicate too much torsional clearance in
the joint, if this is the case replace the joint.
Smoothing and bearing marks do not justify a
joint replacement.
t Inspect the cage for tears.
Install
Press the required quantity of grease into the

joint part.
Grease quality and grease quantity Anchor.
Insert the cage with the hub in the joint part.
61

Note
The cage must be inserted in the correct position.
Press in opposite balls one after the other,
during this process observe the prior position of

the ball hub relatively to the ball cage and to the


joint part.
Insert new circlip in the groove of the shaft.
Spread any residual grease in the joint boot

Anchor.
Installing the joint boot Fig..

Inspecting inner CV joint

Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected
for wear and damage.
Removing
Note
The ball hub and joint part are paired and must be marked before removal. Do not interchange the bearing
track assignment.

Swivel the ball hub


with the ball cage.
Press the ball hub and
the ball cage out of the
joint part -arrow-.
Press out the balls from

the cage.

62

Swivel the ball hub out


of the ball cage over
the ball bearing track
-arrows-.
Inspect the joint part,
ball hub, ball cage and
balls for small broken
out depressions (pitting
= point corrosion) and
seizing marks.
Note
Load alteration shocks
indicate too much
torsional clearance in the
joint. If this is the case,
replace the joint.
Smoothing and bearing
marks do not justify a
joint replacement.
Install

Insert the ball hub in


the ball cage over the
two chamfers. The
fitting location is
random. Press the balls
into the cage.
Insert the hub with
cage upright into the
joint part.
Note

63

When inserting make sure the greatest distance


-a- on the joint part is close to the short distance
t
-b- on the hub after it has been swivelled in
-arrow-.
Chamfer on inner diameter of the ball hub
t (serration) must point towards the largest
diameter of the joint part.

Swivel in the hub. To


do so swivel the hub

out of the cage -arrowsuntil the balls are at


bearing track distance.

64

Lock the hub with the


balls into position by

exerting considerable
pressure on the cage
-arrow-.
Inspect the operation of
the inner CV joint
The CV joint is
correctly assembled if
the ball hub in the joint
l part can be rolled by
hand up and down the
entire linear
compensation.
Push the clamp and the
joint boot onto the
drive shaft.
Install drive shaft.
Press the specified
grease quantity for the
inner joint into the joint
from both sides.
Spread the prescribed

grease quantity evenly


into the joint boot.
Grease quality and grease
quantity Anchor.
Installing the joint boot

Fig..

Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint

Special tools and workshop equipment required


t
Pressure plate -MP 3-406t
Pressure spindle -MP 3-448t
Pipe section -MP 3-4012t Tensioning pliers, e.g. -V.A.G 1275-, -V.A.G 1682t
Workshop press, e.g. -V.A.G 1290 At
Circlip pliers (commercially available)
Grease quality and grease quantity
Note
The inner joints and the inner tripod joints must only be filled with high temperature grease from the
relevant repair kit electronic catalogue of original parts.
t
Grease quantity for outer CV joint Anchor.
t Grease quantity for inner tripod joint Anchor.
Note
t

t Assignment of the drive shafts electronic catalogue of original parts


65

t Grease joint if necessary, when replacing the joint boot.


t On tripod joints only apply grease in the joint, never in the grease boot.

1Joint boot for outer CV joint


q
inspect for tears and chafing points
q
Assignment Electronic Catalogue of Original Parts
2Open warm-type clamp
q
replace
q
tensioning Fig.
3Open warm-type clamp
q
replace
q
tensioning Fig.
4Drive shaft
q
Assignment Electronic Catalogue of Original Parts
5Joint part
q
grease Anchor
q
Assignment Electronic Catalogue of Original Parts
6Fillister head screw with internal serrations
q
replace after each removal
q initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 18 = 20 Nm + 90
M10 x 23 = 50 Nm + 45
q
Assignment Electronic Catalogue of Original Parts
7Rollers
8Tripod spider
q
Chamfer -arrow- points towards the drive shaft serration
9Circlip
q
replace
66

q
insert into the groove at the shaft
10 O-ring seal
q
no longer necessary for the assembly of the repaired drive shaft
11 Oblong gasket ring
q
The gasket ring belongs to the repair set
q The gasket ring is not fitted in the series, it is only necessary for the spare parts sector
q
Assignment Electronic Catalogue of Original Parts
12 Cover
q
is damaged when removing.
is no longer necessary for the assembly of the repaired drive shaft and is therefore only available as a
q
spare part
13 Open warm-type clamp
q
for tripod joint
q
always replace
14 Joint boot for tripod joint
q
inspect for tears and chafing points
15 Open warm-type clamp
q
for tripod joint
q
always replace
q
tensioning Anchor
16 Disc spring
q
Fitting position Fig.
17 Thrust ring
q
Fitting position Fig.
18 Circlip
q
replace
q
insert into the groove at the shaft
19 Outer CV joint
q
must be replaced completely
q
removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q
grease Anchor
q
check Chapter

Disassembling and assembling the tripod joint AAR 2900

Special tools and workshop equipment required


t
Chapter
Grease quality and grease quantity
Anchor
Dismantling

Open warm-type clamp on joint part.


Open the open warm-type clamp at the drive shaft and push back the joint boot.

67

Clamp the drive shaft on the joint part in a vice


with protective jaws.
Lever off the cover with a screwdriver -1-.
Note

If the cover cannot be levered off, do likewise


on the opposite side of the cover.
The cover is damaged when levering off, it is
t no longer necessary for the assembly of the
repaired drive shaft.
t

Remove O-ring seal -arrow- from slot.


Mark fitting position of parts -1- ... -3- with the

help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they
are not fitted in their original position again
t
when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from

the vice.
Ensure that the rollers do not topple off the tripod
spider and fall onto the floor!
Hold the drive shaft with the joint part
vertically and with the other hand gradually
push back the joint part.

68

Clamp the drive shaft in a vice with protective


jaws.
Mark the fitting position of the rollers -1- to the

tripod spider -2- with a felt-tip pen.


Remove rollers -1- and place them down on a

clean surface.

Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.

69

Hold the drive shaft and press out of the tripod


spider.
Remove the joint part along with the joint boot

from the drive shaft.


Clean the drive shaft and the joint part.
Assembling together
Push a small open warm-type clamp for the

joint boot onto the drive shaft.


Insert the joint boot on the drive shaft.
Insert the joint part on the drive shaft.
Mounting the tripod spider

Clamp the drive shaft in a vice with protective


jaws.
Note

Chamfer -arrow- on the tripod spider must point


towards the drive shaft. Chamfer serves as an
assembly aid.
Position the tripod spider on the drive shaft
according to the marking and drive in up to the
stop.
Insert new circlip and pay attention to correct

position.
Fit the rollers corresponding to the markings

onto the tripod spider.


Remove the drive shaft from the vice.
Slide the joint part over the rollers and hold

down.
Clamp joint part into the vice.

70

Insert the oblong gasket ring -A- from the


repair set into the groove -arrow-.
Note

Direct sealing occurs between the tripod joint


(joint part) and the joint flange (on the gearbox
t
side) due to the oblong profile shape of the
gasket ring.
t The cover is no longer necessary.

Press the high temperature grease from the


repair set evenly into the tripod joint (on the
tripod spider side) -arrow A- and into the rear
side of the tripod joint -arrow B-.
Grease quality and grease quantity
Anchor
Installing the joint boot.
Tighten open warm-type clamp using pliers.

Tighten open warm-type clamp on the drive shaft


side with tensioning pliers e.g. -V.A.G 1275-.

71

Cover the tripod joint with a cardboard disc -Aand adhesive tape -B-.
Note

Cover the tripod joint after the repair with a


self-cut, clean cardboard disc -A- and adhesive
tape -B-. This prevents the tripod spider, the
t joint part and the grease mass from clogging up
with dirt. In addition, this prevents that the
tripod joint is inadvertently pushed back when
installing the drive shaft.
The adhesive tape and the cardboard disc
should be removed only immediately before
t
screwing the drive shaft together with the joint
flange.

Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint

Special tools and workshop equipment required


t
Pressure plate -MP 3-406t
Pressure plate -MP 3-407t
Pressure spindle -MP 3-408t
Spacer sleeves -MP 3-458/2t
Pressure spindle -MP 6-405t
Strutting bushing -MP 6-428t
Tensioner -MP 6-429t
Workshop press, e.g. -V.A.G 1290 At Tensioning pliers, e.g. -V.A.G 1275-, -V.A.G 1682t
Circlip pliers (commercially available)
Grease quality and grease quantity
Note
The inner joints and the inner tripod joints must only be filled with high temperature grease from the
relevant repair kit electronic catalogue of original parts.
t
Grease quantity for outer CV joint Anchor.
t Grease quantity for inner tripod joint Anchor.
Note
t

t Assignment of the drive shafts electronic catalogue of original parts


72

t Grease joint if necessary, when replacing the joint boot.


t On tripod joints only apply grease in the joint, never in the grease boot.

1Joint boot for outer CV joint


q
inspect for tears and chafing points
q
Assignment Electronic Catalogue of Original Parts
2Open warm-type clamp
q
replace
q
tensioning Fig.
3Fillister head screw with internal serrations
q
replace after each removal
q initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 28 = 20 Nm + 90
q
Assignment Electronic Catalogue of Original Parts
4Shim
q
Assignment Electronic Catalogue of Original Parts
5Joint part
q
grease Anchor
q
Assignment Electronic Catalogue of Original Parts
6Tripod spider with rollers
q
Chamfer -arrow- points towards the drive shaft serration
7Circlip
q
replace
q
insert into the groove at the shaft
8O-ring seal
q
replace
9Cover
q
replace
73

10 Open warm-type clamp


q
for tripod joint
q
always replace
11 Joint boot for tripod joint
q
inspect for tears and chafing points
q
Assignment Electronic Catalogue of Original Parts
12 Drive shaft
q
Assignment Electronic Catalogue of Original Parts
13 Open warm-type clamp
q
replace
q
tensioning Fig.
14 Disc spring
q
Fitting position Fig.
15 Thrust ring
q
Fitting position Fig.
16 Circlip
q
replace
q
insert into the groove at the shaft
17 Outer CV joint
q
must be replaced completely
q
removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q
grease Anchor
q
check Chapter
q
Assignment Electronic Catalogue of Original Parts

Disassembling and assembling the tripod joint AAR 2000

Special tools and workshop equipment required


t
Chapter
Grease quality and grease quantity
Anchor
Dismantling

Open warm-type clamp on joint part.

Push back the joint boot.

74

Straighten the metal tabs -arrows- with a


screwdriver and lever off cover.

Remove O-ring seal -arrow- from slot.


Mark fitting position of parts -1- ... -3- with the

help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they
are not fitted in their original position again
t
when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from

the vice.

75

Clamp the drive shaft in a vice with protective


jaws.

Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.

Hold the drive shaft and push tripod spider off


the drive shaft.
Remove the tripod spider with rollers and lay

aside on a clean surface.


Remove the joint part from the drive shaft.
Remove the joint boot from the drive shaft.
Clean the drive shaft and the joint part.
Assembling together
Insert the joint boot on the drive shaft.
Insert the joint part on the drive shaft.
Install tripod joint
Note

Chamfer on the tripod spider must point towards


the drive shaft. Chamfer serves as an assembly
aid.

76

Position the tripod spider on the drive shaft


according to the marking and drive in up to the
stop.
Insert new circlip and pay attention to correct

position.
Slide the joint part over the rollers and hold

down.
Remove the drive shaft from the special tool

and clamp in the vice.

Press the high temperature grease from the


repair set evenly into the tripod joint (on the
tripod spider side) -arrow A- and into the rear
side of the tripod joint -arrow B-.
Grease quality and grease quantity
Anchor
Installing the joint boot.
Note
The bead in the joint boot must fit into the groove
of the joint part.
Remove drive shaft from the vice and clamp

the joint part.

77

Insert new gasket ring -arrow- from the repair


kit in the groove.
Fit the new cover on the joint part.
Note

The bores of the cover and joint part must be


flush.
Tighten open warm-type clamp using pliers.
Grease quantity

Outer joint
mm

Total quantity of
grease (g)
Spread evenly in the
joint

81

90

90

110

90
90

110
110

98

130

Inner joint mm

94 (synchronous
running) 1)
100 (synchronous
running) 1)
108 (tripod) 1)
124 (tripod) 1)
100 (synchronous
running) 2)

Total quantity of
grease (g)

of which in
Joint
(g)

Joint boot
(g)

90

45

45

120

60

60

110
140

110
140

_
_

190

190

1)

Valid for all vehicles, except 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
Valid for vehicles with 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
Grease quality - outer CV joint
The outer CV joints can be filled with the following grease qualities:
t Grease for operating at normal temperatures, part no.: -G 052 738 A2t
Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3Grease quality - inner CV joint
The inner CV joints can be filled with the following grease qualities:
t
Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3Note
2)

t -G 052 133 A2- Can with a grease quantity of 90 g


t -G 052 133 A3- Can with a grease quantity of 120 g
t Grease joint if necessary, when replacing the joint boot.
t Spread the quantity of grease for the joint evenly in the joint on the left and right.
t Spread the quantity of grease for the joint boot evenly in the joint boot - only on the side of the joint.
Rear suspension, drive shaft
78

Repairing rear axle - drum brake


Removing and installing rear suspension

Special tools and workshop equipment required


t Tester for brake-power regulator, e.g. -V.A.G 1310t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2t Brake filling and bleeding device, e.g. -VAS 5234t
Remove plugs for brake line
t
Brake fluid Chapter
t
Assembly paste -G 052 150 A2Removing

Remove wheels.

Release the hand-brake.


Note
Do not slacken the mounting bracket on body for the removal of the rear axle, otherwise the overall track
of the rear axle must be checked, adjusted if necessary.

Remove the screws -1- while the vehicle is


standing on its wheels. To do so, raise the

vehicle if necessary until the screws can be


reached.
Raise the vehicle to the height required for
installation in order to relieve tension from coil
spring.
Tilt the rear centre console, if necessary

remove Body Work; Rep. gr.68

79

Release adjusting nut -arrow-.

Remove the hand-brake cables -1- from the


hand-brake lever.
Pull hand-brake cables out of guide tubes.

Unclip brake cables -arrows-.


Detach retaining clips -2- from brake hose

fixture.

Separate brake lines.


Note
Seal lines with plugs.
Unplug connectors from the wheel speed

sensors.
Unclip the wheel speed sensor cable from the

bracket.
Only on vehicles fitted with brake-power
regulator (vehicles without ABS):

80

Unscrew bolt -1- of the brake-power regulator.


Valid for all vehicles:
Support the rear axle with gearbox jack with
adapter, e.g. -V.A.G 1383A- with -V.A.G
1359/2-.

Unscrew bolt -1- of the brake-power regulator.


Install
Before inserting the rear axle, grease the
kidney-shaped cavities of the rubber-metal
bearings with assembly paste -G 052 150 A2-.
Installation is carried out in the reverse order.
Note
When tightening the screw of the rubber-metal
t bearing, the axle body must be in the horizontal
position (unladen condition).
When installing the hand brake cables, pay
t attention to the correct fitting position
Chapter.
Bleeding Brake System Chapter.
If fitted, inspect the load-sensitive brake
pressure regulator and set if necessary
Chapter.
Once the steering gear has been installed it is then
important to check the position of the steering
wheel during a test drive.
If the vehicle drifts, a chassis alignment must be
performed.
Note
After slackening or changing the mounting
bracket, check the overall track of the rear axle,
adjust if necessary.
Tightening torques:
Shock absorber to body
t
Use new screws!
Rear suspension to bearing bracket
Pipe screws, screws to brake lines

30 Nm + 90
45 Nm + 90
14 Nm

81

Summary of components of rear axle

Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.

1Wheel screw, 120 Nm


24 Nm
3Brake disc
t
reset brake before removing the brake drum
4Cap
t
replace after each removal
t
press off Fig.
t
inserting Fig.
5Self-locking twelve-point nut 70 Nm +40
t
replace after each removal
6Wheel hub with wheel bearing and pulse rotor
t
only on vehicles with ABS
t The wheel bearing and the wheel hub are fitted together in one housing
82

this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
work are not possible
t
removing and installing Chapter
7Wheel hub with wheel bearing without pulse rotor
t
only on vehicles without ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
removing and installing Chapter
t
must be replaced completely
850 Nm + 60
t
replace after each removal
9Brake carrier with brake shoe
10 Holder for hand-brake cable
t
replace
11 Hand-brake cable
12 Self-locking nut
t
replace after each removal
13 Self-locking screw, 30 Nm + 90
t
replace after each removal
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side
14 45 Nm + 90
t
replace after each removal
t
insert from the outside of the vehicle
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
15 Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t avoid slackening in order to remove the rear axle
16 Holder for hand-brake cable
17 Rubber-metal bearing
t
removing and installing Chapter
18 Socket nut
19 Brake-power regulator
t
only on vehicles without ABS
t
testing and adjusting Chapter
20 20 Nm
21 16 Nm
22 20 Nm + 45
t
replace after each removal
23 Balancing weight
24 Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
25 ABS wheel speed sensor
t
only on vehicles with ABS
26 8 Nm
27 bottom base
28 Coil spring
t
removing and installing Chapter
t

83

t check for paint damage, if necessary eliminate paint damage


t Assignment Electronic Catalogue of Original Parts
t only use helical springs of the same make on the rear axle
29 top base
t
installing Anchor
30 40 Nm + 90
t
replace after each removal
t
insert from the inside of the vehicle
t when tightening, take the installation angle of the rear axle to the shock absorber into account Fig.
While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and
t
tighten the screw
31 Self-locking screw, 30 Nm + 90
t
replace after each removal
if thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the notes of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 1 screw point per vehicle side
32 Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
t only use helical springs of the same make on the rear axle
Note
Shock absorbers are not to be repaired.
33 Self-locking nut
t
replace after each removal
34 Brake line
35 Axle stud
t
Straightening work is not allowed!
t
Re-cutting the thread is not allowed
36 Protection against stones
37 Fixing element for protection against stones
t Protection against stones included in the scope of delivery

84

Installation angle of rear axle/shock absorber


1Shock absorber
2track control arm
approx. 104

85

Replacing the rubber-metal bearing


Replacing the rubber-metal bearing - version 1

Special tools and workshop equipment required


t
Assembly device -MP5-400/1t
Assembly device -MP5-400/2t
Assembly device -MP5-400/3t
Assembly device (screw) -MP5-401/2t
Assembly device (nut) -MP5-401/3t
Assembly device (bearing) -MP5-402t
Pipe -T10263/6t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2Removing:

Raise vehicle and remove rear wheels.


Unscrew screws of front wheelhouse liners on both vehicle sides Body Work; Rep. gr.66.

Unhook handbrake cable from the holders


-arrows- (on both vehicle sides).

Release the clamps -arrow A- for attaching the


brake lines from the brake line holders (on both
vehicle sides).

86

Remove the screw -1- from the brake line


holder on the right vehicle side.
Unhook the brake lines from the line holders.

Do not separate the brake lines.


Vehicles with ABS
Unhook the ABS line from the clips.

Vehicles fitted with load-sensitive brake pressure


regulator (vehicles without ABS)

Release screw -1-.


Continued for all vehicles

Insert wooden insert -A- into the adapter e.g.


-V.A.G 1359/2Support the axle with engine/gearbox jack with

adapter.
Vehicles with fixing screws mounted on the
outside

87

Unscrew the nuts of the fixing screws -1- from


the axle.
Remove fixing screws -1- from the axle.
Vehicles with fixing screws mounted on the
inside

Remove the screws -2- of the bearing bracket


for the axle on the right vehicle side from the
body.
Note
Before removing the screws of the bearing
brackets for the axle, mark the position of the
bearing bracket on the body.
Remove the fixing screw -1- for the axle on the
left vehicle side from the bearing bracket for
the axle.
Slightly lower the rear axle out of the bearing

brackets so that the brake line is not damaged.


Remove the fixing screw -1- for the axle on the
right vehicle side from the bearing bracket for
the axle.
Remove the bearing bracket from the axle.
Continued for all vehicles
Secure axle e.g with wire to body.

Position assembly devices, as shown, and pull


the rubber-metal bearing -1- out of the axle
body -2-.
Note

88

The pipe -T10263/6- must be installed on the


rubber-metal bearing in such a way that the
contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g
with a sharp knife so that the pipe cutout
-arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the
plastic shoulder/rubber-metal bearing breaks
off. In case of breakage, a loud crack can be
heard.
Pull out rubber-metal bearing by turning the
assembly device (nut) -MP5-401/3-.
Counterhold the assembly devices by hand
when completing the pull-out process.
Remove assembly devices and unscrew
assembly device (nut) -MP5-401/3-.

Clamp the pipe -T10263/6- in the vice, as


shown in the fig.
Remove the rubber-metal bearing from the pipe
-T10263/6-, for example using a screwdriver,
drive out with a hammer if necessary.
Installing:

89

Fasten rubber-metal bearing -1- with assembly


devices and nut -2- and insert into the axle
body -3-.
Pay attention to the correct fitting position of

the rubber-metal bearing.

Fitting position of the rubber-metal bearing


Align orientation nubs -1- or orientation bead

-2- to edge of track control arm -3--arrow-.

90

Insert the rubber-metal bearing -1- by turning


the nut -MP 5-401/3- up to the stop in the axle
body -2-.
Check the fitting position of the rubber-metal

bearing.
Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
Vehicles with fixing screws mounted on the
outside
Carefully raise the rear axle so that the rubber metal bearing engages in the bearing brackets
for the axle.

Insert the new fixing screws -1- into the


bearing brackets for the axle.
Screw new nuts onto the fixing screws -1- for

bearing brackets of the rear axle and tighten.


Vehicles with fixing screws mounted on the
inside
Position the bearing bracket for the axle on the

right vehicle side on the rubber-metal bearing.

Insert a new fixing screw -1- from the inside


into the bearing bracket for the axle on the right
vehicle side.
Carefully raise the rear axle so that the rubber metal bearing engages on the left vehicle side
in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on
the right vehicle side rests at the same time
against the body in the marked position.
Screw the new fixing screws -2- of the bearing
bracket for the axle on the right vehicle side
into the body and tighten.
Continued for all vehicles
Note
When tightening the rubber-metal bearing screws
and nuts, the axle body must be in the unladen
condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
Vehicles fitted with load-sensitive brake pressure
91

regulator (vehicles without ABS)

Screw in the screw -1-.


Inspecting or adjusting the brake-power

regulator Chapter.
Continued for all vehicles

Install the screw -1- for the brake line holder on


the right vehicle side.
Hook on the brake lines in the line holders.

Push clamps -arrow A- into the brake hose


fixtures (on both vehicle sides).
Note

When installing the hand brake cables, pay


attention to the correct fitting position
Chapter.

92

Hook hand brake cables into the holders


-arrows- (on both vehicle sides).
Screw in screws of front wheelhouse liners on
both vehicle sides Body Work; Rep. gr.66.
Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the
test drive.
Caution

If after the test drive and with the front wheels


pointing straight ahead the steering wheel is off
straight, perform a chassis alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle
t
Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure
t
Use new screws!
t
Install in the marked position
Brake line holder to vehicle body
Screw for brake-power regulator

45 Nm + 90

30 Nm + 90

16 Nm
16 Nm

Replacing the rubber-metal bearing - version 2

Special tools and workshop equipment required


t
Assembly device -MP5-400/1t
Assembly device -MP5-400/2t
Assembly device -MP5-400/3t
Assembly device (nut) -T10254/4t
Assembly device (screw) -T10254/5t
Pipe -T10263/6t
Hydraulic cylinder -VAS 6178t
Foot pump -VAS 6179t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2Removing:

Raise vehicle and remove rear wheels.


Unscrew screws of front wheelhouse liners on both vehicle sides Body Work; Rep. gr.66.

93

Unhook handbrake cable from the holders


-arrows- (on both vehicle sides).

Release the clamps -arrow A- for attaching the


brake lines from the brake line holders (on both
vehicle sides).

Remove the screw -1- from the brake line


holder on the right vehicle side.
Unhook the brake lines from the line holders.

Do not separate the brake lines.


Vehicles with ABS
Unhook the ABS line from the clips.

94

Vehicles fitted with load-sensitive brake pressure


regulator (vehicles without ABS)

Release screw -1-.


Continued for all vehicles

Insert wooden insert -A- into the adapter e.g.


-V.A.G 1359/2Support the axle with engine/gearbox jack with

adapter.
Vehicles with fixing screws mounted on the
outside

Unscrew the nuts of the fixing screws -1- from


the axle.
Remove fixing screws -1- from the axle.
Vehicles with fixing screws mounted on the
inside

95

Remove the screws -2- of the bearing bracket


for the axle on the right vehicle side from the
body.
Note
Before removing the screws of the bearing
brackets for the axle, mark the position of the
bearing bracket on the body.
Remove the fixing screw -1- for the axle on the
left vehicle side from the bearing bracket for
the axle.
Slightly lower the rear axle out of the bearing

brackets so that the brake line is not damaged.


Remove the fixing screw -1- for the axle on the
right vehicle side from the bearing bracket for
the axle.
Remove the bearing bracket from the axle.
Continued for all vehicles
Secure axle e.g with wire to body.

Connect hydraulic line -1- of hydraulic pump


-VAS 6179- with quick coupling to hydraulic
cylinder -VAS 6178-.
Connect compressed air supply -2- with quick

coupling to hydraulic pump -VAS 6179-.

Position assembly devices, as shown, screw


together and counterhold by hand.
Note

96

The pipe -T10263/6- must be installed on the


rubber-metal bearing in such a way that the
t
contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g
with a sharp knife so that the pipe cutout
t
-arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the
plastic shoulder/rubber-metal bearing breaks
t
off. In case of breakage, a loud crack can be
heard.

Carefully depress the pedal of the hydraulic


pump -VAS 6179--arrow A-.
The hydraulic cylinder -VAS 6178- is therefore
activated.

Pull the rubber-metal bearing -1- out of the


axle body -2-.
Counterhold the assembly devices by hand

when completing the pull-out process.

97

Carefully depress the pedal of the hydraulic


pump -VAS 6179--arrow B-.
While doing so, the hydraulic cylinder -VAS
6178- returns to the initial position.
Remove assembly devices and unscrew

assembly device (nut) -T10254/4-.

Clamp the pipe -T10263/6- in the vice, as


shown in the fig.
Remove the rubber-metal bearing from the pipe
-T10263/6-, for example using a screwdriver,
drive out with a hammer if necessary.
Installing:

98

Position assembly devices, as shown, screw


together and counterhold by hand.
1Rubber-metal bearing
2Axle body
Pay attention to the correct fitting position of

the rubber-metal bearing.

Fitting position of the rubber-metal bearing


Align orientation nubs -1- or orientation bead

-2- to edge of track control arm -3--arrow-.


Carefully depress the pedal of the hydraulic

pump -VAS 6179--arrow A-.

99

The hydraulic cylinder -VAS 6178- is therefore


activated.

Insert the rubber-metal bearing -1- up to the


stop into the axle body -2-.
Check the fitting position of the rubber-metal

bearing.

Carefully depress the pedal of the hydraulic


pump -VAS 6179--arrow B-.
While doing so, the hydraulic cylinder -VAS
6178- returns to the initial position.
Remove assembly devices and unscrew

assembly device (nut) -T10254/4-.


Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
Vehicles with fixing screws mounted on the
outside
Carefully raise the rear axle so that the rubber metal bearing engages in the bearing brackets
for the axle.

100

Insert the new fixing screws -1- into the


bearing brackets for the axle.
Screw new nuts onto the fixing screws -1- for

bearing brackets of the rear axle and tighten.


Vehicles with fixing screws mounted on the
inside
Position the bearing bracket for the axle on the

right vehicle side on the rubber-metal bearing.

Insert a new fixing screw -1- from the inside


into the bearing bracket for the axle on the right
vehicle side.
Carefully raise the rear axle so that the rubber metal bearing engages on the left vehicle side
in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on
the right vehicle side rests at the same time
against the body in the marked position.
Screw the new fixing screws -2- of the bearing
bracket for the axle on the right vehicle side
into the body and tighten.
Continued for all vehicles
Note
When tightening the rubber-metal bearing screws
and nuts, the axle body must be in the unladen
condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
Vehicles fitted with load-sensitive brake pressure
regulator (vehicles without ABS)

101

Screw in the screw -1-.


Inspecting or adjusting the brake-power

regulator Chapter.
Continued for all vehicles

Install the screw -1- for the brake line holder on


the right vehicle side.
Hook on the brake lines in the line holders.

Push clamps -arrow A- into the brake hose


fixtures (on both vehicle sides).
Note

When installing the hand brake cables, pay


attention to the correct fitting position
Chapter.

102

Hook hand brake cables into the holders


-arrows- (on both vehicle sides).
Screw in screws of front wheelhouse liners on
both vehicle sides Body Work; Rep. gr.66.
Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the
test drive.
Caution

If after the test drive and with the front wheels


pointing straight ahead the steering wheel is off
straight, perform a chassis alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle
t
Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure
t
Use new screws!
t
Install in the marked position
Brake line holder to vehicle body
Screw for brake-power regulator

45 Nm + 90

30 Nm + 90

16 Nm
16 Nm

Removing and installing shock absorber/spring

Special tools and workshop equipment required


t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2Note
t The coil spring does not have to be removed in order to remove the shock absorber.
t The shock absorber does not have to be removed in order to remove the coil spring.
Remove the shock absorber
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

Remove wheel and raise vehicle.


Raise the relevant side of the axle body with the gearbox jack.

103

Screw out screws -1- and -2- and take out


shock absorber.
Remove spring
Remove wheel trim cap, for light-alloy wheels

remove the cap (pull-off hook in tool kit).


Remove wheel and raise vehicle.
Pull the wheel speed sensor cable out of the

supports.
Raise the relevant side of the axle body with

the gearbox jack.

Release screw -2-.


Lower the gearbox jack and remove the helical

spring.
Install
Installation is carried out in the reverse order.
Note

Make sure that the top base (rubber) for the


t spring is correctly fitted when inserting it into
the support of the body.
t Pay attention to colour coding.
The bottom short circuit in coil must always
t
point to the centre of the vehicle.

The beginning of the spring -arrow- must be


positioned at the stop at the top of the base.
Tightening torques:
Chapter.

104

Disassembling and assembling shock absorber

1Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
Note
The shock absorbers must not be disassembled and repaired.
2Protective cap
3Protective tube
4Stop buffer
5Top shock absorber bushing
6Self-locking screw, 25 Nm
t
replace after each removal
t counterhold the piston rod of the shock absorber in order to slacken and tighten the nut
7Protective cap

105

Repairing rear axle - disc brake


Removing and installing rear suspension

Special tools and workshop equipment required


t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2t Brake filling and bleeding device, e.g. -VAS 5234t
Remove plugs for brake line
t
Brake fluid Chapter
t
Assembly paste -G 052 150 A2Removing:
Note
Do not slacken the bracket for bonded rubber bush on body for the removal of the rear axle, otherwise the
overall track of the rear axle must be checked, adjusted if necessary.

Remove the screws -1- while the vehicle is


standing on its wheels. To do so, raise the
vehicle if necessary until the screws can be
reached.
Raise the vehicle to the height required for
installation in order to relieve tension from coil
spring.
Remove wheels.
Release the hand-brake.

106

Unclip brake cables -arrows-.


Detach retaining clips -2- from brake hose

fixture.

Separate brake line.


Note
Seal lines with plugs.

Unscrew the fixing screws -A- of the brake


caliper housing and secure the brake caliper
housing with wire to the body.
Unplug connectors from the wheel speed

sensors.
Unclip the speed sensor cable from the

brackets.
Support the rear axle with gearbox jack with
adapter, e.g. -V.A.G 1383 A- with -V.A.G
1359/2-.

Release the hexagon screws -1- of the rubbermetal bearing and remove the rear axle.
Install
Before inserting the rear axle, grease the
kidney-shaped cavities of the rubber-metal
bearings with assembly paste -G 052 150 A2-.
Installation is carried out in the reverse order.
Note

When tightening the screw of the rubber-metal


t bearing, the axle body must be in the horizontal
position (unladen condition).
When installing the hand brake cables, pay
t attention to the correct fitting position
Chapter.
Bleeding Brake System Chapter.
Once the steering gear has been installed it is then
important to check the position of the steering
wheel during a test drive.
If the vehicle drifts, a chassis alignment must be
performed.
107

Note
After slackening or changing the mounting
bracket, check the overall track of the rear axle,
adjust if necessary.
Tightening torques:
Shock absorber to body
t
Use new screws!
Rear suspension to bearing bracket
t
Use new screws and nuts!
Pipe screws to brake lines
Fixing screws for brake caliper

30 Nm + 90
45 Nm + 90
14 Nm
30 Nm + 30

Summary of components of rear axle

Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.

108

1234t
t
t

Wheel screw, 120 Nm


4 Nm
Brake disc
Cap
replace after each removal
press off Chapter, - Pos. 5
drive in Chapter, - Pos. 5
109

5Self-locking twelve-point nut 70 Nm +40


t
replace after each removal
6Wheel hub with wheel bearing and pulse rotor
t
only on vehicles with ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
removing and installing Chapter
t
must be replaced completely
730 Nm + 90
t
replace after each removal
8Cover plate
9Holder for hand-brake cable
t
replace
10 Hand-brake cable
11 45 Nm + 90
t
replace after each removal
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
12 Self-locking screw, 30 Nm + 90
t
replace after each removal
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
13 Self-locking nut
14 Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t avoid slackening in order to remove the rear axle
15 Holder for hand-brake cable
16 Rubber-metal bearing
t
removing and installing Chapter
17 20 Nm + 45
t
replace after each removal
18 Balancing weight
19 ABS wheel speed sensor
t
only on vehicles with ABS
20 8 Nm
21 Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
22 bottom base
23 Coil spring
t
removing and installing Chapter
t check for paint damage, if necessary eliminate paint damage
t Assignment Electronic Catalogue of Original Parts
t per rear axle only use helical springs of the same make
24 top base
t
installing Anchor
25 40 Nm + 90
t
replace after each removal
t
insert from the outside of the vehicle
t when tightening, take the installation angle of the rear axle to the shock absorber into account Fig.
110

While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and
tighten the screw
26 Self-locking screw, 30 Nm + 90
t
replace after each removal
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
27 Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
t per rear axle only use shock absorbers of the same make
Note
t

Shock absorbers are not to be repaired.


28 Self-locking nut
t
replace after each removal
29 Axle stud
t
Straightening work is not allowed!
t
Re-cutting the thread is not allowed
30 Protection against stones
31 Fixing element for protection against stones
t Protection against stones included in the scope of delivery
32 Brake line
33 30 Nm + 30
t
replace after each removal
34 Brake caliper
t
repairing Chapter

111

Installation angle of rear axle/shock absorber


1Shock absorber
2track control arm
- approx. 104

112

Replacing the rubber-metal bearing


Replacing the rubber-metal bearing - version 1

Special tools and workshop equipment required


t
Assembly device -MP5-400/1t
Assembly device -MP5-400/2t
Assembly device -MP5-400/3t
Assembly device (screw) -MP5-401/2t
Assembly device (nut) -MP5-401/3t
Assembly device (bearing) -MP5-402t
Pipe -T10263/6t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2Removing:

Raise vehicle and remove rear wheels.


Unscrew screws of front wheelhouse liners on both vehicle sides Body Work; Rep. gr.66.

Unhook handbrake cable from the holders


-arrows- (on both vehicle sides).

Release the clamps -arrow A- for attaching the


brake lines from the brake line holders (on both
vehicle sides).

113

Remove the screw -1- from the brake line


holder on the right vehicle side.
Unhook the brake lines from the line holders.

Do not separate the brake lines.


Vehicles with ABS
Unhook the ABS line from the clips.

Vehicles fitted with load-sensitive brake pressure


regulator (vehicles without ABS)

Release screw -1-.


Continued for all vehicles

Insert wooden insert -A- into the adapter e.g.


-V.A.G 1359/2Support the axle with engine/gearbox jack with

adapter.
Vehicles with fixing screws mounted on the
outside

114

Unscrew the nuts of the fixing screws -1- from


the axle.
Remove fixing screws -1- from the axle.
Vehicles with fixing screws mounted on the
inside

Remove the screws -2- of the bearing bracket


for the axle on the right vehicle side from the
body.
Note
Before removing the screws of the bearing
brackets for the axle, mark the position of the
bearing bracket on the body.
Remove the fixing screw -1- for the axle on the
left vehicle side from the bearing bracket for
the axle.
Slightly lower the rear axle out of the bearing

brackets so that the brake line is not damaged.


Remove the fixing screw -1- for the axle on the
right vehicle side from the bearing bracket for
the axle.
Remove the bearing bracket from the axle.
Continued for all vehicles
Secure axle e.g with wire to body.

Position assembly devices, as shown, and pull


the rubber-metal bearing -1- out of the axle
body -2-.
Note

115

The pipe -T10263/6- must be installed on the


rubber-metal bearing in such a way that the
contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g
with a sharp knife so that the pipe cutout
-arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the
plastic shoulder/rubber-metal bearing breaks
off. In case of breakage, a loud crack can be
heard.
Pull out rubber-metal bearing by turning the
assembly device (nut) -MP5-401/3-.
Counterhold the assembly devices by hand
when completing the pull-out process.
Remove assembly devices and unscrew
assembly device (nut) -MP5-401/3-.

Clamp the pipe -T10263/6- in the vice, as


shown in the fig.
Remove the rubber-metal bearing from the pipe
-T10263/6-, for example using a screwdriver,
drive out with a hammer if necessary.
Installing:

116

Fasten rubber-metal bearing -1- with assembly


devices and nut -2- and insert into the axle
body -3-.
Pay attention to the correct fitting position of

the rubber-metal bearing.

Fitting position of the rubber-metal bearing


Align orientation nubs -1- or orientation bead

-2- to edge of track control arm -3--arrow-.

117

Insert the rubber-metal bearing -1- by turning


the nut -MP 5-401/3- up to the stop in the axle
body -2-.
Check the fitting position of the rubber-metal

bearing.
Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
Vehicles with fixing screws mounted on the
outside
Carefully raise the rear axle so that the rubber metal bearing engages in the bearing brackets
for the axle.

Insert the new fixing screws -1- into the


bearing brackets for the axle.
Screw new nuts onto the fixing screws -1- for

bearing brackets of the rear axle and tighten.


Vehicles with fixing screws mounted on the
inside
Position the bearing bracket for the axle on the

right vehicle side on the rubber-metal bearing.

Insert a new fixing screw -1- from the inside


into the bearing bracket for the axle on the right
vehicle side.
Carefully raise the rear axle so that the rubber metal bearing engages on the left vehicle side
in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on
the right vehicle side rests at the same time
against the body in the marked position.
Screw the new fixing screws -2- of the bearing
bracket for the axle on the right vehicle side
into the body and tighten.
Continued for all vehicles
Note
When tightening the rubber-metal bearing screws
and nuts, the axle body must be in the unladen
condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
Vehicles fitted with load-sensitive brake pressure
118

regulator (vehicles without ABS)

Screw in the screw -1-.


Inspecting or adjusting the brake-power

regulator Chapter.
Continued for all vehicles

Install the screw -1- for the brake line holder on


the right vehicle side.
Hook on the brake lines in the line holders.

Push clamps -arrow A- into the brake hose


fixtures (on both vehicle sides).
Note

When installing the hand brake cables, pay


attention to the correct fitting position
Chapter.

119

Hook hand brake cables into the holders


-arrows- (on both vehicle sides).
Screw in screws of front wheelhouse liners on
both vehicle sides Body Work; Rep. gr.66.
Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the
test drive.
Caution

If after the test drive and with the front wheels


pointing straight ahead the steering wheel is off
straight, perform a chassis alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle
t
Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure
t
Use new screws!
t
Install in the marked position
Brake line holder to vehicle body
Screw for brake-power regulator

45 Nm + 90

30 Nm + 90

16 Nm
16 Nm

Replacing the rubber-metal bearing - version 2

Special tools and workshop equipment required


t
Assembly device -MP5-400/1t
Assembly device -MP5-400/2t
Assembly device -MP5-400/3t
Assembly device (nut) -T10254/4t
Assembly device (screw) -T10254/5t
Pipe -T10263/6t
Hydraulic cylinder -VAS 6178t
Foot pump -VAS 6179t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2Removing:

Raise vehicle and remove rear wheels.


Unscrew screws of front wheelhouse liners on both vehicle sides Body Work; Rep. gr.66.

120

Unhook handbrake cable from the holders


-arrows- (on both vehicle sides).

Release the clamps -arrow A- for attaching the


brake lines from the brake line holders (on both
vehicle sides).

Remove the screw -1- from the brake line


holder on the right vehicle side.
Unhook the brake lines from the line holders.

Do not separate the brake lines.


Vehicles with ABS
Unhook the ABS line from the clips.

121

Vehicles fitted with load-sensitive brake pressure


regulator (vehicles without ABS)

Release screw -1-.


Continued for all vehicles

Insert wooden insert -A- into the adapter e.g.


-V.A.G 1359/2Support the axle with engine/gearbox jack with

adapter.
Vehicles with fixing screws mounted on the
outside

Unscrew the nuts of the fixing screws -1- from


the axle.
Remove fixing screws -1- from the axle.
Vehicles with fixing screws mounted on the
inside

122

Remove the screws -2- of the bearing bracket


for the axle on the right vehicle side from the
body.
Note
Before removing the screws of the bearing
brackets for the axle, mark the position of the
bearing bracket on the body.
Remove the fixing screw -1- for the axle on the
left vehicle side from the bearing bracket for
the axle.
Slightly lower the rear axle out of the bearing

brackets so that the brake line is not damaged.


Remove the fixing screw -1- for the axle on the
right vehicle side from the bearing bracket for
the axle.
Remove the bearing bracket from the axle.
Continued for all vehicles
Secure axle e.g with wire to body.

Connect hydraulic line -1- of hydraulic pump


-VAS 6179- with quick coupling to hydraulic
cylinder -VAS 6178-.
Connect compressed air supply -2- with quick

coupling to hydraulic pump -VAS 6179-.

Position assembly devices, as shown, screw


together and counterhold by hand.
Note

123

The pipe -T10263/6- must be installed on the


rubber-metal bearing in such a way that the
t
contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g
with a sharp knife so that the pipe cutout
t
-arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the
plastic shoulder/rubber-metal bearing breaks
t
off. In case of breakage, a loud crack can be
heard.

Carefully depress the pedal of the hydraulic


pump -VAS 6179--arrow A-.
The hydraulic cylinder -VAS 6178- is therefore
activated.

Pull the rubber-metal bearing -1- out of the


axle body -2-.
Counterhold the assembly devices by hand

when completing the pull-out process.

124

Carefully depress the pedal of the hydraulic


pump -VAS 6179--arrow B-.
While doing so, the hydraulic cylinder -VAS
6178- returns to the initial position.
Remove assembly devices and unscrew

assembly device (nut) -T10254/4-.

Clamp the pipe -T10263/6- in the vice, as


shown in the fig.
Remove the rubber-metal bearing from the pipe
-T10263/6-, for example using a screwdriver,
drive out with a hammer if necessary.
Installing:

125

Position assembly devices, as shown, screw


together and counterhold by hand.
1Rubber-metal bearing
2Axle body
Pay attention to the correct fitting position of

the rubber-metal bearing.

Fitting position of the rubber-metal bearing


Align orientation nubs -1- or orientation bead

-2- to edge of track control arm -3--arrow-.


Carefully depress the pedal of the hydraulic

pump -VAS 6179--arrow A-.

126

The hydraulic cylinder -VAS 6178- is therefore


activated.

Insert the rubber-metal bearing -1- up to the


stop into the axle body -2-.
Check the fitting position of the rubber-metal

bearing.

Carefully depress the pedal of the hydraulic


pump -VAS 6179--arrow B-.
While doing so, the hydraulic cylinder -VAS
6178- returns to the initial position.
Remove assembly devices and unscrew

assembly device (nut) -T10254/4-.


Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
Vehicles with fixing screws mounted on the
outside
Carefully raise the rear axle so that the rubber metal bearing engages in the bearing brackets
for the axle.

127

Insert the new fixing screws -1- into the


bearing brackets for the axle.
Screw new nuts onto the fixing screws -1- for

bearing brackets of the rear axle and tighten.


Vehicles with fixing screws mounted on the
inside
Position the bearing bracket for the axle on the

right vehicle side on the rubber-metal bearing.

Insert a new fixing screw -1- from the inside


into the bearing bracket for the axle on the right
vehicle side.
Carefully raise the rear axle so that the rubber metal bearing engages on the left vehicle side
in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on
the right vehicle side rests at the same time
against the body in the marked position.
Screw the new fixing screws -2- of the bearing
bracket for the axle on the right vehicle side
into the body and tighten.
Continued for all vehicles
Note
When tightening the rubber-metal bearing screws
and nuts, the axle body must be in the unladen
condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
Vehicles fitted with load-sensitive brake pressure
regulator (vehicles without ABS)

128

Screw in the screw -1-.


Inspecting or adjusting the brake-power

regulator Chapter.
Continued for all vehicles

Install the screw -1- for the brake line holder on


the right vehicle side.
Hook on the brake lines in the line holders.

Push clamps -arrow A- into the brake hose


fixtures (on both vehicle sides).
Note

When installing the hand brake cables, pay


attention to the correct fitting position
Chapter.

129

Hook hand brake cables into the holders


-arrows- (on both vehicle sides).
Screw in screws of front wheelhouse liners on
both vehicle sides Body Work; Rep. gr.66.
Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the
test drive.
Caution

If after the test drive and with the front wheels


pointing straight ahead the steering wheel is off
straight, perform a chassis alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle
t
Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure
t
Use new screws!
t
Install in the marked position
Brake line holder to vehicle body
Screw for brake-power regulator

45 Nm + 90

30 Nm + 90

16 Nm
16 Nm

Removing and installing shock absorber/spring

Special tools and workshop equipment required


t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2Note
t The coil spring does not have to be removed in order to remove the shock absorber.
t The shock absorber does not have to be removed in order to remove the coil spring.
Remove the shock absorber
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

Remove wheel and raise vehicle.

130

Screw out screws -1- and -2- and take out


shock absorber.
Remove spring
Remove wheel trim cap, for light-alloy wheels

remove the cap (pull-off hook in tool kit).


Remove wheel and raise vehicle.
Disconnect the plug connection of the wheel

speed sensor cable.

Release screw -2-.


Lower the gearbox jack and remove the helical

spring.
Install
Installation is carried out in the reverse order.
Note

Make sure that the top base (rubber) for the


t spring is correctly fitted when inserting it into
the support of the body.
t Pay attention to colour coding.
The bottom short circuit in coil must always
t
point to the centre of the vehicle.

The beginning of the spring -arrow- must be


positioned at the stop at the top of the base.

Disassembling and assembling shock absorber

131

1Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
Note
The shock absorbers must not be disassembled and repaired.
2Protective cap
3Protective tube
4Stop buffer
5Top shock absorber bushing
6Self-locking nut, 25 Nm
t
replace after each removal
t counterhold piston rod of shock absorber at the tip in order to slacken and tighten the hexagon nut
7Protective cap

132

Repairing the wheel bearing


Repairing the wheel bearing, vehicles with front-wheel drive - drum brake

Special tools and workshop equipment required


t
Drive bushing -MP 3-427t
Assembly device -MP 5-403t
Hub cap extractor -MP 5-404t
Puller Kukko -20/2t
Puller Kukko -204/1-

14 Nm
2Brake drum
t reset brake before removing the brake drum Fig.
3Cap
t
replace after each removal
t
press off Fig. and Fig.
t
inserting Fig.
4Self-locking twelve-point nut 70 Nm +40
t
replace after each removal
5Wheel hub with wheel bearing and pulse rotor
t
only on vehicles with ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
133

Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel
t bearing, the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with
wheel bearing Fig..
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is
t
therefore not pressed on separately.
6Wheel hub with wheel bearing without pulse rotor
t
only on vehicles without ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
Note
Item
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
7Axle stud
t
Straightening work is not allowed!
8Axle body
t
Straightening work is not allowed!
t
Re-cutting the thread is not allowed

Resetting brake
To do so, use a screwdriver to push the wedge

up through a hole in the brake drum.


Remove the brake drum Chapter.

134

Press off cap


Release cap from its position by gently tapping

the claw.

Press off cap

135

Remove the wheel bearing housing from the axle


stud
Use puller (commercially available) Kukko
-20/2-.

Remove inner ring of the bearing from axle stud


Use puller (commercially available) Kukko
-204/1-.
Note
Do not damage the ABS wheel speed sensor
when pulling off the inner ring of the bearing.

Pull wheel hub with wheel bearing onto axle stud


Use assembly device -MP 5-403-.
Screw wheel hub with wheel bearing up to the

stop onto axle stud.


Screw on assembly device -MP 5-403- and pull

wheel hub with wheel bearing up to the stop.

136

Pull wheel hub with wheel bearing onto axle stud


Unscrew assembly device -MP 5-403- and

screw on new twelve-point nut and tighten.


Install brake drum Chapter.

Drive in cap
Note
t Replace cap after each removal.
Damaged caps allow moisture to penetrate.
t
Therefore absolutely use the shown tool.

Tightening torques:
Wheel hub with wheel bearing on axle stud

70 Nm + 40

Repairing the wheel bearing - disc brake

Special tools and workshop equipment required


t
Drive bushing -MP 3-427t
Assembly device -MP 5-403t
Hub cap extractor -MP 5-404t
Puller Kukko -20/2t
Puller Kukko -204/1-

137

1Brake disc, internally ventilated


t Assignment Electronic Catalogue of Original Parts
2Wheel screw, 120 Nm
34 Nm
4Brake disc
Assignment Electronic Catalogue of Original Parts
5Cap
t
replace after each removal
t
press off Fig. and Fig.
t
inserting Fig.
6Self-locking twelve-point nut 70 Nm +40
t
replace after each removal
7Wheel hub with wheel bearing and pulse rotor
t
only on vehicles with ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this wheel hub/wheel bearing unit is maintenance-free and has no play; it is not possible to undertake any
t
kind of adjustment or repair work on it!
t
only replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel
t bearing, the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with
wheel bearing Fig.
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is
t
therefore not pressed on separately.
138

8Axle body
t
removing and installing Chapter
9Brake caliper
t
dismantling Fig.
10 Axle stud
t
Straightening work is not allowed!
t
Re-cutting the thread is not allowed.

Press off cap


Release cap from its position by gently tapping

the claw.

Press off cap

139

Remove brake caliper


Unscrew screws -A-, remove brake caliper and

attach e.g. with wire to body.


Note
Do not unscrew the brake hose to remove the
brake caliper.
Unscrew the fixing screw of the brake disc and

remove brake disc.


Release twelve-point nut.

Remove the wheel bearing housing from the axle


stud
Use puller (commercially available) Kukko
-20/2-.

Remove inner ring of the bearing from axle stud


Use puller (commercially available) Kukko
-204/1-.
Note
Do not damage the ABS wheel speed sensor
when pulling off the inner ring of the bearing.

140

Pull wheel hub with wheel bearing onto axle stud


Use assembly device -MP 5-403-.
Fit the wheel hub with wheel bearing as far as

possible onto the axle stud.


Screw on assembly device -MP 5-403- and pull

wheel hub with wheel bearing up to the stop.

Pull wheel hub with wheel bearing onto axle stud


Screw on assembly device -MP 5-403- and

tighten wheel hub with twelve-point nut.


Install brake disc, screw in phillips head screw

and tighten.

Drive in cap
Note
t Replace cap after each removal.
Damaged caps allow moisture to penetrate.
t
Therefore absolutely use the shown tool.
Install brake caliper and tighten Allen screws.

Tightening torques:
Wheel hub with wheel bearing on axle stud
Securing screw for brake disc
Screws for brake caliper

70 Nm + 40
4 Nm
65 Nm

141

142

Repairing rear axle (vehicles with four-wheel drive)


Rear axle with four-wheel drive - Overview

Note
t
t

Always replace the self-locking nuts and screws.


Always replace the rusted screws/nuts.

1Assembly carrier
t
Summary of components Chapter
2Final drive
t removing and installing manual gearbox; Rep. gr.39.
t
repairing Manual Gearbox; Rep. gr.39
3Cross member
4Clamp
5Anti-roll bar
t If necessary eliminate paint damage and carry out protection work against corrosion
6Pressurized shock absorber
t
Summary of components Chapter
t
removing and installing Chapter
7The wheel bearing
143

t
pressing in and pressing out Chapter
8Trailing arm
t
Summary of components Chapter
9Suspension arm
t
Summary of components Chapter
10 Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
t
Summary of components Chapter
11 Stop buffer
t
Summary of components Chapter
12 Coil spring
t
Summary of components Chapter
13 Propshaft
t removing and installing manual gearbox; Rep. gr.39.
t
repairing Manual Gearbox; Rep. gr.39
14 60 Nm
15 Support for final drive

144

Coil spring and shock absorber on vehicles with four-wheel drive - Summary of components

160 Nm
t
replace after each removal
2Shock absorber bushing
3Pressurized shock absorber
t
removing and installing Chapter
t
check Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
can be replaced individually
t per rear axle only use shock absorbers of the same make
4Anti-roll bar
5Self-locking nut 25 Nm
t
replace after each removal
6110 Nm
7Coupling rod
8Trailing arm
t The thread -arrow A- for the support of the stop buffer Item is no longer applicable as of 08.99
if it is intended to install the stop buffer Item in the trailing arm before the manufacturing date 08.99,
t
the thread -arrow A- must be bored out to 10.5 mm
9Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
10 Stop buffer with threaded pin, 10 Nm
t
is no longer inserted as of 08.99
t the stop buffer is delivered as a spare part Item
145

11 Stop buffer with positioning pin


t
as of 08.99
t the correct installation position is determined by the positioning pin
t the positioning pin must be removed on the underside when using vehicles produced before 08.99
t The beginning of the spring coil must lie against the leg -arrowt
Fitting position of the coil spring Anchor
12 Coil spring
t
removing and installing Chapter
t check for paint damage, if necessary eliminate paint damage
t
check colour coding
t Assignment Electronic Catalogue of Original Parts
t
replace axle-wise
t per rear axle only use shock absorbers of the same make
13 Base
14 Thread in the frame side rail
if the thread of the weld nuts in the frame side rail is damaged, it can be repaired using Heli-Coli threaded
t
insert
t the rework of the thread for the weld nuts is permissible on maximum two screw points per vehicle side
t Observe the installation instructions of the manufacturer
15 Thread in the cross member
if the thread of the weld nut in the cross member is damaged, it can be repaired using Heli-Coli threaded
t
insert
t Observe the installation instructions of the manufacturer

Removing and installing coil spring

Special tools and workshop equipment required


t
Spring tensioning device, e. g. -V.A.G 1752/1t
Spring holder set, e.g. -V.A.G 1752/15The spring holder set consists of:
t Spring holder, -V.A.G 1752/1 5 L. U-. (bottom left)
t Spring holder, -V.A.G 1752/1 5 L. O-. (top left)
t Spring holder, -V.A.G 1752/1 5 R. U-. (bottom right)
t Spring holder, -V.A.G 1752/1 5 R. O-. (top right)
Note
The spring holder set -V.A.G 1752/15- was developed specially for vehicles with four-wheel drive. This
enables to securely remove and install the coil springs.
Extremely high forces are produced when tensioning the coil springs. Thus pay particular attention to the
t
following safety instructions.
WARNING
t

t Ensure that the spring holders are positioned as close as possible to the spring coils.
t During the tensioning operation, ensure that the spring holder is correctly located at the spring coils.
t
Do not use impact screwdriver!
Remove left coil spring

146

Mount the spring holder, e.g. -V.A.G 1752/1 5


L. U-, on the spring tensioning device, e.g.
-V.A.G 1752/1-.

Position the spring holder, e.g. -V.A.G 1752/1 5


L. O-, onto the highest spring coil within reach.

Insert spring tensioning device, e.g. -V.A.G


1752/1-.
Note

Do not use any impact screwdriver or anything


similar when tensioning the coil spring.

147

Turn the spindle of the spring tensioning device


clockwise until the claws -arrows- of the spring
tensioning device and the spring holder engage.
Insert the screw -1- from below onto the top
spring holder, screw on hexagon nut and
tighten.
Turn the spindle of the spring tensioning device

until the coil spring is slightly tensioned.


- Check if the spring holders are correctly
positioned at the spring coils, if necessary correct
position

Note
Make sure to end the tensioning operation once
the spring coils touch each other

Tension coil spring sufficiently until it can be


removed.
Take the coil spring with the spring tensioning

device out of the vehicle.


Take the coil spring out of the spring

tensioning device.
1 - Spring holder, e.g. -V.A.G 1752/1-.
2 - Spring holder, e.g. -V.A.G 1752/1 5 L. O-.
3 - Spring holder, e.g. -V.A.G 1752/1 5 L. U-.
Install left coil spring

The beginning of the spring coil must be


positioned in the spring holder as shown on the
spring holder -arrow-.
1Beginning of spring coils
Insert the coil spring into the spring tensioning
device, e.g. -V.A.G 1752/1-, with the spring
holders, e.g. -V.A.G 1752/1 5 L. U- and -V.A.G
1752/1 5 L. O- position.
- Check if the spring holders are correctly
positioned at the spring coils, if necessary correct
position.
Note
Do not use any impact screwdriver or anything
t similar when tensioning or detensioning the
coil spring.
Make sure to end the tensioning operation once
t
the spring coils touch each other.
Tension the coil spring sufficiently until it can

be installed in the vehicle.


148

Check which version of the stop buffer is


mounted on the trailing arm.
-I- - Stop buffer without stop for the coil spring
-arrow-Il- - Stop buffer with stop for the coil spring
-arrowInsert the coil spring with the spring tensioning
device into the vehicle according to the fitting
position.
Fitting position of the left coil spring

Vehicles without stop on the stop buffer:


The beginning of the spring coil -3- must be at
the 9.00 o'clock (9:00) position.
-1- Coil spring
-2- Stop buffer without stop for the coil spring
-F- direction of travel
Note
The theoretical line between 12.00 o'clock
(12:00) and 6.00 o'clock (6:00) faces parallel to
t
the longitudinal vehicle axis in direction of
travel.
The 9.00 o'clock (9:00) position is the same for
t
the left and right coil spring.
Never apply a mirror-image procedure for
t
installing the right coil spring.
Vehicles with stop on the stop buffer:
The beginning of the spring coil -3- must be
positioned at the stop -arrow-.
-1- Coil spring
-2- Stop buffer with stop for the coil spring
-F- direction of travel
Note
The fitting position is the same for the left and
right coil spring.
Never apply a mirror-image procedure for
t
installing the right coil spring.
Release the tension of the coil spring by turning
the spindle of the spring tensioning device anticlockwise.
- Check the correct fitting position of the coil
spring while carrying out the detentioning
procedure.
t

149

Unscrew the hexagon nut -1- and remove the


screw with the spring holder.
Take the coil spring out of the spring

tensioning device.
Removing and installing right coil spring
The removal and installation procedure of the
right coil spring is carried out in the same way as
for the left coil spring Chapter.
Instead of the special tools
Spring holder, e.g. -V.A.G 1752/1 5 L. U-.
t
(bottom left)
Spring holder, e.g. -V.A.G 1752/1 5 L. O-. (top
t
left)
the
Spring holder, e.g. -V.A.G 1752/1 5 R. U-.
t
(bottom right)
Spring holder, e.g. -V.A.G 1752/1 5 R. O-.
t
(bottom right) must be used.
Fitting position of the right coil spring
The fitting position of the right coil spring is
identical to the fitting position of the left coil
spring Anchor.

Removing and installing shock absorber

Special tools and workshop equipment required


t
Gearbox jack, e.g. -V.A.G 1383 At
Adapter, e.g. -V.A.G 1359/2Removing

Raise vehicle.

Remove wheel.

Remove coil spring Chapter.

Unclip wheel speed sensor cable from holder.

If necessary, partially slacken the wheel house


trim panel.

150

Unscrew top screw of shock absorber -arrow-.


Slowly lower trailing arm with gearbox jack
and adapter, e.g. -V.A.G 1383 A- with -V.A.G
1359/2-.

Unscrew bottom screw of shock absorber


-arrow-.
Remove shock absorber.
Install

If necessary, unbolt the coupling rod from the


anti-roll bar -arrow-.
In doing so, this facilitates the positioning of the
bottom screw for the shock absorber.
Further installation occurs in reverse order.

Tightening torques:
Shock absorber to body
60 Nm
t
Use new screws!
Shock absorber at trailing arm
110
Therefore the vehicle must be positioned on its wheels with the weight load of a person seated on Nm
t
the rear seat.
151

Anti-roll bar to coupling rod


t
Use new screws!
Wheel bolts

25 Nm
120
Nm

Trailing arm and suspension arm - Summary of components

Note
t
t
t
t
t

Never load the wheel bearing if the drive shaft was removed!
If the vehicle should be lowered onto its wheels and moved, the outer joint of a drive shaft must be
temporarily inserted.
Welding and straightening work is not allowed on the bearing and wheel control components of the
wheel suspension.
Self-locking nuts must always be replaced.
Always replace corroded self-locking nuts and screws.

1t

39 Nm
replace after each removal
152

t initially tighten crosswise to 10 Nm, then tighten crosswise to the recommended tightening torque
2Shim
3Assembly carrier
t
removing and installing Chapter
4Drive shaft with inner CV joint
t
removing and installing Chapter
t
repairing Chapter
570 Nm + 90
t
M12 x 1.5 x 80
t
replace after each removal
6Screw
t
M12 x 1.5 x 75
t
replace after each removal
7Top suspension arm
t
removing and installing Chapter
t different versions, assignment Electronic Catalogue of Original Parts
8Guide joint
t
removing and installing Chapter
9Collar screw, 80 Nm
10 Brake carrier with brake caliper
t
repairing Chapter
t
Removing and installing brake pads Chapter
11 10 Nm
12 Self-locking twelve-point nut
t
tighten Chapter
t
replace after each removal
13 4 Nm
14 Brake disc
t Assignment Electronic Catalogue of Original Parts
15 Brake disc, internally ventilated
t Assignment Electronic Catalogue of Original Parts
16 Wheel hub with pulse rotor for wheel speed sensor
t
The pulse rotor is welded with the wheel hub
t
Check axial run-out of pulse rotor Chapter
t
pressing in and pressing out Chapter
17 Circlip
t
replace after each removal
t
pay attention to correct position
18 Wheel bearing
t
pressing in and pressing out Chapter
t
replace, is damaged when pressing out
t The spare part only as a set wheel bearing with mounting parts (- Pos. 12 and - Pos. 17)
19 Cover plate
20 Self-locking nut, 70 Nm + 90
t
replace after each removal
21 Bottom suspension arm
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
22 Guide joint
t
removing and installing Chapter
153

23 90 Nm
t
replace after each removal
t
insert from the outside of the vehicle
24 Rubber-metal bearing
t
for trailing arm
t
removing and installing Chapter
25 Trailing arm
t
removing and installing Chapter
t The thread -arrow A- for the support of the stop buffer - Pos. 29 is no longer applicable as of 08.99
if it is intended to install the stop buffer - Pos. 30 in the trailing arm before the manufacturing date 08.99,
t
the thread -arrow A- must be bored out to 10.5 mm
26 75 Nm
t
replace after each removal
27 Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t the track can be corrected by moving the mounting bracket
28 Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
29 Stop buffer with threaded pin, 10 Nm
t
is no longer inserted as of 08.99
t the stop buffer is delivered as a spare part - Pos. 30
30 Stop buffer with positioning pin
t
as of 08.99
t the correct installation position is determined by the positioning pin
t the positioning pin must be removed on the underside when using vehicles produced before 08.99
t The beginning of the spring coil must lie against the leg -arrowt Fitting position of the coil spring Chapter and Chapter
31 Wheel speed sensor
t
removing and installing Chapter
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
32 8 Nm
33 Flange shaft of the rear axle gearbox

Pressing out and pressing in

Special tools and workshop equipment required


t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V. A. G 1359/2t Foot pump with high-pressure hose, e.g. -V.A.G 1389 A/1- (Paschke)
t Hydraulic removal and installation device for wheel bearing, e.g. -V.A.G 1459 B- (Paschke)
with the following individual tools:
t Hollow piston cylinder, e.g. -HKZ-15-, with pressure plate, e.g. -E-0-204Tt
Tie bolt, e.g. E-0-217 + 218
t
Special nut, e.g. -E-8-214t
Pressure plate, e.g. -E-5t
Centering with clamp, e.g. -E-76-2t
Supplementary kit, e.g. -V.A.G 1459 B/2with the following individual tools:
154

t
t
t
t
t
t
t
t

Pressure bushing, e.g. -E-44Bell, e.g. -E-40Pressure plate, e.g. -E-6-1Pressure plate, e.g. -E-13-1Thrust washer, e.g. -E-39- (-VAS 5146-)
Thrust plate -MP 3-467Washer -MP 6-416Extractor -Kukko 18-0Raise vehicle.
Remove wheel.
Removing drive shaft Chapter
Unscrew fixing screws -1- from brake carrier
and remove brake carrier with brake caliper.
Note

Top fixing screw of the brake carrier covered.


Tie brake caliper to the body. The brake line

must not be exposed to tension.


Screw out the Phillips head screws of the brake

disc and remove brake disc.


Remove the ABS wheel speed sensor from the

trailing arm housing Chapter.


Press out the wheel hub

Insert the thrust washer -1-.


Position the thrust washer -1- in such a way that it
rests fully on the screw heads -2-.
1 - Thrust washer, e.g. -E-39- (-VAS 5146-)

155

Mount centering with clamp, e.g. -E-76-2-.


Hollow piston cylinder, e.g. -HKZ-15-, with
1pressure plate, e.g. -E-0-204T- hydraulic
2Tie bolt, e.g. -E-0-2173 - Centering with clamp, e.g. -E-76-2High-pressure hose with quick coupling,
4 - component part of the foot pump, e.g. -V.A.G
1389 A/1-

Mount hollow piston cylinder -1- with tie bolt


-2-, bell -5- and special nut -4-.
Hollow piston cylinder, e.g. -HKZ-15-, with
1pressure plate, e.g. -E-0-204T2Tie bolt, e.g. -E-0-2173 - Pressure plate, e.g. -E-39- (-VAS 5146-)
4Special nut, e.g. -E-8-2145Bell, e.g. -E-40High-pressure hose with quick coupling,
6 - component part of the foot pump, e.g. -V.A.G
1389 A/1Build up a pressure by pumping with the foot

pump.
Check if all the tools are correctly centred, if

necessary correct position.


Note

Place gearbox jack with adapter, e.g. -V.A.G


1383/A- with -V.A.G 1359/2- underneath (risk of
accident due to falling parts while the wheel hub
is being pressed out).
Press the wheel hub out of the wheel bearing

by pumping.
Press out the wheel bearing

156

Remove circlip -1-.

Position the pressure plate -3- onto the reverse


side of the wheel bearing.
Mount hollow piston cylinder -1- with tie bolt

-2- and special nut -4-.


Hollow piston cylinder, e.g. -HKZ-15-, with
1pressure plate, e.g. -E-0-204T2Tie bolt, e.g. -E-0-2173Pressure plate, e.g. -E-54Special nut, e.g. -E-8-2145Bell, e.g. -E-44High-pressure hose with quick coupling,
6 - component part of the foot pump, e.g. -V.A.G
1389 A/1Build up a pressure by pumping with the foot

pump.
Check if all the tools are correctly centred, if

necessary correct position.


Press the wheel bearing out of the wheel
bearing housing of the trailing arm by
pumping.

Pull the inner ring of the bearing off the wheel


hub.
Insert washer -MP 6-416- as shown.
Screw the extractor -Kukko 18-0- into the

washer -MP 6-416-.


Position thrust plate -MP 3-467- onto wheel
hub and pull off the inner ring of the bearing by
turning the threaded spindle.
Press in the wheel bearing
Position the wheel bearing at the wheel-bearing

housing.

157

Position the pressure plate -3- onto the reverse


side of the wheel bearing housing.
Position hollow piston cylinder -1- with tie bolt

-5-, thrust piece -2- and special nut -4-.


Hollow piston cylinder, e.g. -HKZ-15-, with
1pressure plate, e.g. -E-0-204T2 - Pressure plate, e.g. -E-5-13-13Pressure plate, e.g. -E-6-14Special nut, e.g. -E-8-2145Tie bolt, e.g. -E-0-217High-pressure hose with quick coupling,
6 - component part of the foot pump, e.g. -V.A.G
1389 A/1Build up a pressure by pumping with the foot

pump.
Check if all the tools are correctly centred, if

necessary correct position.


Press the wheel bearing into the wheel bearing

housing of the trailing arm by pumping.


Note

t Replace circlip after each disassembly.


When inserting the circlip, pay attention to the
t
correct position of it.

Insert the new circlip -1-.


Pressing in the wheel hub
Position the wheel hub at the wheel bearing.

158

Mount centering with clamp, e.g. -E-76-2-.


Hollow piston cylinder, e.g. -HKZ-15-, with
1pressure plate, e.g. -E-0-204T2Tie bolt, e.g. -E-0-2173 - Centering with clamp, e.g. -E-76-2High-pressure hose with quick coupling,
4 - component part of the foot pump, e.g. -V.A.G
1389 A/1-

Position the pressure plate -4- onto the reverse


side of the wheel bearing housing.
Note

The shoulder -arrow- of the pressure plate -4must point to the special nut -3-.
Position hollow piston cylinder -1- with tie bolt

-2- and special nut -3-.


Hollow piston cylinder, e.g. -HKZ-15-, with
1pressure plate, e.g. -E-0-204T2Tie bolt, e.g. -E-0-2173Special nut, e.g. -E-8-2144Pressure plate, e.g. -E-5High-pressure hose with quick coupling,
5 - component part of the foot pump, e.g. -V.A.G
1389 A/1Build up a pressure by pumping with the foot

pump.
Check if all the tools are correctly centred, if

necessary correct position.


Then press in the wheel hub by pumping with

the foot pump.


Further installation occurs in reverse order.
Install ABS speed sensor Chapter.

Install brake disc.


Install brake carrier with brake caliper.
Install drive shaft Chapter.
Tightening torques:
Screw for ABS wheel speed sensor
Screw for brake disc
Brake carrier with brake caliper to trailing arm
Tighten drive shaft to flange shaft M8, diagonally across in 2 steps (I and II)
t
Use new screws!
Wheel bolt
Nut to wheel hub
159

8 Nm
4 Nm
80 Nm
I
II
10 Nm 39 Nm
120 Nm
50 Nm + 60

t
Always use new nut!
Tightening process Chapter.

Removing and installing rubber-metal bearing for trailing arm

Special tools and workshop equipment required


t
Assembly device -MP 5-401t
Assembly device -MP 5-402t
Assembly device -T10030t
Assembly device -T30016Remove trailing arm

Raise vehicle.

Remove wheel.

Remove coil spring -1- Chapter.


Unbolt the bracket for brake line -2- from the

trailing arm.
Unclip the brake line from the holder.

Mark the fitting position of the mounting


bracket on the body -arrows-.
Unscrew mounting bracket from body.

160

Mark the fitting position of the mounting


bracket -3- to the trailing arm -1-, e.g. with a
felt-tip pen.
See arrows and dot-dash line.
Unscrew screw -2- and remove mounting

bracket -3- from trailing arm.


Remove rubber-metal bearing from trailing arm.

Position the special tools as shown in the fig.


Pull out the rubber-metal bearing by turning

the spindle.
-A- Ring spanner
Insert rubber-metal bearing

Position the special tools as shown in the fig.


Insert the rubber-metal bearing by turning the

spindle.
Install trailing arm
The installation is carried out in the reverse order
Chapter.
If the fitting position of the mounting bracket to
the trailing arm was not marked, the fitting
position must be determined Chapter.

Removing and installing guide joint

Special tools and workshop equipment required


161

t
t
t
t

Assembly device -MP 5-401Assembly device -MP 5-402Assembly device -T10030Assembly device -T30017WARNING

If the top and bottom guide joint must be replaced, first of all remove the coil spring.

Remove coil spring Chapter.


Remove guide joint

Raise vehicle.

Remove wheel.

Unscrew bottom suspension arm from trailing


arm -arrow-.
Screw the wheel screw into the brake disc up to

the stop.

Fit the socket with two extensions onto the


wheel screw.
Press the extension slightly towards the top

-arrow- and release screw -2-.


Do not slacken the screw for the top
1suspension arm!
3Trailing arm
4 - Do not remove bottom suspension arm!
5Top suspension arm
Press the bottom suspension arm downwards
only as far as necessary so that the assembly
device can be mounted.

162

Position the special tool as shown.


Pull out the guide joint by turning the spindle.
Install bottom guide joint

Before positioning, mark the pressure piece


-T10030/1A- along the entire circumference.
Distance: 3 mm
The marking must be to the open side.
Note

The marking is needed for positioning the guide


joint in the trailing arm.

Position the special tool as shown.


Press in the guide joint -1- by turning the
spindle until the marking on the pressure piece

-T10030/1 A- reaches the support on the


trailing arm.
Slacken special tools, do not remove.
Check whether the guide joint is centred in the

support of the trailing arm.


If this is not the case, correct the fitting position

of the guide joint accordingly.


Install bottom suspension arm Chapter.

Attach the wheel.

Lower the vehicle.


Remove top guide joint
WARNING
If the top and bottom guide joint must be
replaced, first of all remove the coil spring.

Raise vehicle.

Remove wheel.
163

Unscrew screws -A-, remove brake caliper and


tie up with wire or anything similar.
Note

Do not unscrew the brake hose to remove the


brake caliper.
Screw out the screw for the brake disc and

remove the brake disc.

Unscrew screw -1- from the assembly carrier.


Unscrew nut -2- for top suspension arm.

Unscrew the nut of screw -1-.


Screw the wheel screw into the wheel hub up

to the stop.
Fit the socket with two extensions onto the

wheel screw.
Press the extension slightly towards the top

-arrow- and release screw -1-.

164

Press the extension downwards only as far as


necessary -arrow 1- so that the top suspension
arm -arrow 2- can be removed upwards.
Note
If the extension is pressed downwards too much,
the drive shaft can get damaged.
Pull the screw and the top suspension arm out

of the assembly carrier.

Position the special tool as shown.


Pull out the guide joint by turning the spindle.
Install top guide joint.

Before positioning, mark the pressure piece


-T10030/1A- along the entire circumference.
Distance: 3 mm
The marking must be to the open side.
Note

The marking is needed for positioning the guide


joint in the trailing arm.

165

Position the special tool as shown.


Press in the guide joint -1- by turning the
spindle until the marking on the pressure piece

-T10030/1 A- reaches the support on the


trailing arm.
Slacken special tools, do not remove.
Check whether the guide joint is centred in the

support of the trailing arm.


If this is not the case, correct the fitting position

of the guide joint accordingly.


Install top suspension arm Chapter.

Attach the wheel.

Lower the vehicle.

Removing and installing trailing arm

Special tools and workshop equipment required


t
Gearbox jack, e.g. -V.A.G 1383 At
Adapter, e.g. -V.A.G 1359/2Removing

Raise vehicle.

Remove wheel.

Remove coil spring -1- Chapter.


Unbolt the bracket for brake line -2- from the

trailing arm.
If necessary, unclip the brake line from the

holder.

Lower the vehicle.


Remove rear centre console Body

Work; Rep. gr.70.


Release the hand-brake.

166

Release the adjusting nut -1- so far until the


hand-brake cable can be unhooked from the
compensating clamp -2-.

Raise vehicle.

Lift off the clip -1- with a screwdriver and pull


down to remove.
Press the brake lever -2- in the -direction of the

arrow- and unhook the hand-brake cable -3-.

Remove the rubber grommet -arrow A- from


the trailing arm.
Unhook the hand-brake cable out of the bracket
-arrow- and pull it out of the trailing arm in
-direction of arrow-.
Remove drive shaft on the side Chapter.

167

Unclip cable for ABS wheel speed sensor from


bracket -arrows-.
Remove the ABS wheel speed sensor from the

trailing arm housing.

Unscrew fixing screws -1- from brake carrier


and remove brake carrier with brake caliper.
Note

Top fixing screw of the brake carrier covered.


Tie brake caliper to the body. The brake line

must not be exposed to tension.


Screw out the Phillips head screws of the brake

disc and remove brake disc.

168

Release the screws -1- and -2- for the


suspension arm.
3Top suspension arm
4Bottom suspension arm
5Trailing arm

Position the gearbox jack with adapter, e.g.


-V.A.G 1383A- with -V.A.G 1359/2-, under the
trailing arm.
Unscrew screw -1- of shock absorber.

169

Separate the brake lines at the pipe connection


-1-.
Close off immediately brake lines.
Mark the installed position of the bracket on

the body.
Unscrew mounting bracket from body

-arrows-.
Note

If it is intended to replace the trailing arm, the


mounting bracket must be modified.
The installation position of the mounting
t bracket must then be adjusted as described on
page Anchor.
Determine the fitting position of the bracket to
the trailing arm
t

Dimension -a- is 53.5 + 2 mm


1Bearing bracket
2Trailing arm
Install
Installation is carried out in the reverse order.
Bleeding Brake System Chapter.
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.

Tightening torques:
Brake carrier with brake caliper to trailing arm
Mounting bracket to trailing arm
Bracket to body
Suspension arm to trailing arm
t
Use new screws and nuts!
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Tighten drive shaft to flange shaft M8 diagonally across in 2 steps (I and II)
t
Use new screws!
Pipe connection of brake line
Wheel bolt
Nut to wheel hub
t
Always use new nut!
Tightening process Chapter.

170

80 Nm
90 Nm
75 Nm
70 Nm +
90
110 Nm

II
10
39
Nm
Nm
14 Nm
120 Nm
50 Nm +
60

Removing and installing suspension arm

WARNING
If the top and bottom suspension arm must be replaced, first of all remove the coil spring.

Remove coil spring Chapter.


Remove bottom suspension arm

Raise vehicle.

Remove wheel.

Unscrew bottom suspension arm from trailing


arm -arrow-.
Screw the wheel screw into the brake disc up to

the stop.

Fit the socket with two extensions onto the


wheel screw.
Press the extension slightly towards the top

-arrow- and release screw -2-.


Do not slacken the screw for the top
1suspension arm!
3Trailing arm
4Bottom suspension arm
5Top suspension arm

171

Screw out the screw -2- on the assembly


carrier.
Remove the bottom suspension arm -4- from

the assembly carrier.


Install bottom suspension arm
Further installation occurs in reverse order.
The screws for the bottom suspension arm must
only be tightened when the vehicle is standing on
its wheels!
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.

Tightening torques:
Suspension arm to trailing arm
t
Use new screws and nuts!
Suspension arm to assembly carrier
t
Use new screws and nuts!

70 Nm + 90
70 Nm + 90

Remove top suspension arm


WARNING
If the top and bottom suspension arm must be replaced, first of all remove the coil spring.

Raise vehicle.

Remove wheel.

Unscrew screw -1- from the assembly carrier.


Unscrew nut -2- for top suspension arm.

172

Unscrew the nut of screw -1-.


Screw the wheel screw into the brake disc up to

the stop.
Fit the socket with two extensions onto the

wheel screw.
Press the extension slightly towards the top

-arrow- and release screw -1-.

Press the extension downwards only as far as


necessary -arrow 1- so that the top suspension
arm -arrow 2- can be removed upwards.
Note
If the extension is pressed downwards too much,
the drive shaft can get damaged.
Pull the screw and the top suspension arm out

of the assembly carrier.


Install top suspension arm
Further installation occurs in reverse order.
The screws for the top suspension arm must only
be tightened when the vehicle is standing on its
wheels!
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.
Tightening torques:
Suspension arm to trailing arm
t
Use new screws and nuts!
Suspension arm to assembly carrier
t
Use new screws and nuts!
Assembly carrier to body
t
Use new screw!

70 Nm + 90
70 Nm + 90
110 Nm + 90

173

Summary of components - Assembly carrier with final drive

160 Nm
2Cross member
3Rubber-metal bearing for final drive
t
removing and installing Chapter
t Observe fitting position: kidney-shaped openings or arrow must point vertically upwards or downwards
4Rubber-metal bearings for assembly carrier
t are supplied as spare parts in a sealed plastic bag
t do not use any rubber-metal bearings which have been stored openly
t
removing and installing Chapter
t Observe fitting position: ribbed side must point upwards
5110 Nm + 90
t
replace after each removal
6Assembly carrier
t
removing and installing Chapter
7Support for final drive
840 Nm + 45
t
M10 x 40
t
replace after each removal
940 Nm + 45
174

t
M10 x 55
t
replace after each removal
10 Rear final drive
t removing and installing manual gearbox; Rep. gr.39.
11 Self-locking nut, 25 Nm
t
replace after each removal
12 Anti-roll bar
13 20 Nm
t mate both screws and initially tighten to 5 Nm, subsequently tighten
14 Clamp
15 Coupling rod

Removing and installing assembly carrier with final drive

Special tools and workshop equipment required


t
Gearbox jack, e.g. -V.A.G 1383 At
Support, e.g. -T10031Removing

Raise vehicle.

Remove wheels.

Remove coil springs Chapter.


Open double pipe clamp downstream of catalytic converter and remove rear exhaust pipe.

Remove heat shield from rear silencer.


Note
After unscrewing the propshaft, absolutely mark the fitting position. In the event of an offset installation,
the imbalance is too great.

Unscrew the propshaft from the final drive.


1 - Propshaft with mass damper
2Flange for propshaft
Do not turn the propshaft or the flange for the
propshaft.
Mark the fitting position of the propshaft and

the flange for the propshaft -Pfeile-.

Lower the vehicle.


Remove the centre console Body

Work; Rep. gr.68.


Release the hand-brake.

175

Release the adjusting nut -1- so far until the


hand-brake cable can be unhooked from the
compensating clamp -2-.

Raise vehicle.

Lift off the clip -1- with a screwdriver and pull


down to remove.
Press the brake lever -2- in the -direction of the

arrow- and unhook the hand-brake cable -3-.

Remove the rubber grommet -arrow A- from


the trailing arm.
Note

If it is intended to only lower the assembly


carrier, e.g. when replacing the rubber-metal
bearings, the hand-brake cables must not be
pulled out of the trailing arm.
Unhook the hand-brake cable out of the bracket
-arrow- and pull it out of the trailing arm in
-direction of arrow-.

176

Unclip cable for ABS wheel speed sensor from


holder -arrows-.
Remove the ABS wheel speed sensor from the

trailing arm housing.

Separate the brake lines at the pipe connection


-1-.
Close off immediately brake lines.

Unscrew bottom screw of shock absorber


-arrow-

177

Position the gearbox jack with adapter, e.g.


-V.A.G 1383 A- with -T10031-, under the
assembly carrier -1-.

Guide the bolts -1- into the holes of the


assembly carrier -arrows-.
Disconnect vacuum line and electrical line.
Mark the installed position of the bracket on

the body.

Unscrew mounting bracket from body


-arrows-.

178

Release screws for assembly carrier -arrows-.


Slowly lower rear axle with gearbox jack and

adapter, e.g. -V.A.G 1383 A- with -T10031-.


Install
Installation is carried out in the reverse order.
Tighten the screws for the assembly carrier and
the mounting brackets on the marked fitting
position.
Bleeding Brake System Chapter.
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.

Tightening torques:
Bracket to body
t
Use new screws!
Assembly carrier to body
t
Use new screws!
Propshaft at final drive
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Pipe connection of brake line
Wheel bolt

Removing and installing rubber-metal bearing for assembly carrier

Special tools and workshop equipment required


t
Pipe section -MP 3-409t
Assembly device -MP 5-402t
Assembly device -T10030Removing

Raise vehicle.

Remove wheels.

Remove coil springs Chapter.


Remove assembly carrier with final drive Chapter.
179

75 Nm
110Nm +
90
60 Nm
110 Nm

14 Nm
120 Nm

Position the special tools.


Pull out the rubber-metal bearing by turning

the spindle.
Install
Note
The rubber-metal bearings are supplied as spare
parts in a sealed plastic bag.
Do not use any rubber-metal bearings which
t
have been stored openly!
t

Mount the rubber-metal bearing with the


special tools.
For the correct installation position of the rubbermetal bearing in the assembly carrier, the ribbed
side must point in the -direction of the arrow B-.
The collar of the special tool -T10030/4--arrow
A- points to the rubber-metal bearing -1-.
If necessary, coat the rubber-metal bearing with

water for inserting.

Position the rubber-metal bearing and the


special tools on the assembly carrier.
Insert the rubber-metal bearing by turning the

spindle.
-A- Ring spanner
The ribbed side of the rubber-metal bearing

must point upwards -arrow-.


Note

For removing and installing the front rubbermetal bearings on the assembly carrier, the
spindle must be inserted from below.
Further installation occurs in reverse order.
Install assembly carrier with final drive

Chapter.
Bleeding Brake System Chapter.
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.
Tightening torques:
180

Bracket to body
t
Use new screws!
Assembly carrier to body
t
Use new screws!
Propshaft at final drive
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Pipe connection of brake line
Wheel bolt

Removing and installing rubber-metal bearing for final drive

Special tools and workshop equipment required


t
Assembly device -MP 5-401t
Assembly device -MP 5-402t
Assembly device -T10030t
Assembly device -T30016
Raise vehicle.

Remove wheels.

Remove coil springs Chapter.

Remove assembly carrier with final drive


Chapter.
To do so, use gearbox jack with adapter, e.g.

-V.A.G 1383 A- with -T10031-.

Support final drive -1-.


Note

For reason of clarity the surrounding was not


shown in the fig. S42-0100.

181

75 Nm
110Nm +
90
60 Nm
110 Nm

14 Nm
120 Nm

If necessary, remove the anti-roll bar -3-.

Release screws -1-.


Remove the clamp -2- and the anti-roll bar with

bearing and coupling rod.


4Assembly carrier
Note
For reason of clarity the surrounding was not
shown in the fig. S42-0101.

Remove plug connection -1- from holder.


Unscrew splined nut -arrows-.
Remove suspension arm -2- from final drive.

Slacken the internal serration screw -1- of the


support for final drive -2- on both sides.
Move the final drive by approx. 15 to 20 mm

-arrow-.

182

Position the special tools.


Pull out the rubber-metal bearing by turning

the spindle.
Install
Fitting position of the rubber-metal bearing

The kidney-shaped openings -A- or the arrow on


the rubber-metal bearing -1- must point vertically
upwards or downwards.
Permissible variation of the vertical line 2.
If necessary, coat the rubber-metal bearing with

water for inserting.

Position the special tools.


1Rubber-metal bearing
Insert the rubber-metal bearing by turning the

spindle.
Install assembly carrier with final drive

Chapter.

183

If removed, install the anti-roll bar -3- with the


coupling rod, a 2nd mechanic is required.
Position the clamp -2- on the bearing, mate

both screws -1- and initially tighten to 5 Nm.


Tighten both screws to the specified tightening

torque.
4Assembly carrier
Further installation occurs in reverse order.
Bleeding Brake System Chapter.
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.

Tightening torques:
Bracket to body
t
Use new screws!
Assembly carrier to body
t
Use new screws!
Anti-roll bar to assembly carrier
Propshaft at final drive
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Cross member for final drive to assembly carrier
Support for final drive to assembly carrier
Pipe connection of brake line
Wheel bolt

184

75 Nm
110Nm +
90
20 Nm
60 Nm
110 Nm

60 Nm
60 Nm
14 Nm
120 Nm

Repairing drive shaft


Removing and installing a drive shaft

Special tools and workshop equipment required


t
Extractor -MP 6-425t
Torque wrench, e.g. -V.A.G 1756Removing
Note
The wheel bearing must not be loaded when the twelve-point nut is loose. At full load the wheel bearing
is initially damaged through the vehicle's own weight, thus shortening the life of the wheel bearing.
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
t
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Assignment Electronic Catalogue of Original Parts
Left and right drive shaft
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).

Raise the vehicle until the front axle is free of stress.


Thus the wheel must still touch the ground.

Slacken twelve-point nut.

Raise the vehicle to working height.


t

Unscrew the drive shaft -1- from the flange


shaft of the final drive -2-.
Left drive shaft

Press the exhaust system -1- to the side using


an assembly lever.
Remove inner joint of drive shaft -2- from final

drive.
The further work procedure is now valid again for
both sides.
Release twelve-point nut.
Note

While pushing out the drive shaft make sure there


is sufficient clearance.

185

Push out the drive shaft.


AWheel bolts
Remove the drive shaft.
Install
Remove possible paint and/or corrosion residue
from the thread/the serration of the outer joint
Before inserting the drive shaft, moisten the

following parts with oil.


t Serration of the outer joint
t Thread of the outer joint
t Serration of the wheel hub
The contact surface and the thread of the new
t
twelve-point nut

Insert drive shaft.


Insert outer joint as far as possible into the

serration of the wheel hub.


Insert the outer joint into the wheel hub by
screwing on the twelve-point nut until the outer
joint rests in the wheel bearing.
Position the inner joint of the drive shaft onto
the flange shaft of the final drive and tighten
the screws to 39 Nm.
Lower vehicle, when doing so, ensure that the

wheels do not yet touch the ground.


If the wheel bearings are loaded through the
vehicle's own weight, the wheel bearing will be
initially damaged. This shortens the life of the
wheel bearing.
Depress brake pedal (assistance of second

mechanic required) or pull on the handbrake.


Tighten new twelve-point nut to 250 Nm and

release by one turn.


Torque wheel hub a further min. 90.
Tighten twelve-point nut:
Tightening torque:
50 Nm + 60
Note

186

The torque wrench is recommended e.g. for


tightening the twelve-point nut -V.A.G 1756-.

Repairing drive shaft with CV joint

Special tools and workshop equipment required


t
Circlip pliers, e.g. -VW 161 At
Pressure plate -MP 3-406t
Pressure plate -MP 3-407t
Pressure spindle -MP 3-448t
Strutting bushing -MP 6-428t
Tensioner -MP 6-429t
Tensioning pliers, e.g. -V.A.G 1682t
Workshop press, e.g. -V.A.G 1290 ANote
t
t
t

Assignment Electronic Catalogue of Original Parts


Grease joint if necessary, when replacing the joint boot.
Spread the grease mass evenly in the joint boot.

187

1Outer CV joint
t
must be replaced completely
t
removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t
grease Chapter
t
check Chapter
2Circlip
t
replace
t
insert into the groove at the shaft
3Thrust ring
t
Fitting position Fig.
4Disc spring
t
Fitting position Fig.
5Open warm-type clamp
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682- Fig.
6Joint boot
t
Material: Hytrel (Polyelastomere)
t
inspect for tears and chafing points
7Open warm-type clamp
t
replace
t
tensioning Fig.
8Drive shaft (solid shaft)
t Assignment Electronic Catalogue of Original Parts
939 Nm
t
M8 x 48
10 Shim
188

11 Open warm-type clamp


t
replace
t
tensioning Fig.
12 Joint boot for inner CV joint
t
Material: Hytrel (Polyelastomere)
t
inspect for tears and chafing points
t
remove with a drift
13 Disc spring
t
Fitting position Fig.
14 Inner CV joint
t
must be replaced completely
t
pressing off Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
15 Gasket
t The adherend on the inner CV joint must be free of grease and oil!
t
replace
t Remove the protective foil and stick the gasket into the inner joint
16 Circlip
t
replace
t remove and install with sprung pliers, e.g. -VW161 AGrease quality and grease quantity
Note
The CV joints are filled with grease for operating at normal temperatures e.g. -N 052 738.00-.
Grease
of which in:
Outer joint
Total amount
Joint
Joint boot
mm
[g]
[g]
[g]
90
90
40
40
Inner joint
100
120
50
70

189

Removing outer CV joint


Drive off the drive shaft with a strong blow of

a plastic hammer.

Pressing out the inner CV joint


Note
t First of all drive off joint boot with a drift.
t
Support ball hub.

Fitting position of the disc spring at inner joint


1Disc spring

190

Fitting position of the disc spring and thrust ring


on the outer joint
1Disc spring
2Thrust ring

Pressing in the inner CV joint


Note
Chamfer on inner diameter of the ball hub
(serration) must point towards the bearing collar
of the drive shaft.
Press the joint up to the stop.

Insert the circlip.


Note

t
t
t
t
t

In view of the hard material (as opposed to


rubber) of the joint boot, which requires the use
of a stainless steel open warm-type clamp, the
latter can only be correctly tightened with
tensioning pliers, e.g. -V.A.G 1682-.
Tightening torque: 20 Nm
Use a torque wrench.
Make sure the thread of spindle -A- of the
tensioning pliers is smooth. If necessary grease
with grease, e.g. molykote -MOS2-.
If it is not smooth, e.g. if the thread is dirty, the
necessary clamping force of the open warmtype clamp is not reached at the given torque.

191

Tighten the open warmtype clamp on the outer


joint (at the large
diameter)
Position the tensioning
pliers, e.g. -V.A.G
1682-, as shown in the
fig. Make sure the

cutting edges of the


pliers are positioned in
the corners -arrows Bof the open warm-type
clamp.
Tighten the open warmtype clamp by turning
the spindle with a
torque wrench (do not
tilt the pliers during this
process).
Spindle of tensioning
Apliers
Cutting edges of
Btensioning pliers
Tighten the open warm-type clamp on the outer
joint (small diameter)
Position the tensioning pliers, e.g. -V.A.G
1682-, as shown in the fig. Make sure the

cutting edges of the pliers are positioned in the


corners -arrows B- of the open warm-type
clamp.
Tighten the open warm-type clamp by turning
the spindle with a torque wrench (do not tilt the
pliers during this process).
ASpindle of tensioning pliers
B - Cutting edges of tensioning pliers
CTorque wrench

192

Tighten the open warm-type clamp on the inner


joint
Position the tensioning pliers, e.g. -V.A.G
1682-, as shown in the fig. Make sure the

cutting edges of the pliers are positioned in the


corners -arrows B- of the open warm-type
clamp.
Tighten the open warm-type clamp by turning
the spindle with a torque wrench (do not tilt the
pliers during this process).
ASpindle of tensioning pliers
B - Cutting edges of tensioning pliers
CTorque wrench

193

Wheels, tyres. axle align


Vehicle alignment
General points

The vehicle must only be aligned using an alignment gauge released by the manufacturer!
It is recommended to align the front and rear axles during each vehicle alignment procedure.
Otherwise correct vehicle driving behaviour cannot be guaranteed!
Note
Only perform a vehicle alignment after the first 1000 to 2000 km to allow the helical springs to fully
settle.
t During adjustment work try to approximate the nominal values.
For vehicles equipped with ESP, the basic setting must be carried out after the axial measurement,
t
function 04, group 060 Chapter.
If the fitting position of the rear axle and hence the running direction of the vehicle are not considered this
could result in a skewed steering wheel.
Removing and installing steering wheel Body Work; Rep. gr.69.
It is necessary to perform a vehicle alignment in the event of:
t
incorrect driving behaviour;
t damage caused by accident and if parts have been replaced;
t
axle parts have been removed;
t
there is unilateral tyre wear.
Front axle part replaced Chassis alignment required Rear axle part replaced Chassis alignment required
yes
no
yes
no
track control arm
X
Shock absorber
X
Wheel-bearing housing
X
Coil spring
X
Track rod/track-rod ends
X
Complete rear axle
X
1)
Steering gear
X
Assembly carrier
X
1)
Assembly carrier
Bottom suspension arm
X
X
Top suspension arm 1)
Suspension strut
X
Trailing arm 1)
X
t

1)

Only on vehicles with four-wheel drive

194

Test conditions

l Determine the chassis version according to the vehicle data sticker Chapter.
Check the wheel suspensions, wheel bearing, steering and steering linkage for impermissible play and
l
damage, if necessary repair.
l Check tyre inflation pressure, if necessary correct BookletOctavia or fuel-tank cap sticker.
Check the tyre tread depth. The difference between the left and right tyres on an axle must not exceed 2
l
mm.
l The unladen weight of the vehicle must correspond with the vehicle documents.
Unladen weight: Weight of the vehicle with full fuel tank and full water reservoir for windscreen
wiper/washer and headlamp cleaning system, spare wheel, tool kit, jack and without driver. The spare
wheel, tool kit and jack must be located in the position prescribed by the vehicle manufacturer.
Vehicle must be aligned, with the springs having been repeatedly deflected and having returned to their
l
original position.
l Make sure that during alignment no sliding base and no rotating plate touch the limit stop.
l The steering wheel must be in the posItion required to drive straight ahead .
Very important!
The measuring device must be positioned and adjusted in compliance with the specifications; observe the
l
manufacturer's instructions!
If necessary obtain information on your alignment gauge from the manufacturer.
In the course of time the alignment platform and alignment gauge/alignment computer may deviate from
their original adjustment/setting.
The alignment platform and alignment gauge/alignment computer must be tested and adjusted during a
maintenance operation at least once a year or following the manufacturer's instructions and if necessary be
adjusted!
Treat these precision instruments with great care.

Measurement preliminaries

The lateral runout on the rims must be balanced (compensated).


Correct toe-in adjustment is impossible if the rim run-out has not been compensated!
Comply with the instructions of the alignment gauge manufacturer.

Perform a rim runout compensation.

Lower vehicle and deflect the springs.


Insert brake pedal arrester, e.g. -V.A.G

1238/B-.
Overview of the work sequence for vehicle
alignment
The following sequence of work steps must
always be respected!
Determine what chassis has been mounted in
1 - the vehicle. This information can be found on
the vehicle data sticker Chapter.
Check camber on front axle, if necessary take
2the mean Chapter.
3 - Check camber on rear axle Chapter.
Checking the track on the rear axle, if
4 - necessary taking the mean/adjusting
Chapter.
Vehicles with front-wheel drive: The track of the
195

rear axle is not adjustable, only take the mean of


the track.
Vehicles with four-wheel drive: The track on the
rear axle is adjustable.
Check the track on the front axle, if necessary
5adjust Chapter.
The following always applies!
Always check the transversal inclination of the
vehicle before adjustment if one of the measuring
values is outside the tolerance Chapter.

196

Chassis terms
Nominal values for vehicle alignment

t
t

Nominal values front axle Chapter


Nominal values rear axle Chapter

Checking the transversal inclination of the vehicle

Transversal inclination of the vehicle straight-ahead position


It is possible the vehicle is skew if the measured values lie outside the tolerance of the nominal values for
the front and rear axle ( Chapter).
RHD vehicles or e. g. vehicles with an automatic gearbox may be slightly skew.
This is normal and is due to the fitting locations of the assemblies and the related weight transfer.
Deflect the vehicle repeatedly and allow the springs to return to their original position.
Note
Only determine dimension a on the rear axle.
Determining dimension a for the left and

right vehicle side.


-a-left - left vehicle side
-a-right- right vehicle side
= 90
Compare dimensions -a-left and -a-right.
The deviation between -a-left and -a-right must
neither exceed nor fall short of 5.0 mm.
Correct any deviations outside the tolerance of

5.0 mm.
If the deviation is exceeded, e.g. 8,0 mm, correct
the difference on the rear axle on the relevant side
by placing weights in the boot.
Suitable weights are e.g. sand bags approx. 10
kg

Checking the camber on the front axle, if necessary take the mean

The camber cannot be adjusted, it can only be centred!


If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
It is only possible to evenly center the camber within the tolerance range by shifting the complete enginegearbox assembly carrier.

197

Release screws -1- and - 2-.


Move the assembly carrier until the camber is

equal on both sides.


Subsequently check the castor.
When moving the assembly carrier the castor may
change.
Tighten the assembly carrier with new screws.

Tightening torques:
Assembly carrier to body
t
Screw position -1t
Use new screws!
Assembly carrier to body
t
Screw position -2t
Use new screws!

100Nm + 90

100Nm + 90

198

Checking the camber on the rear axle

The camber cannot be adjusted.


If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
If the measured values still lie outside the tolerance, check the axle body for damage and if necessary
replace.

Checking the track on the rear axle, if necessary taking the mean/adjusting

If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
Vehicles with front-wheel-drive
The overall track of the rear axle is not adjustable.
It is only possible to take the mean of the individual track values equally by moving the mounting brackets.
Loosen all screws of the mounting bracket -1-.
Move the bracket of the rear axle -1- in

transverse direction.
-2- Rear axle body
Tighten screws: 30 Nm + 90.
Always use new screws!
If the measured values still lie outside the
tolerance, check the axle body for damage and if
necessary replace.
Vehicles with four-wheel drive
The overall track value of the rear axle is
adjustable.

Loosen all screws of the mounting bracket -1-.


Move the mounting bracket -1- in transverse

direction.
2Trailing arm
Tighten screws: 75 Nm.
Always use new screws!
Check the overall track after adjusting the
single track. The overall track must correspond
with the specified nominal value Chapter.

199

Checking the track on the front axle, adjusting if necessary

If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
Release counternut -1 -.
Adjust track by turning the left and/or right

track rod.
Position open-end wrench on hexagon -arrow-.
Check that the bellows have not become twisted
after turning the track rods!
Twisted bellows wear fast. Bellows replace if
damaged.
Tighten counternut -1- with 50 Nm and again

check track value.


After tightening counternut -1- the set value may
change slightly.
Make sure this value remains within the tolerance
for the nominal value. If this is not the case repeat
the track adjustment operation.

Checking the left and right steering angle

This check is only required if:


t the steering angles differ by more than 2 from the steering centre.
t at full steering angle the tyres come into contact with components on the front axle or body on one side,
t
the left/right turning clearance circle differs.
The distance between the components on the
front axle and the tyres -arrow- must be the same
on both sides at maximum steering angle.
If the distance is unequal it is possible to correct
the distance by turning the left and right track
rod.
Example:
The distance between the front axle components
and the tyres is smaller on the right than on the
left.
Release the counternuts on the track rods.
Turn the track rod on the left (slightly unscrew

from track-rod end).


Turn the track rod on the right to the same

extent (screw into track-rod end).

Check overall track.


After this adjustment procedure the overall track
must correspond with the specified nominal
value!
Tighten counternuts to 50 Nm.
After tightening the counternuts the set value may
change slightly.
Make sure this value remains within the tolerance
for the nominal value. If this is not the case repeat
200

the overall track adjustment operation.


Check that the bellows have not become twisted
after turning the track rods!
Twisted bellows wear fast. Bellows replace if

damaged.

Calculation of the misalignment on the rear axle

Note
The indicated values are only given as an example.
For track values with the same preceding sign (+/+ or -/-) subtract the smaller value from the greater

value and divide by 2.


Track value
Track value
on the left rear wheel
on the right rear wheel
+ 15'
+ 5'
15' - 5' = 10'
10' : 2 = 5'
Misalignment of the rear axle = 5'
Value with a different preceding sign (+/-) are added up and the sum is divided by 2.
Track value
Track value
on the left rear wheel
on the right rear wheel
+ 15'
+ 5'
15' + 5' = 20'
20' : 2 =10'
Misalignment of the rear axle = 10'
The relevant result is the actual deviation of the running direction from the longitudinal vehicle axis.

201

Wheels and tyres

Wheel/tyre combinations Chapter


General points

For safety reasons never change tyres individually but at least in axle pairs.
Tyres with the greatest tread depth must always be fitted at the rear.
It is recommended to fit tyres of the same make, same type and tread pattern on all wheels.
When replacing the disc wheel or the tyre always replace the rubber valve.
Mount the tyre with the DOT marking pointing towards the outside of the wheel. This applies only to the
left side of the vehicle for directional tyres.
For directional tyres mount a wheel/tyre combination for the right side of the vehicle as spare wheel.

Disc wheel

Note
t Because of design variations the disc wheel and wheel trim cap may differ from the figure.
t When using anti-theft wheel bolts, the anti-theft bolt must be as close as possible to the valve.

12t
t
3-

Tyres
Wheel rims
6J x 14 H2, ET38
6J x 15 H2, ET38
Wheel screw, 120 Nm
202

4Remove wheel trim cap


5Pull-off hook
6Wheel bolt key
t
included in tool kit
7Balancing weights
t
max. 60 g allowed per rim flange
8Retaining spring for balancing weights
9Valve
t only use valve in accordance with spare part catalogue

Light-alloy wheel

Because of design variations the light alloy rim and wheel trim cap may differ from the figure.

12t
t
t
345t
67-

Tyres
Light-alloy rim
6J x 15H2, ET38
6.5J x 15 H2, ET43
6.5J x 16 H2, ET42
Wheel screw, 120 Nm
Wheel bolt key
Pull-off shackle
included in tool kit
Cap
Wheel trim cap
203

8Adapter for anti-theft wheel bolt


9Cap for anti-theft wheel bolt
10 Anti-theft wheel bolt, 120 Nm
11 Balancing weights
t
max. 60 g allowed per rim flange
12 Retaining spring for balancing weights
13 Valve
t only use valve in accordance with spare part catalogue
Vehicles with tyre repair set

koda vehicles are equipped, depending upon vehicle equipment, with a spare wheel or a tyre repair set
(BREAKDOWN SET).

The tyre repair set is located in the luggage


compartment where the spare wheel is normally
situated. In addition to the compressor -1-, it also
contains a tyre inflation bottle with sealant -2-.

Tyre sealant

The tyre sealant in the bottle is perishable.

Therefore, the best before date is given on the


bottle -arrow-.
In this example the best before date 05/2003 has
expired, therefore the bottle must be replaced. If
the bottle was opened, e.g. when having a flat
tyre, it must also be replaced.

204

205

Tyre disassembly

A tyre which was filled or sealed with tyre sealant must be cleaned, e.g. with a damp cloth, after detaching it
from the wheel rim (when it is repaired).
WARNING
The tyre sealant must not come in contact with the eyes or the skin.
The tyre sealant is harmful to your health, it can cause eye irritation or allergy.
Wear safety gloves and safety goggles during work.

Detach the tyre from the wheel rim.

Clean the wheel rim e.g. with a damp cloth.


Change the damaged tyre, if necessary contact Customer Service regarding a possible tyre repair.

Assembly of new tyres

Ensure that the wheel rim is cleaned.

Fit a new tyre valve e.g. using the tool -VAS


6459--1-.
Screw out valve core.
Inflate tyre to 0.3...0.4 MPa (3...4 bar),
whereby the bead must be heard to slip off the
rim edge.
Screw in valve core.
Correct the pressure to the required value.
Balance the wheel.

206

Disposing of tyre sealant

t Tyre sealant or residues of this should not be mixed with other wastes / fluids.
Residues of tyre sealant must be collected and stored in plastic tanks and transferred to the contract dealer
t who is responsable for waste materials. This is also valid for agents with expired best before dates.
Sealant as waste is listed in the waste catalogue under the number 08 04 10 as hazardous waste.

207

ABS, ADR, TCS, EDL, ESP


Antilock braking system (ABS) ITT Mark 20 IE
Safety precautions, basic information on fault finding and on repairing ABS and ABS/EDL ITT
Mark 20 IE

The ABS, ABS/EDL are vehicle safety systems; system knowledge is required for working on such
systems.
Faults are indicated by the warning light for the
-ABS K47--1- and the red warning light for the
hand brake/brake fluid level -KU/33--2-.
t
Certain faults are not detected until after a
minimum speed of 20 km/h has been exceeded
(conduct a road test).
If the ABS warning light -K47- and the warning
light for the hand brake/brake fluid level
-K14/33- do not light up and if in spite of this
t
the brake system is not fully operational, look
for the fault in the conventional brake system
Chapter and Chapter.
Notes on rectifying sudden faults Technical
Service Handbook binder Current Flow
t
Diagrams, Electrical Fault Finding and Fitting
Locations
t

208

Notes on repair work on ABS and ABS/EDL ITT Mark 20 IE

t
t
t
t
t

t
t
t
t
t
t
t
t
t
t
t
t
t
t
t

Before commencing work on the ABS system it is necessary to interrogate the fault memory in order to
check complaints and conduct specific fault finding.
Do not separate plug connections unless the ignition is switched off.
Before commencing work on the ABS, ABS/EDL, switch off the ignition and disconnect the earth strap at
the battery. On models fitted with a coded radio set, pay attention to the coding; determine if necessary.
Welding work using electric welding equipment may affect the ABS, ABS/EDL system.
Before commencing welding work using electrical welding tool:
Disconnect the terminal from the negative pole of the battery and cover the negative pole, if necessary
remove the battery.
Connect the earth connection of the electric welding tool directly to the part to be welded. There must not
be any electrically insulated parts between the earth connection and the welding point.
Electronic control units and electrical wiring must not touch the earth connection or the welding
electrode.
Do not drive the vehicle if the connector is unplugged from the control unit.
Only carry out work on the hydraulic control unit within the repair measures mentioned here.
When carrying out work on the antilock brake system, ensure scrupulous cleanliness, on no account use
agents containing mineral oils, such as oil, greases, etc.
Thoroughly clean connection points and the surrounding area before disconnecting, but do not use any
aggressive cleaning agents, such as brake cleaner, petroleum, thinner or similar.
Place removed parts on a clean surface and cover.
After separating the control unit/hydraulic unit use the transport protection for valve domes.
Carefully cover or close opened components if the repair is not completed immediately. (Use screw plug
from the repair set SP no. -1 HO 698 311 A-)
Do not use fluffy cloths.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
If the system is opened, avoid working with compressed air and avoid moving the vehicle.
Ensure that no brake fluid is able to flow into the connectors.
Observe the current regulations when handling brake fluid Chapter.
After completing work which involved opening the brake system, bleed brake system with brake filling
and bleeding device, e.g. -VAS 5234-, Chapter.
During the subsequent road test, ensure that at least one controlled brake application is performed (pulsing
must be felt on the brake pedal).

209

Required technical information

t Binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
t Self-study programme no. 26: vehicle safety - new technical information
t
Technical Service Handbook

210

Distinguishing features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE
General Instructions

The ABS prevents the wheels from locking during a brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhesion. This also applies when reversing.
The brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake
servo unit.
Vehicles fitted with ABS and ABS/EDL ITT Mark 20 IE do not have a mechanical brake pressure regulator.
Specifically matched software in the control unit, the electronic brake pressure distribution, EBD, regulates
the brake pressure on the rear axle.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104- form the hydraulic control
unit. A repair is only possible in the removed condition.
New control units supplied through the Parts Division are not coded. They must be coded after installation
Chapter.

ABS ITT Mark 20 IE

distinguishing features:
t Dimension -A-: 100 mm.
8 valve domes: The protective sleeves for the
t valves are visible if the control unit is separated
from the hydraulic unit Chapter.
Control unit identification. The control unit
version is shown on the display of the vehicle
system tester -V.A.G 1552-. Select function 01
t
interrogate control unit version Chapter.
ABS without CAN BUS ABS with CAN BUS
electronic catalogue of original parts
t Overview of selectable functions Chapter.

ABS/EDL ITT Mark 20 IE

211

distinguishing features:
t Dimension -A-: 130 mm.
10 valve domes: The protective sleeves for the
t valves are visible if the control unit is separated
from the hydraulic unit Chapter.
Control unit identification. The control unit
version is shown on the display of the vehicle
system tester -V.A.G 1552-. Select function 01
t interrogate control unit version Chapter.
ABS/EDL without CAN BUS ABS/EDL with
CAN BUS electronic catalogue of original
parts
t Overview of selectable functions Chapter.

Fitting position ABS or ABS/EDL ITT Mark 20 IE

Left-hand drive vehicles


1Brake servo unit 10''
2Hydraulic unit
25-pin control unit screwed to the hydraulic
3unit

Right-hand drive vehicles


1Brake servo unit 7''/8''
2Hydraulic unit
25-pin control unit screwed to the hydraulic
3unit

212

213

Self-diagnosis
Self-diagnosis functions

Vehicles with data BUS (CAN BUS)


As the control units are interlinked over a data BUS line, always start fault finding by interrogating the
contents of the fault memories of all the control units fitted to the vehicle.
The interrogation of the fault memory is performed with the key function 00 - Automatic test sequence.
When doing so check whether a possibly stored fault might affect the ABS system.
All vehicles
The 25-pin ABS control unit -J104- together with the hydraulic unit forms a compact unit. The unit is
located in the left of the engine compartment. The control unit is equipped with a fault memory. The
connection for self-diagnosis is located in the storage compartment on the driver's side.
Self-diagnosis relates to the electrical/electronic part of the ABS, i. e. faults are detected only over the
electrical connection to the control unit (e.g. open circuit of a wheel speed sensor).
The control unit detects faults during the operation of the vehicle and stores them in a permanent memory,
whose information is retained even if the battery voltage is disconnected.
Faults which occur sporadically (isolated) are likewise detected and stored. If this fault no longer occurs
during 50 vehicle starts and driving-off procedures, it is erased from the fault memory (fault delete counter),
with the exception of the fault Control unit defective.
After the ignition is switched on, the ABS warning light -K47- and the red warning light for the hand
brake/brake fluid level -K14/33- light up for approx. 2 seconds.
During this period a test sequence (self-check) is performed in the control unit with the following functions:
t
Test of supply voltage, min. 10.0 V
t
Test of control unit including valve coils.
t
Check of control unit coding
t Static test of the wheel speed sensor (without speed signal)
After a start-up, should it appear that the speed signal is not O.K as of approx. 20 km/h, the ABS warning
t
light lights up again -K47-.
Systematically initiate self-diagnosis at the start of fault finding and retrieve the stored information using the
vehicle system tester -V.A.G 1552- or fault read-out scan tool -V.A.G 1551Note
The following description only relates to the vehicle system tester -V.A.G 1552- using the current
program card.
The use of the fault reader -V.A.G 1551- with integrated printer is similar. A minor deviation on the
t
display read-out is possible.
t To end the self-diagnosis or to switch to another address word select function 06 End output.
t Identify the faults displayed by referring to the fault table and subsequently carry out the fault elimination.
On vehicles with the ABS system, the functions Reading measured value block, Coding control unit,
Basic setting (only necessary for vehicles with EDL) and the Final control diagnosis are added to the
self-diagnosis.
t

214

Indication of faults by means of warning


lights -K47- and -K14/33-

If the ABS warning light (-K47-) -1- does not


go out after the ignition is switched on and after
t
completion of the test sequence, the causes of
the fault may be:
a - the voltage supply is less than 11 volts
An ABS fault is present. If an ABS fault is
present, the anti-lock brake system remains
bswitched off while the conventional brake
system remains fully operational.
a wheel speed sensor fault existed after the
last vehicle start (sporadic fault). In case of a
wheel speed sensor fault, the ABS warning
clight goes out automatically after restarting the
vehicle and after a speed above 20 km/h is
reached.
Line interruption between dash panel insert
and control unit -J104- binder Current
dFlow Diagrams, Electrical Fault Finding and
Fitting Locations.
e - Dash panel insert defective
If the ABS warning light goes out but the
warning light for the hand brake/brake fluid
t
level (-K14/33-) remains lit -2-, the causes of
the fault may be:
a - the hand-brake is still applied
bBrake fluid level too low
Line fault binder Current Flow Diagrams,
c - Electrical Fault Finding and Fitting
Locations.
If the ABS warning light -1- and the warning
light for the hand brake/brake fluid -2- do not
t
go out, then the ABS and EBD (Electronic
Brake pressure Distribution) have failed.
In this case, a change in braking behaviour can be
expected as the brake pressure on the rear wheels
is no longer regulated.
the switch -K14/33- for the warning light (dF9-) is defective or incorrectly adjusted

215

Vehicle fitted with ABS/EDL - EDL does not operate

Special tools and workshop equipment required


t
Vehicle system tester -V.A.G 1552t
Diagnostic cable -V.A.G 1551/3Complaint: Vehicle EDL system does not operate
When dealing with this complaint a possible fault cause may be that the brake light switch is incorrectly set
or is not operating Chapter, set display group number 003 and brake light switch Chapter.

216

Perform self-diagnosis
Test requirements

l Approved tyre size fitted to all wheels; tyres inflated to the specified pressure.
Mechanical/hydraulic part of the brake system together with the brake light switch and brake lights
l
operating properly.
No leaks in hydraulic connections and lines (visual inspection of hydraulic unit, brake calipers, wheel
l
brake cylinders, tandem brake master cylinder).
l
Wheel bearings and wheel bearing play O.K.
l Control unit correctly bolted to the hydraulic unit.
l Plug connection on control unit -J104- correctly plugged in (lock is engaged).
l Inspect plug contacts of ABS components for damage and correct fitting.
l All fuses according to current flow diagram O.K (to check remove fuses from the fuse holder).
l
Supply voltage O.K. (minimum 10.0 V).

Connecting vehicle system tester -V.A.G 1552- and selecting function

Special tools and workshop equipment required


t
Vehicle system tester -V.A.G 1552t
Diagnostic cable -V.A.G 1551/3Note
t During self-diagnosis the ABS function is disconnected in the control unit.
t After completing the repair and interrogating the fault memory, it can be erased.

When the ignition is switched off, connect


vehicle system tester -V.A.G 1552- with

diagnostic cable -V.A.G 1551/3- to the


diagnostic connector.

Interrogating control unit version

Readout on display:
Vehicle system test
If no readout appears in the display, check plug connection for self-diagnosis HELP
Select function XX
- electrical test Chapter and further, test steps 14 and 15.
217

Note
Additional operating instructions can be displayed via the HELP button of
the -V.A.G 1552- according to the program.
t The button is used for moving forward in the program.

Switch on ignition.
Readout on display:
Vehicle system test
Enter 03 for address word Brake electronics and confirm
HELP

entry with key Q.


Select function XX
Vehicles without CAN BUS
On the display appears, e.g. the display:
The display shows:
t the control unit identification number, e.g. 1J0907379
t the system designation, e.g. ABSITTAE20GI
1J0907379 ABS ITTAE20GI V00
->
t
the version number, e.g. V00
Coding 03604
WSC XXXXX
t the code No. of the control unit, e.g. 03604
the workshop code (WSC) Operating instructions vehicle
t
system tester V.A.G 1552
Vehicles with CAN BUS
1J0907379H ABS/EDL 20 IE CAN 0001
->
On the display appears, e.g. the display:
Coding
13504
WSC
XXXXX
Vehicles with MK 60
On the display appears, e.g. the display:
Continued for all vehicles
Assignment of the control unit electronic catalogue of original
parts.
Code the control unit Chapter.
If the control unit identification number is not displayed
1C0907379C ABS FRONT MK60 0102
Chapter.
->
Coding 0001025
WSC

Press key.
XXXXX
Note
t

After pressing the HELP button an overview of the possible


functions is displayed:
If the button is pressed, the programme returns to the initial
position.
Vehicle system test
Readout on display:
Select function XX
Overview of selectable functions Chapter.

218

HELP

Overview of selectable functions

00 01 02 03 04 05 06 07 08 1)

Page
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter

Automatic test sequence


Interrogating control unit version
Interrogating fault memory
Actuator diagnosis
Initiate basic setting 1)
Erasing fault memory
Ending output
Coding control unit
Reading measured value block

only required for vehicles with EDL

Interrogating fault memory

Readout on display:
Enter 02 for the function Interrogate fault memory and confirm

the entry with the key Q.

Vehicle system test


HELP
Select function XX

The number of stored faults or No fault recognised appears in the display.

X faults detected!

Press button.
The stored faults are displayed in sequence.
No fault
Note the fault message displayed in the fault table Chapter. For MK60
detected!

Chapter.
If No fault detected, the program returns to its initial position after the button is
pressed:
Readout on display:
End output (function 06) Chapter.
Switch off ignition and disconnected vehicle system

tester.
Note
Vehicle system test
HELP
Select function XX

If a fault is detected:
t
1. Rectify fault (repair)
t 2. Interrogate fault memory (function 02)
t 3. Erase fault memory (function 05)
t 4. End output (function 06)
t
5. Road test
t 6. Interrogate the fault memory again

Automatic test sequence


219

Note
With the automatic test sequence, all fault memory contents of the control units are interrogated.

Switch on ignition
Readout on display:
Vehicle system test
HELP
Enter 00 for function Automatic test sequence and confirm

Select function XX
entry with key Q.
The control unit identification is shown on the display.
1J0907379 H ABS/EDL 20 IE
->
After this all the control unit identifications with possible entries in the CAN 0001
Coding 13504
fault memories appear in the display.
WSC XXXXX
End output (function 06) Chapter.

Fault table

Note
As the control units are interlinked over a data BUS line, always start fault finding by activating the key
t function 00 Automatic test sequence on all control units fitted to the vehicle. This allows to interrogate
all the control units fitted in the vehicle in order to determine their possible faults.
All the possible faults which can be detected by the ABS control unit -J104- and can be displayed by the
t
-V.A.G 1552-, are listed according to their 5-digit fault code.
t
The fault table may also display the fault type.
t The column Fault elimination refers to certain test steps in the electrical test.
Before replacing components found to be faulty, test all corresponding plug connections, lines and earth
t connections according to the current flow diagram binder Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
After carrying out the repair, always interrogate and erase the fault memory using the vehicle system
t
tester -V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
t After the test drive interrogate the fault memory again.
Vehicles without CAN BUS
Readout on
Possible cause of fault
Rectifying fault
display
-V.A.G 1552No fault
If after repair No fault detected is displayed, the self-diagnosis is completed. If the ABS
detected
does not operate without fault in spite of the display read-out No fault detected, proceed as
follows: 1. Perform a test drive at a speed above 20 km/h, 2. Interrogate the fault memory
again, if still no fault is stored, 3. continue fault finding without self-diagnosis and perform
the electrical test completely Chapter.
00283
Open circuit, short-circuit to positive or
Inspect wiring and plug connections according
Front left
to earth or loose contact in the wiring
to the current flow diagram binder Current
t
wheel speed
between wheel speed sensor -G47- and
Flow Diagrams, Electrical Fault Finding and
sensor -G47ABS control unit -J104Fitting Locations
Perform electrical Test Chapter.
t

Damage to the pulse rotor or to the


wheel speed sensor -G47-

t Wheel speed sensor coil -G47- defective

220

Check the wheel speed sensor -G47- and the


pulse rotor for damage.

Replace pulse rotor or wheel speed sensor


-G47- Chapter and Chapter.

If the fault occurs again:


Replace ABS control unit -J104- Chapter.

t ABS control unit -J104- defective

Readout on
Possible cause of fault
display -V.A.G
155200283
Open circuit, short-circuit to positive or
Front left wheel to earth or loose contact in the wiring
t
speed sensor
between wheel speed sensor -G47- and
-G47ABS control unit -J104signal outside
the tolerance 1)

Rectifying fault

Inspect wiring and plug connections


according to the current flow diagram

binder Current Flow Diagrams,


Electrical Fault Finding and Fitting
Locations
Perform electrical Test Chapter.

Electrical malfunctions due to external


Reading measured value block Chapter

t interference (high-frequency irradiation,


display group number 001.
e.g. non-insulated ignition cable)
t

Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G47- and

speed sensor -G47the pulse rotor for damage.

Air gap between wheel speed sensor


t -G47- and pulse rotor too great (signal
N.O.K.)
00283
Air gap between wheel speed sensor
Front left wheel t -G47- and pulse rotor too great (signal
speed sensor
N.O.K.)
-G47mechanical fault
1)

t
1)

Exhaust valves in the hydraulic unit


-N55- defective

Replace pulse rotor or wheel speed sensor


-G47- Chapter and Chapter.

Check the installation of the wheel speed


sensor -G47- and the pulse rotor Chapter
and Chapter.
Reading measured value block Chapter;

display group number 002.


Performing actuator diagnosis Chapter.
If the fault occurs again:
Replace hydraulic unit -N55- Chapter.

The type of fault can only be detected as of 20 km/h (perform test drive).

Readout on
Possible cause of fault
Rectifying fault
display -V.A.G
155200285
Open circuit, short-circuit to positive or
Inspect wiring and plug connections
Front right
to earth or loose contact in the wiring
according to the current flow diagram
t
wheel speed
between wheel speed sensor -G45- and binder Current Flow Diagrams,
sensor -G45ABS control unit -J104Electrical Fault Finding and Fitting
Locations
Perform electrical Test Chapter.
t

Damage to the pulse rotor or to the


wheel speed sensor -G45-

t Wheel speed sensor coil -G45- defective


t ABS control unit -J104- defective

00285
Front right

Replace pulse rotor or wheel speed sensor


-G45- Chapter and Chapter.
If the fault occurs again:
Replace ABS control unit -J104
Chapter.

t Open circuit, short-circuit to positive or


221

Check the wheel speed sensor -G45- and


the pulse rotor for damage.

Inspect wiring and plug connections

speed sensor
-G45signal outside
the tolerance 1)

to earth or loose contact in the wiring


between wheel speed sensor -G45- and
ABS control unit -J104-

according to the current flow diagram


binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations.
Perform electrical Test Chapter.

Electrical malfunctions due to external


Reading measured value block Chapter;

t interference (high-frequency irradiation,


display group number 001.
e.g. non-insulated ignition cable)
t

Damage to the pulse rotor or to the


wheel speed sensor -G45-

Air gap between wheel speed sensor


t -G45- and pulse rotor too great (signal
N.O.K.)
00285
Air gap between wheel speed sensor
Front right
t -G45- and pulse rotor too great (signal
speed sensor
N.O.K.)
-G45mechanical fault
1)

t
1)

Exhaust valves in the hydraulic unit


-N55- defective

Check the wheel speed sensor -G45- and


the pulse rotor for damage.

Replace pulse rotor or wheel speed sensor


-G45- Chapter and Chapter.

Check the installation of the wheel speed


sensor -G45- and the pulse rotor Chapter
and Chapter.
Reading measured value block Chapter;

display group number 002.


Performing actuator diagnosis Chapter.
If the fault occurs again:
Replace hydraulic unit -N55- Chapter.

The fault can only be detected as of 20 km/h (perform test drive).

Readout on
display -V.A.G
155200287
Rear right wheel
t
speed sensor
-G44-

Possible cause of fault

Rectifying fault

Open circuit, short-circuit to positive or


Inspect wiring and plug connections
to earth or loose contact in the wiring
according to the current flow diagram
between wheel speed sensor -G44- and binder Current Flow Diagrams,
ABS control unit -J104Electrical Fault Finding and Fitting
Locations.
Perform electrical Test Chapter.
Damage to the pulse rotor or to the
wheel speed sensor -G44-

t Wheel speed sensor coil -G44- defective


t ABS control unit -J104- defective

Check the wheel speed sensor -G44- and


the pulse rotor for damage.

Replace pulse rotor or wheel speed sensor


-G44- Chapter and Chapter.
If the fault occurs again:
Replace ABS control unit -J104
Chapter.

00287
Open circuit, short-circuit to positive or
Inspect wiring and plug connections
Rear right speed to earth or loose contact in the wiring
according to the current flow diagram
t

sensor -G44between wheel speed sensor -G44- and


binder Current Flow Diagrams,
signal outside
ABS control unit -J104Electrical Fault Finding and Fitting
1)
the tolerance
Locations.
Perform electrical Test Chapter.
Electrical malfunctions due to external
Reading measured value block Chapter;

t interference (high-frequency irradiation,


display group number 001.
e.g. non-insulated ignition cable)
222

Damage to the pulse rotor or to the


wheel speed sensor -G44-

Air gap between wheel speed sensor


t -G44- and pulse rotor too great (signal
N.O.K.)
00287
Air gap between wheel speed sensor
Rear right speed t -G44- and pulse rotor too great (signal
sensor -G44N.O.K.)
mechanical fault
1)

t
1)

Exhaust valves in the hydraulic unit


-N55- defective

Check the wheel speed sensor -G44- and


the pulse rotor for damage.

Replace pulse rotor or wheel speed sensor


-G44- Chapter and Chapter.

Check the installation of the wheel speed


sensor -G44- and the pulse rotor Chapter
and Chapter.
Reading measured value block Chapter;

display group number 002.


Performing actuator diagnosis Chapter.
If the fault occurs again:
Replace hydraulic unit -N55- Chapter.

The fault can only be detected as of 20 km/h (perform test drive).

Readout on
Possible cause of fault
display -V.A.G
155200290
Open circuit, short-circuit to positive or
Speed sensor
to earth or loose contact in the wiring
t
rear left -G46between wheel speed sensor -G46- and
ABS control unit -J104-

Rectifying fault

Inspect wiring and plug connections


according to the current flow diagram

binder Current Flow Diagrams,


Electrical Fault Finding and Fitting
Locations.
Perform electrical Test Chapter.

Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the

speed sensor -G46pulse rotor for damage.

t Wheel speed sensor coil -G46- defective


t ABS control unit -J104- defective

00290
Open circuit, short-circuit to positive or
Rear left wheel
to earth or loose contact in the wiring
t
speed sensor
between wheel speed sensor -G46- and
-G46ABS control unit -J104signal outside
the tolerance 1)

Replace pulse rotor or wheel speed sensor


-G46- Chapter and Chapter.
If the fault occurs again:
Replace ABS control unit -J104
Chapter.

Inspect wiring and plug connections


according to the current flow diagram

binder Current Flow Diagrams,


Electrical Fault Finding and Fitting
Locations.
Perform electrical Test Chapter.

Electrical malfunctions due to external


Reading measured value block Chapter;

t interference (high-frequency irradiation,


display group number 001.
e.g. non-insulated ignition cable)
t

Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the

speed sensor -G46pulse rotor for damage.

Air gap between wheel speed sensor


t -G46- and pulse rotor too great (signal
N.O.K.)
00290
Air gap between wheel speed sensor
Rear left speed t -G46- and pulse rotor too great (signal
sensor -G46N.O.K.)
223

Replace pulse rotor or wheel speed sensor


-G46- Chapter and Chapter.

Check the installation of the wheel speed


sensor -G46- and the pulse rotor Chapter
and Chapter.

mechanical fault

t
1)

Reading measured value block Chapter;


display group number 002.
Performing actuator diagnosis Chapter.
If the fault occurs again:
Replace hydraulic unit -N55- Chapter.

1)

Exhaust valves in the hydraulic unit


-N55- defective

The fault can only be detected as of 20 km/h (perform test drive).

Readout on
Possible cause of fault
Rectifying fault
display -V.A.G
155200668
Open circuit, short-circuit to positive
Inspect wiring and plug connections according
t
Onboard
or earth
to the current flow diagram binder Current

voltage tml. 30
Flow Diagrams, Electrical Fault Finding and
signal outside
Fitting Locations
the tolerance
Perform electrical test Chapter and continue.
01044
ABS control unit -J104- incorrectly
Check coding of the ABS control unit -J104t

Control unit
coded
Chapter
wrongly coded
Bridge in the multi-pin connector to
Inspect wiring and plug connections according
the ABS control unit -J104- from
to the current flow diagram binder Current
t
contact 3 to contact 14 interrupted or
Flow Diagrams, Electrical Fault Finding and
short-circuited
Fitting Locations.
Perform electrical test Chapter and

continue.
01130
Electrical malfunctions due to

Erase fault memory.


ABS operation
external interference (high-frequency Perform a test drive at a speed above 20 km/h.
t
implausible
irradiation, e.g. non-insulated ignition Interrogate the fault memory again.
signal1)
cable)
Open circuit, short-circuit to positive
Inspect wiring and plug connections according
or earth
to the current flow diagram binder Current
Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
Perform electrical test Chapter and

continue.
If the fault occurs again:
t ABS control unit -J104- defective
Replace ABS control unit -J104- Chapter.
t

01276
Plug connection E-engine to control Performing actuator diagnosis Chapter.
t
ABS hydraulic
unit
pump -V64signal outside
the tolerance 1)
Open circuit, short-circuit to positive
Inspect wiring and plug connections according
t
or earth
to the current flow diagram binder Current
Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
Perform electrical Test Chapter.
t ABS hydraulic pump -V64- defective

224

If the hydraulic pump -V64- starts without


fault when carrying out the test step no. 18 in
the electrical test Chapter, then the ABS
control unit must be replaced -J104-.

t ABS control unit -J104- defective


1)

Replace ABS control unit -J104- Chapter.

The fault can only be detected as of 20 km/h (perform test drive).

Readout on display
Possible cause of fault
-V.A.G 155201312
ABS control unit -J104t
Databus drive
incorrectly coded
1)
defective
or
Engine control unit
t
incorrectly coded
t

Databus drive
defective 1)
sporadic

Open circuit, short-circuit


to positive or earth

Rectifying fault

Check coding of the ABS control unit -J104 Chapter

Check engine control unit Rep. gr. 01 of the


relevant engine identification character

Inspect wiring and plug connections according to the


current flow diagram binder Current Flow

Diagrams, Electrical Fault Finding and Fitting


Locations.
Perform electrical test Chapter and continue.

Ignition key turns too

slowly in the ignition lock

Erasing fault memory Chapter


No further measures required.
Inform customer (inform).

01314
Open circuit in the data
Check databus cables and plug connections according
Engine control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow

no communication
positive or to earth
Diagrams, Electrical Fault Finding and Fitting
Locations
Perform electrical test Chapter and continue.
01315
Open circuit in the data
Check databus cables and plug connections according
Gearbox control
t BUS lines, short-circuit to to the current flow diagram binder Current Flow

unit 2)
positive or to earth
Diagrams, Electrical Fault Finding and Fitting
no communication
Locations
Perform electrical test Chapter and continue.
01316
Open circuit in the data
Check databus cables and plug connections according
Brake control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow

no communication
positive or to earth
Diagrams, Electrical Fault Finding and Fitting
Locations
Perform electrical test Chapter and continue.
1)

The fault data BUS drive defective does not result in the ABS warning light -K47- or the hand
brake/brake fluid level warning light -K14/33- lighting up. The ABS function is fully maintained.
2)
Only on vehicles with automatic gearbox.
Readout on display
-V.A.G 155218256
Please read out fault
memory of the engine
CU

Possible cause of fault


t

Rectifying fault

Fault entry in 4AV


Read out fault memory of the engine control unit
control unit
Rep. gr. 01 of the relevant engine identification
character

225

65535
Control unit defective

ABS control unit


-J104- defective

Replace control unit -J104- Chapter.

Erasing fault memory

Requirements:
l
Fault memory was interrogated

Press key.
Readout on display:
Enter 05 for the function Erase fault memory and confirm the

entry with the key Q.


Vehicle system test
Readout on display:
The fault memory is erased

Press key.
Readout on display:
Vehicle system test
Note

Vehicle system test


HELP
Select function XX
->

HELP

Select function XX

If this readout appears in the display then the test sequence is


t
incorrect.
Carefully follow the test sequence step by step: first interrogate the
t
fault memory, then erase.

Vehicle system test


HELP
Select function XX
Caution!
Fault memory was not
interrogated

Ending output

Enter 06 for the function End output and confirm with the key Q.
Readout on display:

Switch off ignition.


Vehicle system test
Disconnect plug connection from vehicle system tester.
HELP

Switch on ignition.
Select function XX
The ABS warning light -K47- and the hand brake/brake fluid level warning
light -K14/33- must go out after approx. 2 seconds.

Coding control unit

Special tools and workshop equipment required


t
Vehicle system tester -V.A.G 1552t
Diagnostic cable -V.A.G 1551/3The control unit built into the vehicle is coded. New control units supplied by the spare part storeroom are
not coded and must be recoded after being installed
Coding requirements
The coding is only possible if the workshop code (WSC) is entered in the vehicle system tester -V.A.G
1552-.
Test sequence
Determine the engine identification characters and the type of ABS hydraulic control unit fitted on the
226

vehicle.
Connect the vehicle system tester -V.A.G 1552- and enter the address word 03 brake electronics with

the ignition switched on Chapter.


Readout on display:
Vehicle system test
Enter 07 for the function Coding control unit and confirm the HELP

Select function XX
entry with key Q.
Readout on display:
Code control unit
Enter the correct code number for the vehicle and confirm
Q

with key Q.
Enter code number XXXXX
(0Table of codes Chapter.
32767)
Table of codes
Code number - model year
Engine identification characters Engine
ABS version 1997
1998
1999
2000 2001
AMD
1,4 Itr./44 kW ABS

03604 03604
AMD
1,4 Itr./44 kW ABS/EDL

03604 03604
AEE
1,6 Itr./55 kW ABS
03604 03604 03604 03604
AEE
1,6 Itr./55 kW ABS/EDL 03604 03604 03604 03604
AEH
1,6 Itr./74 kW ABS
03604 03504 03504 03504
AEH
1,6 Itr./74 kW ABS/EDL 03604 13504 13504 13504
AGN
1,8 Itr./92 kW ABS
03604 03504 03504

AGN
1,8 Itr./92 kW ABS/EDL 03604 13504 13504

AGU
1,8 Itr./110 kW ABS

03504 03504 03504


AGU
1,8 Itr./110 kW ABS/EDL
13504 13504 13504
AGP
1.9 Itr./50 kW ABS
03604 03604 03304 03304
AGP
1.9 Itr./50 kW ABS/EDL 03604 03604 03304 03304
AGR
1.9 Itr./66 kW ABS
03604 03504 03304 03304
AGR
1.9 Itr./66 kW ABS/EDL 03604 13504 13304 13304
AHF
1.9 Itr./81 kW ABS
03604 03504 03304 03304
AHF
1.9 Itr./81 kW ABS/EDL 03604 13504 13304 13304
AQY
2.0 ltr./85 kW ABS

03304
AQY
2.0 ltr./85 kW ABS/EDL

13504
ARX
1.8 ltr./110 kW 4x4

13504
AGR
1.9 ltr./66 kW 4x4

13504 13504
ATD
1.9 ltr./74 kW 4x4

13504
AZJ
2.0 ltr./85 kW 4x4

13504
Vehicles without CAN BUS
The control unit coding appears in the display, e.g. 03604: 1J0907379 A ABS/EDL ITT AE 20 GI V00 ->
Coding 03604
WSC XXXXX
Vehicles with CAN BUS
The control unit coding appears in the display, e.g.
1J0907379 H ABS/EDL 20 IE CAN 0001
13504:
->
Coding 13504
WSC
Continued for all vehicles
XXXXX

Press key.
Vehicle system
Readout on display:
test
Enter 06 for the function End output and confirm with the key Q.
HELP
Note
Select function XX
227

The ABS warning light -K47- and the hand brake/brake fluid level warning light
t -K14/33- will light up and will remain lit up if the control unit is incorrectly
coded.
There is a simultaneous entry in the fault memory Chapter; interrogate fault
t
memory 02.
If the control unit is coded with an approved code, no fault entry is made in the
t
fault memory and the ABS warning light does not flash.
If the control unit is not coded (Code 00000), the ABS warning light -K47- and
t the hand brake/brake fluid level warning light flash -K14/33- (once per second).
In this case no entry is made in the fault memory.

Reading measured value block

Special tools and workshop equipment required


t
Vehicle system tester -V.A.G 1552t
Diagnostic cable -V.A.G 1551/3The control unit can transmit many measured values. These measured values provide information about the
operating condition of the system or the connected sensors. In many cases the transmitted measured values
are useful for fault finding and fault elimination. As all measured values cannot be analysed
simultaneously, they are concentrated in individual display groups which can be selected via display group
numbers.
Safety measures
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the rear seat and have a second person operate them
t
there.
If the test and measuring devices are operated from the passenger seat, the passenger could be injured by
t
the release of the passenger airbag in the event of an accident.
Test sequence and test table with measured values
Connect the vehicle system tester -V.A.G 1552- and enter the address word 03 brake electronics with

the ignition switched on Chapter.


Readout on display:
Enter 08 for the function Read measured value block and
Vehicle system test

HELP
confirm the entry with Q.
Select function XX
Test of the wheel speed sensor assignment
Display group number 001:
Readout on display:
Reading measured value block
Enter display group number
Enter 01 for the display group number 01 and confirm entry with

XXX
key Q.
In the measured value block there are always 4 display fields
-arrows- 1 through 4.

Reading measured value block 1


->
->1
->2
->3
->4

Read-out on display: (stationary vehicle)


Reading measured
The current wheel speeds are displayed. They serve to check the wheel speed
value block 1
->
sensor assignment to the wheel. (To this end raise the vehicle and turn the wheel 0 km/h 0 km/h 0 km/h
by hand.)
0 km/h
Example:
Reading measured value block 1
Read-out on display: (moving wheels)
->
The current front right wheel speed is displayed.
0 km/h 4 km/h 0 km/h 0 km/h
To this end raise the vehicle and have a second mechanic turn the
228

wheel by hand.
Display field
1
2
3
4

Denomination
Front left wheel speed (km/h)
Front right wheel speed (km/h)
Rear left wheel speed (km/h)
Rear right wheel speed (km/h)

Readout on -V.A.G 15520 ... 255 1)


0 ... 255 1)
0 ... 255 1)
0 ... 255 1)

Press the key C.


If the button is pressed, subsequently enter 08 in order to return to the work sequence Read measured
value block.
Testing the wheel speed sensor
Display group number 002:
Readout on display:
Reading measured
value block
Enter 02 for the display group number 02 and confirm entry with key Q.
Enter display
The ABS control unit stores the first usable voltage signals from the wheel speed
group number XXX
sensor when starting and displays them as fixed values in the measured value block.
In the measured value block there are always 4 display fields -arrows1 through 4.
The values displayed in the display field 1 and 2 must on no account
be above 6 km/h.
The values displayed in the display field 3 and 4 must on no account
be above 2 km/h.
If the values are more, a fault can be present in the installation of the Reading measured value block
2
->
wheel speed sensor.
->1
->2
->3
Possible causes of fault:
->4
t Air gap between wheel speed sensor and pulse rotor too great.
Check if the wheel speed sensor is correctly bolted to the wheel

bearing housing.
Exterior damage to the wheel speed sensor or the pulse rotor (change
t
damaged component).

Replace the damaged component.


Display field
Denomination
Readout on -V.A.G 15521
Front left wheel speed (km/h)
0 ... 255
2
Front right wheel speed (km/h)
0 ... 255
3
Rear left wheel speed (km/h)
0 ... 255
4
Rear right wheel speed (km/h)
0 ... 255

Readout on display (stationary vehicle):


Drive off slowly until values are displayed on the display of the

vehicle system tester -V.A.G 1552-.


Deviations of the display fields 1 and 2 within 6 km/h are O.K. (see
example).
Deviations of the display fields 3 and 4 within 2 km/h are O.K. (see
example).
Example:
Read-out on display (when starting slowly):
Press the key C.
If the button is pressed, subsequently enter 08 in order to return to the
work sequence Read measured value block.
229

Reading measured value


block 2
->
255 km/h 255 km/h 255 km/h
255 km/h

Reading measured value


block 2
->
3 km/h 6 km/h 2 km/h 1
km/h

Test of the brake light switch for the ABS and the ABS/EDL function
Display group number 003
Readout on display:
Enter 03 for the display group number 03 and confirm entry with

key Q.

Reading measured value block


Enter display group number
XXX

Reading measured value block 3


->
->1
->2
->3
->4
Reading measured value block 3
->
0

In the measured value block there are always 4 display fields


-arrows- 1 through 4.
Readout on display:
Display field
1

Test conditions
t Brake pedal not actuated

Readout on -V.A.G 1552not activated

2
3
4

t Brake pedal actuated


not assigned
not assigned
not assigned

activated

If the display of the -V.A.G 1552-, despite the foot brake activated -0- or the foot brake not activated -1-,
is:

Perform electrical test Chapter and continue.


There is also the possibility that the brake light switch is not correctly set Chapter.
Enter 06 for the function End output and confirm with the key Q.

Actuator diagnosis

Special tools and workshop equipment required


t
Vehicle system tester -V.A.G 1552t
Diagnostic cable -V.A.G 1551/3The final control diagnosis is a part of the electrical test. The final control diagnosis is used to test the
pump motor, it is also used to check the correct operation of the hydraulic circuits (assignment of brake
pressure lines to the wheel brakes, and also the operation of the valves) to ensure they are correctly
connected and are not leaking.
Note
The vehicle must be raised so that the wheels are clear of the ground (2nd mechanic required for rotating
the wheels).
t It is possible to quit the test sequence at any time by pressing key -C-.
After depressing the brake pedal several times, the vacuum in the brake servo unit is reduced. Greater
t effort is then required to operate the brake pedal in order to achieve the same fluid pressure in the brake
system as with vacuum assistance.
Once the vacuum in the brake servo unit has been reduced, it is possible that the wheels do not lock
t
start engine in order to build up vacuum in the brake servo unit.
t Operate the vehicle system tester by referring to the read-out on the display.
Example:
Read-out on display of vehicle system tester -V.A.G 1552- during the final control diagnosis
(e.g. front left wheel, FL)
Final control diagnosis
- ->
IFL = Inlet valve front left
IFL:VBAT OFL:0V Wheel FL locked
VBAT = V-Battery voltage, voltage present on valve
t

230

OFL = Outlet valve front left


0V = 0 Volt; no voltage on valve
locked/free = Wheel status; must be checked by 2nd mechanic
Hydr-P = Hydraulic pump
Final control diagnosis
- ->
Performing actuator diagnosis
Connect the vehicle system tester -V.A.G 1552- and enter the address EDL valves/Hydr.p: VBAT

word 03 brake electronics with the ignition switched on Chapter. Wheel FL/FR block

Release the hand-brake.


Vehicle system test
HELP
Readout on display:
Select
function
XX
Enter 03 for the function Actuator diagnosis.
Readout on display:

Confirm the entry with key Q


The ABS hydraulic pump -V64- must run.
Vehicle system test
Q
Note
03-Actuator diagnosis

During the next work steps, the ABS warning light flashes 2 times and the
hand brake/brake fluid level warning light flashes 4 times per second.
Final control diagnosis
- ->
Readout on display:
Hydraulic
pump
ABS
-V64
Press the button within the next 60 seconds.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal.
Operate brake

Press key.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFL: 0V OFL: 0V Wheel FL
mechanical/hydraulic part of the brake system.
locked

Press key.
Readout on display:

Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must run
IFL: 0V OFL: 0V Wheel FL
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFL: 0V OFL: VBAT Wheel FL
mechanical/hydraulic part of the brake system.
free

Press key.
ABS hydraulic pump -V64- no longer runs
Readout on display:
Final control diagnosis

Press key.
- ->
Brake pedal must be felt to yield.
IFL: 0V OFL: 0V Wheel FL
If the brake pedal does not yield, there is a fault in the hydraulic unit. If
free
this is the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFL: 0V OFL: 0V Wheel FL
mechanical/hydraulic part of the brake system.
locked

Press key.
Final control diagnosis
- ->
Readout on display:
231

Take your foot off the brake pedal.


Release brake

Press key.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal.
Release brake

Press key.
Readout on display:

Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must run.
IFR: 0V OFR: 0V Wheel FR
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis

Press key.
- ->
Brake pedal must be felt to yield.
IFR: 0V OFR: 0V Wheel FR
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
free
the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFR: 0V OFR: 0V Wheel FR
mechanical/hydraulic part of the brake system.
locked

Press key.
Readout on display:
Final control diagnosis
- ->
Take your foot off the brake pedal.
Release brake

Press key.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal
Operate brake

Press key.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IRL:0V ORL:0V
Wheel RL
mechanical/hydraulic part of the brake system.
locked

Press key.
Readout on display:

Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must run.
IRL:VBAT ORL:0V
Wheel RL
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
- ->
If the wheel locks, it is possible that the brake pressure lines to the
IRL:VBAT ORL:VBAT
Wheel RL
wheel brakes are wrongly connected.
free

Press key.
ABS hydraulic pump -V64- no longer runs.
Readout on display:
Final control diagnosis

Press key.
- ->
Brake pedal must be felt to yield.
IRL:VBAT ORL:0V
Wheel
If the brake pedal does not yield, there is a fault in the hydraulic unit. If
RL free
this is the case replace the hydraulic unit Chapter.
Final control diagnosis
Readout on display:
-

232

->

Instruct the 2nd mechanic to rotate the relevant wheel by hand.


IRL:0V ORL:0V
Wheel RL
If the wheel does not lock, it is possible that there is a fault in the
locked
mechanical/hydraulic part of the brake system.

Press key.
Readout on display:
Final control diagnosis
- ->
Take your foot off the brake pedal.
Release brake

Press key.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal
Operate brake

Press key.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IRR:0V ORR:0V
Wheel RR
mechanical/hydraulic part of the brake system.
locked

Press key.
Readout on display:

Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must not run.
IRR:VBAT ORR:0V
Wheel RR
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
- ->
If the wheel locks, it is possible that the brake pressure lines to the
IRR:VBAT ORR:VBAT
Wheel RR
wheel brakes are wrongly connected.
free

Press key.
ABS hydraulic pump -V64- no longer runs.
Readout on display:
Final control diagnosis

Press key.
- ->
Brake pedal must be felt to yield.
IRR:VBAT ORR:0V
Wheel
If the brake pedal does not yield, there is a fault in the hydraulic unit. If
RR free
this is the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IRR:0V ORR:0V
Wheel RR
mechanical/hydraulic part of the brake system.
locked

Press key.
Readout on display:
Final control diagnosis
- ->
Take your foot off the brake pedal.
Release brake

Press key.
Read-out on display: (for vehicles with EDL)
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
If the wheels do not lock, there is a fault in the hydraulic part of the ABS - ->
EDL valves/ Hydr.p:VBAT
system. If this is the case replace the hydraulic unit Chapter.
Wheel FL/FR block.

Press key.
The ABS warning light -K47- goes out.
Function unknown or cannot
- ->
Readout on display:
be
carried
out
at
the
moment
Note
The final control diagnosis is completed
233


Press key.
Readout on display:
Note
If the ABS warning light does not go out, there is a fault in the
t
system.
Carefully follow the test sequence step by step: first interrogate the
t
fault memory, then erase.

Ending output Chapter.

Vehicle system test


HELP
Select function XX

Basic setting

Special tools and workshop equipment required


t
Vehicle system tester -V.A.G 1552t Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3Ct Brake filling and bleeding device, e.g. -VAS 5234t
Brake fluid Chapter
On models with EDL, the basic setting is used for bleeding the hydraulic unit.
It is only necessary to carry out the basic setting if at least one chamber of the brake fluid reservoir has run
completely empty (e.g. leakage in the brake system).
Note
Operate the vehicle system tester by referring to the read-out on the display.
WARNING
When replenishing brake fluid with a brake filling and bleeding appliance, it is important to ensure that the
filling pressure of 0.1 MPa is not exceeded.
If the filling pressure of 0.1 MPa (1 bar) is exceeded, proper bleeding of the hydraulic unit is no longer
assured.

Connect the brake filling and bleeding device.


Connect vehicle system tester -V.A.G 1552- and enter the address word 03 - brake electronics - with the

ignition switched on Chapter.


Vehicle system test
HELP
Readout on display:
Select
function
XX
Enter function 04 Initiate basic setting.
Vehicle system test
Q
Readout on display:
04
Basic
setting
Confirm the entry with the key Q.
Readout on display:
Vehicle system test
HELP

Enter 001
Enter display group number XXX
Confirm the entry with the key Q.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
Readout on display:
Release pedal;FR+FL bleeder screws

Press button.
OPEN
Note
234

If you are using the -V.A.G 1551- a -3- appears instead of


the .
Readout on display:
System in basic setting
t Hydraulic pump starts running.
Please wait . . . (10 sec.)
Readout on display:

Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
3
Readout on display:
Release pedal;FR+FL bleeder screws OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
2
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
5
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
6
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
7
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
8
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
9
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
10
Readout on display:
Actuate pedal 10x; Bleeder screws CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
235

10

11

System in basic setting


11
Readout on display:
Release pedal;FR+FL bleeder screws OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
12
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.

Readout on display:

14

14

System in basic setting


15
Release pedal;FR+FL bleeder screws OPEN

System in basic setting


Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
16
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.

Readout on display:

12

System in basic setting


13
Release pedal;FR+FL bleeder screws OPEN

System in basic setting


Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
14
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.

Readout on display:

12

System in basic setting


Part bleeding ended...

17

Vehicle system test


Readout on display:
Select function XX
Enter 06 for the function End output.
Vehicle system test
Readout on display:
06 - End output
Confirm the entry with the key Q.
Readout on display:
Vehicle system test

Switch off ignition.


Enter address word XX
Disconnect the plug connection -V.A.G 1552-.

Bleed brake system.

236

16

HELP
Q

HELP

Electrical test of the ABS and ABS/EDL ITT Mark 20 IE

Special tools and workshop equipment required


t
Test box -V. A.G 1598/21t
Measuring tool set -V.A.G 1594 At
Handheld multimeter, e.g. -V.A.G 1526 AThe test steps as of Chapter apply to:
Vehicles for which the final control diagnosis does not indicate the fault source. In this case the full
t
electric inspection must be carried out.
Vehicles for which the final control diagnosis does give a direct indication of the fault source. Then only
t
perform the test steps recommended in the fault table (targeted approach).

Test conditions

The fuses must be OK in compliance with the current flow diagram binder Current Flow Diagrams,
l Electrical Fault Finding and Fitting Locations To check, remove fuses from the fuse holder on the
battery and the fuse holder on the left of the dash panel.
Before starting the test switch off the ignition and electrical consumers (headlights, lighting, blowers
l
etc.).

Remove the multi-pin plug connection from the


ABS control unit -J104- and connect the test
l
box -V.A.G 1598/21--1- to the plug of the
wiring loom -2-.
The specified values are specific to the -V.A.G
1526 A- and do not necessarily apply for other
measuring tools.

Multi-pin plug connection with contact assignment

Note
All unlisted contacts are not yet assigned and must under no circumstances be connected to other
components!

237

Contact assignment of the multi-pin plug


connection -T25- wiring loom / ABS control unit
-J104-

Contac
Wiring to component ...
t
1
Front left speed sensor -G472
Front left speed sensor -G473
Jumper to contact -144
Voltage supply terminal -155
Rear left wheel speed sensor -G466
Rear left wheel speed sensor -G467
Plug connection -T16a/7 K- - cable
8
Earth terminal 31
9
Voltage supply of battery +
10
Data BUS cable (CAN-L) binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
11
Data BUS cable (CAN-H) binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
14
Jumper to contact 3
16
ABS warning light
18
Brake light switch -F19
Front right speed sensor -G4520
Front right speed sensor -G4522
Rear right wheel speed sensor -G4423
Rear right wheel speed sensor -G4424
Left earth point under battery
25
Voltage supply of battery +

238

Contact assignment of the plug connections for


the voltage supply and the self-diagnosis with the
vehicle system tester -V.A.G 1552Contact 4 = Earth (terminal 31)
Contact 5 = Earth (terminal 31)
Contact 16 = Positive (terminal 30)
Contact 7 = -K- cable via cable connection diagnosis - to ABS control unit -J104- contact 7

239

Overview of test steps

Test steps in the test table


Chapter
Voltage supply of the ABS hydraulic pump -V64- to the ABS control unit - Perform test step 1.
-J104Voltage supply of the valves in the hydraulic unit -N55- to the ABS control - Perform test step 2.
unit -J104Voltage supply (terminal 15) to the ABS control unit -J104- Perform test step 3.
Function of the brake light switch -F- Perform test step 4.
Resistance of the front right speed sensor -G45- Perform test step 5.
Resistance of the front left speed sensor -G47- Perform test step 6.
Resistance of the rear right speed sensor -G44- Perform test step 7.
Resistance of the rear left speed sensor -G46- Perform test step 8.
Voltage signal of the front right speed sensor -G45- Perform test step 9.
Voltage signal of the front left speed sensor -G47- Perform test step 10.
Voltage signal of the rear right speed sensor -G44- Perform test step 11.
Voltage signal of the rear left speed sensor -G46- Perform test step 12.
Jumper
- Perform test step 13.
Voltage supply for -V.A.G 1552-, plug connection -T16- Perform test step 14.
Resistance of the K cable for -V.A.G 1552-, plug connection -T16- Perform test step 15.
Function of the ABS warning light -K47- Perform test step 16.
Function of the hand brake/brake fluid level warning light -K14/33- Perform test step 17.
Function of the ABS hydraulic pump -V64- Perform test step 18.
Checking the databus cables
- Perform test step 19.
Component to be tested

Test table

The denominations of the bushes of the test box -V.A.G 1598/21- are identical to the contact
t denominations of the ABS control unit -J104- in the current flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
If the measured values deviate from the nominal values, perform the fault eliminating measures listed in
t
the right part of the table.
t Once these values are reached, additionally check the cables for short-circuit to positive and earth.
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and plugs of the
test devices and measuring cables (e.g. with contact spray) and repeat test. Before replacing the relevant
t
components test the cables and connections more specifically for nominal values below 10 , repeat the
resistance measurement on the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
Test covers
Specified Measures for deviations from nominal
Test
l
step 1598/21value
conditions value
bushes
additional

works
1
8 + 25 Voltage supply of the l Ignition off 10.0-14.5V Test wiring of contact 8 to earth.
ABS hydraulic pump
Test wiring of contact 25 via the
-V64- to the ABS
240

control unit -J104-

9 + 24

4+8

8 + 18

fuse to battery positive binder


Current Flow Diagrams, Electrical
Fault Finding and Fitting
Locations

Voltage supply of the l Ignition off 10.0-14.5V Test wiring of contact 24 to earth.
valves in the ABS
Test wiring of contact 9 via the fuse
hydraulic unit -N55- to
to battery positive binder

the control unit -J104Current Flow Diagrams, Electrical


Fault Finding and Fitting
Locations
Voltage supply
l Ignition on 10.0-14.5V Test wiring of contact 8 to earth.
(terminal 15) to the
Test wiring of contact 4 to the
control unit -J104 connector of terminal 15 (relay
plate).
Function of the brake l Ignition off 0,0-0,5 V
Test fuses.
light switch -FBrake pedal
Test brake light switch -F- and read
l
not actuated
measured value block Chapter;
display group number 003
Test wiring of contact 8 to earth.
Test wiring of contact 18 to the
brake light switch binder

Current Flow Diagrams, Electrical


Fault Finding and Fitting
Locations
approx.
Actuate
Check brake light switch -F

brake pedal. battery


Chapter.
voltage

Switch on measuring range: resistance measurement (2 k)


Test -V.A.G
Test covers
Specified Measures for deviations from nominal
Test
l
step 1598/21value
conditions value
bushes
additional

works
5
19 + 20 Resistance of the l Ignition off 1,0 ... 1.3
Disconnect plug connection on speed

front right speed


k
sensor -G45-.
sensor -G45Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
Throughout the test, move cables (loose

contact).
If the lines are not found to be faulty:
Replace speed sensor -G45- Chapter.
6

1 +2

Resistance of the
front left speed
sensor -G47-

l Ignition off 1,0 ... 1.3


Disconnect plug connection on speed

k
sensor -G47-.
Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
241

Throughout the test, move cables (loose


contact).

If the lines are not found to be faulty:


Replace speed sensor -G47- Chapter.
7

22 + 23

Resistance of the
rear right speed
sensor -G44-

l Ignition off 1,0 ... 1.3


Disconnect plug connection on speed

k
sensor -G44-.
Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
Throughout the test, move cables (loose

contact).
If the lines are not found to be faulty:
Replace speed sensor -G44- Chapter.

5+6

Resistance of the
rear left speed
sensor -G46-

l Ignition off 1,0 ... 1.3


Disconnect plug connection on speed

k
sensor -G46-.
Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
Throughout the test, move cables (loose

contact).
If the lines are not found to be faulty:
Replace speed sensor -G46- Chapter.

Switch on measuring range: voltage measurement (2 V )


Test -V.A.G
Test covers
l Test conditions Specified value Measures for deviations from nominal
step 1598/21value
additional

bushes
works
9
19 + 20 Voltage signal l Vehicle raised
Check the installation of the wheel
of the front
speed sensor -G45- and the pulse
l Ignition off
right speed
rotor.
sensor -G45Turn front right Alternating
Check wheel speed sensor -G45- to
voltage min.
wheel by
ensure it is correctly connected

1
65
mV
approx. 1 /s
read measured value block,
Chapter, display group number
001
10
1+2
Voltage signal l Vehicle raised
Check the installation of the wheel
of the front left l Ignition off
speed sensor -G47- and the pulse
speed sensor
rotor.
-G47Turn front left Alternating
Check wheel speed sensor -G47- to
voltage min.
wheel to
ensure it is correctly connected

65 mV
approx. 1 1/s
read measured value block,
Chapter, display group number
001.
11
22 + 23 Voltage signal l Vehicle raised
Check the installation of the wheel
242

of the rear right l Ignition off


speed sensor
-G44 Turn rear right Alternating
voltage min.
wheel by
190 mV
approx. 1 1/s

12

5+6

Voltage signal
of the rear left
speed sensor
-G46-

l Vehicle raised
l Ignition off
Turn rear left
wheel to
approx. 1 1/s

speed sensor -G44- and the pulse


rotor.
Check wheel speed sensor -G44- to
ensure it is correctly connected

read measured value block,


Chapter, display group number
001.
Check the installation of the wheel
speed sensor -G46- and the pulse
rotor.

Alternating
voltage min.
190 mV

Check wheel speed sensor -G46- to


ensure it is correctly connected

read measured value block,


Chapter, display group number
001.

Switch on measuring range: resistance measurement (200 )


Test -V.A.G
Test
Specified Measures for deviations from nominal value
Test
l
step 1598/21covers
conditions value
bushes
additional

works
13
3+14
Jumper l Ignition off 0.0 - 1.0 Check the cables and the contacts in the plug
binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
If there is a deviation from the specified value:

Replace jumper.

Switch on measuring range: voltage measurement (20 V =)


Test -V.A.G
Test covers
Specified
l Test conditions
step 1598/21value
additional works
bushes
14
Voltage supply for l Ignition off
10.0 -V.A.G 1552-,
14.5 V
Connect the handheld
plug connection
multimeter -V.A.G 1552

-T16a-1)
A- with the measuring
tool set -V.A.G 1594 A- to
-T16a-1)

Measures for deviations from


nominal value
Test wiring of -T16a/4- to
earth.
Test wiring of -T16a/16- via
fuse to terminal 30 binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations

Contact 4 - earth
contact 16 - positive
1)

Chapter, contact assignment of the plug connection for the voltage supply and the self-diagnosis with
the vehicle system tester -V.A.G 1552-.
Switch on measuring range: resistance measurement (200 )
Test -V.A.G
Test covers
l Test conditions
step 1598/21 additional works
243

Specified Measures for deviations


value
from nominal value

bushes
15
-

Resistance of the l
max. 1.5
Ignition off
Check the cables of
-K- cable for
-T16a/7- via wiring
Disconnect the multi-pin plug
-V.A.G 1552-, connection from the ABS
-Diagnose - an Kontakt 7
plug connection
binder Current Flow
control unit -J104-.
-16a-1)
Diagrams, Electrical Fault
Connect test box V.A.G

Finding and Fitting


1598/21.
Locations
Connect the handheld
multimeter -V.A.G 1526- with
the measuring tool set -V.A.G

1594- to the contacts -T16/7-1)


and -T25/7- of the multi-pin
plug connection from the ABS
control unit -J104-.

1)

Chapter, contact assignment of the plug connection for the voltage supply and the self-diagnosis with
the vehicle system tester -V.A.G 1552-.
Functional test: ABS warning light -K47Test -V.A.G
Test covers
Test
l
step 1598/21conditions
bushes
additional
works
16
Function of l Ignition on
the ABS
warning light
-K47-

Specified value

Measures for deviations from nominal


value

The warning light


-K47- lights up for
approx. 2 seconds
and goes out

Test cable from contact 7 and 9 of the


blue plug on the dash panel insert to
earth.
Test cable from contact 19 of the blue
plug on the dash panel insert to contact

16 of the ABS plug binder Current


Flow Diagrams, Electrical Fault Finding
and Fitting Locations
Check dash panel insert, fault in the
dash panel insert: Electrical
System; Rep. gr.90

Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G
Test covers
Specified value
Test
l
step 1598/21conditions
bushes
additional

works
17
_
Function of the
Brake fluid The warning light
l
hand brake/brake
level O.K. -K14/33- lights up
fluid level warning l Ignition on for approx. 2
light -K14/33seconds and goes
out

244

Measures for deviations from


nominal value

Test cable from contact 7 and 9


of the blue plug on the dash
panel insert to earth.
Test cable from contact 29 of the
blue plug on the dash panel
insert to the brake fluid level
warning contact -F34-.
Test cable from contact 13 of the
green plug on the dash panel
insert to the handbrake warning

switch -F9-.
Test brake fluid level warning
contact -F34- in the cap

binder Current Flow


Diagrams, Electrical Fault
Finding and Fitting Locations
Check dash panel insert, fault in
the dash panel insert:
Electrical System; Rep. gr.90
Replace handbrake warning

switch -F9- Chapter

Functional test: Hydraulic pump -V64Test -V.A.G


Test covers
Specified value
l Test conditions
step 1598/21 additional works
bushes
18
_
Function of the l
Ignition off
hydraulic
Disconnect the plug
pump -V64- connection -T2- of the
hydraulic pump -V64- on the
ABS control unit -J104-.
Connect earth and battery
voltage to the plug
connection -T2/1- of the
hydraulic pump -T2/2-.

Measures for
deviations from
nominal value

Chapter,
Perform actuator
Hydraulic pump
diagnosis.
starts running
without fault (max.
Replace ABS

10 secs.)
control unit -J104 Chapter

Hydraulic pump
does not run

Replace hydraulic
unit -N55 Chapter

Switch on measuring range: resistance measurement (200 /20 M)


Test -V.A.G
Test
Specified Measures for deviations from nominal
l Test conditions
step 1598/21- covers additional works
value
value
bushes
19
11 + 10 Data
l
Ignition off
BUS
l Measuring range 200 set
cables
Disconnect the multi-pin
plug connections from the
control units connected to a
data BUS line.
Connect test box -V.A.G

1598/21-.
max. 1.5 Test the wiring according to the
Check the data BUS cable

for open circuit.


current flow diagram binder
Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
l Measuring range 20 M set
245

Remove fuse.

Check cables for short circuit to positive term. or


earth.

Test the wiring according to the


current flow diagram binder
Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations

Electric/electronic components and fitting locations ABS, ABS/EDL Mark 20


All the components marked with

1)

are covered by the self-diagnosis.

1-

Brake servo unit with master brake cylinder and brake fluid reservoir

Summary of components Chapter

2t
t
t
3t
4-

Hydraulic control unit

1)

Fitting position: in left of engine compartment


removing and installing Chapter
repairing Chapter
Diagnostic connection
Fitting location: in the storage compartment on the driver's side
ABS warning light -K47246

Fitting location: in the dash panel insert, function:

The ABS warning light comes on:

for about 2 seconds after the ignition is switched on or the engine is started

if a fault is detected (e.g. open circuit to wheel speed sensor)

5-

Hand brake/brake fluid level warning light -K14/33-

Fitting location: in the dash panel insert, function:

The hand brake/brake fluid level warning light comes on:

if hand-brake is applied

if low brake fluid level

for about 2 seconds after ignition is switched on


if the electronic brake pressure distribution fails, i.e. when the ABS warning light comes on
Chapter

6-

Parts of ABS system on rear axle

(only disc brake shown in illustration)


Rear right and left wheel speed sensors -G44- / -G44- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter

Pulse rotor for the wheel speed sensor at the rear on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter

7t

is open in off position

setting up to MY 1999 Chapter, vehicles as of MY 2000 Chapter


removing and installing vehicles up to MY 1999 Chapter, vehicles as of MY 2000
Chapter

t
8t

Brake light switch -F-

must be tested in the measured value block Chapter


Parts of ABS system on front axle
Front right and left wheel speed sensors -G45- / -G47- 1)
removing and installing Chapter

Installing wheel speed sensor cables Chapter

Pulse rotor for front wheel speed sensor

check Chapter
247

removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter

Removing and installing the hydraulic control unit and the bracket
Note

Make absolutely sure that no brake fluid gets into the plug connector housing of the control
unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
Special tools and workshop equipment required
t
t
t

Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3CBrake pedal arrester, e.g. -V.A.G 1238/B-

Caps from the repair set SP no. -1 HO 698 311 A-

Brake filling and bleeding device e.g. -VAS 5234-

t
t

Extraction bottle (commercially available)


Brake fluid Chapter

248

1t

Hydraulic control unit

the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
hydraulic control unit.

t
t
2-

the hydraulic control unit must be removed and installed as a whole unit
repairing Chapter
Brake line, 14 Nm

t between the master brake cylinder/floating piston circuit and ABS hydraulic unit
3t
4t
5t
6t
7-

Brake line, 14 Nm
ABS hydraulic unit to front left brake caliper
Brake line, 14 Nm
ABS hydraulic unit to wheel cylinder/rear right brake caliper
Brake line, 14 Nm
ABS hydraulic unit to wheel cylinder/rear left brake caliper
Brake line, 14 Nm
ABS hydraulic unit to front right brake caliper
Brake line, 14 Nm

t between master brake cylinder/push rod piston circuit and hydraulic unit
249

8-

Multi-pin connector/ABS control unit

t
t

25-pin
do not disconnect the plug connector before the self-diagnosis is complete, switch off the
ignition before disconnecting the plug connector

9-

Self-locking nut, 20 Nm

10 -

Support

11 -

Dowel screw, 8 Nm

12 -

Cap nut, 25 Nm

Remove the hydraulic control unit


Note

Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

re-set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia

Disconnect battery.
Note

The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Using an extraction bottle extract as


much brake fluid as possible from the
brake fluid reservoir.

250

Press brake pedal and lock in place with


brake pedal load, e.g. -V.A.G 1238/B-.

Attach the bleeder hose of the bleeding


bottle onto the bleeder screw of the front
left brake caliper and open the bleeder
screw.

Close the bleeder screw once the brake


fluid flowed out.

Disconnect the bleeder hose from the


bleeder screw.

Release the multi-pin connector and


remove it from the hydraulic unit.
Note

Make sure that no brake fluid gets onto the


contacts.

251

In order to collect the brake fluid, position


an absorption fleece under the hydraulic
control unit.
Note

The brake lines around the hydraulic unit


must not be bent.
Protect the brake lines from the master
brake cylinder to the hydraulic unit

against dirt, see -arrows-, with the caps


from the repair set SP no. -1 HO 698 311
A-.
On vehicles with the steering located on
the left, tie up the unscrewed brake lines
with a welding wire as far to the top until
the cable extremities protrude beyond
the brake fluid gauge of the expansion
reservoir -arrows-.

Unscrew the remaining brake lines from


the hydraulic unit.

The connections of the hydraulic lines on


the hydraulic unit must be closed with
the screw plugs -Pos. 2- and -Pos. 3- from
the repair set SP no. -1 HO 698 311 A-.
-Pos. 1- Transport protection for valve
domes (foam material).

252

Unscrew the screws -arrows- on the


bracket for the hydraulic control unit.

Remove the hydraulic control unit .

Install the hydraulic control unit


Note

Only then remove plugs from the


t hydraulic unit when the relevant brake
line is installed.
If the plugs were already removed from
the hydraulic unit before the brake line is
t installed, then brake fluid may escape
and adequate filling and bleeding can no
longer be guaranteed.

Screw hydraulic control unit onto


bracket.
Note

Do not tighten screws. This facilitates the


screwing of the individual brake lines onto
the hydraulic control unit.

Connect the brake lines to the hydraulic


unit and tighten Chapter.

Tighten the hydraulic control unit


-arrows-.

Insert the multi-pin connector on the ABS


control unit and lock.

Further installation occurs in reverse order.

Connect battery Electrical


System; Rep. gr.27.

Bleeding Brake System Chapter.

Code the control unit Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Removing and installing bracket


Removing
Remove the hydraulic control unit
253

Chapter.
Unscrew nuts -1- and cap nut -3-.

Remove holder -2-.

Install
Installation is carried out in the reverse
order.
Tightening torques:
Nuts to body: 20 Nm
Use new nuts!
Cap nut to body: 25 Nm

Repairing the hydraulic control unit


Special tools and workshop equipment required
t

Caps from the repair set SP no. -1 HO 698 311 A-

Disassembly and assembly of the hydraulic control unit is described on an ABS unit. The
work procedure for the other versions of the ABS ITT Mark 20 IE is identical Chapter.
The repair of the hydraulic control unit is carried out by separating the ABS control unit
-J104- from the hydraulic unit -N55- which is connected to the hydraulic pump -V64-. The
defective component is replaced.
Disassembling the hydraulic control unit

Disconnect the plug for the hydraulic pump motor from the control unit.

Unscrew screws -Pfeile- from the control


unit and remove the control unit.
Note

254

During the removal of the control unit -bmake sure that the valve domes of the
hydraulic unit -a- do not tilt along with the
solenoid coils of the control unit.

Cover the solenoid coils of the control


unit with a non-fluffing cloth.

After separating the hydraulic unit from the


ABS control unit, fit on the transport
protection -1- from the repair set SP no.
-1H0 698 311 A- for the valve domes.
This is a requirement for possible
guarantee claims.

255

ABS hydraulic unit (-N55-) and hydraulic


pump (-V64-) -a-:
t

Hydraulic unit: The valve block includes


the control valves.

Do not separate the hydraulic pump


-V64- from the hydraulic unit -N55-.

When changing the hydraulic unit, the


transport protection for valve domes
( Fig., Pos. 1) must be inserted on the
t
old part and the old part must be closed
with the screw plugs ( Fig., Pos. 2 and
3).

ABS control unit (J104) -b-:


Contact assignment Chapter
Test requirements Chapter
Install the hydraulic control unit
Note

There must be no impurities present


around the control unit/valve block.

When assembling the control unit and the


hydraulic unit make sure the valve domes
t
of the hydraulic unit do not tilt along with
the solenoid coils of the control unit.

Screw the ABS control unit to the


hydraulic unit. Tightening torque max. 4
Nm (always use the supplied screws).
Mount the plug of the hydraulic pump
motor.

256

Checking/removing and installing parts of the ABS system on the front axle
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 500 V
t

Solid lubricant paste -G 000 650-

Removing and installing wheel speed sensor


Removing

Raise vehicle.
Separate plug connection of wheel speed
sensor/wheel speed sensor cable -arrow-.
Release screw -2-.
Take the wheel speed sensor -G45- /
-G47- out of the wheel bearing housing.

Install
Clean the inner surface of the hole before
inserting the wheel speed sensor and
coat with a solid lubricant paste -G 000
650-.

Insert the wheel speed sensor in the bore


of the wheel-bearing housing and tighten
the screw to 8 Nm.
Fit together the plug connection of wheel
speed sensor cable/wheel speed sensor.
Actuate steering from left to right up to
the stop and check for free movement of
the wheel speed sensor cable.
Lower the vehicle.

Check pulse rotor or remove and install

Raise vehicle.

Remove wheel.

257

While turning the brake disc, check the


pulse rotor -1- for any dirt or damage.

If the chunking of the pulse rotor is


blocked by dirt, the pulse rotor must be
cleaned.

If the pulse rotor is damaged, the wheel


hub and the pulse rotor must be replaced
Chapter.

Attach the wheel.

Lower the vehicle.

Check axial run-out of pulse rotor

Raise vehicle.

Remove wheel.

Turn the wheel hub and check the


distance between the pulse rotor and the

wheel speed sensor for evenness (axial


run-out tolerance). In this test, the wheel
bearing play must be accounted for.
l

The axial run-out tolerance of the pulse


rotor is 0.3 mm.
If the axial run-out tolerance is not kept,
change the pulse rotor together with the
wheel hub Chapter.

Attach the wheel.

Lower the vehicle.

Removing and installing the wheel speed


sensor cables
Removing
Note

It is prohibited to repair shielded leads of


the ABS system.

t Before disconnecting the battery


determine the code of radio sets fitted
258

with anti-theft coding.


t

After connecting the battery, perform the


following:

on vehicles with radio encoding, carry


out the coding,

set clock,

initialise power windows on vehicles


fitted with power windows
BookletOctavia

Disconnect battery.
Note

The following 2 work steps do not apply to


the 1.6 ltr./55 kW engine:

Disconnect the plug of the air mass


meter -1- from the air guide pipe of the
air filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Release the multi-pin connector and


remove it from the ABS control unit.

259

Slacken the cap of the multi-pin


connector using a screwdriver and
remove it.

Release secondary lock (purple) with a


small screwdriver in the -direction of the
arrow-.

260

Contact assignment of the plug connection


wiring loom/ABS control unit -J104-

Contact

Wiring to component ...

19 + 20

Front right wheel speed sensor -G45-

1 +2

Front left wheel speed sensor -G47-

22 + 23

Rear right wheel speed sensor -G44-

5+6

Rear left wheel speed sensor -G46-

Press out the relevant contacts using a


suitable ejection tool from the wiring
loom repair kit.

Release plug connection on wheel speed


sensor and separate plug connector.

Remove defective wheel speed sensor


cable.

Install
Draw in new wheel speed sensor cable.

Connect wheel speed sensor cable to


wheel speed sensor.

261

Clip in wheel speed sensor cable


-arrows-.
Note

When assembling the wheel speed sensor


cable make sure it is not twisted when
installed in the wheelhouse.

Insert contact in the plug housing and


insert the single cable seal with a
suitable plug-in tool from the wiring loom
repair kit up to the stop.

Secure the contacts with the secondary


lock and position the cap of the multi-pin
connector.
Connect battery Electrical
System; Rep. gr.27.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 Vt

Solid lubricant paste -G 000 650262

Remove and install wheel speed sensor (disc brake - front-wheel drive)
Removing

Raise vehicle.

Separate plug connection -1- wheel


speed sensor cable/wheel speed sensor.

Release screw -2-.


Take the wheel speed sensor -G44- /
-G46- out of the axle stud.

Install
Clean the inner surface of the hole before
inserting the wheel speed sensor and
coat with a solid lubricant paste -G 000
650-.

Insert the wheel speed sensor in the bore


of the axle stud and tighten the screw -2to 8 Nm.

Connect plug connection -1- wheel speed


sensor cable/wheel speed sensor.

Remove and install wheel speed sensor


(drum brake)
Removing and installing the wheel speed
sensor occurs in the same way as for the
disc brake version - front-wheel drive
Chapter.
12-

Plug connection wheel speed sensor


cable/wheel speed sensor
Screw for fixing the wheel speed
sensor.

Check pulse rotor or remove and install


(disc brake and drum brake)
Note

The figures show only the rear axle with


disc brake.

Parts of the ABS system on the rear axle


t with drum brake are analogous to the
version with disc brake.
263

Raise vehicle.

Remove wheel.

Vehicles with disc brakes:

Unscrew screws -A-, remove brake caliper


and tie up laterally with wire or anything
similar.
Brake lines must not be exposed to
tension.
Vehicles with drum brakes:
Remove the brake drum Chapter.
All vehicles:

Check pulse rotor by turning the brake


disc or the wheel hub

Note

t It is prohibited to repair shielded leads of


264

the ABS system.


Before disconnecting the battery
t determine the code of radio sets fitted
with anti-theft coding.
t

After connecting the battery, perform the


following:

on vehicles with radio encoding, carry


out the coding,

set clock,

initialise power windows on vehicles


fitted with power windows
BookletOctavia
t

The figures show only the rear axle with


disc brake.

Parts of the ABS system on the rear axle


t with drum brake are analogous to the
version with disc brake.

Disconnect battery.

Raise vehicle.

Remove wheel.

Release plug on wheel speed sensor and


separate plug connection -arrow-.

123

Pulse rotor
Wheel speed sensor
Wheel speed sensor screw

Remove luggage compartment side trim


panel Body Work; Rep. gr.70.

265

Locate the welded joint on the wheel


speed sensor cable.

Remove the isolating grommet from the


welded joint.

Separate the wheel speed sensor cable in


front of the welded joint using the wire
stripper from the wiring loom repair kit
and remove the defective line piece.

Strip as of 15 mm from the cable


extremity using the wire stripper and turn
the stripped cable halfway.

Draw in new wheel speed sensor cable.

Fit together the plug connection of wheel


speed sensor cable/wheel speed sensor.

266

Clip in wheel speed sensor cable


-arrows-.
Note

When assembling the wheel speed sensor


make sure the wheel speed sensor cable is
not twisted when installed in the
wheelhouse.
Separate the 2-pin plug, if present, on the
new wheel speed sensor cable using the

wire stripper, strip as of 15 mm from the


cable extremity and turn the stripped
cable halfway.
Instead of the welding spot, the wheel
speed sensor cable must be connected
using a suitable crimp connector from the
wiring loom repair kit.

Install luggage compartment side trim


panel Body Work; Rep. gr.70.
Attach the wheel.
Connect battery Electrical
System; Rep. gr.27.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Removing and installing as well as adjusting brake light switch up to model year 1999
Special tools and workshop equipment required
t

Polycarbamide grease -G 052 152 A2Note

The brake light switch must be removed for setting.

Remove footwell covering on driver's side Body Work; Rep. gr.68.


Unplug connector from brake light switch.

267

Remove brake light switch -1- by turning


90 to the left.

To adjust, pull out the plunger -2- of the


brake light switch fully.
Note

Before assembling the brake light switch


grease the contact surface of the brake
pedal tappet with polycarbamide grease -G
052 142 A2-.

Press down brake pedal as far as possible


by hand.
Guide the brake light switch through the
assembly opening and install by turning
90 to the right.
Release brake pedal.
Mount plug on brake light switch.
Install footwell covering on driver's side
Body Work; Rep. gr.68.

Check operation of the brake lights.


Actuate brake pedal all the brake lights
must light up.
Release brake pedal brake lights must go
out.

Removing and installing as well as adjusting brake light switch as of model year 2000

Special tools and workshop equipment required


t
Polycarbamide grease -G 052 152 A2Note
The brake light switch must be removed for setting.

Unplug connector from brake light switch.

268

Remove brake light switch by turning 45 to


the left.
To adjust, pull out the plunger as far as the stop.
The plunger is adjusted automatically when
assembling the brake light switch.
Note

Before assembling the brake light switch grease


the contact surface of the brake pedal tappet with
polycarbamide grease -G052 142 A2-.
Guide the switch through the assembly
opening, press against the pedal and attach by
turning it 45 to the right.
The brake pedal always remains in the off
position in this case (do not depress!).
Insert the plug for the brake light switch.
Inspecting proper operation of the brake light.
After installing the brake light switch, check
whether brake pedal is in the end position (release
position).

Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
for vehicles with ABS, ABS/EDL Mark 20
Note

t The hydraulic control unit must be removed and installed completely Chapter.
t

Repairing Chapter.

t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.

269

1t

Brake servo unit


check Chapter

removing and installing - LHD vehicles Chapter

removing and installing - RHD vehicles Chapter

2t

Screw cap
with integrated brake fluid level warning contact -F34-

3-

Brake fluid reservoir

4-

Sealing ring

t
567t

replace
Self-locking nut, 20 Nm
Retaining pin
Master brake cylinder
cannot be repaired, replace completely in the event of faults

removing and installing - LHD vehicles Chapter

removing and installing - RHD vehicles Chapter

8t

Self-locking nut, 20 Nm
only for vehicles with 74 kW, 92 kW and 110 kW engine
270

9t

Heat shield
only for vehicles with 74 kW, 92 kW and 110 kW engine

10 -

Cap nut, 25 Nm

11 12 13 -

8 Nm
Dampening rubber
Support

14 -

Self-locking nut, 20 Nm

15 -

Control unit for ABS or ABS/EDL

16 17 t

Brake line connection


Hydraulic unit to front right brake caliper

21 -

Brake line

Master brake cylinder/push rod piston circuit to hydraulic unit

22 t

Brake line connection

Hydraulic unit to wheel cylinder/rear left brake caliper

20 -

Brake line connection

Hydraulic unit to wheel cylinder/rear right brake caliper

19 t

Brake line connection


hydraulic unit to front left brake caliper

18 t

Hydraulic control unit for ABS or ABS/EDL

Brake line

Master brake cylinder/push rod piston circuit THV to hydraulic unit

271

Self-diagnosis of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
The self-diagnosis for four-wheel drive vehicles with Haldex coupling is almost identical for
vehicles with ABS/EDL.
Note

Only the differences to the normal ABS/EDL system are described in the self-diagnosis.
Characteristic feature of four-wheel drive vehicles with the Haldex coupling
A longitudinal acceleration sender is positioned in the ABS system -G251-.
t
t

Fitting position Chapter


Fault table Chapter

The longitudinal acceleration sender must be switched off for checking the brake system on a
roller type test stand -G251- Chapter, initiate basic setting, display group number 040.
The reactivation of the longitudinal acceleration sender -G251- is performed by switching the
ignition off and on once.
All four-wheel drive vehicles with Haldex coupling are fitted with the EDL (electronic
differential lock).

Interrogating control unit version


Connect vehicle system tester -V.A.G 1552- Chapter.
Interrogating control unit version page Chapter
Readout on display:

1J0 907 379L ABS/EDL 20 IE CAN


V006
->
Coding 13504
WSC XXXXX

The display shows:


t
t
t
t
t
t

the control unit identification number, e.g. 1J0 907


379L
the system designation, e. g. ABS/EDL 20 IE
Data BUS: CAN
the version number, e.g. V006
the code No. of the control unit, e.g. 13504
the workshop code (WSC) Operating instructions
vehicle system tester V.A.G. 1552

Assignment of the control unit electronic catalogue of


original parts
Code the control unit Chapter.
272

Interrogate the fault memory Chapter.

273

Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling
Readout on display
-V.A.G 155201279
Longitudinal
acceleration sender
-G251electrical fault in the
circuit

Possible cause of fault

Open circuit, short-circuit to


positive or earth

Rectifying fault

Read measured value block


Chapter, display group 006
Check wiring and plug connections
according to the current flow
diagram

Perform electrical test Chapter


The fitting position of the
t longitudinal acceleration
sender -G251- is not O.K.
t

Longitudinal acceleration
sender -G251- defective

Check the fitting position of the


longitudinal acceleration sender
-G251

01279
Longitudinal
acceleration sender
-G251implausible signal

Replace longitudinal acceleration


sender -G251- Chapter
Perform null balance:
Initiate basic setting Chapter,
display group number 069

Read measured value block


Chapter, display group number
006
The fitting position of the
t longitudinal acceleration
sender -G251- is not O.K.
t

Longitudinal acceleration
sender -G251- defective

Check the fitting position of the


longitudinal acceleration sender
-G251

01324
Open circuit, short-circuit to
Four-wheel drive control t positive or earth in the data
unit -J492- no
BUS lines
communication

Replace longitudinal acceleration


sender -G251- Chapter
Perform null balance:
Initiate basic setting Chapter,
display group number 069

Read measured value block


Chapter, display group number
125
Test the wiring and plug
connections of the data BUS wiring
according to the current flow
diagram
Perform electrical test Chapter

Code ABS/EDL control unit


Code number for ABS/EDL four-wheel drive vehicles with Haldex coupling Chapter.
274

Code the control unit Chapter.


Reading measured value block
Chapter

Check longitudinal acceleration sender -G251Reading measured value block Chapter.


Display group 006
Readout on display:
Reading measured value block

Enter 006 display group number 006 and confirm with Enter display group number XXX

key Q.
Reading measured value block 6
0.00 m/s2

Readout on display:
Display
field
1

Test conditions

->

Display on V.A.G. 1552

Longitudinal acceleration sender


t

Specified value for vehicle at


standstill:

+ 0.5m/s2

t Specified value forwards:

Value increases constantly

t Specified value backwards:

Value increases constantly with negative


preceding sign (-)

not assigned

not assigned

not assigned

If the readout differs from the specified values as of:

Perform electrical test page Chapter.

Checking the data BUS cable


Reading measured value block Chapter.
Display group number 125
Readout on display:

Reading measured value block


Enter display group number XXX

275

Enter 125 for display group number 125 and confirm


entry with key Q.
Confirm the entry with the key Q.

Readout on display:
Display field

Reading measured value block 125


->
Engine 1
four-wheel 1
gearbox 1

Test conditions

Display on V.A.G. 1552

Data BUS to engine control unit


1

t
t

Connection available

no connection

Data BUS to four-wheel drive control unit


2

t
t

Connection available

no connection

Data BUS to automatic gearbox control unit


3

t
t

Connection available

no connection

not assigned

If the readout differs from the specified values as of:

t
t
t

Read fault memory of the control units connected to the data BUS
Engine control unit
Gearbox control unit (only for automatic gearbox)
Four-wheel drive control unit.
Test the wiring according to the current flow diagram binder Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations

276

Initiating basic setting


The function 04 Initiate basic setting is extended by two display groups for all four-wheel
drive vehicles with Haldex coupling:
t

The display group number 040 is required for switching off the longitudinal acceleration
sender -G251-, e.g. to check the brake system on a roller type test stand Chapter.

The display group number 069 is required for the null balance of the longitudinal
acceleration sender -G251- Chapter.
Note

The reactivation of the longitudinal acceleration sender -G251- is performed by switching the
ignition off and on once.

Initiate basic setting Chapter.

Switch off longitudinal acceleration sender -G251-

Note
No Login procedure is performed for switching off the longitudinal acceleration sender.
Display group number: 040
Readout on display:
Basic setting
HELP
Enter 0, 4 and 0 for the display group number 040 and confirm with Enter display group number

key Q.
XXX

The ABS warning light flashes


Readout on display:
The longitudinal acceleration sender -G251- is now switched off.
After completing the test, the longitudinal acceleration sender must be reactivated by switching the

ignition off and on once -G251-.

Null balance of the longitudinal acceleration sender -G251-

Note
The Login procedure must be first of all performed for the null balance. To do so first enter the
workshop code in the vehicle system tester -V.A.G 1552-.
Display group number 069
Readout on display:
Vehicle system test
HELP
Enter 11 for the function Login procedure and confirm

Select function XX
with Q.
Login procedure
Readout on display:
Enter code number XXXX
Enter code number 40168 and confirm with key Q.
Readout on display:
Vehicle system test
Select function 04 for Initiate basic setting and confirm entry HELP

Select function XX
with key Q.
277

HELP

Readout on display:
Basic setting
HELP
Enter 069 for the display group number 069 and confirm the entry with Enter display group number

the key Q.
XXX

ABS warning light flashes.


Readout on display:
System in basic setting
69
Thus the balance is completed.
Balance o.k.
0.3m/s2
The value does not precisely decrease to 0.00 m/s2.
If this readout appears on the display, the login procedure was not
Function is unknown or cannot
->
successfully performed.
be carried out at the moment

Repeating the login procedure.


If this readout appears on the display, the measured values are not within
the tolerance range allowed for the null balance.
1Interrogate fault memory (function 02)
System in basic setting
2Erase fault memory (function 05)
69
3End output (function 06)
Balance not possible
4Switch off ignition.
5.0m/s2
5Switch on ignition.
6Perform null balance again.

Press .
Readout on display:
Vehicle system test
HELP

Enter 06, End output.


Select function XX
The ABS warning light comes on for approx. 2 seconds.

Electrical test of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
Electrical test ABS/EDL Chapter.
Multi-pin plug connection with contact assignment Chapter.

Additional contact assignment of the multipin plug connection -T25- wiring loom/ABS
control unit -J104-

Contact

Wiring to component ...

13

Longitudinal acceleration sender -G251-

15

Longitudinal acceleration sender -G251278

17

Longitudinal acceleration sender -G251-

Overview of test steps (test steps Chapter)


Component to be tested

Test steps in the test table Chapter

Actuate the longitudinal acceleration sender -G251-

Perform test step 20.

Test table
Test steps 1 to 19 Chapter
The denominations of the bushes of the test box -V.A.G 1598/21- are identical to the
t contact denominations of the ABS control unit -J104- in the current flow diagram binder
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
t

If the measured values deviate from the nominal values, perform the fault eliminating
measures listed in the right part of the table.

Once these values are reached, additionally check the cables for short-circuit to positive
and earth.

t Electrical continuity tests with the measuring tool set -V. A. G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (e.g. with contact spray) and repeat test.
t Before replacing the relevant components test the cables and connections more
specifically for nominal values below 10 , repeat the resistance measurement on the
component.
Test V.A.G
Test covers
ste 1598/21
p
bushes
20

Test conditions
additional works

Cables for
l
Ignition off
longitudinal
acceleration l Set measuring range 200
sender -G251- Disconnect the electrical plug
connection from the
longitudinal acceleration
sender -G251 Disconnect the multi-pin
connector -T25a- from the
279

Specifie Measures for deviations


d value from nominal value

ABS control unit -J104

Connect test box -V.A.G


1598/21-

max.
Check the cables between
the multi-pin connector of the 1.5
longitudinal acceleration

sender -G251- and the multipin connector of the ABS


control unit -J104- for
interruption.

Test the wiring


according to the
current flow diagram

binder Current Flow


Diagrams, Electrical
Fault Finding and Fitting
Locations

l Set measuring range 20 M

Take out the fuse S9


Check cables for short-circuit
to positive or to earth

280

Test the wiring


according to the
current flow diagram

binder Current Flow


Diagrams, Electrical
Fault Finding and Fitting
Locations

Electric/electronic components and fitting locations (four-wheel drive)


All the components marked with

12t
t
t
3t
4t
t

1)

are covered by the self-diagnosis.

Brake master cylinder brake servo unit


Hydraulic control unit

1)

Fitting position: in left of engine compartment


removing and installing Chapter
repairing Chapter
Diagnostic connection
Fitting location: in the storage compartment on the driver's side
ABS warning light -K47Fitting location: in the dash panel insert, function:
The ABS warning light comes on:
281

for about 2 seconds after ignition is switched on and/or engine start

if a fault is detected (e.g. open circuit to wheel speed sensor) Chapter

5t

Hand brake/brake fluid level warning light -K14/33Fitting location: in the dash panel insert, function:

The warning light lights up:

if hand-brake is applied

if low brake fluid level

for about 2 seconds after ignition is switched on


if the electronic brake pressure distribution fails, i.e. when the ABS warning light comes on
Chapter

6-

Parts of ABS system on rear axle

(only disc brake shown in illustration)


Rear right and left wheel speed sensors -G44- / -G46- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter

Pulse rotor for the wheel speed sensor at the rear on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter.

7t

Brake light switch -FBrake light switch is open in off position

setting up to MY 1999 Chapter, as of MY 2000 Chapter

removing and installing up to MY 1999 Chapter, as of MY 2000 Chapter

must be tested in the measured value block Chapter

8-

Front right and left wheel speed sensors -G45- / -G47- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter

Pulse rotor for the wheel speed sensor at the front on the right and left

Parts of ABS system on front axle

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter.

9-

Longitudinal acceleration sender -G251-1)


282

t
t

Fitting location: on the central pipe to the right, near the right pillar -Aremoving and installing Chapter

Removing and installing longitudinal acceleration sender -G251Removing

Remove the glove compartment in the dash panel Body Work; Rep. gr.70.

The longitudinal acceleration sender is


located on the central pipe to the right -1-.

Disconnect plug connection -4-.


Unscrew nut -2- (20 Nm) and remove
longitudinal acceleration sender -3-.

Install

Installation is carried out in the reverse


order.

Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - fourwheel drive
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 550 V
t

Solid lubricant paste -G 000 650-

Removing and installing wheel speed sensor on the rear axle (disc brake) - four-wheel drive
Removing

Raise vehicle.

283

Open the cover -2- of the plug


connection -1-.

Separate plug connection -1- wheel


speed sensor/wheel speed sensor cable.

Release screw -1-.


Pull the wheel speed sensor -G44- / -G46from the trailing arm.

Install
Clean the inner surface of the hole before
inserting the wheel speed sensor and
coat the wheel speed sensor with a solid
lubricant paste -G 000 650-.

Insert the wheel speed sensor into the


hole of the trailing arm and tighten the
screw -1- to 8 Nm.
Connect the wheel speed sensor to the
wheel speed sensor cable and close the
cover -2- of the plug connection -1-.

Check pulse rotor or remove and install


(four-wheel drive)

Raise vehicle.

Remove wheel.

284

Unscrew fixing screws -1- from brake


carrier and remove brake carrier with
brake caliper.
Note

Top fixing screw of the brake carrier


covered.

Tie brake caliper to the body.

The brake line must not be exposed to


tension.

While turning the brake disc, check the


pulse rotor for any dirt or damage.

If the chunking of the pulse rotor is


blocked by dirt, the pulse rotor must be
cleaned.

If the pulse rotor is damaged, the wheel


hub and the pulse rotor must be replaced
Chapter.

Install brake caliper:

Attach the wheel.

Lower the vehicle.

Tightening torques:
Brake carrier with brake caliper to trailing arm
Wheel bolts

65 Nm
120 Nm

Remove and install the wheel speed sensor cables (four-wheel drive)
Note

t
t

It is prohibited to repair shielded leads of the ABS system.


Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

re-set clock

initialise power windows on vehicles fitted with power windows BookletOctavia


285

Disconnect battery.

Raise vehicle.

Remove wheel.

Open the cover -2- of the plug


connection -1-.
Disconnect the plug connection -1- from
the wheel speed sensor cable/wheel
speed sensor.

Remove luggage compartment side trim


panel Body Work; Rep. gr.70.

Locate the welded joint on the wheel


speed sensor cable.

Remove the isolating grommet from the


welded joint.

286

Separate the wheel speed sensor cable in


front of the welded joint using the wire
stripper from the wiring loom repair kit
and remove the defective line piece.

Strip as of 15 mm from the cable


extremity using the wire stripper and turn
the stripped cable halfway.

Draw in new wheel speed sensor cable.

Fit together the plug connection of wheel


speed sensor cable/wheel speed sensor
-1- and close cover -2-.
Clip in wheel speed sensor cable
-arrows-.
Note

When assembling the wheel speed sensor


make sure the wheel speed sensor cable is
not twisted when installed in the
wheelhouse.
Separate the 2-pin plug, if present, on
the new wheel speed sensor cable using

the wire stripper, strip as of 15 mm from


the cable extremity and turn the stripped
cable halfway.
287

Instead of the welding spot, the wheel


speed sensor cable must be connected
using a suitable crimp connector from the
wiring loom repair kit.

Install luggage compartment side trim


panel Body Work; Rep. gr.70.
Attach the wheel.
Connect battery Electrical
System; Rep. gr.27.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

288

Antilock braking system ABS/ EDL/ESP Mark 20


Safety precautions, basic information on fault finding and on repairing
t

The ABS/EDL/ESP is a vehicle security system; system knowledge is required for working
on such systems.

Indication of faults by means of warning


lights:

ABS (-K47-) -1Hand brake/brake fluid level (-K14/331-)


-2ESP (-K155-) -3- Chapter.

Certain faults are not detected until after


t a minimum speed of 20 km/h has been
exceeded (conduct a road test).
If the ABS warning light -K47- and the
warning light for the hand brake/brake
fluid level -K14/33- do not light up and if
t in spite of this the brake system is not
fully operational, look for the fault in the
conventional brake system Chapter
and Chapter.
Notes on rectifying sudden faults
Technical Service Handbook binder
t
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.

Notes on repair work on ABS/EDL/ESP Mark 20


The same notes which apply for the ABS Mark 20 and the ABS/EDL Mark 20 also apply for the
repair work on the ABS/EDL/ESP Mark 20 Chapter.
Required technical information

t Binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
t
Technical Service Handbook
t Self-study programme no. 26 vehicle safety - new technical information
t Self-study programme no. 28 electronic stability program, basis, construction, function

289

Distinguishing features of the ABS/EDL ITT Mark 20 IE and the ABS/EDL/ESP ITT Mark 20 IE
General Instructions

The ABS prevents the wheels from locking during a brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhesion. This also applies when reversing.
A description of the structure and function of the ABS and the EDL can be found in self-study programme
No. 26.
The electronic stability program -ESP- recognises critical driving conditions and stabilises the vehicle by
individual wheel braking and by intervention in the engine control. This occurs independently of a brake or
accelerator pedal activation.
The ESP is active over the entire speed range. If the ESP is in regulating mode, the ESP warning lights flash
three times per second.
The description of the structure and function of the ESP can be found in self-study programme No. 28.
The brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake
servo unit.
Vehicles fitted with ABS/EDL/ESP ITT Mark 20 IE do not have a mechanical brake pressure regulator.
Specifically matched software in the control unit, the electronic brake pressure distribution, EBD, regulates
the brake pressure on the rear axle.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104- form the hydraulic control
unit. A repair is only possible in the removed condition.
New control units supplied through the Parts Division are not coded. They must be coded after installation.

ABS/EDL/ESP ITT Mark 20 IE


distinguishing features:
Note

t
t

Dimension -A-: 135 mm.


Inlying electrical plug connection
between hydraulic unit and control unit.

12 valve domes: The protective sleeves


for the valves are visible if the control
t
unit is separated from the hydraulic unit
Chapter.
t

-1- 47-pin control unit.

Control unit identification. The control


unit version is shown on the display of
t the vehicle system tester -V.A.G 1552-.
Select function 01 interrogate control
unit version Chapter.
t

Overview of selectable functions


Chapter.
290

Fitting position ABS/EDL/ESP ITT Mark 20 IE

Left-hand drive vehicles


1Brake servo unit 10''
2Hydraulic unit
47-pin control unit screwed to the hydraulic
3unit

Right-hand drive vehicles


1Brake servo unit 7''/8''
2Hydraulic unit
47-pin control unit screwed to the hydraulic
3unit

291

Self-diagnosis of the ABS/EDL/TCS/ESP Mark 20


Description of the function

As the control units are interlinked over a data BUS line, always start fault finding by interrogating the
contents of the fault memories of all the control units fitted to the vehicle.
The interrogation of the fault memory is performed with the key function 00 Automatic test sequence.
When doing so check whether a possibly stored fault might affect the ABS system.
Self-diagnosis relates to the electrical/electronic part of the ABS, i. e. faults are detected only over the
electrical connection to the control unit (e.g. open circuit of a wheel speed sensor).
The 47-pin ABS control unit -J104- together with the hydraulic unit forms a compact unit. The unit is
located in the left of the engine compartment. The control unit is equipped with a fault memory. The
connection for self-diagnosis is located in the storage compartment on the driver's side.
The control unit detects faults during the operation of the vehicle and stores them in a permanent memory,
whose information is retained even if the battery voltage is disconnected.
Faults which occur sporadically (isolated) are likewise detected and stored. If this fault which affects the
data BUS system no longer occurs during 15 vehicle starts and driving-off procedures or 50 vehicle starts
and driving-off procedures and if the fault does no longer reappear with other faults, it is erased from the
fault memory (fault delete counter) with the exception of the fault control unit defective.
After the ignition is switched on and/or the engine is started, the ABS warning lights -K47-, the red warning
light for the hand brake/brake fluid level -K14/33- and the ESP warning light -K155- flash for approx. 2
seconds.
During this period a test sequence (self-check) is performed in the control unit with the following functions:
t
Test of supply voltage, min. 10.0 V
t
Test of control unit including valve coils.
t
Check of control unit coding
t Static test of the wheel speed sensor (without speed signal)
After a start-up, should it appear that the speed signal is not O.K as of approx. 20 km/h, the ABS warning
t
light lights up again -K47-.
Initiate self-diagnosis at the start of fault finding and retrieve the stored information using the vehicle
system tester -V.A.G 1552- or the fault read-out scan tool -V.A.G 1551-.
Note
The following description only relates to the vehicle system tester -V.A.G 1552- using the current
program card.
The use of the fault reader -V.A.G 1551- with integrated printer is similar. A minor deviation on the
t
display read-out is possible.
t To end the self-diagnosis or to switch to another address word select function 06 End output.
t Identify the faults displayed by referring to the fault table and subsequently carry out the fault elimination.
t

Indication of faults by means of warning lights -K47-, -K14/33- and -K155-

292

Arrangement of warning lights

Pos. Denomination
1

ABS warning light -K47-

Hand brake/brake fluid level warning light -K14/33-

ESP warning light -K155-

WARNING

Once the ABS warning light -K47- and the hand brake/brake fluid level warning light -K14/33have lit up, then the rear wheels can already lock when braking lightly.
Overview
Meaning

ABS warning Hand brake/brake fluid


light -K47- level warning light
-K14/33-

ESP warning
light -K155-

Ignition on (if the systems are OK, the


lights go out after approx. 3 s)

lights up

lights up

lights up

ESP failure or ESP deactivated by means


of button; ABS, EDL and EBD are active

does not
light up

does not light up

lights up

System O.K.

does not
light up

does not light up

does not
light up

ESP intervention

does not
light up

does not light up

flashes

lights up

does not light up

lights up

ABS/EDL/ESP failure; EBD remains active


(e.g. a wheel speed sensor is defective)

293

ABS/EDL/ESP/EBD failure; (e.g. a wheel


speed sensor is defective)

lights up

lights up

lights up

Brake fluid level too low; all systems


O.K.

does not
light up

lights up

does not
light up

Warning light -K47If the ABS warning light (-K47-) -1- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
The antilock braking system is switched off
if an ABS fault -b- is present. The EBD
function (Electronic Brake pressure
Distribution) is furthermore active while the
conventional brake system remains fully
operational. Interrogate the fault memory
Chapter.
-c- a sporadic fault existed on a wheel
speed sensor after the last vehicle start
In case of a wheel speed sensor fault -c-,
the ABS warning light goes out
automatically -K47- after restarting the
vehicle and after a speed above 20 km/h is
reached.
-d- The line of the ABS control unit -J104for operating the ABS warning light -K47- in
the dash panel insert -J218- is interrupted
binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
-e- Dash panel insert defective

294

Warning light -K47- and -K14/33If the ABS warning light goes out (-K47-)
-1- but the warning light for the hand
brake/brake fluid level (-K14/33-) -2t
remains lit and 3 warning tones are
audible, the following can be the causes
of the fault:
-a- the brake fluid level is too low
-b- the hand-brake is still applied
-c- the switch -F9- for the warning light
-K14/33- is defective or incorrectly adjusted
-d- a fault in the operation of the hand
brake/brake fluid level warning light
-K14/33- binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations.
If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
t light (-K14/33-) -2- light up, then the ABS
system and the EBD (Electronic Brake
pressure Distribution) have failed.
If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
light (-K14/33-) -2- light up and 3 warning
t
tones are audible, then the ABS and the
EBD (Electronic Brake pressure
Distribution) have failed.
Note

The warning light for the hand brake/brake


fluid level (-K14/33-) -2- only lights up after
exceeding a speed of 10 km/h once or an
engine speed of 2000 rpm.
WARNING

Once the ABS warning light -K47- and the


hand brake/brake fluid level warning light
-K14/33- have lit up, then the rear wheels
can already lock when braking lightly.

295

Warning light -K155If the ESP warning light (-K155-) -3- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
There is a fault which exclusively effects
the ESP. The ABS/EDL and EBD safety
systems on the vehicle remain fully
functional. Interrogate the fault memory
Chapter.
-a- Short circuit to positive in ESP button
-E256-b- Short circuit to earth in the operation of
the ESP warning light -K155-c- the line for operating the ESP warning
light -K155- is interrupted binder
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
-d- the ESP system was switched off using
the ESP button -E256If the ESP warning light lights up -K155- for
approx. 100 milliseconds after switching on
the ignition, a coding without ESP control
was entered.
Code the control unit Chapter.
If the ESP warning light -K155- flashes
while driving, the ESP system is operating
in regulating mode.
Warning light -K47-, -K14/33- and -K155If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) -3- remains lit, the
control unit is not yet coded.
Code the control unit Chapter.

296

Vehicle fitted with ABS/EDL/ESP - EDL does not operate


Special tools and workshop equipment required
t
t

Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3 A-

Complaint: Vehicle EDL system does not operate


When dealing with this complaint a possible fault cause may be that the brake light switch is
incorrectly set or is not operating Chapter, set display group number 003 and brake light
switch, Chapter.

297

Electrical test of the ABS/EDL/ESP ITT Mark 20 IE


Special tools and workshop equipment required
t
t

Handheld multimeter, e.g. -V.A.G 1526 AMeasuring tool set -V.A.G 1594/A-

Test box -V.A.G 1598/A-

Adapter -V.A.G 1598/33-

The test steps Chapter apply only to vehicles with ABS/EDL/ESP,


t

for which the self-diagnosis does not indicate the fault source. In this case the full electric
inspection must be carried out.

for which the self-diagnosis gives a direct indication of the fault source. Then only perform
the test steps recommended in the fault table (targeted approach).

Test conditions
l

Before starting the test switch off the ignition and electrical consumers (headlights,
lighting, blowers...).

Fuses S13, S15, S162, S163 must be O.K. binder Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations To check, remove fuses from the fuse holder.
Note

The following 2 work steps do not apply to the 1.6 ltr./55 kW engine.
Remove air filter

Disconnect the plug of the air mass


meter -1- from the air guide pipe of the
air filter.

Screw out screws -2- at the air filter -3and lay it aside.

Connect test box -V.A.G1598 A- with


adapter -V.A.G 1598/33-

298

Disconnect the multi-pin connector -1- in


the -direction of arrow a- and remove it
from the ABS control unit -arrow b-.

Connect the test box -V.A.G 1598 A- with


adapter -V.A.G 1598/33--1- to the plug of
the wiring loom -2-.
Note

The specified values are specific to the


handheld multimeter -V.A.G 1526 A- and do
not necessarily apply for other measuring
tools.

Multi-pin plug connection with contact assignment


Note

All unlisted contacts are not yet assigned and must under no circumstances be connected to
other components!

299

Contact assignment of the plug connection


-T16a- (diagnostic connection) with the
vehicle system tester -V.A.G 1552-

Contact 4 -Earth (terminal 31)


Contact 16 -Positive (terminal 30) for S12
Contact 7 --K- cable via cable connection - diagnosis - to ABS control unit -J10- 4, contact 39

Contact assignment of the plug connection


-T47a- wiring loom/ABS control unit -J104-

Conta
ct

Wiring to component ...

Solenoid coil for brake pressure -N247-

Earth point on the left below the battery

Front right speed sensor -G45-

Front right speed sensor -G45-

Control unit with display unit for radio and navigation (only for navigation system)
300

Rear right wheel speed sensor -G44-

Rear right wheel speed sensor -G44-

Jumper to contact 18

Lateral acceleration sender -G200- (earth lead)

10

Brake pressure sender 2 -G214-

11

Yaw rate sender -G202- (earth lead)

12

Brake pressure sender 1 -G201-

13

Brake detection switch of the ESP -F83-1)

14

not assigned

15

Earth point on the left below the battery

16

Voltage supply of battery + (via S162)

17

Solenoid coil for brake pressure -N247-

18

Jumper to contact 8

19

Data BUS cable binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations

20

Data BUS cable binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations

21

not assigned

22

ABS warning light -K47-

23

Brake light switch -F-

24

TCS/ESP button -E256- / voltage supply relay for warning light -K155-

25

Lateral acceleration sender -G200- (voltage line)

26

Brake pressure sender 2 -G214-

27

Yaw rate sender -G202- (voltage line)

28

Brake pressure sender 1 -G201-

29

Brake detection switch of the ESP -F83-1)

30

not assigned

31

Brake light suppression relay -J508-

32

Brake detection switch of the ESP -F83-1)

33

Front left speed sensor -G47301

34

Front left speed sensor -G47-

35

Control unit with display unit for radio and navigation (only for navigation system)

36

Rear left wheel speed sensor -G46-

37

Rear left wheel speed sensor -G46-

38

not assigned

39

Plug connection -T16a/7-, -K- cable

40

Lateral acceleration sender -G200- (signal line)

41

Brake pressure sender 2 -G214-

42

Yaw rate sender -G202- (signal line)

43

Brake pressure sender 1 -G201-

44

Voltage supply terminal 15 via S 13

45

not assigned

46

Earth point on the left below the battery

47

Voltage supply battery + (via S163)

1)

Brake detection switch ESP -F83- is identical to release switch of the solenoid coil for
brake pressure -F84-.

Overview of test steps


Component to be tested
Voltage supply of the ABS hydraulic pump -V64-

- Perform test step 1

Voltage supply of the valves in the hydraulic unit

- Perform test step 2

Voltage supply of the control unit -J104-

- Perform test step 3

Function of the brake light switch -F-

- Perform test step 4

Brake light suppression relay -J508-

- Perform test step 5

Jumper

- Perform test step 6

Resistance of the front right speed sensor -G45-

- Perform test step 7

Resistance of the front left speed sensor -G47-

- Perform test step 8

Resistance of the rear right speed sensor -G44-

- Perform test step 9

Resistance of the rear left speed sensor -G46-

- Perform test step 10

Voltage signal of the front right speed sensor -G45-

- Perform test step 11

302

Voltage signal of the front left speed sensor -G47-

- Perform test step 12

Voltage signal of the rear right speed sensor -G44-

- Perform test step 13

Voltage signal of the rear left speed sensor -G46-

- Perform test step 14

Function of the ABS warning light -K47-

- Perform test step 15

Function of the hand brake/brake fluid level warning light -K14/33-

- Perform test step 16

Function of the ESP warning light -K155-

- Perform test step 17

Function of the ESP button -E256-

- Perform test step 18

Actuation of the steering angle sender -G85-

- Perform test step 19

Actuation of the lateral acceleration sender -G200-

- Perform test step 20

Actuation of the yaw rate sender -G202-

- Perform test step 21

Actuation of the brake pressure sender -1--G201-

- Perform test step 22

Actuation of the brake pressure sender -2--G214-

- Perform test step 23

Actuation of the solenoid coil for brake pressure -N247-

- Perform test step 24

Actuation of the brake detection switch -F83-1)

- Perform test step 25

Test of the data BUS cable

- Perform test step 26

Voltage supply for -V.A.G 1551-, plug connection -T16a-

- Perform test step 27

Resistance of the -K- cable for the self-diagnosis, plug connection -T16a- - Perform test step 28

1)

The brake detection switch -F83- is identical to the release switch of the solenoid coil for
brake pressure -F84-.

303

Test table
Notes for the test table
The denominations of the bushes of the test box -V.A.G 1598 A- with adapter -V.A.G
1598/33- are identical to the contact denominations of the control unit -J104- in the current
t
flow diagram binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (e.g. with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on the
component.

Test steps 1 - 20
Test steps 21 - 28 Chapter
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
Test covers
step 1598 Abushes

Specifie Measures for deviations from


Test
l condition d value nominal value
s
additional
works

15 + 47 Voltage supply of the ABS Ignition


l
hydraulic pump -V64off
(terminal 30) at the ABS
control unit -J104-

10.0Test wiring of contact


14.5V -T47a/47- via fuse S163 to
battery positive.

46 + 16 Voltage supply for the


valves in the ABS
hydraulic unit -N55(terminal 30) at the ABS
control unit -J104-

10.0Test wiring of contact

14.5V
-T47a/16- via fuse -S162- to
battery positive.

Ignition
off

Test wiring of contact


-T47a/15- to earth binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations

Test wiring of contact


-T47a/46- to earth binder
Current Flow Diagrams,
Electrical Fault Finding and
304

Fitting Locations
3

44 + 46 Voltage supply of the ABS Ignition


l
control unit -J104on
(terminal 15)

10.0Test wiring of contact

14.5V
-T47a/44- via fuse S13 and
ignition starter switch.
Test wiring of contact
-T47a/46- to earth binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations

Switch on measuring range:


voltage measurement (20 V =) in test step 4, resistance measurement (200 )/(20 M) in
test step 4a
Test -V.A.G
Test
step 1598 A- covers
bushes
4

23 + 46 Brake
light
switch
-F-

Test conditions

additional works

Ignition off

Specifie Measures for deviations from nominal


d value value

0,0-0,5
If necessary set brake light switch

V
Chapter.

Brake pedal not


actuated

Actuate brake pedal 10.014.5V


4a

Brake
light
switch
-F-

Measuring range
200 set

Replace brake light switch


Chapter.

Check contact 1 of the brake light


switch -F- to fuse S13.

Pull out the multi-pin


connector from the
brake light/brake
pedal switch

Test wiring for open circuit.

Repair the wiring according to the


current flow diagram binder
Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations

Pull out the multi-pin


connector -T47a- from
the ABS control unit
-J104-

max.1.5

Test wiring for open


circuit

Test wiring of contact


23 (control unit) to
contact 1 (brake light
switch)
l Measuring range
305

20 M set

Remove fuse S13


Check cables for
short-circuit to
positive or to earth

Switch on measuring range: voltage measurement (20 V =)


Test -V.A.G
Test covers
step 1598 Abushes

23 + 46 Brake light
suppression
relay -J508-

Specifie Measures for deviations from nominal


Test
conditions d value value

additional
works

l Ignition on
Brake
l pedal
actuated

31 + 15

Bridge
bushes 31
and 15

10.0- Brake light suppression relay -J508-.


14.5V

0,0-0,5
V

Test the wiring according to the current


flow diagram for open circuit and short
circuit binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G 1598 Test
step A- bushes covers
6

8 + 18

Table of l
codes

Test conditions
additional works
Ignition off
Detach multi-pin connector
-T47aConnect test box -V.A.G 1598
A- with adapter -V.A.G
1598/33-

Test wiring for open circuit

306

Specified Measures for deviations


value
from nominal value
max. 1.5 Test wiring of contact 8

to contact 18 for open


circuit

Switch on measuring range: resistance measurement (2 k)


Test -V.A.G
step 1598 Abushes

3+4

Test covers

Specifie Measures for deviations from nominal


Test
conditions d value value

additional
works
Resistance of the
Ignition
l
front right speed
off
sensor -G45-

1,0 ...
Separate plug connection on speed

1.3 k
sensor.

Test wiring according to the current


flow diagram.

Throughout the test, move cables


binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations
If the lines are not found to be faulty:

33 + 34 Resistance of the
Ignition
l
front left speed
off
sensor -G47-

Replace wheel speed sensor -G45 Chapter

1,0 ...
Separate plug connection on speed

1.3 k
sensor.

Test wiring according to the current


flow diagram.

Throughout the test, move cables


binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations
If the lines are not found to be faulty:

7+6

Resistance of the
Ignition
l
rear right speed
off
sensor -G44-

Replace wheel speed sensor -G47 Chapter

1,0 ...
Separate plug connection on speed

1.3 k
sensor.

Test wiring according to the current


flow diagram.

Throughout the test, move cables


binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations
If the lines are not found to be faulty:

307

Replace wheel speed sensor -G44 Chapter

10

37 + 36 Resistance of the
Ignition
l
rear left speed
off
sensor -G46-

1,0 ...
Separate plug connection on speed

1.3 k
sensor.

Test wiring according to the current


flow diagram.

Throughout the test, move cables


binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations
If the lines are not found to be faulty:

Replace speed sensor -G46 Chapter.

Switch on measuring range: voltage measurement (20 V ~)


Test -V.A.G Test covers
step 1598 Abushes
11

l Test conditions Specified


value
additional

works

Measures for deviations from


nominal value

3 + 4 Voltage signal l Vehicle raised Alternating


Check the installation of the
of the front
voltage min. wheel speed sensor and the
l Ignition off
right speed
65 mV
pulse rotor.
sensor -G45Turn front right
Check wheel speed sensor -G45 wheel by
to ensure it is correctly

approx. 1 turn
connected and read measured
per sec.
value block Chapter, display
group number 001

12 33 + 34 Voltage signal l Vehicle raised


of the front
l Ignition off
left speed
sensor -G47Turn front left
wheel by
approx. 1 turn
per sec.

Alternating
Check the installation of the
voltage min. wheel speed sensor and the
65 mV
pulse rotor.

13

Alternating
Check the installation of the
voltage min. wheel speed sensor and the
190 mV
pulse rotor.

7 + 6 Voltage signal l Vehicle raised


of the rear
l Ignition off
right speed
sensor -G44Turn rear right
wheel by
approx. 1 turn
per sec.

Check wheel speed sensor -G47to ensure it is correctly

connected and read measured


value block Chapter, display
group number 001

Check wheel speed sensor -G44to ensure it is correctly


connected and read measured
value block Chapter, display
308

group number 001


14 36 + 37 Voltage signal l Vehicle raised
of the rear
l Ignition off
left speed
sensor -G46Turn rear left
wheel by
approx. 1 turn
per sec.

Alternating
Check the installation of the
voltage min. wheel speed sensor and the
190 mV
pulse rotor.
Check wheel speed sensor -G46to ensure it is correctly

connected and read measured


value block Chapter, display
group number 001

Functional test: ABS warning light -K47Test -V.A.G Test


ste 1598 covers
p
Abushes
15

l Test conditions

additional works

Specified
value

Function
of the ABS
warning
l
light -K47-

The warning
The fault memory
was interrogated and light -K47lights up for
there is no fault in
the fault memory of approx. 2
the ABS control unit seconds and
goes out
-J104again
l Ignition off
The multi-pin
connector is inserted
l on the ABS control
unit -J104- and
locked

Measures for deviations from


nominal value

If the ABS warning light does not


light up for approx. 2 seconds:
Test wiring of contact
-T47a/22- (control unit) to
contact -T32a/19- (dash panel

insert) for short-circuit to


earth. Binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting Locations

Check dash panel insert, fault


in the dash panel insert
Electrical System; Rep. gr.90

Switch on ignition

Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G Test covers
ste 1598
p
Abushes
16

Test
conditions

additional
works

Specified
value

Function of the
Brake fluid
l
hand
level is O.K.
brake/brake
l Ignition off
309

Measures for deviations from


nominal value

fluid level
warning light
-K14/33-

Multi-pin
connector
inserted on
l
control unit
-J104- and
locked

Switch on
ignition

Functional test: ESP warning light -K155Test -V.A.G Test


ste 1598 covers
p
Abushes
17

l Test conditions Specified


value
additional

works

Function l Ignition off


of the ESP
Multi-pin
warning
connector
light
inserted on
-K155l
control unit
-J104- and
locked

The warning
light -K155lights up for
approx. 2
seconds and
goes out

Measures for deviations from nominal


value

Test wiring of contact -T47a/22(control unit) via the voltage supply

relay -J535- to contact -T32b/14(dash panel insert) for open circuit


and short-circuit to positive.
If the warning light -K155- remains lit:
Test wiring of contact -T47a/22(control unit) via the voltage supply
relay -J535- to contact -T32b/14
(dash panel insert) for short-circuit
to earth binder Current Flow
Diagrams, Electrical Fault Finding
and Fitting Locations

Switch on

ignition

Check dash panel insert, fault in the


dash panel insert.

Test the ESP button -E256 Electrical System ; Rep. gr.90

Test voltage supply relay for


warning light -K155- binder
Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations

Functional test: Warning light for TCS/ESP button -E256- in test step 18; voltage supply (20
310

V=) in test step 18a


Test -V.A.G Test covers l Test conditions
Specified value Measures for deviations from
ste 1598 Anominal value

additional
works
p
bushes
18

Function of l Ignition off


the
The function of
TCS/ESP
the TCS/ESP
button
l warning light
-E256-K155- was tested
with test step 17

The warning
light -K155lights up for
approx. 2
seconds and
goes out again

The multi-pin
connector is
l inserted on the
ABS control unit
-J104- and locked

Switch on
ignition
Operate TCS/ESP Warning light
-K155- comes
button
on

Perform test step 18a

Operate TCS/ESP Warning light


-K155- goes out
button once
again

18a 15 + Function of
Switch off

24 the
ignition
TCS/ESP
Pull out the multibutton
pin connector
-E256from the ABS
control unit -J104-

Test wiring of contact


-T47a/15- (control unit) to
earth.
Test wiring of contact
-T47a/24- (control unit) to
contact -T4f/2- (TCS/ESP
button) for open circuit or
short-circuit to positive or to
earth.

Connect test box


-V.A.G 1598 Awith adapter
-V.A.G 1598/33

Switch on
ignition

Button -E256- not 3,5-5,0 V


pressed and
warning light
-K155- lights up

Button -E256-

8,0 - 14,5V
311

Test wiring of contact


-T47a/24- (control unit) to
contact -T32b/14- (dash panel
insert) for open circuit and
short-circuit to positive or to
earth.
Test voltage supply of contact

held pressed and


warning light
-K155- lights up

-T4f/1- (TCS/ESP button) via


fuse S13 for open circuit
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting Locations

Replace TCS/ESP button


Body Work; Rep. gr.70.

Switch on measuring range:


voltage measurement (20 V =) in test step 19, resistance measurement (200 )/(20 M) in
test step 19a
Test -V.A.G Test covers
ste 1598 Ap
bushes
19

l Test conditions
additional works

Specifie Measures for deviations from


d value nominal value

Earth connection l Ignition off


and voltage
Pull out the multisupply of the
pin connector
steering angle
-T47a- from the ABS
sender -G85control unit -J104Disconnect the plug
connection from the
steering angle
sender

Test wiring of contact -T6w/4(steering angle sender) to


fuse S15 for open circuit.

Repair the wiring according to


the current flow diagram

binder Current Flow


Diagrams, Electrical Fault
Finding and Fitting Locations

Test the voltage


supply of the

steering angle
sender at the plug
connection -T6w

19a

Cables for
steering angle
sender -G85-

Test wiring between 10.0contact -T6w/4- and 14.5V


contact -T6w/1Ignition on
Test wiring between 10.0contact -T6w/5- and 14.5V
contact -T6w/1-

Measuring range
200 set

Connect test box


-V.A.G 1598 A- with
312

Test wiring of contact -T6w/5(steering angle sender) to


fuse S13 for open circuit
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting Locations

adapter -V.A.G
1598/33

check the following


wiring for open
circuit:

Wiring of contact
-T6w/3- (steering

angle sender) with


contact -T47a/19(control unit)
Wiring of contact
-T6w/2- (steering

angle sender) with


contact -T47a/20(control unit).

Wiring of contact
T6w/1 to earth

Measuring range
20 M set

Remove fuse S13

max. Test wiring for open circuit.


1.5
Repair the wiring according to
the current flow diagram

binder Current Flow


Diagrams, Electrical Fault
Finding and Fitting Locations

Check cables for


short-circuit to
positive or to earth

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G Test covers
ste 1598 Ap
bushes
20

Test conditions

additional works

Cables for
l
Ignition off
lateral
Measuring range 200
acceleration
l
set
sender -G200

Remove fuse S13

Pull out the multi-pin


connector -T47a- from
the ABS control unit
-J104 Connect test box
-V.A.G 1598 A- with
adapter -V.A.G
313

Specifie Measures for deviations from


d value nominal value

1598/33Disconnect the plug


connection -T3n- from
Check the following

line connections for an


open circuit:
Wiring of contact
-T3n/1- (lateral

acceleration sender)
with contact -T47a/40(control unit)

max. Test wiring for open circuit.


1.5
Repair the wiring according
to the current flow diagram
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations

Wiring of contact
-T3n/2- (lateral

acceleration sender)
with contact -T47a/9(control unit)
Wiring of contact
-T3n/3- (lateral

acceleration sender)
with contact -T47a/25(control unit)
l

max.
1.5

Measuring range
20 M set
Remove fuse S13
Check cables for shortcircuit to positive or to
earth

314

Test steps 21 - 28
Switch on measuring range: resistance measurement (200 )/(20 M)
Test V.A.G
Test
step 1598 A covers
bushes
21

Test conditions

additional works

Specifie Measures for deviations from


d value nominal value

Cables for l
Ignition off
yaw rate
Measuring range 200
sender
l
set
-G202Pull out the multi-pin
connector -T47a- from
the ABS control unit
-J104-.
Connect test box
-V.A.G 1598 A- with
adapter -V.A.G
1598/33Disconnect the plug
connection -T3m- from
the yaw rate sender
-G202

Check the following


line connections for an
open circuit:

Wiring of contact
-T3m/1- (yaw rate
sender) with contact
-T47a/42- (control unit)

Test wiring for open circuit.

max.
1.5

Wiring of contact
-T3m/2- (yaw rate
sender) with contact
-T47a/11- (control unit)
Wiring of contact
-T3m/3- (yaw rate
sender) with contact
-T47a/27- (control unit)
l

Measuring range
20 M set
Remove fuse S13

Check cables for shortcircuit to positive or to


earth
315

Repair the wiring according to


the current flow diagram

binder Current Flow


Diagrams, Electrical Fault
Finding and Fitting Locations

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G Test covers l
ste 1598 A
p
bushes
22

Cables for
brake
pressure
sender 1
-G201-

l
l

Test conditions
additional works

Specifie Measures for deviations from


d value nominal value

Ignition off
Measuring range 200
set
Pull out the multi-pin
connector -T47a- from the
ABS control unit -J104Connect test box -V.A.G
1598 A- with adapter
-V.A.G 1598/33-

Disconnect the plug


connection -T30- from the
brake pressure sender
-G201

Check the following line


connections for an open
circuit:

Wiring of contact -T30/1(brake pressure sender)

via plug connection


-T14c/1- with contact
-T47a/28- (control unit)
Wiring of contact -T30/2(brake pressure sender)

via plug connection


-T14c/2- with contact
-T47a/12- (control unit)
Wiring of contact -T30/3(brake pressure sender)

via plug connection


-T14c/3- with contact
-T47a/43- (control unit)
l

Measuring range 20 M
set

Check cables for short316

Test wiring for open circuit.


max.
1.5

Repair the wiring according


to the current flow diagram
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations

circuit to positive or to
earth

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G Test covers l
ste 1598 A
p
bushes
23

Cables for
brake
pressure
sender 2
-G214-

l
l

Test conditions
additional works

Specifie Measures for deviations from


d value nominal value

Ignition off
Measuring range 200
set
Pull out the multi-pin
connector -T47a- from the
ABS control unit -J104Connect test box -V.A.G
1598 A- with adapter
-V.A.G 1598/33-

Disconnect the plug


connection -T3p- from the
brake pressure sender
-G201-

Check the following line


connections for an open
circuit:

Wiring of contact -T3p/1- max.


(brake pressure sender 2) 1.5

via plug connection


-T14c/12- with contact
-T47a/26- (control unit)
Wiring of contact -T3p/2(brake pressure sender 2)

via plug connection


-T14c/13- with contact
-T47a/10- (control unit)
Wiring of contact -T3p/3(brake pressure sender)

via plug connection


-T14c/14- with contact
-T47a/41- (control unit)

317

Test wiring for open circuit.

Repair the wiring according


to the current flow diagram
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations

Measuring range 20 M
set
Remove fuse S13

Check cables for short circuit to positive or to


earth

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G Test covers l
ste 1598 A
p
bushes
24

Test conditions
additional works

Specifie Measures for deviations from


d value nominal value

Cables for
l
Ignition off
solenoid coil
l Measuring range 200 set
for brake
pressure
Pull out the multi-pin

-N247connector -T47a- from the


ABS control unit -J104

Connect test box -V.A.G


1598 A- with adapter -V.A.G
1598/33Disconnect plug connection
T6x at brake servo unit

Check the following line


connections for an open
circuit:
Wiring of contact -T6x/4(solenoid coil for brake
pressure -N247-) via plug
connection -T14c/7- with
contact -T47a/17- (ABS
control unit)
Wiring of contact -T6x/3(solenoid coil for brake
pressure -N247-) via plug
connection -T14c/8- with
contact -T47a/17- (ABS
control unit -J104-).

318

max.
1.5

Test wiring for open


circuit.

Repair the wiring according


to the current flow diagram
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations

l Measuring range 20 M set

Remove fuse S13

Check cables for short circuit to positive or to


earth
l Measuring range 200 set

Disconnect multi-pin
connector T14c

The brake servo unit must


1.0 ... be replaced if the
2.0 k
specified value is not
reached Chapter.

Check contacts -7- and -8 in the plug connection


-T14c- to the solenoid coil
for brake pressure -N247-

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G Test
ste 1598 A- covers
p
bushes
25

Specifie Measures for deviations from


d value nominal value

Test conditions
additional works

Brake
l
Ignition off
detection
l Measuring range 200 set
switch
-F83Pull out the multi-pin

connector -T47a- from the


ABS control unit -J104

Connect test box -V.A.G 1598


A- with adapter -V.A.G
1598/33Disconnect plug connection
-T6x- at brake servo unit

Check the following line


connections for an open
circuit:
Wiring of contact -T6x/1(brake detection switch
-F83-) via plug connection
-T14c/5- with contact
-T47a/13- (ABS control unit
-J104-)
Wiring of contact -T6x/2(brake detection switch
319

Test wiring for open circuit.

-F83-) via plug connection


-T14c/6- with contact
-T47a/29- (ABS control unit
-J104-)

Repair the wiring according


to the current flow diagram
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations

Wiring of contact -T6x/5(brake detection switch


-F83-) via plug connection
-T14c/9- with contact
-T47a/327- (ABS control unit
-J104-).
l Measuring range 20 M set

Remove fuse S13


Check cables for short-circuit
to positive or to earth

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G Test
l
ste 1598 A- covers

p
bushes

Specifie Measures for deviations from


d value nominal value

Test conditions
additional works

26 19+20 Data l
Ignition off
BUS
cables l Measuring range 200 set
Disconnect the multi-pin plug
connections from the control
units connected to a data BUS
line (connection in the dash
panel wiring loom -A122- and
-A121-)

Connect test box -V.A.G 1598 Awith adapter -V.A.G 1598/33-

Check the following line


connections for an open circuit:

to the steering angle sender

to the engine control unit


to the automatic gearbox
control unit 1)

Wiring of contact -T47a/19(control unit) via connection


A121 to contact -T6w/3320

max. Test wiring for open circuit.


1.5
Repair the wiring according

(steering angle sender -G85-)

to the current flow diagram


binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations

Continue via connection A121 to


the connected control units

Wiring of contact -T47a/20 (control unit) via connection


A122 to contact -T6w/2(steering angle sender -G85-).
Continue via connection A122 to
the connected control units
according to current flow
diagram
l Measuring range 20 M set

1)

Remove fuse S13


Check cables for short-circuit to
positive or to earth

Only on vehicles with automatic gearbox

Switch on measuring range: voltage measurement (20 V =)


Test -V.A.G Test covers
ste 1598 Ap
bushes
27

Test conditions

additional works

Specifie Measures for deviations


d value from nominal value

Voltage supply for l


Ignition on
vehicle system
Connect the handheld 10.0tester -V.A.G
multimeter, e.g. -V.A.G 14.5V
1552-, plug
connection -T16a- 1526 A-, with the
measuring tool set
-V.A.G 1594 A- to -T16a1)

Test wiring between


contact -T16a/4- and
contact -T16a/1-

1)

Test wiring of -T16a/4- to


earth.

Test wiring of -T16a/1- via


-S5-.

Repair the wiring


according to the current
flow diagram binder
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations

Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter

Switch on measuring range: resistance measurement (200 )


321

Test -V.A.G Test covers


step 1598 Abushes
28

l Test conditions
additional works

-K- cable for the l Ignition off


self-diagnosis,
plug connection Measuring range
l
200 set
T16a

Specifie Measures for deviations from


d value nominal value

max.
Test wiring of contact -T16a/7
1.5
to contact -T47a/39-

Remove fuse S13

Repair the wiring according to


the current flow diagram

binder Current Flow


Diagrams, Electrical Fault
Finding and Fitting Locations

Pull out the multipin connector

-T47a- from the


ABS control unit
-J104Connect test box
-V.A.G 1598 A- with
adapter -V.A.G
1598/33Test wiring
between contact
-T16a/7- and
contact -T47a/39l

Measuring range
20 M set

Remove fuse S13

Check cables for


short-circuit to
positive or to earth

322

Repair the wiring according to


the current flow diagram

binder Current Flow


Diagrams, Electrical Fault
Finding and Fitting Locations

Electric/electronic components and fitting locations ABS/EDL/ESP Mark 20

1-

Brake servo unit with master brake cylinder and brake fluid reservoir

The brake servo unit includes the following components:


t

Release switch of the solenoid coil for brake pressure -F84-; This switch is identical to the
brake detection switch ESP -F83-.

The brake detection switch ESP-F83- is tested by self-diagnosis

Solenoid coil for brake pressure in the brake servo unit -N247-

The solenoid coil for brake pressure in the brake servo unit -N247- is tested by selfdiagnosis

2t

Brake pressure sender 1 -G201are checked by self-diagnosis

t The brake pressure sender 1 and the brake pressure sender 2 are equal parts
t The fitting location for the brake pressure sender 1 can also be the Pos. 3 for the brake
323

pressure sender 2
t

removing and installing Chapter

3-

Brake pressure sender 2 -G214-

are checked by self-diagnosis

t The brake pressure sender 2 and the brake pressure sender 1 are equal parts
t

The fitting location for the brake pressure sender 2 can also be the Pos. 2 for the brake
pressure sender 1

removing and installing Chapter

4-

Cable duct

Brake detection switch -F83-

Solenoid coil for brake pressure

5-

Plug connection -T14c-

Brake detection switch -F83-

Solenoid coil for brake pressure in the brake servo unit -N247-

Brake pressure sender -1--G201-

Brake pressure sender -2--G214-

6t

Lateral acceleration sender -G200Fitting location: next to the steering column under the dash panel

is checked by self-diagnosis

7t

Yaw rate sender -G202Fitting location: next to the steering column under the dash panel

is checked by self-diagnosis

8t

Fitting location: on the steering column between the steering wheel and the steering
column switch

t
9t
t
10 t
t

Steering angle sender -G85-

is checked by self-diagnosis
ESP warning light -K155Fitting location: in the dash panel insert
function Chapter
Hand brake/brake fluid level warning light -K14/33Fitting location: in the dash panel insert
function Chapter
324

11 t

ABS warning light


Fitting location: in the dash panel insert

function Chapter

12 -

Parts of ABS system on rear axle

(only disc brake shown in illustration)


t

Rear right and rear left wheel speed sensors -G44/G46-

t
t

is checked by self-diagnosis
Pulse rotor for the wheel speed sensor at the rear on the right and left

removing and installing Chapter

Installing wheel speed sensor cables Chapter


Pulse rotor for the wheel speed sensor at the rear on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter

13 t

Front right and front left wheel speed sensors -G45/G47- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter


Pulse rotor for the wheel speed sensor at the front on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter

14 t

Voltage supply relay for warning light -K155--J535Fitting location: additional relay carrier, space 7

15 t

Parts of ABS system on front axle

Diagnostic connection

Fitting location: in the storage compartment on the driver's side

16 t

Brake light switch -Fis open in off position

setting up to MY 1999 Chapter, as of MY 2000 Chapter

removing and installing up to MY 1999 Chapter, as of MY 2000 Chapter

must be tested in the measured value block Chapter

17 -

Control unit for ABS/EDL/ESP -J104325

Fitting location: at the hydraulic unit in left of engine compartment

t
t
t

is checked by self-diagnosis
Check the multi-pin plug connection to the control unit Chapter
Do not disconnect the multi-pin plug connection before the self-diagnosis is complete.
switch off the ignition before disconnecting the plug connector.

18 t
t
t

Hydraulic unit for ABS/EDL/ESP -N55Fitting position: left of engine compartment

the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
inlet and exhaust valves
is checked by self-diagnosis

when changing the hydraulic unit, absolutely close the old part with a plug from the
mounting part kit; SP no. Electronic Catalogue of Original Parts

Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104-)
Chapter

t
t

Do not separate the hydraulic pump -V64- from the valve block.
Repairing the hydraulic control unit Chapter

Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket
Note

Make absolutely sure that no brake fluid gets into the plug connector housing of the control
unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
Special tools and workshop equipment required
t

Vehicle system tester -V.A.G 1552-

Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3A-

Brake pedal load, e.g. -V.A.G 1238/B-, or -V.A.G 1869/2-

t
t
t
t

Mounting part kit, SP no. Electronic Catalogue of Original Parts The mounting part kit
consists of a plug and a protective cap
Brake filling and bleeding device, e.g. -VAS 5234Extraction bottle (commercially available)
Brake fluid Chapter

326

1t
t

47-pin
do not disconnect the plug connector before the self-diagnosis is complete, switch off the
ignition before disconnecting the plug connector

2t

Multi-pin connector/ABS control unit

Hydraulic control unit

the hydraulic pump -V64-, the ABS hydraulic unit -N55- and the ABS control unit -J104- form
the hydraulic control unit

t the hydraulic control unit must be removed and installed completely Chapter.
t
3t
4t
5t
6t

repairing Chapter
Brake line, 14 Nm
between master brake cylinder/floating piston circuit and hydraulic unit
Brake line, 14 Nm
ABS hydraulic unit to front left brake caliper
Brake line, 14 Nm
ABS hydraulic unit to rear right brake caliper
Brake line, 14 Nm
ABS hydraulic unit to wheel cylinder/rear left brake caliper
327

7t

Brake line, 14 Nm
ABS hydraulic unit to front right brake caliper

8-

Brake line, 14 Nm

t between master brake cylinder/push rod piston circuit and hydraulic unit
9-

Self-locking nut, 20 Nm

10 -

Support

11 -

Dowel screw, 8 Nm

12 -

Cap nut, 25 Nm

Remove the hydraulic control unit


Note

Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia

Disconnect battery.
Note

The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:

328

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Using an extraction bottle extract as


much brake fluid as possible from the
brake fluid reservoir.

Press brake pedal and lock in place with


brake pedal load, e.g. -V.A.G 1238/B- or
-V.A.G 1869/2-.

Attach the bleeder hose of the bleeding


bottle onto the bleeder screw of the front
left brake caliper and open the bleeder
screw.

Close the bleeder screw once the brake


fluid flowed out.

Disconnect the bleeder hose from the


bleeder screw.

Release the multi-pin connector -1- (arrow a-) and disconnect it from the
hydraulic control unit (-arrow b-).
Note

Make sure that no brake fluid gets onto the


contacts.

329

In order to collect the brake fluid,


position an absorption fleece under the
hydraulic control unit -1-.
Note

The brake lines around the hydraulic unit


must not be bent.
Screw out the brake lines from the
master brake cylinder to the hydraulic

unit, see -arrows-, and protect them


against dirt with the screw plugs from the
mounting part kit.
On vehicles with the steering located on
the left, tie up the unscrewed brake lines
with a welding wire as far to the top until
the cable extremities protrude beyond
the brake fluid gauge of the expansion
reservoir.

Unscrew the remaining brake lines from


the hydraulic unit.

The connections of the hydraulic lines on


the hydraulic unit must be closed with
the plugs from the mounting part kit.

-Pos. 1- Protective cap for valve domes


(foam material).
The plugs -Pos. 2 and 3- as well as the
protective cap -Pos. 1- are part of the
scope of delivery of the mounting part kit
SP no. for mounting part kit Electronic
Catalogue of Original Parts

330

Unscrew the screws -arrows- on the


bracket for the hydraulic control unit.
Note

The third fixing screw for the hydraulic


control unit is covered by the hydraulic
pump -V64-.
Remove the hydraulic control unit .
Install the hydraulic control unit
Note

Only then remove plugs from the


t hydraulic unit when the relevant brake
line is installed.
If the plugs were already removed from
the hydraulic unit before the brake line is
t installed, then brake fluid may escape
and adequate filling and bleeding can no
longer be guaranteed.

Screw hydraulic control unit onto


bracket.
Note

Do not tighten screws. This facilitates the


screwing of the individual brake lines onto
the hydraulic control unit.

Connect the brake lines to the hydraulic


unit and tighten Chapter.

331

Tighten the hydraulic control unit


-arrows-.
Note

The third fixing screw for the hydraulic


control unit is covered by the hydraulic
pump -V64-.

Insert the multi-pin connector on the ABS


control unit and lock.

Further installation occurs in reverse order.

Connect battery Electrical


System; Rep. gr.27.

Code the control unit Chapter.

Bleeding Brake System Chapter.

If the control unit was replaced while


repairing the hydraulic control unit -J104-,
a null balance must be performed for the
following components:
t

Steering angle sender -G85-

t Lateral acceleration sender -G200t

Brake pressure sender 1 -G201-

Brake pressure sender 2 -G214-

Initiate basic setting and perform null


balance Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter

Removing and installing bracket


Removing

Remove the hydraulic control unit


Chapter.

332

Unscrew nuts -1- and cap nut -3-.

Remove holder -2-.

Install
Installation is carried out in the reverse
order.

Tightening torques:
Nuts to body
t

20 Nm

Use new screws!

Cap nut to body

25 Nm

Repairing the hydraulic control unit ABS/EDL/ESP


Special tools and workshop equipment required
t

Mounting part kit, SP no. Electronic Catalogue of Original Parts. The mounting part kit
consists of a plug and a protective cap

Disassembling the hydraulic control unit

333

The repair of the hydraulic control unit is


carried out by separating the ABS control
unit (-J104-) -1- from the hydraulic unit (N55-) -2-, which is connected to the
hydraulic pump (-V64-) -3-.
Only the ABS control unit (-J104-) -1- or the
hydraulic unit (-N55-) -2- with the hydraulic
pump (-V64-) -3- can be replaced. The
hydraulic unit and the hydraulic pump
must not be separated from each other
and therefore cannot be replaced
individually.

Screw out the screws from the control


unit -arrows- and remove the ABS control
unit from the hydraulic unit.
Note

When removing the ABS control unit -b-,


make sure the valve domes -1- of the
hydraulic unit -a- do not tilt along with the
solenoid coils -2- of the ABS control unit
-b-.

Cover the solenoid coils of the control


unit with a non-fluffing cloth.

334

After separating the hydraulic unit from


the ABS control unit, fit the protective
cap -1- onto the valve domes of the
hydraulic unit.
Note

The protective cap -1- and the plugs -2t and -3- are component parts of the
mounting part kit.
The plugs and the protective cap of the
newly installed hydraulic units can be
t
used instead of thoses from the mounting
part kit.

ABS hydraulic unit (-N55-) and hydraulic


pump (-V64-) -a-:
t

Hydraulic unit: The valve block includes


the control valves.

Do not separate the hydraulic pump


-V64- from the hydraulic unit -N55-.

When changing the hydraulic unit, the


protective cap for valve domes
( Anchor, Pos. 1) must be inserted on
t the old part and the old part must be
closed with the screw plugs ( Anchor,
Pos. 2 and 3). This is a requirement for
possible guarantee claims.
1 - Valve domes of the hydraulic unit
2-

Solenoid coils of the control unit

ABS control unit (-J104-) -b-:


If the ABS control unit was replaced while
repairing the hydraulic control unit -J104-,
a null balance must be performed for the
following components:
t

Steering angle sender -G85335

t Lateral acceleration sender -G200t

Brake pressure sender 1 -G201-

Brake pressure sender 2 -G214-

Initiate basic setting Chapter.

Contact assignment Chapter,


Test requirements Chapter
Assembling the hydraulic control unit
Note

There must be no impurities present


around the control unit/valve block.

When assembling the control unit and


the hydraulic unit make sure the valve
t domes of the hydraulic unit do not tilt
along with the solenoid coils of the
control unit.

Screw the ABS control unit to the


hydraulic unit. Tightening torque: 4 Nm
(always use the supplied screws).

Checking/removing and installing parts of the ABS system on the front axle
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 Vt

Solid lubricant paste -G 000 650-

Removing and installing wheel speed sensor


Chapter
Check pulse rotor or remove and install
Chapter
Check axial run-out of pulse rotor
Chapter
Removing and installing the wheel speed sensor cables
Note

336

t
t

It is prohibited to repair shielded leads of the ABS system.


Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia


Removing

Disconnect battery.
Note

The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:

Disconnect the plug of the air mass


meter -1- from the air guide pipe of the
air filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Release the multi-pin connector -1- (arrow a-) and disconnect it from the ABS
control unit -arrow b-.

Unlock the cap -1- of the multi-pin


337

connector -2- using a screwdriver and


remove it.

Release secondary lock (purple) with a


small screwdriver in the -direction of the
arrow-.

Contact assignment of the plug connection


-T47a- wiring loom/ABS control unit -J104-

Contact
3+4

Wiring to component ...


Front right wheel speed sensor -G45-

33 + 34

Front left wheel speed sensor -G47-

6+7

Rear right wheel speed sensor -G44-

36 + 37

Rear left wheel speed sensor -G46338

Press out the relevant contacts using a suitable ejection tool from the wiring loom repair
kit.

Release plug connection on wheel speed sensor and separate plug connector.

Remove defective wheel speed sensor cable.

Install

Draw in new wheel speed sensor cable.


Connect wheel speed sensor cable to wheel speed sensor.

Clip in wheel speed sensor cable


-arrows-.
Note

When assembling the wheel speed sensor


cable make sure it is not twisted when
installed in the wheelhouse.

339

Insert contact in the plug housing and


insert the single cable seal with a
suitable plug-in tool from the wiring loom
repair kit up to the stop.

Secure the contacts with the secondary


lock (purple).

Lock the secondary lock (purple) with a


small screwdriver in the -direction of the
arrow-.

Position the cap on the multi-pin


connector.

Insert the multi-pin connector on the ABS


control unit -J104- and lock.

Connect battery Electrical


System; Rep. gr.27.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

340

Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
Removing and installing parts of the ESP system
The description of the structure and function of the ESP can be found in self-study
programme No. 28.
t
t

Remove and install yaw rate sender -G202- and lateral acceleration sender -G200 Chapter
Remove and install steering angle sender -G85- Chapter

Special tools and workshop equipment required


t
t

Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3A-

Remove and install yaw rate sender -G202- and lateral acceleration sender -G200The removal and installation procedure of the yaw rate sender -G202- and the lateral
acceleration sender -G200- is the same except for the direct replacement of the sender to be
removed.
Note

Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia


Removing

Disconnect battery.

341

Remove the bottom part of the dash


panel -1- Body Work; Rep. gr.70.

Remove the bottom part of the steering


column trim panel -2- Body Work; Rep.
gr.70.

The yaw rate sender (-G202-) -1- and the


lateral acceleration sender (-G200-) -2- are
fixed with a common bracket -3- at the
mounting bracket for the steering column
-a-.
Note

Due to the common bracket, the senders


cannot be removed separately. After
removing the bracket, the yaw rate sender
-G202- and the lateral acceleration sender
-G200- can be replaced separately.

Disconnect the plugs -arrows- from the


yaw rate sender -G202- and from the
lateral acceleration sender -G200-.
Unscrew screw -5- and remove bracket
-3- with yaw rate sender -G202- and
lateral acceleration sender -G200-.

Replace yaw rate sender -G202-

342

Unscrew the nuts -a- from the yaw rate


sender (-G202-) -1-.

Remove the yaw rate sender (-G202-) -1from the bracket -3-.

-2- Lateral acceleration sender -G200Insert the new yaw rate sender (-G202-)
-1- into the bracket -3- and align it
straight.

Screw on nuts -a- and tighten.

Replace lateral acceleration sender -G200-

Lever off the holder -2- from the lateral


acceleration sender (-G200-) -1- using a
screwdriver.
Remove the lateral acceleration sender (G200-) -1- from the bracket -4-.

-3- Yaw rate sender -G202-

Insert the new lateral acceleration sender


(-G200-) -1- into the bracket -3-.

-4- Yaw rate sender -G202Note

The inclined side -arrow- of the lateral


acceleration sender (-G200-) -1- must point
in the direction of the holder -2-.
Push the holder -2- over the lateral
acceleration sender (-G200-) -1- and
lock.
Install

343

Mount the bracket -3- with the lateral


acceleration sender (-G200-) -2- and the

yaw rate sender (-G202-) -1- on the


mounting bracket -4- for the steering
column -a-.

Insert and tighten screw -5-.


Fit on plug for yaw rate sender (-G202-)
-1- and plug for lateral acceleration
sender (-G200-) -2- (arrows).

Install the bottom part of the steering


column trim panel Body Work; Rep.
gr.70.

Install bottom part of dash panel Body


Work; Rep. gr.70.

Connect battery Electrical


System; Rep. gr.27.

Initiate basic setting Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Tightening torques:
Yaw rate sender (-G202-)

9 Nm

Bracket at mounting bracket for steering column

20 Nm

Removing and installing steering angle sender -G85Special tools and workshop equipment required
t
t

Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3ANote

Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia.


Removing
344

Disconnect battery.

Put the front wheels in straight ahead position.

Remove steering wheel Body Work; Rep. gr.69.

Unscrew screws -1-, -2-, -3- and -4-.


Remove the handle for the steering
wheel adjuster as well as the top and
bottom part of the steering column trim
panel.
- Check whether the front wheels are in the
straight-ahead position.

If necessary, fit on the steering wheel


and put the front wheels in a straight
ahead position.
Remove steering wheel.

The steering angle sender -G85- is fitted


together with the coil spring -2- in the
housing -1-.
Note

The following two work steps must only be


performed when reinstalling at a later
stage the same housing with a coil spring.

345

Position the steering angle sender in the


centre position:

A yellow dot must be visible in the window


-1-.
The markings -arrows- must be flush.
Make sure this position is maintained.

Secure the coil spring -2- against


unintentional turning by covering it with
adhesive tape -1-.

-3- Housing

Disconnect plugs -1- and -2-

346

Carefully release catch hooks -arrowsand remove housing -1- with steering
angle sender -G85- and coil spring.

Install
Slide housing -1- with steering angle
sender -G85- and coil spring onto the
steering column and lock into position
with steering column switch -arrows-.

Connect both plug connections.


Note

After removing the transport protection or


the adhesive tape do not turn the coil
spring, only the positioning of the steering
angle sender -G85- in centre position is
allowed.

Removing transport protection or


adhesive tape.

Position the steering angle sender in the


centre position:

A yellow dot must be visible in the window


-1-.
Markings -arrows- must be flush with each
other.
Make sure this correct position is
maintained.

Remove the top and bottom part of the


steering column trim panel as well as the
handle for the steering wheel adjuster.

Install steering wheel Body work; Rep.


gr.69.

Connect battery Electrical


System; Rep. gr.27.

Perform the basic setting of the steering


angle sender -G85- Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

347

Removing and installing as well as setting the brake light switch


up to MY 1999 Chapter
as of MY 2000 Chapter

Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
for vehicles with ABS/EDL/ESP Mark 20
Note

t The hydraulic control unit must be removed and installed completely Chapter.
t

Repairing Chapter.

t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
t

The complete master brake cylinder and brake servo unit can be replaced independently of
one another.

348

1-

Brake servo unit

check Chapter

removing and installing - LHD vehicles Chapter

removing and installing - RHD vehicles Chapter

2-

Self-locking nut 28 Nm

3-

Gasket

for brake servo unit

4t

Bellows
pay attention to correct position, risk of suction noises

5-

Holder

is attached to the edge of the brake servo unit

serves for the support of the plug - Pos. 15

6t

Screw cap
with integrated brake fluid level warning contact -F34-

7-

Brake fluid reservoir

8-

Sealing ring

replace

9-

Retaining bracket

for fixing the wiring loom - Pos. 16

10 t

moisten with brake fluid and press in expansion reservoir

11 t

Master brake cylinder

cannot be repaired, replace completely in the event of faults

t
13 t
t
14 t

Retaining pin
fit through the master brake cylinder

12 t

Plugs

removing and installing Chapter


Brake pressure sender -1--G201in the floating piston circuit
removing and installing Chapter
Brake pressure sender -2--G214in the push rod piston circuit
349

removing and installing Chapter

15 t

Connector

Connection wiring loom dash panel/engine compartment

16 -

Wiring loom

17 -

Self-locking nut, 20 Nm

18 -

Heat shield

only for vehicles fitted with a 110 kW engine

19 -

Cap nut, 25 Nm

20 -

Dowel screw, 8 Nm

21 -

Dampening rubber

22 -

Support

23 -

Self-locking nut, 20 Nm

24 -

Control unit for ABS/EDL/ESP

25 -

Hydraulic unit for ABS/EDL/ESP

26 -

Brake line connection, 14 Nm

hydraulic unit to front left brake caliper

27 t

Hydraulic unit to wheel cylinder/rear right brake caliper

28 t

Brake line connection, 14 Nm


Hydraulic unit to front right brake caliper

30 -

Brake line, 14 Nm

Master brake cylinder/push rod piston circuit to hydraulic unit

31 t

Brake line connection, 14 Nm

Hydraulic unit to wheel cylinder/rear left brake caliper

29 -

Brake line connection, 14 Nm

Brake line, 14 Nm

Master brake cylinder/push rod piston circuit to hydraulic unit

32 33 t
t

Plugs
Vacuum hose
with non-return valve
insert in brake servo unit.

350

351

Antilock braking system (ABS) MK60


Safety precautions, basic information on fault finding and on repairing ABS and ABS/TCS/EDL
MK 60
Antilock braking system (ABS) ITT Mark 20 IE Chapter.
Notes on repair work on ABS and ABS/TCS/EDL MK 60
Antilock braking system (ABS) ITT Mark 20 IE Chapter.
Required technical information
t Binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
t

ABS Self-study programme

Technical Service Handbook

General Instructions
Chapter.

ABS and ABS/TCS/EDL


The ABS and ABS/TCS/EDL do not differ on the exterior.
t

Control unit identification

The control unit version appears in the display of -V.A.G 1552-. Select function 01 interrogate
control unit version Chapter. electronic catalogue of original parts
t

Overview of selectable functions Chapter.

Fitting position ABS or ABS/TCS/EDL MK 60


Chapter

Electric/electronic components and fitting locations ABS/EDL/TCS Mark 60


All the components marked with

1)

are covered by the self-diagnosis.

352

1-

Brake servo unit with master brake cylinder and brake fluid reservoir

Summary of components Chapter

2t
t
t
3t
4t
t

Hydraulic control unit

1)

Fitting position: in left of engine compartment


removing and installing Chapter
repairing Chapter
Diagnostic connection
Fitting location: in the storage compartment on the driver's side
ABS warning light -K47Fitting location: in the dash panel insert, function:
The ABS warning light comes on:

for about 2 seconds after the ignition is switched on or the engine is started

if a fault is detected (e.g. open circuit to wheel speed sensor) Chapter

5-

Hand brake/brake fluid level warning light -K14/33-

Fitting location: in the dash panel insert, function:

The hand brake/brake fluid level warning light comes on:

if hand-brake is applied
353

if low brake fluid level

for about 2 seconds after ignition is switched on


if the electronic brake pressure distribution fails, i.e. when the ABS warning light comes on
Chapter

6-

Parts of ABS system on rear axle

(only disc brake shown in illustration)


Rear right and rear left wheel speed sensors -G44/G46- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter

Pulse rotor for the wheel speed sensor at the rear on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter

7t

Brake light switch -Fis open in off position

setting up to MY 1999 Chapter, as of MY 2000 Chapter

removing and installing up to MY 1999 Chapter, as of MY 2000 Chapter

must be tested in the measured value block Chapter

8t

Parts of ABS system on front axle


Front right and front left wheel speed sensors -G45/G47- 1)
removing and installing Chapter
Installing wheel speed sensor cables Chapter
Pulse rotor for the wheel speed sensor at the front on the right and left
check Chapter

removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter

Removing and installing the hydraulic control unit and the bracket
Note

Make absolutely sure that no brake fluid gets into the plug connector housing of the control
354

unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
Special tools and workshop equipment required
t

Vehicle system tester -V.A.G 1552-

Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

Brake pedal load, e.g. -V.A.G 1238/B-

Caps from the repair set SP no. -1 HO 698 311 A-

Brake filling and bleeding device, e.g. -VAS 5234-

Extraction bottle (commercially available)

Brake fluid Chapter

1t

Hydraulic control unit

the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
hydraulic control unit.

t the hydraulic control unit must be removed and installed completely Chapter
t the connections of the brake lines are embedded on the hydraulic control unit
t
2-

repairing Chapter
Support
355

3-

Nut, 20 Nm

4-

8 Nm

5t

Brake line, 14 Nm
Hydraulic unit to wheel cylinder/rear left brake caliper

6t

Brake line, 14 Nm
Hydraulic unit to wheel cylinder/rear right brake caliper

7-

Multi-pin connector/control unit

t
t

47-pin
Do not disconnect the plug connection before the self-diagnosis is complete. switch off the
ignition before disconnecting the plug connector.

8-

Brake line, 14 Nm

t between master brake cylinder/push rod piston circuit and hydraulic unit
9-

Brake line, 14 Nm

hydraulic unit to front left brake caliper

10 t

Brake line, 14 Nm

between master brake cylinder/floating piston circuit and hydraulic unit

11 t

Brake line, 14 Nm
Hydraulic unit to front right brake caliper

Remove the hydraulic control unit


Note

t
t

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
After connecting the battery, check the vehicle equipment:
on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia.

Disconnect battery.
Note

The following 2 work steps do not apply to the 1.4 ltr./55 kW engine:
356

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Using an extraction bottle extract as


much brake fluid as possible from the
brake fluid reservoir.

Press brake pedal and lock in place with


brake pedal load, e.g. -V.A.G 1238/B-.

Attach the bleeder hose of the bleeding


bottle onto the bleeder screw of the front
left brake caliper and open the bleeder
screw.

Close the bleeder screw once the brake


fluid flowed out.

Disconnect the bleeder hose from the


bleeder screw.

Release the multi-pin connector and


remove it from the control unit -arrows-.
Note

Make sure that no brake fluid gets onto the


contacts.

In order to collect the brake fluid,


position an absorption fleece under the
hydraulic control unit.
Note

Do not bend the brake lines around the


hydraulic control unit.
357

Screw out the brake lines from the


master brake cylinder to the hydraulic

unit, see -arrows-, and protect them


against dirt with the caps from the repair
set.
On vehicles with the steering located on
the left, tie up the unscrewed brake lines
with a welding wire as far to the top until
the cable extremities protrude beyond
the brake fluid gauge of the expansion
reservoir -arrows-.

Unscrew the remaining brake lines from


the hydraulic unit.
The connections of the hydraulic lines on
the hydraulic unit must be closed with
the screw plugs from the repair set.

Unclip the cable for clutch control -arrow


A-.

Unscrew the screws -arrows B- on the


bracket for the hydraulic control unit.

Remove the hydraulic control unit .


Install the hydraulic control unit
Note

Only then remove plugs from the hydraulic


unit when the relevant brake line is
installed.

Screw hydraulic control unit onto


bracket.
Note

Do not tighten screws. This facilitates the


screwing of the individual brake lines onto
the hydraulic control unit.

Connect the brake line to the hydraulic


control unit and tighten Chapter.

358

Tighten the hydraulic control unit -arrows


B-.

Clip on the cable for clutch control


-arrow A-.

Insert the multi-plug connector on the


control unit and lock.

Further installation occurs in reverse order.

Connect battery Electrical


System; Rep. gr.27.

Bleeding Brake System Chapter.

Code the control unit Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Repairing the hydraulic control unit


Note

The components of the hydraulic control unit are fitted together and connected by 2
screws.

Before removing the Torx screws, secure the hydraulic pump against unintentional
separation from the hydraulic pump with adhesive tape.

t The hydraulic pump and the hydraulic unit constitute a replacement part.
WARNING

The hydraulic pump must not be separated from the hydraulic unit.

359

1-

Torx screws, 8 Nm

2-

Hydraulic unit

The hydraulic unit consists of: -a- Hydraulic pump for ABS or ABS/TCS/EDL -V64--b- Hydraulic
unit for ABS or ABS/TCS/EDL -N55t

the valve block includes the control valves

t after separating them from the control unit, fit on the transport protection for valve domes
3t
t

Control unit for ABS or ABS/TCS/EDL -J104-

when removing them from the hydraulic unit, the valve domes of the hydraulic unit must
not tilt along with the solenoid coils of the control unit
Cover the solenoid coils with a non-fluffing cloth

Contact assignment Chapter

Test requirements Chapter

Assembling the hydraulic control unit


Note

t There must be no impurities present around the control unit/valve block.


360

When assembling the control unit and the hydraulic unit make sure the valve domes of the
hydraulic unit do not tilt along with the solenoid coils of the control unit.

Checking/removing and installing parts of the ABS system on the front axle
Chapter.
Removing and installing the wheel speed sensor cables
Removing
Note

t
t
t

It is prohibited to repair shielded ABS cables.


Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
After connecting the battery, check the vehicle equipment:
on vehicles with radio encoding, carry out the coding,

set clock,
initialise power windows on vehicles fitted with power windows.
Disconnect battery.
Note

The following 2 work steps do not apply to the 1.4 ltr./55 kW engine:

Disconnect the plug of the air mass


meter -1- from the air guide pipe of the
air filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

361

Release the multi-pin connector and


remove it from the control unit -arrows-.

Unclip the cap of the multi-pin connector


using a screwdriver -arrows- and remove
it.

Release secondary lock (purple) with a


small screwdriver in the -direction of the
arrow-.

362

Contact assignment of the plug connection


wiring loom/ABS control unit -J104-

Contact

Wiring to component

33 + 34

Front right wheel speed sensor -G45-

45 + 46

Front left wheel speed sensor -G47-

42 + 43

Rear right wheel speed sensor -G44-

36 + 37

Rear left wheel speed sensor -G46-

Press out the relevant contacts using a suitable ejection tool from the wiring loom repair
kit.

Release plug connection on wheel speed sensor and separate plug connector.

Remove defective wheel speed sensor cable.

Install

Draw in new wheel speed sensor cable.


Connect wheel speed sensor cable to wheel speed sensor.

363

Clip in wheel speed sensor cable


-arrows-.
Note

When assembling the wheel speed sensor


cable make sure it is not twisted when
installed in the wheelhouse.
Insert the contact in the plug housing and
insert the single wire seal with a suitable
plug-in tool from the wiring loom repair
kit up to the stop.

Secure the contacts with the secondary


lock and position the cap of the multi-pin
connector.
Connect battery Electrical
System; Rep. gr.27.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
Chapter.

Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
ABS/EDL/TCS Mark 60
Note

t The hydraulic control unit must be removed and installed completely Chapter.
t

Repairing Chapter.

t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.

364

1t

Brake servo unit


check Chapter

removing and installing - LHD vehicles Chapter

removing and installing - RHD vehicles Chapter

2t
3t
4-

Sealing ring
replace
Screw cap
with integrated brake fluid level warning contact -F34Brake fluid reservoir

5t
6-

Plugs
moisten with brake fluid and press in expansion reservoir
Retaining pin

7-

Master brake cylinder

8-

Self-locking nut, 20 Nm

t
9t

replace
Brake line
Master brake cylinder/push rod piston circuit THV to hydraulic unit
365

10 t

Brake line

Master brake cylinder/push rod piston circuit to hydraulic unit

11 t

Self-locking nut, 20 Nm
only fitted on certain models

replace

12 t

Heat shield
only fitted on certain models

13 t

Hydraulic control unit


removing and installing Chapter

repairing Chapter

Connections of brake lines Chapter

14 t

Support
with rubber insulation

15 -

Insert flange nut, 20 Nm

16 -

8 Nm

Electrical test ABS/EDL/ TCS Mark 60


Special tools and workshop equipment required
t
t
t
t

Handheld multimeter, e.g. -V.A.G 1526 AMeasuring tool set -V.A.G 1594 ATest box -V.A.G 1598 AAdapter e.g. -V.A.G 1598/36-

The test steps as of page Anchor apply only for vehicles with ABS/EDL/TCS
t

Vehicles for which the final control diagnosis does not indicate the fault source. In this case
the full electric inspection must be carried out.

Vehicles for which the final control diagnosis does give a direct indication of the fault
t source. Then only perform the test steps recommended in the fault table (targeted
approach).
An overview of all the test steps of the electrical test can be found on the page Chapter.

Test requirements
366

Before starting the test switch off the ignition and electrical consumers (headlights,
lighting, blowers etc.).

The fuses must be OK (to check, remove fuses from the fuse holder) binder Current
Flow Diagrams, Electrical Fault Finding and Fitting Locations.

Remove the protective housing for relays from the cable duct.

Disconnect the plug -1- from the control


unit -J104--arrow a- and remove it -arrow
b-.

Connect the test box -V.A.G 1598/36- with


adapter -V.A.G 1598/36--1- to the multipin plug connection of the control unit
-J104--2-.
Note

The specified values are specific to the


-V.A.G 1526 A- and do not necessarily apply
for other measuring tools.

Multi-pin plug connections with contact assignment for ABS, ABS/EDL/TCS


Contact assignment of plug connection -T16a- of diagnostic coupling
Chapter

367

Contact assignment of the plug connection


-T47a- wiring loom/ABS control unit -J104-.
Note
are not used.

45 - Front left wheel speed sensor -G47368

46 - Front left wheel speed sensor -G4747 -

Earth

Overview of test steps


Component to be tested
Voltage supply for the hydraulic pump -V64- to the control unit -J104-

- Perform test step


1

Voltage supply of the valves in the hydraulic unit -N55- to the control unit - Perform test step
-J1042
Voltage supply (ignition starter switch) to the control unit -J104-

- Perform test step


3

Function of the brake light switch -F-

- Perform test step


4

Resistance of the front right speed sensor -G45-

- Perform test step


5

Resistance of the front left speed sensor -G47-

- Perform test step


6

Resistance of the rear right speed sensor -G44-

- Perform test step


7

Resistance of the rear left speed sensor -G46-

- Perform test step


8

Voltage signal of the front right speed sensor -G45-

- Perform test step


9

Voltage signal of the front left speed sensor -G47-

- Perform test step


10

Voltage signal of the rear right speed sensor -G44-

- Perform test step


11

Voltage signal of the rear left speed sensor -G46-

- Perform test step


12

Function of the ABS warning light -K47-

- Perform test step


13

Function of the hand brake/brake fluid level warning light -K14/33-

- Perform test step


14

Function of the TCS button -E132-

- Perform test step


15

Test of the data BUS cable

- Perform test step


369

16
Voltage supply for -V.A.G 1551-, plug connection -T16a-

- Perform test step


17

Resistance of the K cable for the self-diagnosis, plug connection -T16a-

- Perform test step


18

Jumper

- Perform test step


19

Test table
Notes for the test table
The denominations of the bushes of the adapters -V.A.G 1598/36- are identical to the
t contact denominations of the ABS control unit -J104- in the current flow diagram binder
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
step 1598 Abushes

Test covers

Test
conditions

Specified
value

Measures for deviations from


nominal value

additional
works

1 +47 Voltage supply for the l Ignition off


hydraulic pump -V64(terminal 30) to the
control unit -J104-

10.0 14,5V

Test the wiring according to the


current flow diagram binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations.

32 + 16 Voltage supply of the l Ignition off


valves in the hydraulic
unit -N55- (terminal
30) to the control unit
-J104-

10.0 14,5V

Test the wiring according to the


current flow diagram binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations.

4 + 47 Voltage supply

l Ignition on
370

(terminal 15) of the


control unit -J1044

47 + 41 Function of the brake


light switch -F-

l Ignition off
Brake
l pedal not
actuated

Test brake light switch -F- and


0.0 - 0.5 read measured value block
V
Chapter; display group
number 003.
Test the wiring according to the
current flow diagram binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations.

approx.
Check brake light switch -F
battery
Chapter.
voltage

Brake
pedal
actuated

Switch on measuring range: resistance measurement (2 k)


Test -V.A.G
step 1598 Abushes

Test covers

5 33 + 34 Resistance of
the front right
speed sensor
-G45-

l Test conditions

additional
works

l Ignition off

Specified
value

1.0...1.3 k

Measures for deviations from


nominal value

Check wiring according to


current flow diagram.

Throughout the test, do not


move cables binder Current
Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
If the lines are not found to be
faulty:

6 45 + 46 Resistance of
the front left
speed sensor
-G47-

t Ignition off

1.0...1.3 k

Replace speed sensor -G45 Chapter.

Check wiring according to


current flow diagram.

Throughout the test, do not


move cables binder Current
Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
If the lines are not found to be
faulty:
Replace speed sensor -G47371

Chapter.
7 42 + 43 Resistance of
the rear right
speed sensor
-G44-

t Ignition off

1.0...1.3 k

Check wiring according to


current flow diagram.

Throughout the test, do not


move cables binder Current
Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
If the lines are not found to be
faulty:

8 37 + 36 Resistance of
the rear left
speed sensor
-G46-

t Ignition off

1.0...1.3 k

Replace speed sensor -G44 Chapter.

Check wiring according to


current flow diagram.

Throughout the test, do not


move cables binder Current
Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
If the lines are not found to be
faulty:

9 33 + 34 Voltage signal
of the front
right speed
sensor -G45-

l Vehicle raised

l Ignition off

Check the installation of the


wheel speed sensor -G45- and
the rotor.

Turn front right Alternating


Check wheel speed sensor
voltage min. -G45- to ensure it is correctly
wheel by

65 mV
approx. 1 turn
connected and read measured
per sec.
value block Chapter, display
group number 001.

10 45 + 46 Voltage signal l Vehicle raised

of the front left


speed sensor l Ignition off
-G47Alternating
Turn rear left
voltage min.
wheel by

190mV
approx. 1 turn
per sec.

11 42 + 43 Voltage signal
of the rear
right speed

Replace speed sensor -G46 Chapter.

l Vehicle raised

l Ignition off

372

Check the installation of the


wheel speed sensor -G47- and
the rotor.
Check wheel speed sensor
-G47- to ensure it is correctly
connected and read measured
value block Chapter, display
group number 001
Check the installation of the
wheel speed sensor -G44- and
the rotor.

sensor -G44-

Turn rear right Alternating


voltage min.
wheel by

190mV
approx. 1 turn
per sec.

Check wheel speed sensor


-G44- to ensure it is correctly
connected and read measured
value block Chapter, display
group number 001.

12 37 + 36 Voltage signal l Vehicle raised

of the rear left


speed sensor l Ignition off
-G46Alternating
Turn rear left
voltage min.
wheel by

190mV
approx. 1 turn
per sec.

Check the installation of the


wheel speed sensor -G46- and
the rotor.
Check wheel speed sensor
-G46- to ensure it is correctly
connected and read measured
value block Chapter, display
group number 001.

Functional test: ABS warning light -K47Test -V.A.G Test covers Test
l
step 1598 Aconditions
bushes
additional
works
13

Function of
the ABS
warning
light -K47-

Specified value

Measures for deviations from


nominal value

The warning light


Test the wiring according to the
-K47- lights up for current flow diagram binder

approx. 2 seconds Current Flow Diagrams, Electrical


Switch on and goes out
Fault Finding and Fitting
ignition
Locations.
l

Ignition
off

Fault in the dash panel insert.


Electrical System; Rep. gr.90

Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G
step 1598 Abushes

14

Test covers

Function of the hand


brake/brake fluid level
warning light -K14/33-

Test
conditions

additional
works

Specified
value

Measures for deviations


from nominal value

Handbrake Warning light Fault in the dash panel

not applied -K14/33insert Electrical


System; Rep. gr.90
Brake fluid
l
level is O.K.
l

373

l Ignition on

Warning light Fault in the dash panel


Apply

handbrake -K14/33insert Electrical


lights up
System; Rep. gr.90

Functional test: Function of the TCS button -E132Test -V.A.G Test covers Test
l
step 1598 Aconditions
bushes
additional

works
15

Function of l Ignition on
the TCS
button
-E132

TCS button
-E132operated

Specified value

Measures for deviations from


nominal value

The warning light


-K86- lights up for
approx. 2 seconds
and goes out
TCS warning light
-K86- lights up

Test the wiring according to the


current flow diagram binder

Current Flow Diagrams,


Electrical Fault Finding and
Fitting Locations.

Operate TCS TCS warning light


Replace TCS button -E132
button -E132- -K86- goes out
Body Work; Rep. gr.70
once again

Switch on measuring range: resistance measurement (200 /20 M)


Test -V.A.G
Test l
step 1598 A- covers

bushes
16

11
or
15

Specifie
d value

Test conditions
additional works

Data l
Ignition off
BUS
cables l Measuring range 200
set
Disconnect the multi-pin
plug connections from the
control units connected to
a data BUS line:
Connect -V.A.G 1598 Awith adapter -V.A.G
374

Measures for deviations from


nominal value

1598/36

Check the data BUS cable


for open circuit

Set measuring range


20 M

Take out the fuse S9

Check cables for short circuit to positive or to


earth

max.
1.5

Test the wiring according to the


current flow diagram binder

Current Flow Diagrams,


Electrical Fault Finding and Fitting
Locations.

Test the wiring according to the


current flow diagram binder

Current Flow Diagrams,


Electrical Fault Finding and Fitting
Locations.

Switch on measuring range: voltage measurement (20 V =)


Test -V.A.G
ste 1598 Ap bushes
17

1)

Test covers

Test conditions
additional works

Voltage supply l
Ignition off
for -V.A.G
Connect the handheld
1552-, plug
multimeter -V.A.G 1526connection

1)
with the measuring tool
-T16aset -V.A.G 1594- to the
plug connection -T16a-1)

Specifie Measures for deviations from


d value
nominal value

10.0 14,5V

Test the wiring according


to the current flow diagram
binder Current Flow
Diagrams, Electrical Fault
Finding and Fitting
Locations.

Contact assignment of the diagnostic connector Chapter.

Switch on measuring range: resistance measurement (200 )


Test -V.A.G
ste 1598
p
Abushes
18

Test covers

Test conditions
additional works

Resistance of l
Ignition off
the K cable for
-V.A.G 1552-, Disconnect the multi-pin plug
connection from the control
375

Specifie Measures for deviations


d value
from nominal value

plug
connection
-T16a-1)

unit -J104Connect -V.A.G 1598 A- with


adapter -V.A.G 1598/36-

Connect the handheld


multimeter -V.A.G 1526- with
the measuring tool set -V.A.G

1594- to the contacts -T16a/71)


and -T47a/2-2) of the multipin plug connections from the
control unit -J104-.

1)

Contact assignment of the diagnostic connector Chapter.

2)

Contact assignment of the control unit plug Chapter.

max.
1.5

Test the wiring


according to the
current flow diagram

binder Current Flow


Diagrams, Electrical
Fault Finding and
Fitting Locations.

Switch on measuring range: resistance measurement (200 )


Test -V.A.G
step 1598 Abushes

19

Test covers

Specifie
Test
conditions d value

Measures for deviations from nominal


value

additional
works

14 + 38 Jumper for
Ignition
t
ABS/EDL/TCS
off

0.0 - 1.0 Test the wiring according to the current

flow diagram binder Current Flow


Diagrams, Electrical Fault Finding and
Fitting Locations.

376

Antilock braking system ABS/ EDL/TCS/ESP Mark 60


Safety precautions, basic information on fault finding and on repairing
Chapter

Notes on repair work on ABS/EDL/TCS/ESP Mark 60


Chapter

Required technical information


t
t

Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.


Technical Service Handbook

Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02


All the components marked with

1)

are covered by the self-diagnosis.

377

1-

Brake servo unit

with master brake cylinder and brake fluid reservoir

Remove and install brake servo unit Chapter

2t

removing and installing Chapter

3t

Lateral acceleration sender -G200-1)


Fitting location: next to the steering column under the dash panel

4t

Yaw rate sender -G202-1)


Fitting location: next to the steering column under the dash panel

5t

Brake pressure sender -1--G201-1)

Steering angle sender -G85-1)

Fitting location: on the steering column between the steering wheel and the steering
column switch

6-

ABS warning light -K47378

Fitting location: in the dash panel insert

function Chapter

7-

Hand brake/brake fluid level warning light -K14/33-

Fitting location: in the dash panel insert

function Chapter

8-

ESP warning light -K155-

Fitting location: in the dash panel insert

function Chapter

9t

Parts of ABS system on rear axle


Rear right and rear left wheel speed sensors -G44/G46- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter


Pulse rotor for the wheel speed sensor at the rear on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter

10 -

Brake vacuum pump -V192-1)

t only on vehicles with automatic gearbox in combination with EU-4 engines


t
t

Fitting location: on the left of the assembly carrier


is checked by self-diagnosis in the engine control unit Engine, Fuel Injection and Ignition
System; Rep. gr.01

removing and installing Chapter

11 t

Diagnostic connection

Fitting location: in the storage compartment on the driver's side

12 t

Brake light switch -F-1)


is open in off position

adjust Chapter

remove by turning 90 to the left Chapter

install by turning 90 to the right Chapter

must be tested in the measured value block 003 Chapter

13 t

Control unit for ABS/EDL/ESP -J104-

Fitting location: at the hydraulic unit in left of engine compartment


379

t
t
t

is checked by self-diagnosis
Check the multi-pin plug connection to the control unit Chapter
Do not disconnect the multi-pin plug connection before the self-diagnosis is complete.
switch off the ignition before disconnecting the plug connector.

14 t

Hydraulic unit for ABS/EDL/ESP -N55-1)


Fitting position: left of engine compartment

the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
inlet and exhaust valves

when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
Electronic Catalogue of Original Parts

Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104 Chapter

Do not separate the hydraulic pump -V64- from the valve block.

Repairing the hydraulic control unit Chapter

15 t

Front right and front left wheel speed sensors -G45/G47- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter


Pulse rotor for the wheel speed sensor at the front on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter

16 t
t

Parts of ABS system on front axle

Longitudinal acceleration sender -G251-1)

Fitting location: on the central pipe to the right, near the right pillar -Aremoving and installing Chapter

Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02


All the components marked with

1)

are covered by the self-diagnosis.

380

1-

Brake servo unit

with master brake cylinder and brake fluid reservoir

Remove and install brake servo unit Chapter

2t

removing and installing Chapter

3t

Fitting location: next to the steering column under the dash panel

4-

Steering angle sender -G85-1)

Fitting location: on the steering column between the steering wheel and the steering
column switch

5t

Sensor unit for ESP -G419RHD 4x4 vehicles without -G251-

Brake pressure sender -1--G201-1)

ABS warning light -K47Fitting location: in the dash panel insert


381

function Chapter

6-

Hand brake/brake fluid level warning light -K14/33-

Fitting location: in the dash panel insert

function Chapter

7-

ESP warning light -K155-

Fitting location: in the dash panel insert

function Chapter

8-

Parts of ABS system on rear axle


Rear right and rear left wheel speed sensors -G44/G46- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter

Pulse rotor for the wheel speed sensor at the rear on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
Brake vacuum pump -V192-1)

9t

only on vehicles with automatic gearbox in combination with the limit values of exhaust gas
according to EU-4

t
t

Fitting location: on the left of the assembly carrier


is checked by self-diagnosis in the engine control unit Engine, Fuel Injection and Ignition
System; Rep. gr.01

removing and installing Chapter

10 t

Diagnostic connection

Fitting location: in the storage compartment on the driver's side

11 t

Brake light switch -F-1)


is open in off position

adjust Chapter

remove by turning 90 to the left Chapter

install by turning 90 to the right Chapter

check: measured value block 003 Chapter

12 t
t

Control unit for ABS/EDL/ESP -J104-

Fitting location: at the hydraulic unit in left of engine compartment


is checked by self-diagnosis
382

Check the multi-pin plug connection to the control unit Chapter

switch off the ignition before disconnecting the plug connection

13 t

Hydraulic unit for ABS/EDL/ESP -N55-1)


Fitting position: left of engine compartment

the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
inlet and exhaust valves

when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
Electronic Catalogue of Original Parts

Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104 Chapter

Do not separate the hydraulic pump -V64- from the valve block.

Repairing the hydraulic control unit Chapter

14 t

Front right and front left wheel speed sensors -G45/G47- 1)

removing and installing Chapter

Installing wheel speed sensor cables Chapter


Pulse rotor for the wheel speed sensor at the front on the right and left

check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter

15 t

Parts of ABS system on front axle

Longitudinal acceleration sender -G251-1)


Fitting location:

only RHD 4x4 vehicles on the central pipe to the right, near right pillar -A-

383

Distinguishing features ABS/EDL/TCS Mark 60 and ABS/EDL/TCS/ ESP Mark 60


General Instructions
Chapter

Fitting position ABS/EDL/TCS/ESP Mark 60

Left-hand drive vehicles


1Brake servo unit 10''
2Hydraulic unit
47-pin control unit screwed to the hydraulic
3unit

Right-hand drive vehicles


1Brake servo unit 7''/8''
2Hydraulic unit
47-pin control unit screwed to the hydraulic
3unit

384

Self-diagnosis of the ABS/EDL/TCS/ESP Mark 60


Description of the function
Chapter

Indication of faults by means of warning lights -K47-, -K14/33- and -K155-

Arrangement of warning lights

Pos.

Denomination

ABS warning light -K47-

Hand brake/brake fluid level warning light -K14/33-

ESP warning light -K155-

WARNING

Once the ABS warning light -K47- and the hand brake/brake fluid level warning light -K14/33have lit up, then the rear wheels can already lock when braking lightly.
Overview
Meaning

ABS warning Hand brake/brake fluid


light -K47- level warning light
-K14/33-

ESP warning
light -K155-

Ignition on (if the systems are OK, the


lights go out after approx. 3 s)

lights up

lights up

lights up

ESP failure or ESP deactivated by means


of button; ABS, EDL and EBD are active

does not
light up

does not light up

lights up

System O.K.

does not

does not light up

does not

385

light up

light up

ESP intervention

does not
light up

does not light up

flashes

ABS/EDL/ESP failure; EBD remains active


(e.g. a wheel speed sensor is defective)

lights up

does not light up

lights up

ABS/EDL/ESP/EBD failure; (e.g. a wheel


speed sensor is defective)

lights up

lights up

lights up

Brake fluid level too low; all systems


O.K.

does not
light up

lights up

does not
light up

Warning light -K47If the ABS warning light (-K47-) -1- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
The antilock braking system is switched off
if an ABS fault -b- is present. The EBD
function (Electronic Brake pressure
Distribution) is furthermore active while the
conventional brake system remains fully
operational. Interrogate the fault memory
Chapter.
-c- a sporadic fault existed on a wheel
speed sensor after the last vehicle start
In case of a wheel speed sensor fault -c-,
the ABS warning light goes out
automatically -K47- after restarting the
vehicle and after a speed above 20 km/h is
reached.
-d- the connection from the ABS control
unit -J104- to the dash panel insert -J218- is
interrupted binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
-e- Dash panel insert defective

386

Warning light -K47- and -K14/33If the ABS warning light goes out (-K47-)
-1- but the warning light for the hand
brake/brake fluid level (-K14/33-) -2t
remains lit and 3 warning tones are
audible, the following can be the causes
of the fault:
a-

the brake fluid level is too low

b-

the hand-brake is still applied

the switch -F9- for the warning light


c - -K14/33- is defective or incorrectly
adjusted
a fault in the operation of the hand
brake/brake fluid level warning light
d - -K14/33- binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
t light (-K14/33-) -2- light up, then the ABS
system and the EBD (Electronic Brake
pressure Distribution) have failed.
If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
light (-K14/33-) -2- light up and 3 warning
t
tones are audible, then the ABS and the
EBD (Electronic Brake pressure
Distribution) have failed.
Note

The warning light for the hand brake/brake


fluid level (-K14/33-) -2- only lights up after
exceeding a speed of 10 km/h once or an
engine speed of 2000 rpm.
WARNING

Once the ABS warning light -K47- and the


hand brake/brake fluid level warning light
-K14/33- have lit up, then the rear wheels
can already lock when braking lightly.

387

Warning light -K155If the ESP warning light (-K155-) -3- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
There is a fault which exclusively effects
the ESP. The ABS/EDL and EBD safety
systems on the vehicle remain fully
functional. Interrogate the fault memory
Chapter.
a-

Short circuit to positive in ESP button


-E256-

b-

Short circuit to earth in the operation of


the ESP warning light -K155-

the connection from the ABS control unit


-J104- to the dash panel insert -J218- is
c
interrupted binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
d-

the ESP system was switched off using


the ESP button -E256-

If the ESP warning light lights up -K155- for


approx. 100 milliseconds after switching on
the ignition, a coding without ESP control
was entered.
Code the control unit Chapter.
If the ESP warning light -K155- flashes
while driving, the ESP system is operating
in regulating mode.
Warning light -K47-, -K14/33- and -K155If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) remains lit, the
control unit is not yet coded.
Code the control unit Chapter.

Electrical test ABS/EDL/TCS/ESP Mark 60


Special tools and workshop equipment required
388

t
t

Handheld multimeter, e.g. -V.A.G 1526 AMeasuring tool set -V.A.G 1594/A-

Test box -V.A.G 1598/A-

Adapter -V.A.G 1598/36-

The test steps Anchor apply only to vehicles with ABS/EDL/TCS/ESP,


t

for which the self-diagnosis does not indicate the fault source. In this case the full electric
inspection must be carried out.

for which the self-diagnosis gives a direct indication of the fault source. Then only perform
the test steps recommended in the fault table (targeted approach).

Test requirements
Chapter
Note

The following 2 work steps do not apply to the 1.6 ltr./55 kW engine.
Remove air filter

Disconnect the plug of the air mass


meter -1- from the air guide pipe of the
air filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Connect test box -V.A.G 1598 A- with


adapter -V.A.G 1598/36 Chapter

Multi-pin plug connection with contact assignment


Contact assignment of the plug connection -T16a- (diagnostic connection) with the vehicle
system tester -V.A.G1552389

Chapter
Contact assignment of the plug connection
-T47a- wiring loom/ABS control unit -J104Note

Plug contacts which have not been listed


are not used.
1 - Voltage supply of battery + (via S162)
2 - Plug connection -T16a/7-, -K- cable
Signal cable of the longitudinal
3 - acceleration sender -G251- for fourwheel drive vehicles
4 - Voltage supply terminal 15 (via S9)
Earth cable of the longitudinal
5 - acceleration sender -G251- for fourwheel drive vehicles
6-

Lateral acceleration sender -G200(signal)

Voltage supply of the longitudinal


7 - acceleration sender -G251- for fourwheel drive vehicles
89-

Only for vehicles with navigation


system
Jumper to contact 12 for four-wheel
drive vehicles

Only on vehicles equipped with


10
navigation system and Xenon
headlights
Data BUS cable binder Current Flow
11
Diagrams, Electrical Fault Finding and
Fitting Locations
Jumper to contact 38 for front-wheel
12
drive, jumper to contact 9 for fourwheel drive vehicles
13 14 -

TCS/ESP button-E256Jumper to contact 38 for vehicles with


TCS

15 Data BUS cable binder Current Flow


Diagrams, Electrical Fault Finding and
390

Fitting Locations
16 -

Earth

17 -

not assigned

18 Voltage supply of the brake pressure


sender -1--G20119 -

Earth cable of the brake pressure


sender -1--G201-

20 -

Signal cable of the brake pressure


sender -1--G201-

21 a 23 -

not assigned

Earth cable of the lateral acceleration


24
sender -G200- and the yaw rate sender
-G20225 -

not assigned

Voltage supply of the lateral


26
acceleration sender -G200- and the
yaw rate sender -G20227 a 30 -

not assigned

32 - Voltage supply of battery + (via S163)


33 - Front right wheel speed sensor -G4534 - Front right wheel speed sensor -G4536 - Rear left wheel speed sensor -G4637 - Rear left wheel speed sensor -G46Jumper to contact 12 for front-wheel
38
drive and ESP, jumper to contact 14 for
front-wheel drive and TCS
39 a 40 41 -

not assigned

Brake light switch -F-

42 - Rear right wheel speed sensor -G4443 - Rear right wheel speed sensor -G4445 - Front left wheel speed sensor -G4746 - Front left wheel speed sensor -G4747 -

Earth

Overview of test steps


Component to be tested
391

Voltage supply of the ABS hydraulic pump -V64-

- Perform test step 1

Voltage supply of the valves in the hydraulic unit

- Perform test step 2

Voltage supply of the control unit -J104-

- Perform test step 3

Function of the brake light switch -F-

- Perform test step 4

Jumpers

- Perform test step 5

Resistance of the front right speed sensor -G45-

- Perform test step 6

Resistance of the front left speed sensor -G47-

- Perform test step 7

Resistance of the rear right speed sensor -G44-

- Perform test step 8

Resistance of the rear left speed sensor -G46-

- Perform test step 9

Voltage signal of the front right speed sensor -G45-

- Perform test step 10

Voltage signal of the front left speed sensor -G47-

- Perform test step 11

Voltage signal of the rear right speed sensor -G44-

- Perform test step 12

Voltage signal of the rear left speed sensor -G46-

- Perform test step 13

Function of the ABS warning light -K47-

- Perform test step 14

Function of the hand brake/brake fluid level warning light -K14/33-

- Perform test step 15

Function of the ESP warning light -K155-

- Perform test step 16

Function of the TCS/ESP button -E256-

- Perform test step 17

Actuation of the steering angle sender -G85-

- Perform test step 18

Actuation of the lateral acceleration sender -G200-

- Perform test step 19

Actuation of the yaw rate sender -G202-

- Perform test step 20

Actuation of the brake pressure sender -1--G201-

- Perform test step 21

Actuation of the longitudinal acceleration sender -G251-

- Perform test step 22

Test of the data BUS cable

- Perform test step 23

Voltage supply for -V.A.G 1552-, plug connection -T16a-

- Perform test step 24

Resistance of the -K- cable for the self-diagnosis, plug connection -T16a- - Perform test step 25

Test table

392

Note

The denominations of the bushes of the test box -V.A.G 1598 A- with adapter -V.A.G
1598/36- are identical to the contact denominations of the ABS control unit -J104- in the
t
current flow diagram binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
step 1598 Abushes

Test covers

1 + 47 Voltage supply of the


hydraulic pump -V64(terminal 30) at the
control unit -J104-

Specifie
Test
conditions d value

additional
works
l

Ignition
off

10.0 Test wiring of contact -T47a/1


14,5V
via fuse S163 to battery +.
Test wiring of contact to earth
Current flow diagrams,
Electrical fault finding and
Fitting locations

32 + 16 Voltage supply of the


Ignition
l
valves in the hydraulic
off
unit -N55- (terminal 30)
at the control unit -J104-

4 + 47 Voltage supply (terminal


15) of the control unit
-J104-

Measures for deviations from


nominal value

Ignition
on

10.0 Test wiring of contact


14,5V -T47a/32- via fuse S162 to
battery +.
Test wiring of contact -47a/16 to earth Current flow
diagrams, Electrical fault
finding and Fitting locations
10.0 Test wiring of contact -T47a/4
14,5V
via fuse S13 and ignition
starter switch.
Test wiring of contact -47a/47 to earth Current flow
diagrams, Electrical fault
finding and Fitting locations

393

Switch on measuring range:


voltage measurement (20 V =) in test step 4, resistance measurement (200 )/(20 M) in
test step 4a
Test -V.A.G
Test l Test conditions
step 1598 A- covers
additional works
bushes
4

41 + 47 Brake
light
switch
-F-

l
l

Specifie
d value

Ignition off
0.0 - 0.5
V

Brake pedal not


actuated

Measures for deviations from


nominal value

If necessary set brake light switch


Chapter.

Replace brake light switch


Chapter.

Reading measured value block


Chapter, display group number
003.
Brake pedal actuated

4a

Brake
light
switch
-F-

10.0 Check contact 1 of the brake light

14.5 V
switch -F- to fuse S13.

Measuring range 200


set

Repair wiring according to the


current flow diagram Current
flow diagrams, Electrical fault
finding and Fitting locations

Disconnect the multi pin connector -T47afrom the control unit


-J104Pull out the multi-pin
connector from the
brake light/brake pedal
switch

max.
1.5

Test wiring for open


circuit

Test wiring of contact


41 (control unit) to
contact 1 (brake light
switch)
l

Set measuring range


20 M

Remove fuse S13

Check cables for shortcircuit to positive or to


earth

394

Test wiring for open circuit.

Switch on measuring range: resistance measurement (200 )/(20 M)


Test -V.A.G 1598 Test l
step A- bushes covers

12 + 38
14 + 38
9 + 12

Jumper l

Specified Measures for deviations from


value
nominal value

Test conditions
additional works

max. 1.5 Test wiring of contact

9/12/14 to contact 12/38 for


open circuit.

Ignition off
Detach multi-pin
connector -T47aConnect -V.A.G 1598 Awith adapter -V.A.G
1598/36Test wiring for open
circuit

Switch on measuring range: resistance measurement (2 k)


Test -V.A.G
step 1598 Abushes

Test covers

Specifie Measures for deviations from nominal


Test
value
conditions d value

additional
works

33 + 34 Resistance of the
Ignition
l
front right speed
off
sensor -G45-

1.0...1.3 Separate plug connection on speed

k
sensor.

Check wiring according to current


flow diagram.

Throughout the test, do not move


cables Current flow diagrams,
Electrical fault finding and Fitting
locations
If the lines are not found to be faulty:

45 + 46 Resistance of the
Ignition
l
front left speed
off
sensor -G47-

Replace speed sensor -G45 Chapter.

1.0...1.3 Separate plug connection on speed

k
sensor.

Check wiring according to current


flow diagram.

Throughout the test, do not move


cables Current flow diagrams,
Electrical fault finding and Fitting
395

locations
If the lines are not found to be faulty:
Replace speed sensor -G47 Chapter.

Switch on measuring range: resistance measurement (2k)


Test -V.A.G
step 1598 Abushes

Test covers

Specifie Measures for deviations from nominal


Test
value
conditions d value

additional
works

42 + 4 Resistance of the
Ignition
l
rear right speed
off
sensor -G44-

1.0...1.3 Separate plug connection on speed

k
sensor.

Check wiring according to current


flow diagram.

Throughout the test, do not move


cables Current flow diagrams,
Electrical fault finding and Fitting
locations
If the lines are not found to be faulty:

37 + 36 Resistance of the
Ignition
l
rear left speed
off
sensor -G46-

Replace speed sensor -G47 Chapter.

1.0...1.3 Separate plug connection on speed

k
sensor.

Check wiring according to current


flow diagram.

Throughout the test, do not move


cables Current flow diagrams,
Electrical fault finding and Fitting
locations
If the lines are not found to be faulty:

Replace speed sensor -G47 Chapter.

Switch on measuring range: voltage measurement (2 V )


396

Test -V.A.G
step 1598 Abushes

Test covers l Test conditions

additional
works

Specified
value

Measures for deviations from


nominal value

10 33 + 34 Voltage signal l Vehicle raised Alternating


Check the installation of the

of the front
voltage min. wheel speed sensor and the
l Ignition off
right speed
65 mV
pulse rotor.
sensor -G45Turn front right
wheel by
approx. 1 turn
Check wheel speed sensor -G45per sec.
to ensure it is correctly

connected and read measured


value block Chapter, display
group number 001.
11 45 + 46 Voltage signal l Vehicle raised
of the front
l Ignition off
left speed
sensor -G47Turn front left
wheel by
approx. 1 turn
per sec.

Alternating
Check the installation of the

voltage min. wheel speed sensor and the


65 mV
pulse rotor.

12 42 + 43 Voltage signal l Vehicle raised


of the rear
l Ignition off
right speed
sensor -G44Turn rear right
wheel by
approx. 1 turn
per sec.

Alternating
Check the installation of the

voltage min. wheel speed sensor and the


190 mV
pulse rotor.

13 36 + 37 Voltage signal l Vehicle raised


of the rear
l Ignition off
left speed
sensor -G46Turn rear left
wheel by
approx. 1 turn
per sec.

Alternating
Check the installation of the

voltage min. wheel speed sensor and the


190 mV
pulse rotor.

Check wheel speed sensor -G47to ensure it is correctly

connected and read measured


value block Chapter, display
group number 001.

Check wheel speed sensor -G46to ensure it is correctly

connected and read measured


value block Chapter, display
group number 001.

Functional test: ABS warning light -K47397

Test -V.A.G Test covers l Test conditions


ste 1598 A additional works
p bushes
14

Specified value

Function of The fault memory was


the ABS
interrogated and there
warning
l is no fault in the fault
light -K47memory of the control
unit -J104l

The warning
light -K47lights up for
approx. 2
seconds and
goes out

Ignition off

The multi-pin
connector is inserted
l
on the control unit
-J104- and locked

Measures for deviations


from nominal value

If the ABS warning light


does not light up:
Check wiring according to
current flow diagram.

Current flow diagrams,


Electrical fault finding
and Fitting locations
Check dash panel insert,
fault in the dash panel
insert Electrical
System; Rep. gr.90

Switch on ignition

Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G
ste 1598 Ap bushes
15

Test covers

Specified value

l Test conditions

additional
works

Function of the
Brake fluid level
l
hand brake/brake is O.K.
fluid level
l Ignition off
warning light
-K14/33Multi-pin
connector
inserted on
l
control unit
-J104- and
locked

The warning
light -K14/33lights up for
approx. 2
seconds and
goes out

Measures for deviations


from nominal value

Check the brake fluid


level warning contact
-F34- in the screw cap of
the brake fluid reservoir.
Check wiring according to
the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations
Check dash panel insert,
fault in the dash panel
insert Electrical
System; Rep. gr.90

Switch on

ignition

Functional test: ESP warning light -K155Test -V.A.G Test covers l Test conditions
ste 1598 A additional works
398

bushes

16

Function of l Ignition off


The warning light Test wiring for open circuit
the ESP
-K155- lights up and for short-circuit to
Multi-pin
warning
for approx. 2
positive.
connector
light -K155seconds and
If the warning light -K155l inserted on
goes out
remains lit:
control unit
-J104- and locked
Test the wiring of the dash
Switch on
panel insert for short-circuit

ignition
to earth. Current flow
diagrams, Electrical fault
finding and Fitting locations
Check dash panel insert,
fault in the dash panel
insert.
Check ESP button -E256-.
Test voltage supply relay for
warning light -K155-.

Current flow diagrams,


Electrical fault finding and
Fitting locations

Functional test: Warning light -K155- for the function of the ESP button -E256- in test step 17;
voltage supply (20 V=) in test step 17a
Test -V.A.G Test covers l Test conditions
ste 1598 A additional works
p bushes
17

Function of l Ignition off


the
The function of
TCS/ESP
the ESP warning
button
l
light -K155- was
-E256tested with test
step 17

Specified value

The warning
light -K155lights up for
approx. 2
seconds and
goes out

Multi-pin
connector
l inserted on
control unit -J104and locked

Switch on
ignition

399

Measures for deviations from


nominal value

17a

Warning light
-K155- comes
on

Operate ESP
button

Warning light
Operate ESP
button once again -K155- goes out

16 + Function of
Switch off

13 the
ignition
TCS/ESP
Disconnect the
button
multi-pin
-E256
connector from
the control unit
-J104-

Perform test step 18a.

Test wiring of contact -47a/16(control unit) to earth.

Test wiring of contact


-T47a/13- (control unit) to

contact -T4f/2- (ESP button)


for open circuit or short-circuit
to positive or to earth.

Connect -V.A.G
1598 A- with
adapter -V.A.G
1598/36

Switch on
ignition

Button -E256- not


pressed and
warning light
-K155- lights up

3,5-5,0 V

Button -E256 held pressed and


warning light
-K155- lights up

8,0-14,5 V

Test wiring for open circuit and


short-circuit to positive or to
earth.

Test voltage supply of contact


-T4f/1- (ESP button) via fuse

S13 for open circuit Current


flow diagrams, Electrical fault
finding and Fitting locations
Replace ESP button
Electrical System; Rep.
gr.96

Switch on measuring range:


voltage measurement (20 V =) in test step 18, resistance measurement (200 )/(20 ) in test
step 18a
Test -V.A.G
ste 1598 Ap bushes
18

Test covers

l Test conditions

additional works

Earth connection l Ignition off


and voltage
Disconnect the
supply of the
multi-pin connector
400

Specifie Measures for deviations from


d value
nominal value

Test wiring of contact -T6w/4(steering angle sender) to

steering angle
sender -G85-

-T47a- from the


control unit -J104-

fuse S15 for open circuit.


Repair wiring according to
the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations

Disconnect the plug


connection from the
steering angle
sender
Test the voltage
supply of the

steering angle
sender at the plug
connection -T6w

18a

11 + Cables for
15 steering angle
sender -G85-

Test wiring between


contact -T6w/4- and
contact -T6w/1Ignition on
Test wiring between
contact -T6w/5- and
contact -T6w/1-

10.014.5V

Test wiring of contact -T6w/5(steering angle sender) to


10.0- fuse S13 for open circuit
14.5V
Current flow diagrams,
Electrical fault finding and
Fitting locations

Measuring range
200 set
Connect -V.A.G 1598
A- with adapter
-V.A.G 1598/36Check the following
line connections for
an open circuit:

Wiring of contact
-T6w/3- (steering

angle sender) with


contact -T47a/11(control unit)
Wiring of contact
-T6w/2- (steering

angle sender) with


contact -T47a/15(control unit)

Wiring of contact
-T6w/1- to earth

Measuring range 20
MQ set
401

max. Test wiring for open circuit.


1.5
Repair wiring according to
the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations

Remove fuse S15

Check cables for


short-circuit to
positive or to earth

Switch on measuring range: resistance measurement (200 /20 M)


Test -V.A.G
ste 1598 Ap bushes
19

Test covers

Test conditions

additional works

Specifie Measures for deviations from


d value
nominal value

Cables for
l
Ignition off
lateral
Measuring range 200
acceleration
l
set
sender -G200Disconnect the multi pin connector -T47afrom the control unit
-J104

Connect -V.A.G 1598 Awith adapter -V.A.G


1598/36-

Disconnect the plug


connection -T3n- from
the lateral acceleration
sender

Test wiring for open


circuit

Wiring of contact
-T3n/1- (lateral

acceleration sender)
with contact -T47a/6(control unit)

max. Test wiring for open circuit.


1.5
Repair wiring according to
the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations

Wiring of contact
-T3n/2- (lateral

acceleration sender)
with contact -T47a/24(control unit)
Wiring of contact
402

max.
1.5

-T3n/3- (lateral
acceleration sender)
with contact -T47a/26(control unit)
l

Measuring range 20 M
set
Check cables for shortcircuit to positive or to
earth

Switch on measuring range: resistance measurement (200 /20 M)


Test V.A.G
step 1598 A
bushes
20

Test covers

Cables for
lateral
acceleration
sender -G200-

Test conditions

additional works

Ignition off

Specifie Measures for deviations from


d value
nominal value

Measuring range
200 set

Disconnect the multi pin connector -T47afrom the control unit


-J104

Connect -V.A.G 1598


A- with adapter -V.A.G
1598/36-

Disconnect the plug


connection -T3mfrom the yaw rate
sender

Test wiring for open


circuit

Wiring of contact
-T3m/1- (yaw rate
sender) with contact
-T47a/6- (control unit)

Wiring of contact
-T3m/2- (yaw rate
sender) with contact
-T47a/24- (control
403

Test wiring for open circuit.


max.
1.5

Repair wiring according to


the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations

unit)
Wiring of contact
-T3m/3- (yaw rate

sender) with contact


-T47a/26- (control
unit)
Measuring range
20 M set

Check cables for


short-circuit to
positive or to earth

Switch on measuring range: resistance measurement (200 /20 M)


Test -V.A.G
Test covers
step 1598 Abushes
21 -

Cables for
brake
pressure
sender -1-G201-

Test conditions

additional works

Ignition off

Specifie Measures for deviations from


d value nominal value

Measuring range 200


set

Disconnect the multi pin connector -T47afrom the control unit


-J104

Connect -V.A.G 1598 Awith adapter -V.A.G


1598/36-

Disconnect the plug


connection -T30- from
the brake pressure
sender -1--G201

Test wiring for open


circuit

Wiring of contact
-T30/1- (brake pressure
sender) with contact
-T47a/19- (control unit)

Wiring of contact
-T30/2- (brake pressure
404

Test wiring for open circuit.

Repair wiring according to the


max.
current flow diagram

1.5
Current flow diagrams,
Electrical fault finding and
Fitting locations

sender) with contact


-T47a/20- (control unit)
Wiring of contact
-T30/3- (brake pressure
sender) with contact
-T47a/18- (control unit)
l

Measuring range 20 M
set
Check cables for shortcircuit to positive or to
earth

Switch on measuring range: resistance measurement (200 /20 M)


Test -V.A.G
ste 1598
p
Abushes
22

Test covers

Test conditions
additional works

Specifie Measures for deviations


d value
from nominal value

Cables for
l
Ignition off
longitudinal
acceleration l Measuring range 200 set
sender -G251- Disconnect the electrical plug
connection from the
longitudinal acceleration
sender -G251

Disconnect the multi-pin


connector -T25a- from the
control unit -J104Connect test box -V.A.G
1598/21-

max.
Check the cables between
Test the wiring
the multi-pin connector of the 1.5
according to the current
longitudinal acceleration
flow diagram binder
sender -G251- and the multiCurrent Flow Diagrams,
pin connector of the control
Electrical Fault Finding
unit -J104- for open circuit
and Fitting Locations
l Measuring range 20 M set

Take out the fuse S9


Check cables for short-circuit
to positive or to earth
405

Check wiring according


to the current flow

diagram Current flow


diagrams, Electrical
fault finding and Fitting
locations

Switch on measuring range: resistance measurement (200 /20 M)


Test -V.A.G
Test l
step 1598 A- covers

bushes
11 + 15
23

Specifie
d value

Test conditions
additional works

Measures for deviations from


nominal value

Data l
Ignition off
BUS
cables l Measuring range 200 set
Disconnect the multi-pin
plug connections from the
control units connected to
the data BUS
Connect -V.A.G 1598 A with adapter -V.A.G
1598/33 Test wiring for open circuit

to the steering angle


sender

to the engine control unit

to the automatic gearbox


control unit 1)

Wiring of contact -T47a/11 (control unit) to contact


-T6w/3- (steering angle
sender -G85-)

max.
1.5

Continue to the connected


control units

Wiring of contact -T47a/15 (control unit) to contact


-T6w/2- (steering angle
sender -G85-)

Continue to the connected


control units

l Measuring range 20 set


406

Test wiring for open circuit.


Repair wiring according to the
current flow diagram Current
flow diagrams, Electrical fault
finding and Fitting locations

Check cables for short circuit to positive or to


earth

1)

Only on vehicles with automatic gearbox.

Switch on measuring range: voltage measurement (20 V =)


Test -V.A.G
ste 1598 Ap bushes
24

Test covers

Test conditions

additional works

Specifie
d value

Measures for deviations


from nominal value

Voltage supply for l


10.0Ignition on
Test wiring of -T16a/4- to

the vehicle system


14.5V
earth.
Connect
the
handheld
tester -V.A.G 1552-,
multimeter -V.A.G 1526
Test wiring of -T16a/1plug connection

A- with the measuring


via S5.
-T16atool set -V.A.G 1594 ARepair wiring according
to -T16a-1)
to the current flow
Test wiring between
diagram Current flow

contact -T6a/4- and


diagrams, Electrical fault
contact -T16a/1finding and Fitting
locations

1)

Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter.

Switch on measuring range: resistance measurement (200 )


Test -V.A.G
step 1598 Abushes
25

Test covers

l Test conditions
additional works

Resistance of the l Ignition off


-K- cable for the
self-diagnosis, plug Measuring range
l
200 set
connection -T16aDisconnect the
multi-pin connector
-T47a- from the
control unit -J104 Connect -V.A.G
1598 A- with
adapter -V.A.G
407

Specifie Measures for deviations from


d value
nominal value

max.
1.5

Test wiring of contact


-T16a/7- to contact
-T47a/39-.
Repair wiring according to
the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations

1598/33Test wiring
between contact
-T16a/7- and
contact -T47a/39l

Measuring range
20 M set
Check cables for
short-circuit to
positive or to earth

408

Repair wiring according to


the current flow diagram

Current flow diagrams,


Electrical fault finding and
Fitting locations

Brake, brake mechanics

Repairing the front brake


Changing the brake pads of the front brake - Mounting instructions

When changing the pad, observe the following:


Check the protective collar of the piston for brake caliper.
Replace the protective collar if damaged.
When replacing the collar:
Check the contact surfaces of the brake piston and the brake caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and replace the sealing sleeve.
Check the brake piston and the brake caliper (corrosion, grooves on the outside of the cylinder surface),

replace the brake caliper completely if damaged.


For the piston of the brake caliper, press into the initial position:
Check if the piston can be slightly pressed into the brake caliper.
If the piston cannot be slightly pressed into the brake caliper:
Check and clean the brake piston as well as the brake caliper, replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.

Repairing front brake, the floating caliper disc brake FS-III


Special tools and workshop equipment required
t
t
t
t
t
t

Piston jig -MP 9-403Brake pedal load, e.g. -V.A.G 1238/BBrake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note

Observe the instructions for changing the pad Chapter.

After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
t

Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.

Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t

Already used brake fluid must never be used again.


409

Tightening torque of the wheel screws: 120 Nm

12-

4 Nm
Brake disc

Thickness: 22 mm

Wear limit: 19 mm

if worn always replace axle-wise

t
t

unscrew the brake caliper before removing


Do not use force to separate the brake discs from the wheel hub, if necessary use rust
solvent, as you could otherwise damage the brake discs.

Technical data Chapter

3t

Brake pads

with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the
dash panel insert lights up

Thickness 19.5 mm including support plate

Wear limit: 7 mm including support plate

t
t

Inspect thickness BookletOctavia


always replace axle-wise
410

removing and installing Chapter

Observe the instructions for changing the pad Chapter

t 05.98 : do not interchange the inside and outside brake pads Chapter
4-

Brake caliper

removing:

Remove brake pads -Pos. 3

Insert brake pedal load.

Unscrew brake hose -Pos. 7- from brake caliper

Installing:

Install brake pads -Pos. 3-

Screw brake hose -Pos. 7- to brake caliper

Take out brake pedal load.

Bleeding Brake System Chapter

repairing Chapter

Observe the instructions for changing the pad Chapter

5t

Guide bolt, 30 Nm
removing and installing Chapter

67t

Cap
Brake hose with banjo union and hollow screw
cannot be disassembled, must be fully replaced

Tightening torque: 35 Nm

8-

Wheel-bearing housing

910 t

8 Nm
ABS wheel speed sensor

clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)

11 -

Cover plate

12 13 t
t
14 -

10 Nm
Wheel bearing
replace after each removal
pressing in and pressing out Chapter
Circlip
411

15 t

Wheel hub with pulse rotor


only on vehicles with ABS

pressing in and pressing out Chapter

16 t

Wheel hub without pulse rotor


only on vehicles without ABS

Removing and installing brake pads/brake caliper (FS III)


Special tools and workshop equipment required
t
t
t
t

Piston jig -MP 9-403Brake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter

Observe the instructions for changing the pad Chapter.


Removing

Remove wheels.
Note

t
t

When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the brake pad.
Disconnect the plug connection for the brake pad wear indicator (where the vehicle is
fitted with this).

412

Remove caps -2-.


Unscrew and remove the two guide bolts
from the brake caliper.

Remove the brake caliper housing and


secure with wire in such a way that the
weight of the brake caliper does not
burden or damage the brake hose.

Take out the brake pads from the brake


caliper housing.

Install
Note

Before inserting new brake pads, press


piston with piston jig into the brake caliper.
Drain the brake fluid from the brake fluid
reservoir using a ventilation bottle before
pushing back.
Otherwise brake fluid can flow out and lead
to damage - if brake fluid was added in the
meantime.
WARNING

Brake fluid is toxic and must never be


sucked into your mouth through a hose.

Clean the brake caliper housing.


Note

Use spirits only to clean the brake caliper


housing.

413

Push piston back with piston setting and


timing device -MP 9-403-.
Insert brake pads.

05.98 : Do not interchange the inside and


outside brake pads.
Outer pad: black three-finger clip
Inner pad: white coloured piston side

First position the brake caliper housing at


the bottom -arrow-.

Mount the brake caliper housing with


brake pads onto the wheel bearing
housing.
The pin of the brake caliper housing -arrowmust be located behind the guide of the
wheel bearing housing!

Screw the guide bolt into the brake


caliper housing and tighten to 30 Nm.
Connect the plug connection for the
brake pad wear indicator (where the
vehicle is fitted with this).

Insert both caps -2-.

Attach the wheels.


Note

After replacing the brake pads, depress


brake pedal firmly several times when
t the vehicle is stationary to ensure the
brake pads are properly seated in their
normal operating position.
Check brake fluid level after replacing the
t brake pads, if necessary top up with
brake fluid.

414

Repairing the front wheel brake, brake caliper FN -3


Special tools and workshop equipment required
t
t
t
t
t
t

Piston jig -MP 9-403Brake pedal load, e.g. -V.A.G 1238/BBrake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note

Observe the instructions for changing the pad Chapter.

After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
t

Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.

Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t

Already used brake fluid must never be used again.

Tightening torque of the wheel screws: 120 Nm.

415

12t

4 Nm
Brake disc
the max. axial run-out is not marked

t released combination of a brake disc without marking and a wheel hub with marking
t

with a fixing hole for the wheel hub

always replace axle-wise

t
t

unscrew the brake caliper before removing


Do not use force to separate the brake discs from the wheel hub, if necessary use rust
solvent, as you could otherwise damage the brake discs.

t
t
3-

Technical data Chapter


Assignment Electronic Catalogue of Original Parts
Brake disc

t with a marking approx. 5 mm wide for marking the maximum wheel run-out
t released combination of a brake disc with marking and a wheel hub without marking
t
t
t

with 5 fixing holes for the wheel hub


always replace axle-wise
unscrew the brake caliper before removing
416

Do not use force to separate the brake discs from the wheel hub, if necessary use rust
solvent, as you could otherwise damage the brake discs.

Technical data Chapter

Assignment Electronic Catalogue of Original Parts

removing and installing Chapter

4t

Brake pads

with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the
dash panel insert lights up

Technical data Chapter

Inspect thickness BookletOctavia

always replace axle-wise

removing and installing Chapter

Observe the instructions for changing the pad Chapter

5t

Retaining spring
insert in both bores of the brake caliper housing.

replace after each brake pad replacement

6-

Brake carrier

t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t

if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed
grease packing to lubricate the guide bolts)

7t

Brake caliper
removing:
Remove brake pads -Pos. 4
Insert brake pedal load.
Unscrew brake hose -Pos. 10- from brake caliper.

Installing:

Install brake pads -Pos. 4-

t
t
8-

Screw brake hose -Pos. 10- to brake caliper.


Take out brake pedal load.
Bleeding Brake System Chapter.
repairing Chapter
Observe the instructions for changing the pad Chapter
Guide bolt, 30 Nm
417

removing and installing -Pos. 4

9-

Cap

10 t

Brake hose with banjo union and hollow screw


must be replaced completely, do not dismantle

Tightening torque: 35 Nm

11 t

124 Nm
Clean ribbing on the underside

12 -

Wheel-bearing housing

13 14 t

8 Nm
ABS wheel speed sensor

clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste).

15 -

Cover plate

16 17 t

10 Nm
Wheel bearing
replace after each removal

pressing in and pressing out Chapter

18 19 t

Circlip
Wheel hub with pulse rotor

with and without marking for minimum axial run-out

In combination with the wheel hub without marking of the min. axial run-out and the brake
t disc without marking of the min. axial run-out or permissible vice versa, the reduction of the
overall axial run-out of the brake FN 3 is then not effective.
t
t
t

only on vehicles with ABS


pressing in and pressing out Chapter
Assignment Electronic Catalogue of Original Parts

Removing and installing brake pads/brake caliper FN 3


Special tools and workshop equipment required
t
t

Piston jig -MP 9-403Brake filling and bleeding device, e.g. -VAS 5234418

t
t

Bleeding bottle (commercially available)


Brake fluid Chapter

Observe the instructions for changing the pad Chapter.


Removing

Remove wheels.
Note

t
t

When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the brake pad.
Note

Remove caps -arrows-.

Disconnect the plug connection for the


brake pad wear indicator (where the
vehicle is fitted with this).

Lever the retaining spring of the brake


pads out of the brake caliper housing
-arrow- using a screwdriver and remove.

419

Unscrew and remove the two guide bolts


from the brake caliper.

Remove the brake caliper housing and


secure with wire in such a way that the
weight of the brake caliper does not
burden or damage the brake hose.

Take out the brake pads from the brake


caliper housing.

Clean the brake caliper, in particular the


adhesive surfaces for the brake pads
must be free from glue residues and
grease.
Note

Only use alcohol to clean the brake caliper


housing.
Install
Directional brake pads
1 - right brake pad on the piston side
2-

left brake pad on the piston side

In the installed condition, the arrow on the


backing plate of the brake pad must point
downwards. Please pay attention to this!
Note

Before inserting the new brake pads, press


the piston with piston jig into the cylinder.
Drain the brake fluid from the brake fluid
reservoir using a ventilation bottle before
pushing back. Otherwise brake fluid can
flow out and lead to damage if brake fluid
was added in the meantime.
WARNING

Brake fluid is toxic and must never be


sucked into your mouth via a hose!

420

Push back piston.

Insert inner brake pad.

Insert outer brake pad.


Remove the protective foil from the
backing plate of the brake pad.

421

Screw the brake caliper housing with both


guide bolts -arrows- to the brake carrier.

Tightening torque: 30 Nm

Connect the plug connection for the


brake pad wear indicator (where the
vehicle is fitted with this).

Insert both caps -arrows-

Insert the ends of the retaining spring


into the holes of the brake caliper

housing -arrow A- and subsequently press


the retaining spring behind the brake
caliper -arrow B-.

Attach the wheels.


Note

After each brake pad replacement,


forcefully apply the brake pedal
t
repeatedly to ensure the brake pads go
into their normal operating position.
Check brake fluid level after replacing the
t brake pads, if necessary top up with
brake fluid.

422

Removing and installing brake discs (FN 3)


Note

Observe the instructions for changing the pad Chapter.

Brake judder, brake pulsations or steering wheel torsional vibrations can occur with the
t brake FN 3. This is caused by a too great overall axial run-out in the system brake disc wheel hub.
t

In order to reduce the overall axial run-out, the maximum and minimum axial run-out of
the brake disc and the wheel hub is marked with an ink-jet marking.

When handling a fault due to a too great overall axle run-out, the wheel hubs and the
t brake discs which are not marked must be replaced with marked parts. Assignment
Electronic Catalogue of Original Parts
t

If used brake discs with a marking and a 5-hole fixing for wheel hubs are reinstalled, the
position of the brake disc to the wheel hub must be marked before removal.

The combination of marked brake disc/unmarked wheel hub or unmarked brake disc and
marked brake disc is allowed.

The combination of the left vehicle side components without marking and the right vehicle
side components with marking or vice versa is also allowed.

Pay attention that the reduction of the overall run-out on the brake FN 3 is not effective for
the stated combinations.

t
t

Only replace brake discs axle-wise.


Do not use force to separate the brake discs from the wheel hub, if necessary use rust
solvent, as you could otherwise damage the brake discs.

Removing

Remove wheel.
Note

Do not remove the brake hose from the brake caliper.

Remove the brake carrier with the brake caliper and secure with wire in such a way that
the weight of the brake caliper does not burden or damage the brake hose.
Remove the brake disc/wheel hub connecting screw.

Remove the brake disc.

When handling a fault due to a too great overall run-out of the axle

Remove wheel hub Chapter.

Install
423

When handling a fault due to a too great overall run-out of the axle
Install a new wheel hub -1- with an ink-jet
marking approx. 3 mm wide for marking
the minimum axial run-out -arrow A- in
the wheel bearing housing Chapter.
Install a new brake disc -2- on the wheel
hub with an ink-jet marking approx. 5
mm wide for marking the maximum axial
run-out -arrow B-.
Fitting position:
Install the brake disc on the wheel hub in
such a way that the marking of the
minimum axial run-out (wheel hub) and the
maximum axial run-out (brake disc) are
located opposite each other.
Vehicles without a fault
After changing the brake disc (old wheel
hub/new brake disc), a minimisation of
t
the axial run-out is not possible on used
vehicles.
t

The brake discs can be installed without


paying attention to the fitting position.
Install brake disc.

Continued for all vehicles

Further installation occurs in reverse


order.

Tightening torques:
Brake disc to wheel hub

4 Nm

Brake carrier with brake caliper to wheel bearing housing

124 Nm

Wheel bolt

120 Nm

424

Repairing rear wheel brake - front wheel drive (drum brake)


Replacing the brake shoes of the rear brake - Mounting instructions
When changing the brake shoes, pay attention to the following points:

Check the protective collars of the wheel-brake cylinders.

Replace the wheel-brake cylinders if the protective collars are damaged.

Check the wheel-brake cylinder for tightness Fig..

Replace the wheel-brake cylinder if leaking.

Check if the pistons can be slightly pressed into the brake cylinder.

If the pistons cannot be slightly pressed into the brake cylinder:

Replace the wheel-brake cylinder.

Removing and installing rear wheel brake


Special tools and workshop equipment required
t

Measuring tool for brake drum -MP 5-407-

Dial gauge (measuring range 0 -10 mm)

Brake filling and bleeding device, e.g. -VAS 5234-

Brake pedal load, e.g. -V.A.G 1238/B-, or -V.A.G 1869/2-

t
t

Brake fluid Chapter


Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note

After replacing the wheel-brake cylinder, brake carrier and brake shoe, forcefully apply the
brake pedal once to ensure the brake shoes go into their normal operating position.

Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth through a hose.
t

Use the brake pedal load, e.g. -V.A.G 1238/B-, before removing a brake cylinder, a brake
carrier or before separating a brake pipe from the wheel-brake cylinder.

Already used brake fluid must never be used again.

Tightening torque of the wheel screws: 120 Nm.

425

12t

4 Nm
Brake drum
Brake drum diameter 230 mm

Wear limit 231.0 mm

clean carefully, and check for wear, damage, dimensional accuracy and perfect brake
surface

Check noncircularity by means of a special tool -MP 5-407- and the dial gauge (measuring
range 0 - 10 mm).

Permissible noncircularity 0.03 mm. If the measured value is greater than 0.03 mm, the
brake drum must be replaced BookletOctavia.

3-

Cap

press off Fig.

inserting Fig.

4-

Self-locking twelve-point nut 70 Nm +40

replace after each removal

5-

Wheel hub with wheel bearing and pulse rotor

only on vehicles with ABS

replace after each removal


426

must be replaced completely

pressing in and pressing out Chapter

6-

Wheel hub with wheel bearing without pulse rotor

only on vehicles without ABS

must be replaced completely

pressing in and pressing out Chapter

7t

Self-locking screw, 50 Nm + 60
replace after each removal

8t

Brake carrier with brake shoe


removing:

Resetting brake Chapter.

Remove the brake drum.

Insert brake pedal load.

Unscrew brake pipe.

Remove brake carrier.

Installing:

Install brake carrier.

Screw on brake hose.

Take out brake pedal load.

Install the brake drum.

Bleeding Brake System Chapter

repairing Chapter.

910 -

Axle body
Axle stud

11 12 t
t

8 Nm
ABS wheel speed sensor
only on vehicles with ABS

clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)

427

Resetting brake

Use a screwdriver to push the wedge up


through a hole for the wheel screws in the
brake drum.

Repairing rear brake


Special tools and workshop equipment required
t

Hook (commercially available)

Brake filling and bleeding device, e.g. -VAS 5234-

Brake pedal load, e.g. -V.A.G 1238/B-, or -V.A.G 1869/2-

Plastic wedge 3409

Brake fluid Chapter

Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)


Note

After working on the rear axle brake:


t
t

Put hand-brake back.


Forcefully actuate the brake pedal once.

428

1t

Spring cap
to remove push against pressure spring and turn 90

2-

Pressure spring

3-

Locating spring

4-

Pressure rod

t Coat the points of contact with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
5t

Wedge

when removing and installing the brake drum push up through a hole for wheel screw
Chapter

6-

Wheel-brake cylinder

Check tightness Fig.

Repairs not allowed

removing:

Insert brake pedal load.

Unscrew brake hose.

Remove wheel-brake cylinder.


Installing:
429

Install wheel-brake cylinder.

Screw on brake pipe.

Take out brake pedal load.

Bleeding Brake System Chapter.

7-

8 Nm

8-

Tensioning sleeve

9-

Brake carrier

10 t

remove to check brake pad thickness Fig.

11 t

removing and installing Chapter


Minimum pad thickness without supporting shoe 2.5 mm
Check thickness Fig., visual inspection through the inspection hole in the brake carrier, if
necessary BookletOctavia

Always replace brake pads axle-wise

12 13 t

Tension spring
Bottom retractor spring

Coat the contact points with solid lubricant paste -G 000 650-

14 15 t

Brake shoe

Observe the instructions for changing the brake shoe Chapter

t
t

Cap

Top retractor spring


Brake shoe with lever for hand-brake

Observe the instructions for changing the brake shoe Chapter

removing and installing Chapter

Setting the hand-brake Chapter

430

Checking the wheel-brake cylinder for


tightness

Lift off dust cup.

Use a plastic wedge -3409- for this


purpose.

If there is any brake fluid in the dust cup,


replace wheel-brake cylinder.

Make sure the dust cup is not damaged


when lifting it off.

Checking the brake pad thickness through


the inspection hole in the brake carrier.

Unclip the cap from the brake carrier


-arrow-.

Checking the brake pad thickness


through the inspection hole in the brake

carrier. Minimum pad thickness without


supporting shoe (wear dimension) 2,5
mm.
Note

Pay attention to pads greased with brake


fluid or grease.

Removing and installing brake shoes


Special tools and workshop equipment required
t
t

Hook (commercially available)


Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)

Removing

Remove wheels.
Remove the brake drum Chapter.
Remove spring cap with pressure springs.

431

Lever out the brake shoes in the


-direction of arrow- behind the bottom
support plate using a screwdriver.

Lay the brake shoes on the bottom


support plate.

Unhook the retractor spring at the


bottom.

Unhook the hand-brake cable.

Carefully guide the brake shoes out


between the wheel hub and the brake
carrier.

Tighten the brake shoe in the vice.

Unhook the tension spring -1- for wedge


-2-.

Unhook the retractor spring at the top -3with hook -A-.

Unhook the locating spring -1- with hook


-A-.

Remove the pressure rod -2- and the


wedge -3- from the brake shoe.

Install

432

Insert the locating spring in the brake


shoe and position the brake shoe on the
pressure rod.

Grease the contact point of the pressure


rod with solid lubricant paste -G 000
650-, e.g. Wolfrakote Top Paste.

Hook locating spring -1- with hook -A- in


the pressure rod -2-.

Insert the wedge -3- at the same time.


Fitting position:
The raised part -arrow- must remain visible
during installation.

Insert the brake shoe with brake lever in


the pressure rod.
Grease the contact point of the pressure
rod with solid lubricant paste -1-, e.g.
Wolfrakote Top Paste.

Hook on the retractor spring at the top


-3- with hook -A-.

Hook on the tension spring -1- for wedge


-2-.

Guide the brake shoes in between the


wheel hub and the brake carrier.

Position the brake shoe on the brake


cylinder piston.

Hook the hand-brake cable onto the


brake lever.

Insert the bottom retractor spring and lift


the brake shoe behind the bottom
support.
Grease the contact points of the bottom
retractor spring on the brake shoes with
solid lubricant paste -G 000 650-, e.g.
433

Wolfrakote Top Paste.

Insert the pressure spring with spring


cap.

Install the brake drum.

Forcefully actuate the brake pedal once.

Setting the hand-brake.

Attach the wheels.

Setting the hand-brake (drum brake)


Resetting of the hand-brake is not required after resetting of the rear brake due to automatic
resetting of the rear wheel-brake. Resetting is only required after replacing the hand-brake
cable, the brake carrier or the brake pads/brake shoes.
Note

Always replace self-locking adjusting nut.

Release the hand-brake.

Remove ashtray in centre console.

Release Phillips head screws.

Tilt the rear centre console, if necessary


remove Body Work; Rep. gr.68.

1-

Handbrake cable

Forcefully actuate the brake pedal once.

Put the hand-brake lever into the 4th


catch.

434

Tighten adjusting nut -arrow- until both


wheels are hard to turn by hand.
Release hand-brake and check whether
both wheels rotate freely, if necessary
release adjusting nut slightly.

435

Repairing rear wheel-brake - front-wheel drive (disc brake)


Changing the brake pads of the rear wheel disc brake - Mounting instructions

When changing the pad, observe the following:


Check the protective collar of the piston for brake caliper.
Replace the protective collar if damaged.
When replacing the collar:
Check the contact surfaces of the brake piston and the brake caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and replace the sealing sleeve.
Check the brake piston and the brake caliper (corrosion, grooves on the outside of the cylinder surface),

replace the brake caliper completely if damaged.


For the piston of the brake caliper, press into the initial position:
Check if the piston can be slightly pressed into the brake caliper.
If the piston cannot be slightly pressed into the brake caliper:
Check and clean the brake piston as well as the brake caliper, replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.

Removing and installing rear wheel brake


Special tools and workshop equipment required
t

Brake filling and bleeding device, e.g. -VAS 5234-

Brake pedal load, e.g. -V.A.G 1238/B-

Bleeding bottle (commercially available)

t
t

Brake fluid Chapter


Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note

After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t

Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.

Already used brake fluid must never be used again.

Tightening torque of the wheel screws: 120 Nm.

436

1-

4 Nm

2-

Brake disc, internally ventilated

Diameter 256 mm

Thickness 22 mm

Wear limit 20 mm

t
3-

if worn replace axle-wise


Brake disc

Diameter 232 mm

Thickness 9 mm

Wear limit 7 mm

if worn replace axle-wise

4-

Cap

press off Chapter

inserting Chapter

5-

Self-locking twelve-point nut, 70 Nm + 40

replace after each removal

6-

Wheel hub with wheel bearing and pulse rotor


437

only on vehicles with ABS

replace after each removal

must be replaced completely

pressing in and pressing out Chapter

7-

30 Nm + 90

8-

Cover plate

9-

Axle stud

10 -

Hand-brake cable

Setting the hand-brake Chapter

removing and installing Chapter

11 -

Axle body

12 -

ABS wheel speed sensor

clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)

13 -

8 Nm

14 -

30 Nm + 30

15 -

Brake carrier with guide bolts and protective caps

t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t
t

fit a repair set if there is any damage to the protective caps or guide bolts; (use the
enclosed grease packing to lubricate the guide bolts)
Observe the instructions for changing the pad Chapter

16 -

Brake hose with banjo union and hollow screw

must be replaced completely, do not dismantle

Tightening torque of the hollow screw: 35 Nm

do not unscrew the brake line when replacing the brake pad

17 t

always replace

18 t

Self-locking screw, 35 Nm

Brake caliper

do not unscrew the brake line when replacing the brake pad

removing

Remove brake pads -Pos. 19


438

Insert brake pedal load.

Unscrew brake hose -Pos. 16- at brake caliper.

Installing:

Install brake pads -Pos. 19-

Screw brake hose -Pos. 16- to brake caliper

Take out brake pedal load.

Bleeding Brake System Chapter.

t
t

repairing Chapter
Observe the instructions for changing the pad Chapter

t One must first adjust the hand-brake cable after undertaking repair or replacement work
The foot brake must not be applied beforehand!
t

Setting the hand-brake Chapter

19 -

Brake pads

Thickness 17 mm (including the support plate)

Wear limit: 7.5 mm (including supporting plate)

Check thickness: BookletOctavia

always replace axle-wise

t
t

removing and installing Chapter


Observe the instructions for changing the pad Chapter

20 t
t

Pad retaining spring


always replace when changing the brake pads

Observe the instructions for changing the pad Chapter

Removing and installing brake pads


Special tools and workshop equipment required
t

Bleeding bottle (commercially available)

Resetting and turning out tool -T10165-

t
t
t

Assembly device -T10165/1Brake filling and bleeding device, e.g. -VAS 5234Brake fluid Chapter
439

Note

t
t

When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the brake pad.

Removing

Remove wheels.
Unhook the handbrake cable from the brake caliper Chapter.

Unscrew the fixing screws of the brake


carrier while counterholding the guide
bolts.
Remove the brake caliper housing and
secure with wire in such a way that the
weight of the brake caliper does not
burden or damage the brake hose.

Remove the brake pads and the pad


retaining springs.
Note

Only use alcohol to clean the brake caliper


housing.
Clean the brake caliper housing; in
particular the adhesive surface for the
brake pad must be free from glue
residues and grease.
Install
Note

Before inserting new brake pads, press the


piston with a resetting and turning out tool
-T10165- into the cylinder. Drain the brake
fluid from the brake fluid reservoir using a
ventilation bottle before pushing back.
Otherwise brake fluid can flow out and lead
to damage if brake fluid was added in the
meantime.
WARNING

Brake fluid is toxic and must never be


440

sucked into your mouth through a hose.


Insert the resetting and turning out tool
-T10165- in such a way that the surface
t
of the tool -T10165/1- is resting on the
brake caliper.
Use open-jawed spanner on a provided
t spanner surface -arrow A- if the piston is
difficult to move.
When adjusting the piston with a piston
resetting device the automatic
t
adjustment in the brake caliper is
destroyed.

Screw the piston by turning the knurled


wheel of the resetting tool -T10165- to
the right into the brake caliper.

Insert the new pad retaining springs


-arrows- and brake pads in the brake
carrier.

Remove the protective foil from the


supporting plate of the brake pad.
Note

There are four self-locking screws in the


repair set, which must be fitted.

Secure the brake caliper housing using


new self-locking screws.

Counterhold at the guide bolt when


tightening.
Tightening torque: 35 Nm.

Hook the handbrake cable onto the brake


caliper Chapter.
Setting the hand-brake Chapter.
Attach the wheels.
Note

t After each brake pad replacement,


forcefully apply the brake pedal
441

repeatedly to ensure the brake pads go


into their normal operating position.
Check brake fluid level after replacing the
t brake pads, if necessary top up with brake
fluid.

Setting the hand-brake (disc brake)


Resetting of the hand-brake is not required after resetting of the rear brake due to automatic
resetting of the rear wheel-brake. New adjustment is only necessary when the handbrake
cable and brake carrier are replaced or after replacing the brake shoes.
Note

The brake system must be bled and fully operational.

Always replace self-locking adjusting nut.

Release the hand-brake.

Remove ashtray in centre console.

Release Phillips head screws.

Tilt the rear centre console, if necessary


remove Body Work; Rep. gr.68.

1-

Handbrake cable

Forcefully actuate the brake pedal once.

442

Put the hand brake lever in its rest


position. Tighten adjusting nut so far that
the levers -arrow- rise from the stops on
the brake calipers.

Check the distance between the lever


and the stop on the left and right brake
caliper using feeler gauges.

The distance -a- between the lever and the


stop on the left and right brake caliper
must not be less than a minimum of 1 mm
or exceed a maximum of 3mm.

Pull the handbrake on and release it


three times. This will position and set the
components.

If the hand-brake lever is in its rest


position, check whether both wheels
rotate freely, if necessary release
adjusting nut slightly.

Removing and installing hand-brake cable (drum brake)


Removing

Remove rear centre console Body Work; Rep. gr.68.


Release the hand-brake.

443

Release the adjusting nut -1- so far until


the hand-brake cable can be unhooked
from the compensating clamp -2-.

Raise vehicle.

Remove wheel.

Remove the brake drum.


Unhook the hand-brake cable from the
brake lever on the brake shoe.

Unclip hand-brake cable from the clip on


the rear axle body -arrow A- and unhook
from the brackets -arrows-.

Pull hand-brake cable -2- in the direction


of the arrow out of the guide tube -1-.

Install
Installation is carried out in the reverse
order.
Note

When installing the hand brake cables,


t pay attention to the correct fitting
position Chapter.
Before setting the hand-brake, pretension
t the hand-brake cable with the adjusting
nut at the compensation clamp.
t Setting the hand-brake Chapter.

444

Removing and installing hand-brake cable (disc brake)


Removing

Remove rear centre console Body Work; Rep. gr.68.


Release the hand-brake.

Release the adjusting nut -1- so far until


the hand-brake cable can be unhooked
from the compensating clamp -2-.
Raise vehicle.

Lift off the clip -1- with a screwdriver and


pull down to remove.
Press the hand-brake lever -2- in the
-direction of the arrow- and while doing
so unhook the hand-brake cable -3-.

445

Unclip hand-brake cable from the clip on


the rear axle body -arrow A- and unhook
from the brackets -arrows-.

Pull hand-brake cable -2- in -the direction


of the arrow- out of the guide tube -1-.

Install
Installation is carried out in the reverse
order.
Note

When installing the hand brake cables,


t pay attention to the correct fitting
position Chapter.
Before setting the hand-brake, pretension
t the hand-brake cable with the adjusting
nut at the compensation clamp.
t Setting the hand-brake Chapter.

446

Handbrake lever - Summary of components

1-

Handbrake lever

t before the removal, remove the centre console Body Work; Rep. gr.68.
2t

Door handle

pull it out towards the front, first of all press the catch peg below the door handle towards
the bottom using a small screwdriver

3t
4t
56-

Covering for the hand brake lever


removing: Body work; Rep. gr.68.
Centre console
removing: Body work; Rep. gr.68.
1.4 Nm
Nut, 18 Nm

7-

Compensating clamp

8-

Self-locking adjusting nut

t
t

replace after each removal


Setting the hand-brake:
Vehicles with drum brakes Chapter.
447

Vehicles with disc brakes Chapter.

9-

Handbrake cable

Fitting position of the hand-brake cables Fig.

removing and installing (drum brake) Chapter

removing and installing (disc brake) Chapter

different versions for the rear drum brake and disc brake Electronic Catalogue of Original
Parts.

10 -

Switch for hand-brake control

t
t

clipped
replace if defective

Fitting position of the hand-brake cables


Note

Fitting position of the hand-brake cables is


identical on vehicles with drum or disc
brake (only version with drum brake is
shown).

The hand-brake cables are fastened with


clips to the axle body.
The clamping ring arrow -A- at the handbrake cable must rest in the centre of the
clip -arrow B-.

448

Repairing rear wheel-brake - four-wheel drive (disc brake)


Changing the brake pads of the rear wheel disc brake - Mounting instructions

When changing the pad, observe the following:


Check the protective collar of the piston for brake caliper.
Replace the protective collar if damaged.
When replacing the collar:
Check the contact surfaces of the brake piston and the brake caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and replace the sealing sleeve.
Check the brake piston and the brake caliper (corrosion, grooves on the outside of the cylinder surface),

replace the brake caliper completely if damaged.


For the piston of the brake caliper, press into the initial position:
Check if the piston can be slightly pressed into the brake caliper.
If the piston cannot be slightly pressed into the brake caliper:
Check and clean the brake piston as well as the brake caliper, replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.

Removing and installing rear wheel brake


Special tools and workshop equipment required
t

Brake filling and bleeding device, e.g. -VAS 5234-

Brake pedal load, e.g. -V.A.G 1238/B-

Bleeding bottle (commercially available)

t
t

Brake fluid Chapter


Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note

After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t

Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.

Already used brake fluid must never be used again.

Tightening torque of the wheel screws: 120 Nm.

449

12-

80 Nm
Brake carrier with guide bolts and protective caps

t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t

fit a repair set if there is any damage to the protective caps or guide bolts; (use the
enclosed grease packing to lubricate the guide bolts)

Observe the instructions for changing the pad Chapter

3-

Self-locking screw, 35 Nm

always replace

4-

Brake hose with banjo union and hollow screw

must be replaced completely, do not dismantle

Tightening torque of the hollow screw: 35 Nm

t
5t
t

do not unscrew the brake line when replacing the brake pad
Brake caliper
do not unscrew the brake line when replacing the brake pad
removing:
Remove brake pads -Pos. 6
Insert brake pedal load.
450

Unscrew brake hose -Pos. 4- at brake caliper.

Installing:

Install brake pads -Pos. 6-

Screw brake hose -Pos. 4- to brake caliper

Take out brake pedal load.

Bleeding Brake System Chapter.

repairing Chapter

t
t

Observe the instructions for changing the pad Chapter


one must first adjust the hand-brake after undertaking repair or replacement work, the foot
brake must not be applied beforehand!

Setting the hand-brake Chapter

6-

Brake pads

Thickness 17 mm (including the support plate)

Wear limit: 7.5 mm (including supporting plate)

Check thickness: BookletOctavia

always replace axle-wise

t
t

removing and installing Chapter


Observe the instructions for changing the pad Chapter

7-

Pad retaining spring

t
t

always replace when changing the brake pads


Observe the instructions for changing the pad Chapter

8-

Cover plate

910 t
t

10 Nm
Self-locking twelve-point nut
replace after each removal
tighten Chapter

11 12 -

4 Nm
Brake disc, internally ventilated

Diameter 256 mm

Thickness 22 mm

Wear limit 20 mm

if worn replace axle-wise


451

13 -

Brake disc

Diameter 232 mm

Thickness 9 mm

Wear limit 7 mm

if worn replace axle-wise

14 t

Wheel hub with pulse rotor


pressing in and pressing out Chapter

15 t

Circlip
replace after each removal

16 t

Wheel bearing
replace after each removal

pressing in and pressing out Chapter

17 18 -

Trailing arm
Hand-brake cable

Setting the hand-brake Chapter

removing and installing Chapter

19 t

ABS wheel speed sensor

clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)

20 21 t

8 Nm
Drive shaft
removing and installing Chapter

Removing and installing brake pads


Special tools and workshop equipment required
t
t
t
t
t

Resetting tool -T10165Assembly device -T10165/1Brake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
452

Note

t
t

When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking.
Do not unscrew the brake hose when replacing the brake pad.

Removing

Remove rear centre console Body Work; Rep. gr.68.


Release the hand-brake.

Release the adjusting nut -1- so far until


the hand-brake cable can be unhooked
from the compensating clamp -2-.

Raise vehicle.

Remove wheels.

Lift off the clip -1- with a screwdriver and


pull down to remove.
Press the hand-brake lever -2- in the
-direction of the arrow- and while doing
so unhook the hand-brake cable -3-.

453

Unscrew the fixing screws of the brake


carrier while counterholding the guide
bolts.
Note

The brake line and the surrounding


components are not shown to simplify the
illustration.
Remove the brake caliper housing and
secure with wire in such a way that the
weight of the brake caliper does not
burden or damage the brake hose.

Remove the brake pads and pad


retaining springs -arrows-.
Note

Only use alcohol to clean the brake caliper


housing.
Clean the brake caliper housing, in
particular the adhesive surface for the
brake pad must be free from glue
residues and grease.
Install
Note

Before inserting new brake pads, press the


piston with a resetting and turning out tool
-T10165- into the cylinder. Drain the brake
fluid from the brake fluid reservoir using a
ventilation bottle before pushing back.
Otherwise brake fluid can flow out and lead
to damage if brake fluid was added in the
meantime.
WARNING

Brake fluid is toxic and must never be


sucked into your mouth through a hose.

454

Insert the resetting and turning out tool


-T10165- in such a way that the collar of
t
the tool -T10165/1- is resting on the
brake caliper.
Use open-jawed spanner on a provided
t spanner surface -arrow A- if the piston is
difficult to move.
When adjusting the piston with a piston
resetting device the automatic
t
adjustment in the brake caliper is
destroyed.

Screw the piston by turning the knurled


wheel of the resetting tool -T10165- to
the right into the brake caliper.

Insert the new pad retaining springs


-arrows- and brake pads in the brake
carrier.

Remove the protective foil from the


supporting plate of the brake pad.
Note

There are four self-locking screws in the


repair set, which must be fitted.

Secure the brake caliper housing using


new self-locking screws.

Counterhold at the guide bolt when


tightening.
Tightening torque: 35 Nm.

455

Press the hand-brake lever -2- in the


-direction of the arrow- and hook on the
hand-brake cable -3-.
Fit clip -1-.
Setting the hand-brake Chapter.

Attach the wheels.

Lower the vehicle.


Note

After each brake pad replacement,


forcefully apply the brake pedal
t
repeatedly to ensure the brake pads go
into their normal operating position.
t

Check brake fluid level after replacing the


brake pads.

Setting the hand-brake


Resetting of the hand-brake is not required after resetting of the rear brake due to automatic
resetting of the rear wheel-brake. New adjustment is only necessary when the handbrake
cable and brake carrier are replaced or after replacing the brake shoes.
Note

t
t

The brake system must be bled and fully operational.


Always replace self-locking adjusting nut.
Release the hand-brake.
Remove ashtray in centre console.
Release Phillips head screws.

456

Tilt the rear centre console, if necessary


remove Body Work; Rep. gr.68.

1-

Handbrake cable

Forcefully actuate the brake pedal once.

Put the hand brake lever in its rest


position. Tighten adjusting nut so far that
the levers -arrow- rise from the stops on
the brake calipers.

457

Check the distance between the lever


and the stop on the left and right brake
caliper using feeler gauges.

The distance -a- between the lever and the


stop on the left and right brake caliper
must not be less than a minimum of 1 mm
or exceed a maximum of 3mm.

Pull the handbrake on and release it


three times. This will position and set the
components.

If the hand-brake lever is in its rest


position, check whether both wheels
rotate freely, if necessary release
adjusting nut slightly.

Remove and install hand-brake cable, four-wheel drive/disc brake


Removing

Remove rear centre console Body Work; Rep. gr.68.


Release the hand-brake.

Release the adjusting nut -1- so far until


the hand-brake cable can be unhooked
from the compensating clamp -1-.
Raise vehicle.

458

Lift off the clip -1- with a screwdriver and


pull down to remove.
Press the hand-brake lever -2- in the
-direction of the arrow- and while doing
so unhook the hand-brake cable -3-.

Remove the rubber grommet -arrow Afrom the trailing arm.


Unhook the hand-brake cable out of the
bracket -arrow- and pull it out of the
trailing arm in -direction of arrow-.

Pull hand-brake cable -2- in -the direction


of the arrow- out of the guide tube -1-.

Install
Installation is carried out in the reverse
order.
Note

Before setting the hand-brake, pretension


t the hand-brake cable with the adjusting
nut at the compensation clamp.
t Setting the hand-brake Chapter.

459

Summary of Components of Foot Controls, Brake Pedal


Assembly overview of the foot controls, brake pedal - LHD vehicles
WARNING

The travel of the brake pedal must not be shortened by additional floor coverings.
Note

t Grease bearing and contact surfaces with grease -MoS2- (molykote grease).
t

Always replace self-locking nuts.

When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
Mechanics; Rep. gr.20

1t
2t

Bearing bracket
removing and installing Chapter
Self-locking nut, 28 Nm
replace

4 pieces for securing the mounting bracket to the brake servo unit

2 pieces for securing the mounting bracket to the bulkhead


460

3t

Brake light switch

before assembling the brake light switch, clip the brake pedal to the pressure rod of the
brake servo unit Chapter

t removing and installing, setting up to MY 1999 Chapter, as of MY 2000 Chapter


t

Assignment Electronic Catalogue of Original Parts

4t

Accelerator pedal
removing and installing: Engine, Mechanics; Rep. gr.20

5-

Self-locking nut, 25 Nm

6t
t

Brake pedal
separate from the brake servo unit Chapter
removing and installing Chapter

7-

Cap

8-

Screw

9-

Bushing

10 -

Bearing bolt

Assembly overview of the foot controls, brake pedal - RHD vehicles


WARNING

The travel of the brake pedal must not be shortened by additional floor coverings.
Note

t Grease bearing and contact surfaces with grease -MoS2- (molykote grease).
t

Always replace self-locking nuts.

When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
Mechanics; Rep. gr.20.

461

1t
2t

Bearing bracket
removing and installing Chapter
Self-locking nut, 28 Nm
replace
462

4 pieces for securing the mounting bracket to the brake servo unit

1 pieces for securing the mounting bracket to the bulkhead

3t

Brake light switch

before assembling the brake light switch, clip the brake pedal to the pressure rod of the
brake servo unit Chapter

t removing and installing, setting up to MY 1999 Chapter, as of MY 2000 Chapter


t

Assignment Electronic Catalogue of Original Parts

45-

Screw
Brake pedal

separate from the brake servo unit Chapter


removing and installing Chapter
6789-

Cap
Self-locking nut, 25 Nm
Bushing
Bearing bolt

10 11 -

Strut
Self-locking nut, 10 Nm

Separating the brake pedal from the brake servo unit and clipping
Special tools and workshop equipment required
t

Release tool -T10159A-

463

Release screws -2-.


Pull the footwell covering -1- out of the
holders.

Only for LHD vehicles

Release screws -1-.

Removing cover -A-.

On vehicles with manual gearbox,


remove the connecting plate between
the clutch pedal and the brake pedal
-arrows-.
Continued for all vehicles
Remove brake light switch -1- up to MY
1999 Chapter, as of MY 2000
Chapter.
Note

Fig. shows the separation of the brake


pedal from the brake servo unit with the
foot controls removed for clarity.

464

Press the brake pedal towards the brake


servo unit and hold it in position.

1-

Brake pedal

2-

Pressure rod

3-

Retaining lugs

Insert release tool -T10159A- and pull


towards the driver's seat while
counterholding the brake pedal. (At this

moment the pedal must not move


backwards.) This causes the retaining
lugs -3- of the support to be pressed off
the spherical head of the push rod -2-.
Pull the release tool -T10159A- and the
brake pedal jointly towards the driver's

seat. (This causes the brake pedal to be


drawn off the ball knob of the pressure
rod).
Clipping the brake pedal onto the brake
servo unit

Hold the spherical head of the push rod in


front of the support and press the brake

pedal towards the brake servo unit until


the spherical head locks audibly into
place.
Further installation occurs in reverse order.

Installing and setting brake light switch


vehicles up to MY 1999 Chapter,
vehicles as of MY 2000 Chapter.

Tightening torques:
Connecting plate between clutch pedal and brake pedal
465

20 Nm

Removing and installing brake pedal


Special tools and workshop equipment required
t
t

Release tool -T10159AGrease MoS2 (molykote grease)

Removing

Release screws -2-.


Pull the footwell covering -1- out of the
holders.

Only for LHD vehicles

Release screws -1-.

Take off cover -A-.

466

On vehicles with manual gearbox,


remove the connecting plate between
the clutch pedal and the brake pedal
-arrows-.

Unhook throttle control cable.


On vehicles with accelerator pedal
position sender, disconnect the plug
connection below the dash panel.

Continued for all vehicles

Removing brake light switch vehicles up


to MY 1999 Chapter, vehicles as of MY
2000 Chapter.

Separating the brake pedal from the


brake servo unit Chapter.

Remove all the fixing nuts of the foot


controls.

RHD vehicles
Remove the nut for the strut attached to
the mounting bracket and divert the
strut.
Continued for all vehicles

Remove foot controls.


Remove screwed connection of mounting
bracket - brake pedal.
Remove brake pedal.

Install
Note

Grease all bearing and contact surfaces


with grease MoS2.
Installation is carried out in the reverse
order.

Installing and setting brake light switch


vehicles up to MY 1999 Chapter,
vehicles as of MY 2000 Chapter.

Tightening torques:
Brake pedal to bracket
t

Use new screws and nuts!


467

Brake servo unit to mounting bracket


t

28 Nm

Use new nuts!

Connecting plate between clutch pedal and brake pedal

468

20 Nm

Brakes, hydraulics, regulator, servo


Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or
with ABS, ABS/EDL Mark 20
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or
with ABS, ABS/EDL Mark 20 - LHD vehicles
Note
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.

1t
t

Brake servo unit without mechanical brake assistance


all vehicles without ABS
Vehicles with ABS, ABS/EDL up to and including model year 2001

- Brake servo unit with mechanical brake assistance


t
t
t
t

Vehicles with ABS, ABS/EDL as of model year 2002


mechanical brake assistance integrated in the brake servo unit
The brake assistance can only be recognized by the spare part number of the brake servo
unit
Assignment Electronic Catalogue of Original Parts

t The brake assistance cannot be repaired, replace the brake servo unit completely when
469

handling a fault Chapter


- Continued for all brake servo units
t

check Chapter

removing and installing Chapter

if there are faults replace completely

separate from brake pedal Chapter

t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t

Non-return valve (in the vacuum hose of the vacuum pump)

Functional test

It must be possible to blow through the valve in the -direction of the arrow-.

Against the -direction of the arrow- the valve must be closed.

2t

Screw cap
with integrated brake fluid level warning contact -F34-

3-

Brake fluid reservoir

locked with lateral catches in the retaining pin

4t

Plugs
moisten with brake fluid and press in expansion reservoir

5-

Retaining pin

fit through the master brake cylinder

6t

Master brake cylinder

two brake pressure senders (-G201- and -G214-) are additionally installed on vehicles with
ABS/EDL/ESP

cannot be repaired, replace completely in the event of faults

Check tightness Chapter

7t

Self-locking nut 20 Nm
only for vehicles with 74 kW, 92 kW and 110 kW engine

8t

Heat shield
only for vehicles with 74 kW, 92 kW and 110 kW engine

9t
10 -

Self-locking nut 20 Nm
replace
Sealing ring
470

replace

11 -

Plugs

12 -

Vacuum hose

with non-return valve

13 -

Gasket

for brake servo unit

between brake servo unit and bulkhead

14 t

Self-locking nut, 28 Nm
replace

Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or
with ABS, ABS/EDL Mark 20 - RHD vehicles
Note
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.

471

1t
t

Brake servo unit with mechanical brake assistance


all vehicles without ABS
Right-hand drive vehicles with ABS, ABS/EDL

- Brake servo unit with mechanical brake assistance


472

t
t

mechanical brake assistance integrated in the brake servo unit


The brake assistance can only be recognized by the spare part number of the brake servo
unit

t
t

Assignment Electronic Catalogue of Original Parts


The brake assistance cannot be repaired, replace the brake servo unit completely when
handling a fault Chapter

- Continued for all brake servo units


t

check Chapter

removing and installing Chapter

if there are faults replace completely

separate from brake pedal Chapter

t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t

Non-return valve (in the vacuum hose of the vacuum pump)

2t

Screw cap
with integrated brake fluid level warning contact -F34-

3-

Brake fluid reservoir

with lateral catches for locking screw

4-

Plugs

5-

Plugs

t moisten with brake fluid and press expansion reservoir into the sealing surfaces
6-

Self-locking nut, 20 Nm

7-

Master brake cylinder

cannot be repaired, replace completely in the event of faults

Check tightness Chapter

8-

Locking screw for brake fluid reservoir, 10 Nm

9t

Sealing ring
replace

10 t
t

Gasket
for brake servo unit
between brake servo unit and bulkhead
473

replace

11 -

Self-locking nut, 28 Nm

replace

Removing and installing the master brake cylinder - LHD vehicles


Special tools and workshop equipment required
t
t
t
t

Hose clamp -MP 7-602Extraction bottle (commercially available)


Brake fluid Chapter
Repair set SP.-no. -1H0 698 311 ANote

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.

After reconnecting the battery, a few additional operations must be carried out Electrical
System; Rep. gr.27

Removing

Disconnect battery Electrical System; Rep. gr.27.


Note

The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Unscrew screws -2- at the air filter -3and lay it aside.

If necessary, remove the relay carrier


above the brake servo unit on diesel
engines.

474

Disconnect plug -1- from brake fluid level warning contact -F34-.
Using an extraction bottle extract as much brake fluid as possible from the brake fluid
reservoir.

Clamp off the running-on line of the clutch master cylinder -2- with hose clamp -MP 7-602-.

Disconnect the running-on line of the clutch master cylinder -2- from the brake fluid
reservoir -3- and tie up.

Unscrew the brake lines from the tandem master brake cylinder, close the brake lines with
the screw plugs from the repair kit SP no. -1 HO 698 311 A-.

Unscrew the heat shield on 74 kW, 92 kW and 110 kW engine.

Unscrew the tandem master brake cylinder from the brake servo unit.

Install
Installation is carried out in the reverse order.
Replace the gasket ring between the master brake cylinder and the brake servo unit.

When installing the master brake cylinder with the brake servo unit pay attention to the
correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid after installing Chapter.
Connect battery Electrical System; Rep. gr.27.
Bleeding Brake System Chapter.
Bleed clutch system (manual gearbox) Manual Gearbox; Rep. gr.30.
Repairing the clutch control BookletOctavia.
Initiate the basic setting on vehicles with EDL Chapter.
Interrogate the fault memory Chapter.
Erasing fault memory Chapter.

Removing and installing the master brake cylinder - RHD vehicles


Special tools and workshop equipment required
t
t
t
t

Hose clamp -MP 7-602Extraction bottle (commercially available)


Brake fluid Chapter
Repair set SP.-no. -1H0 698 311 ANote

475

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing

Disconnect battery Electrical System; Rep. gr.27.

Vehicles with TDI turbocharger engines


Remove top charge air pipe with connecting hose Engine, Mechanics; Rep. gr.21.
Continued for all vehicles

Disconnect plug -3- from brake fluid level


warning contact -F34-.
Using an extraction bottle extract as
much brake fluid as possible from the
brake fluid reservoir.

Clamp off the running-on line of the


clutch master cylinder -4- with hose
clamp -MP 7-602-.

Disconnect the running-on line of the


clutch master cylinder -4- from the brake
fluid reservoir -2- and tie up.

Unscrew the brake lines from the tandem master brake cylinder -2- and -3-.

Shut-off brake lines with screw plugs from the repair kit SP No. -1 HO 698 311 A-.

Unscrew the tandem master brake cylinder from the brake servo unit.

Install
Installation is carried out in the reverse order.
Replace the gasket ring between the master brake cylinder and the brake servo unit.

When installing the master brake cylinder with the brake servo unit pay attention to the
correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid after installing Chapter.
Connect battery Electrical System; Rep. gr.27.
Note

After reconnecting the battery, a few additional operations must be carried out Electrical
System; Rep. gr.27

Bleeding Brake System Chapter.


Bleed clutch system (manual gearbox) Manual Gearbox; Rep. gr.30.
476

Repairing the clutch control BookletOctavia.


Initiate the basic setting on vehicles with EDL Chapter.
Interrogate the fault memory Chapter.
Erasing fault memory Chapter.

477

Check brake servo unit


Brake servo unit without brake assistance
Functional test

With the engine off press down brake pedal repeatedly with force (this reduces the pressure
already present in the device).

Now hold the brake pedal in brake position using a medium foot pressure and start the
engine.

If the brake servo unit operates perfectly the brake pedal must yield noticeably under your
foot (servo boost takes effect).

If there are any complaints, replace the brake servo unit.

Brake servo unit with mechanical brake assistance


Check the operation of the brake servo unit
Brake servo unit without brake assistance Chapter.
Check the operation of the brake assistance

With the engine running (full vacuum support must be guaranteed) forcefully apply the
brake pedal. While doing so, a "click" must be audible (the brake assistance is activated).

If no "click" is audible, then the brake assistance is defective and the brake servo unit must
be replaced completely.
When subsequently releasing the brake pedal, a considerably reduced force is exerted onto
the foot from the brake pedal when braking.

Removing and installing the brake servo unit - LHD vehicles


Special tools and workshop equipment required
t

Hose clamp -MP 7-602-

Brake pedal load, e.g. -V.A.G 1238 B-

Vehicle system tester -V.A.G 1552-

Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

Brake filling and bleeding device, e.g. -VAS 5234-

t
t
t
t

Release tool -T10159AExtraction bottle (commercially available)


Repair set SP.-no. -1H0 698 311 ABrake fluid Chapter

478

Note

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing

Remove the hydraulic control unit Chapter.

Disconnect plug -1- from brake fluid level


warning contact -F34-.

Clamp off the running-on line of the


clutch master cylinder -2- with hose
clamp -MP 7-602-.

Disconnect the running-on line of the


clutch master cylinder -2- from the brake
fluid reservoir -3- and tie up.
Remove vacuum hose from the brake
servo unit.

Release screws -2-.

Pull the footwell covering -1- out of the


holders.

Separating the brake pedal from the


brake servo unit Chapter.

479

Unscrew the nuts for brake servo unit


-arrows-.

The top right nut is not visible in the figure.


Guide the brake servo unit with master
brake cylinder towards the front and
remove.
Install

Install the brake servo unit with the


master brake cylinder and tighten the
new self-locking nuts to 28 Nm -arrows-.

Clip the brake pedal onto the brake servo


unit Chapter.
Installing and setting brake light switch
vehicles up to MY 1999 Chapter,
vehicles as of MY 2000 Chapter.

Further installation occurs in reverse order.


Fill up with new brake fluid Chapter.

Connect battery Electrical


System; Rep. gr.27.

on vehicles with radio encoding, carry


out the coding.

Re-set clock.
initialise power windows on vehicles
fitted with power windows
BookletOctavia.
480

Bleeding Brake System Chapter.

Bleed clutch system (manual gearbox)


Manual Gearbox; Rep. gr.30.

Repairing the clutch control


BookletOctavia.

Initiate the basic setting on vehicles with


EDL Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Removing and installing the brake servo unit - RHD vehicles


Special tools and workshop equipment required
t
t
t
t
t
t
t
t

Hose clamp -MP 7-602Brake pedal load, e.g. -V.A.G 1238 BBrake filling and bleeding device, e.g. -VAS 5234Vehicle system tester -V.A.G 1552Release tool -T10159AExtraction bottle (commercially available)
Repair set SP.-no. -1H0 698 311 ABrake fluid Chapter
Note

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing

Remove engine cover Engine, Mechanics; Rep. gr.10.

Vehicles with TDI turbocharger engines


Remove top charge air pipe with connecting hose Engine, Mechanics; Rep. gr.21.

Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Mechanics; Rep. gr.26.

Continued for all vehicles

Lay sufficient non-fluffing cloths around the engine.


481

Remove master brake cylinder with brake fluid reservoir Chapter.

Release screws -2-.

Pull the footwell covering -1- out of the


holders.

Separating the brake pedal from the


brake servo unit Chapter.

Unscrew self-locking nuts for brake servo


unit -arrows-.

The top right self-locking nut is not visible


in the figure.

Slacken the brake servo unit towards the


front and remove.

Install

Install the brake servo unit and tighten


the new self-locking nuts -arrows-.

482

Clip the brake pedal onto the brake servo


unit.
Installing and setting brake light switch
vehicles up to MY 1999 Chapter,
vehicles as of MY 2000 Chapter.

Further installation occurs in reverse order.


Fill up with new brake fluid Chapter.

Connect battery Electrical


System; Rep. gr.27.

On vehicles with radio encoding, carry


out the coding.

Set clock.
Initialise power windows on vehicles
fitted with power windows
BookletOctavia.
Bleeding Brake System Chapter.

Bleed clutch system (manual gearbox)


Manual Gearbox; Rep. gr.30.

Repairing the clutch control


BookletOctavia.

Initiate the basic setting on vehicles with


EDL Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

483

Removing and installing the vacuum pump for the brake servo unit
Vehicles with diesel engine
Engine, Mechanics; Rep. gr.15

484

Repairing the front brake caliper, brake caliper FS III


Summary of Components of Brake Caliper FS-III
Special tools and workshop equipment required
t

Piston jig -MP 9-403-

Plastic wedge -3409-

Brake fluid Chapter

Assembly paste -G 052 150 A2Note

Install the complete repair set when undertaklng repairs.

The brake calipers must absolutely be pre-bled before installing them in the vehicle
t (without brake pads) in case of a repair or when replacing them with new brake calipers
Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.

12t
3-

Dust cap
Vent valve, 10 Nm
thinly coat thread with brake fluid or assembly paste before screwing in
Bushing
485

insert into the brake caliper

4-

Guide bolt, 30 Nm

5-

Caps

insert in bushing

6-

Brake caliper

7t

Sealing ring
removing and installing Chapter

8t
t

Piston
removing and installing Chapter
first thinly coat piston with assembly paste or brake fluid

9t

Protective cap
do not damage when inserting the piston

Removing and installing the front brake caliper piston


Special tools and workshop equipment required
t

Piston jig -MP 9-403-

Plastic wedge -3409-

Brake fluid Chapter

Assembly paste -G 052 150 A2-

Removing

486

Press the piston out of the brake caliper


housing using compressed air -arrow-.
Note

Insert wooden plate so that the piston is


not damaged.

Take out gasket ring.

Use a plastic wedge -3409- for this


purpose.
Note

When removing, make sure that the


cylinder surface is not damaged.
Install

Clean the piston and gasket ring surfaces


with white spirits and dry off.

Before installing the piston and gasket


ring in the brake caliper housing, thinly
coat with brake fluid or assembly paste
-G 052 150 A2-.

Insert new gasket ring in the groove of


the brake caliper.

487

Position the new protective cap with the


outer sealing lip on the piston.

Insert the inner sealing lip of the


protective cap with a plastic wedge in the
groove of the cylinder.

Use a plastic wedge -3409- for this


purpose.
Note

To do so hold the piston in front of the


brake caliper housing.

Press the piston into the brake caliper


housing using the piston resetting jig -MP
9-403-.
Note

The outer sealing lip of the collar will


engage in the piston groove.

488

Repairing the front brake caliper, brake caliper FN 3


Assembly overview of the brake caliper FN3
Special tools and workshop equipment required
t

Piston jig -MP 9-403-

Plastic wedge -3409-

Brake fluid Chapter

Assembly paste -G 052 150 A2Note

Install the complete repair set when undertaklng repairs.

The brake calipers must absolutely be pre-bled before installing them in the vehicle
t (without brake pads) in case of a repair or when replacing them with new brake calipers
Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.

1t
23-

Cap
insert in bushing
Guide bolt, 28 Nm
Bushing
489

insert in brake caliper housing

4-

Dust cap

5t

Vent valve, 10 Nm
thinly coat thread with brake fluid or assembly paste before screwing in

6-

Brake caliper

7-

Brake carrier

crewed to the brake caliper

8t

Pad retaining spring


insert with both ends into the bores in the brake caliper

9-

Sealing ring

removing and installing Chapter

10 t
t

Piston
removing and installing Chapter

thinly coat with brake fluid or assembly paste before installing

Piston diameter: 54 mm

11 -

Protective cap

do not damage when inserting the piston

pull with outer sealing lip onto the piston

t insert with the inner sealing lip into the groove of the brake caliper Chapter

Removing and installing the front brake caliper piston


Special tools and workshop equipment required
t

Piston jig -MP 9-403-

Plastic wedge -3409-

Brake fluid Chapter

Assembly paste -G 052 150 A2-

Removing

490

Press the piston out of the brake caliper


housing using compressed air -arrow-.
Note

Insert wooden plate so that the piston is


not damaged.

Take out gasket ring.

Use a plastic wedge -3409- for this


purpose.
Note

When removing, make sure that the


cylinder surface is not damaged.
Install

Clean the piston and gasket ring surfaces


with white spirits and dry off.

Before installing the piston and gasket


ring in the brake caliper housing, thinly
coat with brake fluid or assembly paste
-G 052 150 A2-.

Insert new gasket ring in the groove of


the brake caliper.

491

Position the new protective cap with the


outer sealing lip on the piston.

Insert the inner sealing lip of the


protective cap with a plastic wedge in the
groove of the cylinder.

Use a plastic wedge -3409- for this


purpose.
Note

To do so hold the piston in front of the


brake caliper housing.

Press the piston into the brake caliper


housing using the piston resetting jig -MP
9-403-.
Note

The outer sealing lip of the protective cap


will engage in the piston groove.

492

Repairing the rear brake caliper


Summary of components of the brake caliper
Special tools and workshop equipment required
t

Resetting tool -T10165-

Plastic wedge -3409-

t
t
t

Bleeding bottle (commercially available)


Brake fluid Chapter
Assembly paste -G 052 150 A2Note

Install the complete repair set when undertaklng repairs.

The brake calipers must absolutely be pre-filled with brake fluid before installing them in
t the vehicle (without brake pads) in case of a repair or when replacing them with new brake
calipers Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.

1t
t

Self-locking screw, 35 Nm
replace
counterhold on the guide bolt when releasing and tightening
493

2-

Vent valve, 10 Nm

t thinly coat thread with brake fluid or assembly paste before screwing in -G 052 150 A23-

Dust cap

4-

Guide bolt

grease before fitting protective cap

5-

Protective cap

pull onto brake carrier and guide bolt

6-

Brake carrier with guide bolts and protective caps

t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t

if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed
grease packing to lubricate the guide bolts)

7-

Protective cap

pull with outer sealing lip onto the piston

t insert with the inner sealing lip into the groove of the brake caliper housing Chapter
8-

Piston with automatic adjusting device

removing and installing Chapter

t thinly coat piston with brake fluid or assembly paste before installing -G 052 150 A29-

Sealing ring

take out with a plastic wedge Chapter

10 -

Brake caliper housing with lever for the handbrake cable

t replace brake caliper housing if the lever for the handbrake cable is not sealed
t

pre-bleed brake caliper housing after undertaking repairs Chapter

Removing and installing the rear brake caliper piston


Special tools and workshop equipment required
t

Resetting tool -T10165-

Plastic wedge -3409-

t
t
t

Bleeding bottle (commercially available)


Brake fluid Chapter
Assembly paste -G 052 150 A2-

Removing:
494

Insert the resetting tool -T10165- in such


a way that the collar of the resetting tool
is resting on the piston.

Release the piston by turning the knurled


wheel of the resetting tool -T10165- to
the left.
Use open-jawed spanner on a provided
spanner surface -A- if the piston is difficult
to move.
Note

Make sure that the cylinder surface is not


damaged when removing the gasket ring.

Take out gasket ring with plastic wedge


-3409-.

Installing:

Clean the piston and gasket ring surfaces


with white spirits and dry off.

Before installing the piston and gasket


ring in the brake caliper housing, thinly
coat with brake fluid or assembly paste
-G 052 150 A2-.

Insert new gasket ring in the brake


caliper.

Position the new protective cap with the


outer sealing lip on the piston.

Insert the inner sealing lip of the


protective cap with a plastic wedge
495

-3409- in the groove of the cylinder.


To do so hold the piston with the hand.

Insert resetting tool -T10165-.

To insert use the special tool -T10165/1-.

Screw in piston by turning the knurled


wheel to the right.

Use open-jawed spanner on a provided


spanner surface -A- if the piston is
difficult to move.
Note

When resetting the piston with a


t resetting tool the automatic piston
setting in the brake caliper is destroyed.
It is absolutely necessary, if repairs are
being undertaken, to bleed the brake
t
calipers before installing them in the
vehicle (without brake pads).

Insert brake pads.

Temporary filling of brake caliper

Note
The brake caliper must be positioned vertically for pre-bleeding.

Open vent valve -arrow A-.


Filling up -arrow B- (brake hose connection).

Close vent valve.

496

Summary of components of brake-power regulator

1t
2t
34t
567-

Brake-power regulator
testing and adjusting Chapter
Brake line with pipe screw
Tightening torque of the pipe screw 14 Nm
Oval-head countersunk screw, 21 Nm
Self-locking nut, 21 Nm
replace after each removal
Tension spring
16 Nm
Socket nut

8t

Screw
replace after each removal

Inspecting and adjusting the brake-power regulator


Special tools and workshop equipment required
497

t Brake-power regulator or brake system tester, e. g. -V.A.G 1310- or -V.A.G 1310 AThe brake-power regulator is secured to a
bracket assigned to the mount for rear axle
and is controlled by the rear axle
movement via a spring.
Functional test
Forcefully apply the brake pedal and
release quickly (vehicle is standing on its
wheels). While doing so the lever of the
brake-power regulator must move.
Pressure test and adjustment
Note

The brake-power regulator is adjusted on a


vehicle with unladen weight.
Unladen weight refers to: The weight of an
unladen vehicle (fuel tank empty up to
max. 5 litres, without driver, with spare
wheel, tool kit, jack).

498

Raise vehicle and


connect pressure
gauge to the brake

caliper (left front


wheel) and to the
wheel-brake cylinder
(right rear wheel).

Bleed both pressure


gauges.

Lower vehicle and


repeatedly depress

vehicle and allow to


settle on the rear
axle.

Press brake pedal


and measure
pressures.

Compare measured
pressure values to

the specified
adjusting values
Chapter.

If necessary adjust
brake-power
regulator Chapter.

499

Adjusting values for the load-dependent brake-power regulator


Model/Version

bar

MPa

bar

MPa

Drum brakes on the

Front axle

70

Front axle

100

10

Rear axle

Rear axle

41 ... 47

4,1 ... 4,7

Rear axle

54 ... 60

5,4 ... 6,0

Adjusting brake-power regulator


Test pressure on rear axle too high:

Release tension spring on brake-power regulator.

Test pressure on rear axle too low:

Tighten tension spring on brake-power regulator.


Note

Adjust without load on the brake pedal, observe the following sequence:

Read off values.

Release brake pedal.

Adjust tension spring on brake-power regulator.


Again load brake pedal.
Read-off values and if necessary correct adjustment.
Remove pressure gauge.
Bleeding Brake System Chapter.

Bleed brake system, vehicles with or without ABS or ABS/EDL Mark 20 and Mark 60
Special tools and workshop equipment required
t
t
t

Brake filling and bleeding device, e.g. -VAS 5234Brake pedal load, e.g. -V.A.G 1238/BVehicle system tester -V.A.G 1552- (only for vehicles with ABS/EDL)
Note

Only use new brake fluid complying with the standard Chapter.

t If the system is opened, avoid working with compressed air and avoid moving the vehicle.
500

Bleeding the brake system is described using the brake filling and bleeding device, e.g.
-VAS 5234-.

If one chamber of the brake fluid reservoir has run completely dry, e.g. leakage in the brake
system, bleeding must be carried out using the brake filling and bleeding device, e.g. -VAS
5234-. Then the hydraulic unit is tested with the vehicle system tester -V.A.G 1552- in the
function "basic setting" or with the vehicle diagnosis, measurement and information system
-VAS 505x-.
Note

Only use new brake fluid Chapter.


WARNING

Brake fluid is hygroscopic, i.e. it retains humidity from the ambient air, and must therefore
always be stored in airtight containers.

Brake fluid must never come into contact with fluids containing mineral oils (oil, petrol,
cleaning agent). Mineral oils damage the plugs and boots of the brake system.

Drained (used) brake fluid must never be used again.

Observe the disposal instructions!

Brake fluid is toxic, avoid skin contact.

t Because of its caustic effect brake fluid must not come into contact with paint.
t

Rinse any brake fluid spills with a lot of water.

t Dispose of brake fluid in compliance with the applicable environmental regulations.


Vehicles without ABS or ABS/EDL

Connect up the brake filling and bleeding device e.g. -VAS 5234- but do not yet switch it
on.

Bleeding sequence Chapter


Remove dust caps from the vent valves of the brake calipers/wheel-brake cylinder.

Switch on brake filling and bleeding device e.g. -VAS 5234-.


Leave the bleeder screws on the plugged-on hose of the bleeder bottle open for as long as
is takes until the bubble-free brake fluid flows out.

Vehicles with Mark 20 or Mark 60

Connect up the brake filling and bleeding device e.g. -VAS 5234- but do not yet switch it
on.
Insert brake pedal load.

If one chamber of the brake fluid reservoir has run completely dry (e.g. leakage in the brake
system) first of all a pre-bleeding of the brake system must be performed.
501

Bleeding sequence for vehicles with Mark 20 Chapter


Bleeding sequence for vehicles with Mark 60 Chapter
Then bleed the hydraulic unit with the function Basic setting and the vehicle system tester
-V.A.G 1552-.
A characteristic feature of right-hand drive vehicles
If one chamber of the brake fluid reservoir
has run completely dry (e.g. leakage in the
brake system) or after changing the
hydraulic unit, then the master brake
cylinder must be bled via the bleeder
valves after carrying out the basic setting
-arrows-.
Continued for vehicles with Mark 60
Perform a null balance for the brake
pressure sender -1--G201- after bleeding
the brake system Chapter.
Continued for all vehicles
When replenishing brake fluid with a brake
filling and bleeding device, it is important
to ensure that the filling pressure of 0.1
MPa (1 bar) is not exceeded.
Therefore the brake fluid pressure on the
brake filling and bleeding device must be
regulated down to 0.1 MPa (1 bar)
Operating instructions of the bleeding
device
If the filling pressure of 0.1 MPa (1 bar) is
exceeded, proper bleeding of the hydraulic
unit is no longer assured.

Initiate the basic setting on vehicles with


Mark 20 Chapter.

Initiate the basic setting on vehicles with


Mark 60 Chapter.

After bleeding perform a test drive. While


doing so perform at least one ABS
adjustment!

502

Bleeding brake system with brake filling and bleeding device for vehicles with Mark 20
Special tools and workshop equipment required
t

Brake filling and bleeding device, e.g. -VAS 5234-

Vehicle system tester -V.A.G 1552- (only for vehicles with ABS/EDL)

Brake fluid Chapter

Opening the bleeder screws on the hydraulic unit is not allowed on vehicles with ABS,
ABS/EDL!

Connect up the brake filling and bleeding device, e.g. -VAS 5234-, but do not yet switch it
on.

Remove dust caps from the bleeder screws of the brake calipers/wheel-brake cylinders.

Open the bleed valves in the prescribed sequence with the hose of the bleeding bottle
fitted, switch on the brake filling and bleeding device and bleed both the brake calipers and
the wheel-brake cylinders.

Bleeding sequence
1-

Rear right wheel-brake cylinder/brake caliper

2-

Rear left wheel-brake cylinder/brake caliper

3-

Front right brake caliper

4-

Front left brake caliper

After bleeding close the relevant bleeder screw and fit dust cap.

Switch off the brake filling and bleeding device.

Remove the connection on the brake fluid reservoir.

Vehicles with ABS or with ABS/EDL


A road test must be carried out with these vehicles after bleeding. While doing so perform at
least one ABS adjustment!
Note

For vehicles with brake-power regulator move the rear wheel-brake lever of the regulator
during bleeding.
Change brake fluid BookletOctavia

503

Bleeding the brake system without using the brake filling and bleeding device
Special tools and workshop equipment required
t

Bleeding bottle (commercially available)

Brake fluid Chapter

Opening the bleeder screws on the hydraulic unit is not allowed on vehicles with ABS,
ABS/EDL!
Note

While bleeding continuously check the brake fluid level in the brake fluid reservoir. If
necessary, top up brake fluid up to the MAX marking.

Open the bleeder screw with the hose of the bleeding bottle fitted.

Flush the brake fluid through the brake system by pumping the brake pedal.

Close the vent valve with the pedal pressed down.


Proceed pumping with the pedal at least 10x per wheel brake and repeat the procedure
until no more air escapes.

Bleeding sequence for vehicles with Mark 20


1-

Rear right wheel-brake cylinder/brake caliper

2-

Rear left wheel-brake cylinder/brake caliper

3-

Front right brake caliper

4-

Front left brake caliper

Bleeding sequence for vehicles with Mark 60


1-

Front left brake caliper

2-

Front right brake caliper

3-

Rear left brake caliper

4-

Rear right brake caliper

Vehicles with ABS or with ABS/EDL


A road test must be carried out with these vehicles after bleeding. While doing so perform at
least one ABS adjustment!
Note

For vehicles with brake-power regulator move the rear wheel-brake lever of the regulator
during bleeding.
Change brake fluid BookletOctavia

504

505

Bleeding brake system with brake filling and bleeding device for vehicles with ABS Mark 60

Special tools and workshop equipment required


t Brake filling and bleeding device, e.g. -VAS 5234t
Brake pedal load, e.g. -V.A.G 1238/B Connect up the brake filling and bleeding device, but do not yet switch it on.

Insert brake pedal load.


Open the bleed valves in the prescribed sequence with the hose of the bleeding bottle fitted, switch on the

brake filling and bleeding device and bleed both the brake calipers and the wheel-brake cylinders.
Bleeding sequence
1Front left brake caliper
2Front right brake caliper
3Rear left brake caliper
4Rear right brake caliper
After bleeding the relevant valve, close the vent valve and fit on the dust cap.
After bleeding perform a test drive. While doing so perform at least one ABS adjustment!
Pre-bleed the brake system if one chamber of the brake fluid reservoir has run completely empty (e.g.
leakage in the brake system).
Bleeding sequence
1Bleed the front left and front right brake caliper simultaneously
2Bleed the rear left and rear right brake caliper simultaneously
Leave the bleeder screws on the plugged-on hose of the bleeder bottle open for as long as is takes until

the bubble-free brake fluid flows out.

Checking the master brake cylinder for tightness


Special tools and workshop equipment required
t Brake-power regulator or brake system tester, e. g. -V.A.G 1310- or -V.A.G 1310 At

Brake fluid Chapter

Assembly paste -G 052 150 A2-

Test condition
l

Function and tightness of the brake system O.K.

The brake system includes:


t

Hydraulic control unit or load-dependent brake-power regulator

Brake lines, brake hoses and their connections

Brake calipers and wheel-brake cylinder

Test

Release the bleeder screw on one of the front brake calipers.

506

Connect the
pressure gauge of

the tester -V.A.G


1310- or -V.A.G 1310
A- and bleed.
Push down brake
pedal until the
pressure gauge on
the tester indicates
an overpressure of 5
MPa (50 bar).

Test duration 45
seconds.

The pressure loss


must not exceed
0.40 MPa (4 bar)
throughout the test.
If the pressure loss
exceeds 0.40 MPa (4
bar) replace the
master brake cylinder.
LHD vehicles
Chapter.
RHD vehicles
Chapter.

Repeat the test after


replacing the master
brake cylinder.

Separate the
pressure gauge of
the tester -V.A.G
1310- or -V.A.G 1310
A- from the brake
caliper.
Thinly coat the
thread of the vent
valve with brake
fluid or assembly
paste -G052 150
A2-.

Screw the vent valve


into the brake
caliper and tighten.

Tightening torque: 10
507

Nm

Bleeding Brake
System

Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with
ABS/EDL/ESP Mark 20
Note

The complete master brake cylinder and brake servo unit can be replaced independently of
one another.

1t

Brake servo unit


check Chapter

removing and installing - LHD vehicles Chapter

removing and installing - RHD vehicles Chapter


508

if there are faults replace completely

separate from brake pedal Chapter

Assignment Electronic Catalogue of Original Parts

t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t

Non-return valve (in the vacuum hose of the vacuum pump)

Functional test

It must be possible to blow through the valve in the -direction of the arrow-.

Against the direction of the arrow the valve must be closed.

2-

Self-locking nut 28 Nm

replace

3-

Gasket

for brake servo unit

between brake servo unit and bulkhead

4t

Bellows
pay attention to correct position, risk of suction noises

5-

Holder

is attached to the edge of the brake servo unit

serves for the support of the plug -Pos. 18-

6t

Screw cap
with integrated brake fluid level warning contact -F34-

7-

Brake fluid reservoir

locked with lateral catches in the retaining pin

8-

Sealing ring

replace

9-

Retaining bracket

for fixing the wiring loom -Pos. 16-

10 t

Plugs

moisten with brake fluid and press in expansion reservoir

11 -

Retaining pin
509

fit through the master brake cylinder

12 t

Master brake cylinder

cannot be repaired, replace completely in the event of faults

Check tightness Chapter

13 -

Self-locking nut 20 Nm

replace

14 t

Heat shield

only for vehicles with 74 kW, 92 kW and 110 kW engine

15 t

Brake pressure sender -1--G201in the floating piston circuit

removing and installing Chapter

16 17 t

Wiring loom
Brake pressure sender -2--G214in the push rod piston circuit

removing and installing Chapter

18 t

Connector

Connection wiring loom dash panel/engine compartment

19 -

Plugs

20 t
t

Vacuum hose
with non-return valve
insert in brake servo unit.

Removing and installing brake pressure sender -1--G201- and brake pressure sender -2-G214-

Note

t Before disconnecting the battery determine the code of radio sets fitted with anti-theft
510

coding.
t

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

re-set clock

initialise power windows on vehicles fitted with power windows BookletOctavia


Removing

Disconnect battery.

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Lay sufficient non-fluffing cloths around


the plenum chamber, the engine and the
gearbox.

Using an extraction bottle extract as


much brake fluid as possible from the
brake fluid reservoir.
Attach the hose of the bleeding bottle
onto the bleeder screw of the front left
brake caliper and open the bleeder screw.

Depress the brake pedal at least 15 times


so that the master brake cylinder runs
empty.

Close the front left bleeder screw while


the pedal is pressed down.

511

Disconnect the plug -arrow- of the


relevant brake pressure sender to be
removed.
1-

Master brake cylinder

2-

Brake pressure sender -2--G214- in the


floating piston circuit

3-

Brake pressure sender -1--G202- in the


push rod piston circuit

Remove brake pressure sender -1--G202or brake pressure sender -2--G214-.

Install
Installation is carried out in the reverse
order.

Connect battery Electrical


System; Rep. gr.27.

Only fill up with new brake fluid after


installing.

Bleeding Brake System Chapter.

Bleed clutch system (manual gearbox)


Manual Gearbox; Rep. gr.30.

Perform basic setting of brake pressure


sender -G202- and -G214- Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Tightening torques:
Brake pressure sender -1-

25 Nm

Brake pressure sender -2-

25 Nm

Removing and installing the master brake cylinder - LHD vehicles


Special tools and workshop equipment required
t
t
t
t

Hose clamp -MP 7-602Extraction bottle (commercially available)


Brake fluid Chapter
Repair set SP.-no. -1 HO 698 311 A512

Note

Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia.


Removing

Disconnect battery.

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Remove the relay carrier above the brake


servo unit on diesel engines.

Lay sufficient non-fluffing cloths around


the plenum chamber, the engine and the
gearbox.

Disconnect plug -1- from brake fluid level


warning contact -F34-.
Using an extraction bottle extract as
much brake fluid as possible from the
brake fluid reservoir -5-.

Clamp off the running-on line of the


clutch master cylinder -2- with hose
clamp -MP 7-602-.

Disconnect the running-on line of the


clutch master cylinder -2- from the brake
fluid reservoir -5- and tie up.

34-

Master brake cylinder


Heat shield

513

Disconnect the plug -arrows- of the brake


pressure sender -2- and -3-.

Release the nuts of the master brake


cylinder -1-.

If present, remove the heat shield.

Carefully remove the master brake


cylinder -1- from the brake servo unit.

Install
Installation is carried out in the reverse
order.
Replace the gasket ring between the
master brake cylinder and the brake
servo unit.
When installing the master brake cylinder
with the brake servo unit pay attention to
the correct positioning of the pressure
rod in the master brake cylinder.

Only fill up with new brake fluid after


installing.

Connect battery Electrical


System; Rep. gr.27.

Bleeding Brake System Chapter.


Bleed clutch system (manual gearbox)
Manual Gearbox; Rep. gr.30.
Initiate basic setting Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Tightening torque:
Master brake cylinder to brake servo unit

20 Nm

Removing and installing the master brake cylinder - RHD vehicles


Special tools and workshop equipment required
t
t
t

Hose clamp -MP 7-602Extraction bottle (commercially available)


Brake fluid Chapter
514

Repair set SP.-no. -1H0 698 311 ANote

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing

Disconnect battery Electrical System; Rep. gr.27.

Vehicles with TDI turbocharger engines


Remove top charge air pipe with connecting hose Engine, Mechanics; Rep. gr.21.
Continued for all vehicles

Disconnect plug -3- from brake fluid level


warning contact -F34-.
Using an extraction bottle extract as
much brake fluid as possible from the
brake fluid reservoir.

Clamp off the running-on line of the


clutch master cylinder -4- with hose
clamp -MP 7-602-.

Disconnect the running-on line of the


clutch master cylinder -4- from the brake
fluid reservoir -2- and tie up.

Disconnect the plug of the brake


pressure sender -arrows-.

515

Unscrew the brake lines from the tandem


master brake cylinder -2- and -3-.

Shut-off brake lines with screw plugs


from the repair kit SP No. -1 HO 698 311
A-.

Unscrew the tandem master brake


cylinder from the brake servo unit.

Install
Installation is carried out in the reverse
order.
Replace the gasket ring between the
master brake cylinder and the brake
servo unit.
When installing the master brake cylinder
with the brake servo unit pay attention to
the correct positioning of the pressure
rod in the master brake cylinder.

Only fill up with new brake fluid after


installing Chapter.

Connect battery Electrical


System; Rep. gr.27.
Note

After reconnecting the battery, a few


additional operations must be carried out
Electrical System; Rep. gr.27

Bleeding Brake System Chapter.

Bleed clutch system (manual gearbox)


Manual Gearbox; Rep. gr.30.

Repairing the clutch control


BookletOctavia.

Initiate the basic setting on vehicles with


EDL Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

516

Check brake servo unit


Chapter

Removing and installing the brake servo unit - LHD vehicles


Special tools and workshop equipment required
t
t
t
t
t
t
t
t

Hose clamp -MP 7-602Brake pedal load, e.g. -V.A.G 1238 B- or -V.A.G 1869/2Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3CRelease tool -T 10159 AExtraction bottle (commercially available)
Repair kit -1 HO 698 311 ABrake fluid Chapter
Note

t
t

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
After connecting the battery check the vehicle equipment:
on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia


Removing

Disconnect battery.

517

Disconnect the plug -1- of the air mass


meter from the air guide pipe of the air
filter.

Unscrew screws -2- at the air filter -3and lay it aside.

Remove the relay carrier above the brake


servo unit on diesel engines.

Lay sufficient non-fluffing cloths around


the plenum chamber, the engine and the
gearbox.

Remove hydraulic control unit -1 Chapter.

Disconnect plug -4- from brake fluid level


warning contact -F34-.

Clamp off the running-on line of the


clutch master cylinder -5- with hose
clamp -MP 7-602-.

Disconnect the running-on line of the


clutch master cylinder -5- from the brake
fluid reservoir -3- and tie up.

Detach the vacuum hose -2- from the


brake servo unit.

Press the plug connection -1- out of the


holder -3-.

To do so, press the plug connection -1- in


the direction of the bulkhead.
2

Brake servo unit


Disconnect plug connection -1-.

518

Release screws -2-.

Pull the footwell covering -1- out of the


holders.

Separating the brake pedal from the


brake servo unit Chapter.

Unscrew the nuts for brake servo unit


-arrows-.

The top right nut is not visible in the figure.


Guide the brake servo unit with master
brake cylinder towards the front and
remove.
Install

Install the brake servo unit with the


master brake cylinder and tighten the
new nuts -arrows-.

519

Clip the brake pedal onto the brake servo


unit Chapter.
Installing and setting brake light switch
vehicles up to MY 1999 Chapter,
vehicles as of MY 2000 Chapter.

Further installation occurs in reverse order.


Fill up with new brake fluid Chapter.

Connect battery Electrical


System; Rep. gr.27.
Bleeding Brake System Chapter.
Bleed clutch system (manual gearbox)
Manual Gearbox; Rep. gr.30.
Initiate basic setting Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Tightening torque:

Brake servo unit to foot controls

28 Nm

Removing and installing the brake servo unit - RHD vehicles


Special tools and workshop equipment required
t
t
t
t
t
t
t
t

Hose clamp -MP 7-602Brake pedal load, e.g. -V.A.G 1238 BBrake filling and bleeding device, e.g. -VAS 5234Vehicle system tester -V.A.G 1552Release tool -T10159AExtraction bottle (commercially available)
Repair set SP.-no. -1H0 698 311 ABrake fluid Chapter
Note

Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
520

coding.
Removing

Remove engine cover Engine, Mechanics; Rep. gr.10.

Vehicles with TDI turbocharger engines


Remove top charge air pipe with connecting hose Engine, Mechanics; Rep. gr.21.

Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Mechanics; Rep. gr.26.

Continued for all vehicles

Lay sufficient non-fluffing cloths around the engine.


Remove master brake cylinder with brake fluid reservoir Chapter.

Release screws -2-.

Pull the footwell covering -1- out of the


holders.

Separating the brake pedal from the


brake servo unit Chapter.

Unscrew self-locking nuts for brake servo


unit -arrows-.

The top right self-locking nut is not visible


in the figure.

Slacken the brake servo unit towards the


front and remove.

Install

521

Install the brake servo unit and tighten


the new self-locking nuts -arrows-.

Clip the brake pedal onto the brake servo


unit.

Installing and setting brake light switch


vehicles up to MY 1999 Chapter,
vehicles as of MY 2000 Chapter.

Further installation occurs in reverse order.


Fill up with new brake fluid Chapter.

Connect battery Electrical


System; Rep. gr.27.

On vehicles with radio encoding, carry


out the coding.

Set clock.
Initialise power windows on vehicles
fitted with power windows
BookletOctavia.
Bleeding Brake System Chapter.

Bleed clutch system (manual gearbox)


Manual Gearbox; Rep. gr.30.

Repairing the clutch control


BookletOctavia.

Initiate the basic setting on vehicles with


EDL Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

522

Removing and installing the vacuum pump for the brake servo unit
Vehicles with diesel engine
Engine, Mechanics ; Rep. gr.15

Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with
ABS/EDL/TCS/ESP Mark 60
Note

The complete master brake cylinder and brake servo unit can be replaced independently of
one another.

1t

Brake servo unit without mechanical brake assistance


Right-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60

t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 up to and including model year
523

2001
- Brake servo unit with mechanical brake assistance
t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 as of model year 2002
t

The brake assistance can only be recognized by the spare part number of the brake servo
unit

The brake assistance cannot be repaired, replace the brake servo unit completely when
handling a fault LHD vehicles Chapter, RHD vehicles Chapter

- Continued for all brake servo units


t

check Chapter

t removing and installing LHD vehicles Chapter, RHD vehicles Chapter


t

if there are faults replace completely

separate from brake pedal Chapter

t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t

the electric brake vacuum pump is additionally installed on vehicles with automatic gearbox
and in combination with EU4 -V192-

-V192- check operation Chapter

Remove and install the brake vacuum pump -V192- Chapter

Non-return valve (in the vacuum hose of the vacuum pump)

Functional test

2t
3t

It must be possible to blow through the valve in the -direction of the arrow-.
Against the direction of the arrow the valve must be closed.
Screw cap
with integrated brake fluid level warning contact -F34Brake fluid reservoir, left-hand drive
locked with lateral catches in the retaining pin

4t
5t
6t
7-

Plugs
moistened with brake fluid, press in expansion reservoir
Retaining pin
fit through the master brake cylinder
Master brake cylinder
cannot be repaired, replace completely in the event of faults
Retaining bracket
524

serves to fix the wiring loom

8-

Self-locking nut 20 Nm

always replace

9t

Heat shield
only for vehicles with 74 kW, 92 kW, 110 kW and 132 kW engine

10 t

Brake pressure sender -1--G201removing and installing Chapter

11 t

Sealing ring
always replace

12 t
t

Plugs
Connection for vacuum hose
insert in brake servo unit.

13 t
t
t
14 -

Gasket
for brake servo unit
between brake servo unit and bulkhead
always replace
Self-locking nut 20 Nm

525

Removing and installing brake pressure sender -1--G201When using the hydraulic control unit Mark 60, the master brake cylinder has only one brake
pressure sender.
removing and installing Chapter

Removing and installing master brake cylinder


LHD vehicles Chapter.
RHD vehicles Chapter.

Check brake servo unit


Chapter.

Removing and installing brake servo unit


LHD vehicles Chapter.
RHD vehicles Chapter.

Removing and installing brake vacuum pump -V192-

No provision is made for repairing the brake vacuum pump -V192-. The brake vacuum pump -V192- must
be replaced if a fault arises.
The fitting location of the brake vacuum pump -V192- can be found on the bottom left of the assembly
carrier
Removing

Unscrew the screws -1- at the bracket for the


brake vacuum pump -V192-.
Remove the vacuum hose -arrow- from the

brake vacuum pump -V192-.


Take out the brake vacuum pump -V192-.
Unlock the plug connection and remove it from

the brake vacuum pump.

526

Bracket -arrow- for the brake vacuum pump


-V192-.
Unscrew the counternut -2- from the screw -1-.

Release screw -4-.

Remove bracket.
Unscrew the screws -3- for further disassembly

of the bracket -arrow-.


Install
Installation is carried out in the reverse order.

Tightening torques:
Nut -2- to bracket
Screws -3- to bracket
Screw -4- to bracket
Inner Torx screw for brake vacuum pump -V192- to bracket

20 Nm
8 Nm
20 Nm
8 Nm

Testing brake vacuum pump -V192During the start operation, the brake vacuum pump must start -V192- running briefly.
Work procedure

Run the vehicle on the lift platform, switch off engine.


Start engine.
A second person must check the operation of the brake vacuum pump by touching it with
the hand -V192-.

If the brake vacuum pump -V192- does not run:

Interrogate the fault memory of the engine control unit Engine, Fuel Injection and Ignition
System; Rep. gr.01.

527

Steering
Steering column and steering wheel with airbag
Check the steering column for damage

Special tools and workshop equipment required


t
Locking pin -T10060AVisual inspection

Check the steering column for damage.


If any damage is visible, replace steering column completely.
Test condition
l Universal joint of steering column pulled off steering gear
Functional test
Check whether the steering column turns freely without jerking.
Check whether the length and height of the steering column can be adjusted.
In the event of an accident so-called deformation elements may shift on the steering column.
They are located on the two top bolted connections of the steering column.
If there is any damage remove the steering column until dimension -a- can be checked.

Insert locating pin -T10060A-.


Inspect dimension -a- with a sliding caliper.
Dimension -a-: maximum 23 mm
If a fault is found during one of these inspections,
then the steering column must be replaced.
If this is the case replace the steering column

completely.

Removing and installing steering column


Note

New steering columns supplied as spare parts are secured for transport. This transport
security must be removed once the steering column has been installed.

The steering column is supplied as a spare part with ignition lock housing but without lock
cylinder and ignition starter switch.

t
t

The ignition lock housing can be modified.


Remove and install ignition lock housing Anchor.

t It can happen that on new steering columns, which are supplied as spare parts, the lock
528

cylinder and the ignition starter switch from the old steering column must be refitted or
must be obtained as a spare part and installed Electrical System; Rep. gr.94.
t

Repairing the steering column is not possible.

Replace the self-locking nuts and screws.

t
t

Welding and straightening of the steering components is not allowed.


Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

set clock,

initialise power windows on vehicles fitted with power windows BookletOctavia


Removing

Disconnect battery.

Put the wheels in straight-ahead position.

Release screws -2-.

Pull the footwell covering -1- out of the


holders.

Remove the airbag on the driver's side


Body Work; Rep. gr.69.

Remove steering wheel Body


Work; Rep. gr.69.

Unclip cover for fuse carrier.

529

Remove light switch -3- Electrical


System; Rep. gr.96.

Remove screws -5- for fuse carrier.

Screw out screws -1- and -2-.

Remove bottom part of dash panel -4-.

Unscrew screws -1-, -2-, -3- and -4-.

Remove the top and bottom part of the


steering column trim panel.

530

The figure shows the coil spring -4- on a


vehicle without Electronic Stability Program
(ESP).

Secure the coil spring -4- against


unintentional turning by covering it with
adhesive tape -3-.
Unplug connector -1-.
Carefully remove all the plug connections
from the steering column switch -2-.

-Arrows- Catch hook of coil spring -4Note

The following working step is only


t required when replacing the coil spring or
the steering column switch.
The coil spring must be removed and
t installed when it is in the centre position
(wheel in straightahead position).
t

The coil spring is secured as a spare part


in the centre position with a cable strap.

Release catch hook -arrows- and remove


coil spring -4- from steering column
switch -2-.
Note

If the coil spring remains on the steering


column switch, ensure that the coil spring
does not turn out of the centre position
when placing down the steering column
switch.
Vehicles with ESP
Vehicles with ESP are additionally fitted
with the steering angle sender -G85-. It is
fitted together with the coil spring in the
housing.
The description of the basis, construction
and function of the ESP can be found in
self-study programme No. 28.
- Check whether the front wheels are in the
straight-ahead position.
531

If necessary, fit on the steering wheel


and put the front wheels in a straight
ahead position.
Remove steering wheel.
Note

The following two work steps must only be


performed when reinstalling at a later
stage the same housing with a coil spring.

Position the steering angle sender in the


centre position:

A yellow dot must be visible in the window


-1-.
The markings -arrows- must be flush.

Secure the coil spring -2- against


unintentional turning by covering it with
adhesive tape -1-. -3- Housing

532

Disconnect plug -1- from housing.


Carefully release catch hooks -arrowsand remove housing -1- with steering
angle sender -G85- and coil spring.

Continued for all vehicles

Slacken the screw of the steering column


switch -arrow- until the steering column
switch can be slightly moved.
Remove steering column switch.

Disconnect plugs -1- and -2LHD vehicles

533

Unscrew plastic nuts -1- and remove


cover -A-.

RHD vehicles

Unscrew plastic screw -1-, remove plastic


bushing, screw out plastic nut -2- and
remove cover -A-.

Continued for all vehicles

Release screw -1-.

02.97 if a clamping ring is installed.


Slacken the Allan screw of the clamping
ring -2- so far until the universal joint can
be removed from the steering gear
pinion.

Remove the universal joint from the


steering gear pinion -arrow-.
Note

An assembly securing device is required


to prevent the lower and the upper part
t
of the steering column from separating
during removal of the steering gear.
t If the upper and the lower parts of the
steering column are separated too widely
534

or are pushed into one another then the


gearing system will become separated.
This could cause rattling noises during
operation at a later stage if the gear
teeth are no longer in their original
installed position.

Secure the steering column before


removal.

Push together or pull apart the steering


column until the hole is visible.

For example, fit a clip into the hole


-arrow- in order to secure the position.

LHD vehicles

Unscrew the self-locking nut -1- at the


central pipe and pull out the screw -2-.

RHD vehicles

535

Release the self-locking nut -2- and pull


out the screw -1-.

Continued for all vehicles

Release screws -arrows-.

Remove steering column.


Note

New steering columns are generally


supplied with ignition lock housings.

Ignition lock housings are supplied


individually as a spare part.

Replace ignition lock housing

Remove ignition lock housing Electrical


System; Rep. gr.94.
Bore out pull-off screws -arrows-.

Tighten pull-off screws -arrows- until the


head shears off.

Install ignition lock housing Electrical


system; Rep. gr.94.

Install
Note

New steering columns supplied as spare


parts are secured for transport.

This transport security must be removed


t once the steering column has been
installed.
t It can happen that on new steering
columns, which are supplied as spare
536

parts, a new bushing and pull-off screw


must be fitted before installing the
steering column.
The pull-off screws and the bushing must
t be replaced after each disassembly of the
bushing.

Insert new bushing -1- and install pull-off


screw -2-.

Tighten pull-off screw -2- until the head


shears off.

LHD vehicles

Position steering column to central pipe.


Screw in screws -3-, but do not tighten.

Insert new screw -2-.


Screw on new self-locking nut -1- and
tighten to 10 Nm.

RHD vehicles

537

Position steering column to central pipe.


Screw in screws -3-, but do not tighten.

Insert new screw -1-.


Screw on new self-locking nut -2- and
tighten to 10 Nm.

Continued for all vehicles

Tighten screw -3- to 22 Nm.


Pull out transport security -arrow-.

Slide the universal joint onto the steering


pinion and tighten with new screw -1-.

02.97 if a clamping ring is installed.

Tighten the Allan screw of the clamping


ring -2- to 17 Nm.
Fit cover for universal joint.

Mount plug for ignition starter lock and


immobiliser.

Slide the steering column switch onto the


steering column.

Vehicles without ESP

Slide the coil spring onto the steering


column and lock into position with the
steering column switch.

Vehicles with ESP

538

Slide housing -1- with steering angle


sender -G85- and coil spring onto the
steering column and lock into position
with steering column switch -arrows-.

Mount plug at housing -1-.


Note

After removing the transport protection or


the adhesive tape do not turn the coil
spring, only the positioning of the steering
angle sender -G85- in centre position is
allowed.

After installing a housing -1- remove


transport protection -2-.

After installing a used housing -3remove adhesive tape -1-.

-2- Coil spring

539

Position the steering angle sender -G85in the centre position:

A yellow dot must be visible in the window


-1-.
Markings -arrows- must be flush with each
other.
Make sure this correct position is
maintained.
The further work procedure is now valid
again for all vehicles.

Fit the steering wheel onto the steering


column and screw in the old internal
serration screw and tighten.
Note

The fig. shows the steering column switch


t with coil spring -2- and steering wheel -1on a vehicle without ESP.
On vehicles with ESP, the dimension a
between the coil spring integrated in the
t
housing and the steering wheel is also 3
mm.
Align the steering column switch so that it
is horizontal and set dimension a,
subsequently tighten the clamping screw
-3-.

Demount the steering wheel again.

540

Mount plug -1-.


Fit together the plug connections on the
steering column switch.
Note

After removing the adhesive tape -3-, do


not turn the coil spring out of its centre
position.
Carefully remove the adhesive tape -3-.

Installing the trim panel for steering


column switch Body Work; Rep. gr.70.

Installing the lower part of the dash


panel Body Work; Rep. gr.70.

Install footwell covering on driver's side


Body Work; Rep. gr.68.

Install steering wheel Body work; Rep.


gr.69.

Install the airbag on the driver's side


Body Work; Rep. gr.69.
WARNING

Nobody should be in the vehicle when the


battery is being connected!

Connect battery Electrical


System; Rep. gr.27.

Vehicles without ESP:


Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Vehicles with ESP:

Perform the basic setting of the steering


angle sender Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Removing and installing the ignition lock housing with the steering column mounted

541

Note

Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.

After connecting the battery, perform the following:

on vehicles with radio encoding, carry out the coding,

re-set clock

initialise power windows on vehicles fitted with power windows BookletOctavia


Removing

Remove steering wheel Body Work; Rep. gr.69.


Remove bottom part of dash panel Body Work; Rep. gr.70.
Removing trim panel for steering column switch Body Work; Rep. gr.70.

Disconnect plug -1- for ignition starter


lock and plug -2- for immobiliser.

Removing lock cylinder and ignition


starter switch Electrical System; Rep.
gr.94.

Removing steering-column control


Electrical System; Rep. gr.94

Removing dash panel insert Electrical


System; Rep. gr.90.

Bore out pull-off screws -arrows- and take


out ignition lock housing.

Install

Insert the ignition lock housing and


tighten with new pull-off screws.

Tighten pull-off screws until the head


shears off.

Installing lock cylinder and ignition


starter switch Electrical System; Rep.
gr.94

Installing dash panel insert Electrical


System; Rep. gr.90

Mount plug for ignition starter lock and


542

immobiliser.

Align the steering column switch to the


steering column and tighten Chapter.
Install the trim panel for steering column
switch and the bottom part of the dash
panel Body Work; Rep. gr.70

Install the steering wheel and the airbag


on the driver's side Body Work; Rep.
gr.69
WARNING

Nobody should be in the vehicle when the


battery is being connected!

Connect battery Electrical


System; Rep. gr.27.

Vehicles without ESP


Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

Vehicles with ESP

Perform the basic setting of the steering


angle sender -G85- Chapter.

Interrogate the fault memory Chapter.

Erasing fault memory Chapter.

543

Summary of components of power-steering gear - LHD vehicles


Note

If the front axle is damaged as a result of an accident certain steering components must be
replaced Chapter.

No provision is made for repairing on the power-steering gear. If there are any complaints
about the steering gear, replace it.

t
t
t
t
t

Replace the self-locking nuts and screws.


Welding and straightening of the steering components is not allowed.
Only use semi-fluid gear lubricant AOF 063 000 04 to grease the gear rack (filling capacity
23 to 27 g).
Oil type: hydraulic oil -G 002 000Oil quantity in the system: 0.7 ... 0.9 Itr.

544

1t

Heat shield
centre with mounting bracket on the power-steering gear

2-

Nut, 23 Nm

3-

Bearing bracket

only on gearbox 02K

4-

23 Nm

5-

Steering column universal joint

6-

20 Nm + 90

replace after each removal

7-

Sealing sleeve

Pay attention to installation instructions Anchor

8t
t

Return-flow line
from the power-steering gear to the reservoir for central hydraulic oil
the distance to the power-steering gear must be 10 mm

9t
10 t
11 t
12 t
13 14 15 t
16 t
17 t
18 -

Gasket rings
replace after each removal
Hollow screw, 45 Nm
M16 x 1.5
Hollow screw, 38 Nm
M14 x 1.5
Pressure line (expansion hose)
from the vane pump to the power-steering gear
Counternut, 50 Nm
Steering-knuckle arm of the wheel-bearing housing
Self-locking nut, 50 Nm
replace after each removal
100 Nm + 90
replace after each removal
100 Nm + 90
replace after each removal
20 Nm + 90
545

replace after each removal

19 -

Pendulum support

20 t

40 Nm + 90
replace after each removal

21 t

20 Nm + 90
replace after each removal

22 t

20 Nm + 90
replace after each removal

23 -

Assembly carrier

24 -

Retaining clip

25 -

Nut, 23 Nm

26 -

Clamp with rubber insert

Fitting position:
t

Arrow on the clamp points in the direction of travel

replace the clamp if the thread of the weld nut is damaged

27 t
t

Power-steering gear
adjust Chapter
removing and installing Chapter

Removing and installing hydraulic oil reservoir


Special tools and workshop equipment required
t

Pliers for spring strap clamps

t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-

546

1t
t
2t
t
3t
t
4t
t
5-

Reservoir with screw cap and oil dipstick


Tighten screw cap to 2 Nm
Check the level of hydraulic oil, top up if necessary Chapter
Return-flow line
The longitudinal markings -A- must be flush
Fit the spring strap clamp onto the hose as far as the lateral marking -BSpring strap clamp
to open and close use pliers for spring strap clamps
The tensioning eyes must face to the top
Suction line
The longitudinal markings -A- must be flush
Fit the spring strap clamp onto the hose as far as the lateral marking -B10 Nm

Removing and installing the power-steering gear - LHD vehicles


Special tools and workshop equipment required
547

t
t
t

Hose clamp -MP 7-602Pliers for spring strap clamps


Extractor Matra -V 176-

Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2-

Plug for hydraulic oil reservoir (commercially available)

Plastic screw plugs for line connections on the power-assisted steering gear (commercially
available)

t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Note

t
t

Apart from replacing the bellows and the track rods, no provision is made for further
repairs.
Absolute cleanliness is required when working on the power steering.

t Thoroughly clean the connection points and their surroundings before releasing.
t
t
t
t
t

Place removed parts on a clean surface and cover if the repair cannot be carried out
immediately.
Do not use fluffy cloths.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
Do not use drained hydraulic oil again.

Replace gasket rings.

Disposal Chapter.

Removing

548

Unscrew plastic nuts -1- and remove


cover -A-.

Release screw -1-.


WARNING

Bring the steering wheel in its central


position (with the wheels straight ahead)
and make sure that it does not turn during
repairs as this could damage the coil
spring of the airbag unit.
02.97 if a clamping ring is installed.
Slacken the Allan screw of the clamping
ring -2- so far until the universal joint can
be removed from the steering gear
pinion.

Remove the universal joint from the


steering gear pinion -arrow-.

Pinch off the suction line -1- (hydraulic oil


reservoir/vane pump) with the hose
clamp -MP 7-602- near the vane pump.

The fig. shows the line routing and how to


pinch off the line on the 1.9 ltr./66 kW TDI
engine. For the other engine versions, the
suction line routing is modified. The suction
line must, however, be pinched off near the
vane pump.

549

Open spring strap clamps -arrow- with


pliers for spring strap clamps.

Release the return-flow line from the


hydraulic oil reservoir and allow the
hydraulic oil to flow out into a suitable
vessel.

Close the return-flow opening at the


hydraulic oil reservoir with a plug.

Remove noise insulation panel in the


middle as well as on left and right
-arrows-.
The fig. shows the noise insulation on
vehicles with 1.9 ltr./66 kW TDI and 1.9
ltr./50 kW SDI engines. The noise
insulations of the other engine versions
differ from the fig.

550

Press the track rods off the steering arm


using the extractor Matra -176-.
Note

Screw down the hexagon nut -1sufficiently until the track rod extractor
cannot damage the thread.

Use a pan to collect the drained off


hydraulic oil.

Unscrew the pressure line -2- (expansion


hose) from the power-steering gear and
close with a plastic bag and adhesive
tape.
Shut off the threaded bore for the
pressure line connection -2- at the powersteering gear (e.g. with a plastic screw
plug).
The return line -1- can only be screwed off
the power-steering gear once the assembly
carrier has been lowered.

Slacken the pendulum support on the


gearbox side. To do so, release hexagonal
screws -1- and -2-.

551

Unscrew screws for mounting bracket


-arrows-.
Note

Only on gearbox 02K.

Position gearbox jack with adapter, e.g.


-V.A.G 1383A- with -V.A.G 1359/2-.

Release screws -1- for power-steering


gear.

Release screws -2- and -3- for assembly


carrier.

Lower assembly carrier.

Unscrew return line from clamp -1- and


rotary slide valve housing -2-.

Shut off the return line with a plastic bag


and adhesive tape.

Shut off the threaded bore for the return


line connection at the rotary slide valve
housing -2- (e.g. with a plastic screw
plug).

Unscrew fixing screws for power-steering


gear and remove power-steering gear
towards the rear.

Install
WARNING

After the installation of the power-steering


552

gear, the vehicle must be aligned.


Note

When tightening the lines, ensure that


the lines cannot touch or chafe.

Use new gasket rings for the hose/line


connections.

Coat the sealing sleeve on the steering


t gear with lubricant, e.g. lubricating soap,
before installing the steering gear.
After positioning the steering gear on the
drive shaft make sure that the sealing
sleeve on the steering gear is not bent on
t the assembly plate and it correctly seals
the footwell opening. Otherwise this
could cause water penetration and/or
noise.
t Make sure all sealing surfaces are clean.
t Required tightening torques Chapter.
Before fitting the power-steering gear
t check the centre position of the gear rack
Anchor.
Check the centre position of the power steering gear, if necessary adjust
Anchor.

553

Insert the power-steering gear with the


guide bushing -1- into the assembly
carrier and screw in the screws by hand.

Secure the return line -1- with the


retaining clip -3- and the hexagon nut -2to the clamp with rubber insert -4-.
Note

A distance of 10 mm must be maintained


between the return line -1- and the powersteering gear -5--arrow-.

Secure the return line with new gasket


rings to the rotary slide valve housing.

Check the sealing sleeve at the steering


gear pinion for correct fit.

Raise the assembly carrier and while


doing so, guide the steering gear pinion
into the opening on the base of the
vehicle.

First of all tighten the assembly carrier


with old screws and to the recommended
tightening torques.
Note

554

Within the scope of the chassis alignment,


the old screws for the assembly carrier
attachment must be replaced with new
screws.

Tighten screws for power-steering gear


on the assembly carrier.

Secure the pressure line with new gasket


rings to the rotary slide valve housing.

Screw on pendulum support and bracket


of exhaust system.

Screw on mounting bracket for shift


linkage (only on gearbox 02K).

Insert track rods into steering arm and


tighten. If the joint stub turns along when
tightening, counterhold using an Allen
key (SW 6 mm).

Mount return line to hydraulic oil


reservoir.

Remove the hose clamp from the suction


line.

Slide the universal joint onto the steering


pinion and tighten with new screw; 30
Nm.
02.97 if a clamping ring is installed.

Tighten the Allan screw of the clamping


ring to 17 Nm.
Fit cover for universal joint.

Top up with hydraulic oil Chapter.

Install noise insulation panel.

Align the vehicle Chapter.

Within the scope of the chassis


alignment, the old screws for the

assembly carrier attachment must be


replaced with new screws and tightened
to the specified tightening torque.

Repairing power-steering gear (ZF)


555

Special tools and workshop equipment required


t
t
t
t

Puller Kukko -V/176Caliper gauge


Clamp pliers for hose clamp, e.g. -V.A.G 1275Semi-fluid gear lubricant -TL733-, -NO 52733 00- e.g. -DEA ORNA F6 EPO (AOF 063 000
04)Note

Always replace the steering components -Pos. 1- up to -Pos. 9- after an accident or in the
event of damage to the front axle.

No provision is made for repairing on the power-steering gear. The cause of any problems
t which may arise is determined by the pressure test and tightness test. If there is a fault,
replace the power-steering gear.
t

Welding and straightening of the steering components is not allowed.

Replace the self-locking nuts and screws.

Only use original warm-type clamps.

Only use steering gear grease -AOF 063 000 04- in order to grease the gear rack (filling
capacity 23 ... 27 g).

556

1t

Right track rod end


press off the steering arm Chapter

check Anchor

removing and installing Anchor

Check fitting position

t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter


2-

Counternut, 50 Nm

3-

Open warm-type clamp

replace

removing - open with cutting pliers

tensioning Anchor

4-

Bellows

It is only possible to change the bellows on a removed steering gear

before removing boot detach the track-rod end Chapter

inspect for wear (cuts, splits), inspect sealing surfaces and sealing lips for cleanliness or
damage

5t
t
t
6t

Open warm-type clamp


replace
removing - open with cutting pliers
tensioning Anchor
Track rod
Tightening torque on steering rack: 75 Nm

left and right track rod adjustable

removing and installing Anchor

t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter


7-

Clamp with rubber insert

8-

Power-steering gear

t
t
t
t
9-

no provision made for repairs


removing and installing Chapter
adjust Chapter
Inspecting centre position Anchor
Left track rod end
557

press off the steering arm Chapter

t
t

check Anchor
removing and installing Anchor

Check fitting position

t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter

Inspecting play, attachment and boots of track rod ends

On a raised vehicle (wheels clear of the ground) inspect play by moving the track rods and
the wheels, specified value play: no play

Inspect attachment.
Inspect boots for damage and correct installation.

Remove and install track rod ends


Removing

Press the track rod off the steering arm Chapter.

Slacken the hexagon nut -2- and release


the track rod end -3- from the track rod
-1-.
Install
Note

Track rod ends and track rods modified as


t of vehicle identification number
TMBZZZ1U12W2074066 Chapter.
A mixed assembly of previous and
t modified track rod ends or track rods is
not permissible Chapter.
t

The track rod ends must not be fitted


laterally reversed.

558

When fitting, pay attention to the


marking of the track rod end:

I - Left track rod end -LII - Right track rod end -Rt

Pay attention to the new marking on


modified track rod ends Chapter.

Turn the track rod end up to the stop on


the track rod and align it in such a way
that the stud of the track rod end is in the
installation position.

Tighten counternut to 50 Nm.

Insert the track rod into the steering arm


and tighten the self-locking hexagon nut

to 45 Nm. If the joint stub turns along


when tightening, counterhold using an
Allen key (SW 6 mm).

Check the toe-in of the front axle and the


position of the steering wheel, if
necessary adjust.

Removing and installing track rods


Note

The track rods can only be removed and


installed if the steering gear is removed.
Removing

Clean outside of power steering gear in


the area of the boot.

Open the warm-type clamp and push


back the bellows.

559

Release the track rod from the gear rack.


To do so, use torque wrench with open jawed wrench insert SW 34, e.g. -V.A.G
1332- with -V.A.G 1332/5-. In order to
release, it is necessary to counterhold
with an open-end wrench (SW 21).
Install
Note

Track rod ends and track rods modified as


t of vehicle identification number
TMBZZZ1 Ul2W2074066 Chapter.
A mixed assembly of previous and
t modified track rod ends or track rods is
not permissible Chapter.
In any case, both track rods must be
t replaced when changing the track rods
Chapter.
Turn the track rod on the gear rack and
tighten to 75 Nm. To do so, use torque
wrench with open-jawed wrench insert

SW 34, e.g. -V.A.G 1332- with -V.A.G


1332/5-. In order to tighten, it is
necessary to counterhold with an openend wrench (SW 21).
Note

Align track rod in such a way that the stud


of the track rod end is in the installation
position.

Check the centre position of the powersteering gear Anchor.


Install bellows Anchor.

Check the centre position of the gear rack


of the power-steering gear, if necessary
adjust
Note

Before installing the power-steering gear


place the gear rack in centre position.

t The dimension -a- must be the same on


560

the right and left side of the powersteering gear. If the dimension on the two
sides is not the same, distance -a- must
be corrected.

Check dimension -a-, if necessary adjust.


-a- = 30.5 mm
Install bellows
Inspect boot for wear (cuts, splits) and
inspect sealing surfaces for boot
cleanliness.
Note

Twisted bellows wear fast. Replace bellows


if damaged

Tighten the warm-type clamp using the


hose binding claw, e.g. -V.A.G 1275-.

561

Modified track rod ends


The manufacturing process for the track rod ends was optimized. The outer shape and length
of the thread stem do not change through this.
The track rods must be adapted according to the modified track rod ends Chapter.
Installed as of:
Vehicle identification number TMBZZZ1U2W2074066
Distinguishing features of the previous
track rod ends
Wrench contact area on the shank, with
1 marking R or L wrench size 22 mm
- dimension -a- = 74 -1 mm. The shank
-arrow- is round.
WARNING

These track rod ends must not be installed


on track rods which have the dimension
length -a- Chapter.

562

Distinguishing features of the modified


track rod ends
A - Right track rod end
Hexagon on thread stem, wrench size
1 - 19 mm dimension -a- = 94 + 0.5 mm
marking A for the right
B - Left track rod end
Hexagon on thread stem, wrench size
1 - 19 mm dimension -a- = 94 + 0.5 mm
marking B for the left
WARNING

These track rod ends must not be installed


on track rods which have the dimension
length -a- Chapter.

Modified track rods

The track rods were adapted because of the modified track rod ends.
The track rods were shortened in comparison with the previous version.
Installed as of:
Vehicle identification number TMBZZZ1U2W2074066
Distinguishing feature of the previous track rod
Dimension -a- = 343,1 mm
Distinguishing feature of the modified track rod
Dimension -a- = 318,9 mm
WARNING
A mixed assembly of previous and modified track
rods is not permissible. In any case, both track
rods must be replaced. In addition, the modified
track rods must not be fitted with the previous
track rod ends.

Disposing of the power-steering gear


563

Special tools and workshop equipment required


t
Catch pan for hydraulic oil
Note
t
t
t
t
t

The oils used in the power-steering gears do not contain any harmful substances. These oils may be
disposed of together with the drained engine and gearbox oil.
Dispose of used oils in compliance with the applicable environmental regulations.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral hydraulic
oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or
thinners, chemicals etc.
After "draining" the used parts must be allowed to drip adequately.
When disposing of used parts comply with the legal specifications as there are minor residual amounts of
hydraulic oil in the power-steering gears.

Loosen the pipes -arrows A- by removing the


clips from the power-steering gear. The clips
must not be re-used.
Hold the power-steering gear over a catch pan
and repeatedly turn the steering pinion from

stop to stop until no more hydraulic oil runs out


of the bores. Do not shut off the bores -arrows
B-.
Disposing of the power-steering gear.

Adjusting the power-steering gear (ZF)

Note
Two mechanics are required for this adjustment. The adjustment must be done when the engine is not
running.

Raise vehicle with lift platform.


l
Wheels in a straight ahead position.
Move the steering wheel alternately on the centre axle (approx. 30). If the steering clearance is too

great a rattling noise will be audible.

564

The second mechanic carefully turns the


adjusting screw (arrow) so far into the cover

until no more rattling noises are heard inside


the vehicle.
When performing a test drive, note that the
steering must automatically return to the

straight ahead position after a manoeuvre or


cornering without sticking. Correct the
adjustment if necessary.

Secure the adjusting nut against turning with a


punch mark in the collar of the steering gear
housing.

Check the hydraulic oil level of the power-assisted steering, top up if necessary
Special tools and workshop equipment required
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11S(G002 000)Note

Delivery inspection: oil level at MAX marking BookletOctavia

t Inspection service: oil level between MIN and MAX marking BookletOctavia
Hydraulic oil in a cold condition:

Do not start the engine and put the front wheels in a straight ahead position
Unscrew screw cap.
Wipe the oil dipstick with a clean cloth.
565

Tighten the cap by hand and unscrew again.

Only the oil level for a previously fully screwed in lid applies.

Check oil level: The oil level must be in


the area of the MIN marking (i.e. up to
2 mm above or below this marking).
Note

If the oil level is above the given range,


drain off some oil.

Check the hydraulic system for leaks if


the oil level is below the given range
t
Chapter. It is not enough to simply top
up the oil.
Screw in screw cap and tighten to 2 Nm.
Hydraulic oil at a normal operating
temperature (above approx. 50C):

Let the engine run at idling speed for


approx. 2 minutes with the front wheels
pointing straight ahead.
Unscrew screw cap.

Wipe the oil dipstick with a clean cloth.

Tighten the cap by hand and unscrew


again.

Only the oil level for a previously fully


screwed in lid applies.

Check oil level: The oil level must be


between the MIN and MAX markings.
Note

If the oil level is above the given range,


drain off some oil.

Check the hydraulic system for leaks if


the oil level is below the given range
t
Chapter. It is not enough to simply top
up the oil.
Screw in screw cap and tighten to 2 Nm.

566

Draining, filling and bleeding the power-assisted steering system


Special tools and workshop equipment required
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11S(G002 000)Draining

Do not let the engine run and raise the vehicle until the front wheels are fully off the
ground.
Place the catch pan for hydraulic oil underneath.
Open the hydraulic system on the suction side and return flow side and drain the
hydraulic oil.

Press out the residual hydraulic oil by turning the steering repeatedly from stop to stop.

Lower vehicle and re-connect hydraulic lines.


Note

Do not use drained hydraulic oil again.

t Dispose of hydraulic oil in compliance with the applicable environmental regulations.


Filling and bleeding
Note

t
t
t

Only fill an empty hydraulic system when the engine is cold.


Hydraulic oil -G 002 000-.
Hydraulic oil amount in the system: 0.7 ... 0,91.
Top up hydraulic system Chapter.
If the hydraulic system is empty, fill up
the hydraulic oil reservoir until the MAX
marking on the oil dipstick is reached.
Raise the vehicle until the front wheels
are fully off the ground, put the front
wheels in a straight ahead position.

With the engine off, turn the steering


wheel 10 x from stop to stop.

Check the hydraulic oil level, top up if


necessary Chapter.

Lower the vehicle.

Start engine and run for approx. 5


seconds, the vane pump suctions
567

hydraulic oil.

Switch off engine.


Check the hydraulic oil level, top up if
necessary Chapter.
Start engine.
Turn steering wheel 10 x from stop to
stop.

Therefore, ask a 2nd mechanic to


observe the hydraulic oil level in the
reservoir and if necessary top up with
hydraulic oil so that no air can be sucked

in. If no air bubbles in the reservoir


escape out of the return line, the
hydraulic system is bled. If air bubbles
escape repeatedly, the bleeding
procedure must be repeated.

Switch off engine.


Check the hydraulic oil level, top up if
necessary Chapter.

Any residual air in the steering system will


automatically escape while driving for
approximately 10 to 20 km.

Checking the power steering system for leaks


Note

If metal swarf is found in the hydraulic oil and/or in the reservoir, the reservoir as well as
the suction and pressure lines must be cleaned very carefully and if necessary replaced.

Check the power steering system for tightness after assembly work and in the event of
hydraulic oil loss in the reservoir.

Start engine.

Turn the steering wheel in both directions up to the end stop and hold for a short while.
This will build up the highest possible pressure.

Check all line and hose connections for correct position and tightness.
In the event of leaks tighten the line or hose connections to the allowed tightening torques
or replace the seal or line.

Check hoses and lines for leaktightness. If there are leaks replace the relevant hose or
568

line.

Check vane pump for tightness. If there are leaks, replace the vane pump.

Check the hydraulic oil reservoir for tightness. If there are leaks, replace the reservoir.

Check the level of hydraulic oil, if necessary top up with oil Chapter.
Note

If there is a repeated loss of hydraulic oil from the reservoir and if the hoses and lines as well
as their connections, the vane pump and the reservoir have been thoroughly inspected
repeatedly, remove and inspect the power-assisted steering gear.

Removing the power-assisted steering gear Chapter.


Check the gasket ring for steering pinion
on the valve housing of the powerassisted steering gear -arrow A- for leaks.

Open warm-type clamp of boot and push


back boot.

Check gear rack gasket rings -arrow Bfor leaks.

If hydraulic oil is visible in the steering gear


housing and/or in the boot, replace the
power steering gear.

Installing the power-assisted steering


drive Chapter.
Note

If there is no more hydraulic oil in the


reservoir, the vane pump may have run
dry and may have been damaged.

Replace vane pump Chapter.

569

570

Power steering noises


A closed hydraulic system will always produce running noise.
When the vehicle is stationary with engine running, hissing noises always occur if the steering
wheel is slowly turned or the steering is turned up to the end stops (this must only occur
briefly!).
The increased pumping noise in the steering end stops (during parking manoeuvers) is
system related and technically unavoidable.
For noises that differ from the usual technically unavoidable operating noises take the
following measures:

Check the hydraulic oil level in the reservoir Chapter.

Check the feed pressure of the vane pump Chapter.

Check the connections for leaks (air in the system).

Check V-belt tension.


Check routing of the suction and pressure lines (lines pinched or in contact with other
vehicle parts).

Check the steering gear mounting on the assembly carrier.

Check the screw connection of the vane pump at the bracket/engine.

Check the screw connection of the belt pulley.


Note

In order to determine if the noises come from the power-assisted steering system, it is
recommended to remove the V-ribbed belt of the vane pump and run the engine without vane
pump.

Summary of components of power-steering gear - RHD vehicles


Note

If the front axle is damaged as a result of an accident certain steering components must be
replaced Chapter.

No provision is made for repairing on the power-steering gear. If there are any complaints
about the steering gear, replace it.

t
t

Replace the self-locking nuts and screws.


Welding and straightening of the steering components is not allowed.

t Only use semi-fluid gear lubricant AOF 063 000 04 to grease the gear rack (filling capacity
571

23 to 27 g).
t
t

1-

Oil type: hydraulic oil -G 002 000Oil quantity in the system: 0.7 ... 0.9 Itr.

Heat shield
572

2-

Nut, 23 Nm

3-

23 Nm

4-

Pressure line (expansion hose)

from the vane pump to the power-steering gear

5-

Gasket rings

replace after each removal

6-

Hollow screw, 38 Nm

M14 x 1.5

7-

Nut, 23 Nm

8-

Clamp with rubber insert

Fitting position:
t

Arrow on the clamp points in the direction of travel

replace the clamp if the thread of the weld nut is damaged

9t
t
10 11 t
12 t
13 t
14 t
15 16 t
17 t

Power-steering gear
adjust Chapter
removing and installing Chapter
Assembly carrier
20 Nm + 90
replace after each removal
20 Nm + 90
replace after each removal
20 Nm + 90
replace after each removal
40 Nm + 90
replace after each removal
Pendulum support
20 Nm + 90
replace after each removal
100 Nm + 90
replace after each removal
573

18 t

100 Nm + 90
replace after each removal

19 t

Self-locking nut, 50 Nm
replace after each removal

20 -

Steering-knuckle arm of the wheel-bearing housing

21 -

Counternut, 50 Nm

22 -

Pressure line

23 -

Hollow screw, 38 Nm

M14 x 1.5

24 t

M16 x 1.5

25 t

Return-flow line

from the power-steering gear to the reservoir for central hydraulic oil

27 t

Gasket rings
replace after each removal

26 t

Hollow screw, 45 Nm

Sealing sleeve

Pay attention to installation instructions Chapter

28 t
29 -

20 Nm + 90
replace after each removal
Steering column universal joint

Removing and installing hydraulic oil reservoir


Special tools and workshop equipment required
t

Pliers for spring strap clamps

t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-

574

1t
t
2t
t
3t
t
4t
t
5-

Reservoir with screw cap and oil dipstick


Tighten screw cap to 2 Nm
Check the level of hydraulic oil, top up if necessary Chapter
Return-flow line
The longitudinal markings -A- must be flush
Fit the spring strap clamp onto the hose as far as the lateral marking -BSpring strap clamp
to open and close use pliers for spring strap clamps
The tensioning eyes must face to the top
Suction line
The longitudinal markings -A- must be flush
Fit the spring strap clamp onto the hose as far as the lateral marking -B10 Nm

Removing and installing the power-assisted steering gear - RHD vehicles


Special tools and workshop equipment required
575

t
t
t

Hose clamp -MP 7-602Pliers for spring strap clamps


Extractor Matra -V 176-

Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2-

Plug for hydraulic oil reservoir (commercially available)

Plastic screw plugs for line connections on the power-assisted steering gear (commercially
available)

t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Note

t
t

Apart from replacing the bellows and the track rods, no provision is made for further
repairs.
Absolute cleanliness is required when working on the power steering.

t Thoroughly clean the connection points and their surroundings before releasing.
t
t
t
t
t

Place removed parts on a clean surface and cover if the repair cannot be carried out
immediately.
Do not use fluffy cloths.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
Do not use drained hydraulic oil again.

Replace gasket rings.

Disposal Chapter.

Removing

576

Unscrew the plastic nuts -2- and the


plastic screw with clamp -1- and remove
the cover -A-.

Release screw -1-.


WARNING

Bring the steering wheel in its central


position (with the wheels straight ahead)
and make sure that it does not turn during
repairs as this could damage the coil
spring of the airbag unit.

Remove the universal joint from the


steering gear pinion -arrow-.

Pinch off the suction line -1- (hydraulic oil


reservoir/vane pump) with the hose
clamp -MP 7-602- near the vane pump.

The fig. shows the line routing and how to


pinch off the line on the 1.9 ltr./66 kW TDI
engine. For the other engine versions, the
suction line routing is modified. The suction
line must, however, be pinched off near the
vane pump.

577

Open spring strap clamps -arrow- with


pliers for spring strap clamps.

Release the return-flow line from the


hydraulic oil reservoir and allow the
hydraulic oil to flow out into a suitable
vessel.

Close the return-flow opening at the


hydraulic oil reservoir with a plug.

Remove noise insulation panel in the


middle as well as on left and right
-arrows-.
The fig. shows the noise insulation on
vehicles with 1.9 ltr./66 kW TDI and 1.9
ltr./50 kW SDI engines. The noise
insulations of the other engine versions
differ from the fig.

578

Press the track rods off the steering arm


using the extractor Matra -176-.
Note

Screw down the hexagon nut -1sufficiently until the track rod extractor
cannot damage the thread.

Use a pan to collect the drained off


hydraulic oil.

Loosen the screws -6- of the bracket for


the exhaust pipe.
Note

Before slackening the screws -3- and -4- for


the assembly carrier, mark the fitting
position of the assembly carrier.

Slacken the pendulum support on the


gearbox side. To do so, release hexagonal
screws -1- and -2-.

579

Position gearbox jack with adapter, e.g.


-V.A.G 1383A- with -V.A.G 1359/2-.

Release screws -1- for power-steering


gear.

Unscrew screws -2- and -3- for assembly


carrier.

Lower assembly carrier.

Unscrew the pressure line -1- (expansion


hose) from the power-steering gear and
close with a plastic bag and adhesive
tape.

Shut off the threaded bore for the


pressure line connection -1- (e.g. with a
plastic screw plug).

The return line -2- can only be screwed off


the power-steering gear once the assembly
carrier has been lowered.
Unscrew the return line -2- (expansion
hose) from the power-steering gear and
close with a plastic bag and adhesive
tape.

Shut off the threaded bore for the return


line connection -2- (e.g. with a plastic
screw plug).
Unscrew fixing screws for power-steering
gear and remove power-steering gear
towards the rear.

Install

580

The threaded bush -1- must fit in the hole


of the assembly carrier.

Further installation occurs in reverse


order.
WARNING

After the installation of the power-steering


gear, the vehicle must be aligned.
Note

When tightening the lines, ensure that


the lines cannot touch or chafe.

Use new gasket rings for the hose/line


connections.

Coat the sealing sleeve on the steering


t gear with lubricant, e.g. lubricating soap,
before installing the steering gear.
After positioning the steering gear on the
drive shaft make sure that the sealing
sleeve on the steering gear is not bent on
t the assembly plate and it correctly seals
the footwell opening. Otherwise this
could cause water penetration and/or
noise.
t Make sure all sealing surfaces are clean.
t

Required tightening torques see


Chapter and following.

Before fitting the power-steering gear


t check the centre position of the gear rack
Anchor.
Check the centre position of the power steering gear, if necessary adjust
Anchor.

Tighten the return line as well as the


pressure line with new gasket rings at the
steering gear housing.
Check the sealing sleeve at the steering
gear pinion for correct fit.

Raise the assembly carrier and while


doing so, guide the steering gear pinion
into the opening on the base of the
581

vehicle.

First of all tighten the assembly carrier


with old screws and to the recommended
tightening torques.
Note

Within the scope of the chassis alignment,


the old screws for the assembly carrier
attachment must be replaced with new
screws.

Tighten screws for power-steering gear


on the assembly carrier.

Secure the pressure line with new gasket


rings to the rotary slide valve housing.

Screw on the pendulum support.

Install the bracket for the exhaust pipe.

Mount return line to hydraulic oil


reservoir.

Remove the hose clamp from the suction


line.

Slide the universal joint onto the steering


pinion and tighten with new screw; 30
Nm.

Fit cover for universal joint.

Top up with hydraulic oil Chapter.

Install noise insulation panel.

Align the vehicle Chapter.

Within the scope of the chassis


alignment, the old screws for the

assembly carrier attachment must be


replaced with new screws and tightened
to the specified tightening torque.

Repairing power-steering gear (ZF) - RHD vehicles


Special tools and workshop equipment required
t

Puller Kukko -V/176582

Open-jawed wrench insert, e.g. -V.A.G 1332/5-

Caliper gauge

t
t

Clamp pliers for hose clamp, e.g. -V.A.G 1275Semi-fluid gear lubricant -TL733-, -NO 52733 00- e.g. -DEA ORNA F6 EPO (AOF 063 000
04)Note

Always replace the steering components -Pos. 1- up to -Pos. 9- after an accident or in the
event of damage to the front axle.

No provision is made for repairing on the power-steering gear. The cause of any problems
t which may arise is determined by the pressure test and tightness test. If there is a fault,
replace the power-steering gear.
t

Welding and straightening of the steering components is not allowed.

Replace the self-locking nuts and screws.

Only use original warm-type clamps.

Only use steering gear grease -AOF 063 000 04- in order to grease the gear rack (filling
capacity 23 ... 27 g).

1t

Right track rod end


press off the steering arm Chapter
583

check Anchor

removing and installing Anchor

Check fitting position

t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter


2-

Counternut, 50 Nm

3-

Open warm-type clamp

replace

removing - open with cutting pliers

tensioning Anchor

4-

Bellows

t It is only possible to change the bellows on a removed power steering gear


t
t

before removing boot detach the track-rod end Anchor


inspect for wear (cuts, splits), inspect sealing surfaces and sealing lips for cleanliness or
damage

5t
t
t
6t

Open warm-type clamp


replace
removing - open with cutting pliers
tensioning Anchor
Track rod
Tightening torque on steering rack: 75 Nm

left and right track rod adjustable

removing and installing Anchor

t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter


7t
t
t
t

Power-steering gear
no provision made for repairs
removing and installing Chapter
adjust Chapter
Inspecting centre position Anchor

8-

Clamp with rubber insert

9-

Left track rod end

press off the steering arm Chapter


584

t
t
t

check Anchor
removing and installing Anchor
Check fitting position

t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter

585

Summary of components: Vane pump for power-assisted steering


Summary of components for the vane pump located at the top and bottom
Note

The figure shows a version with the vane pump located at the bottom.

For a vane pump located at the top, the same tightening torques are valid for the fixing
t screws of the vane pump as well as for the hollow screw in order to connect the pressure
line to the vane pump.

1t
t
t
23t
4-

V-ribbed belt
before removing mark running direction
Assignment BookletOctavia
removing and installing Engine, Mechanics; Rep. gr.13
10 Nm + 90
Vibration damper
with the belt pulley for the V-ribbed belt
25 Nm

5-

Tensioning element

6-

Generator
586

7t

Support
The fig. shows a bracket for vehicles not fitted with air conditioning

install free of stress -Pos. 8

8t

45 Nm
for securing the bracket -Pos. 7- at the engine block

install Engine, Mechanics; Rep. gr.13

9-

25 Nm

10 -

Hollow screw, 38 Nm

11 -

Sealing ring

replace

12 -

Pressure line

13 -

Sealing ring

replace

14 t

Vane pump
for power-assisted steering

Check feed pressure Chapter

fill up with hydraulic oil before fitting Chapter

removing and installing Chapter

15 -

25 Nm

16 -

Belt pulley
Note

t
t

for vane pump for vehicles fitted with a 1.4/44 kW engine:


Before removing, the front side of the belt pulley must be marked. The belt pulley must not
be fitted with the front side to the vane pump.

17 -

Allan screw, 25 Nm

18 -

25 Nm

PAS pressure switch

587

Note

The pressure switch screwed into the vane pump is used for the idling speed stabilisation of
the engine while moving the steering wheel when the vehicle is standing still.

1-

Vane pump

2-

Suction line

3-

Pressure line

4t
t
5t

Pressure switch, 15 Nm
switches at 4.0 MPa (40 bar)
Test signal Injection and Ignition System; Rep. gr.24
Sealing ring
replace

6-

Hollow screw, 38 Nm

7-

Sealing ring

t
8-

replace
Colour marking on suction line

t all around white or yellow, must be positioned inside the bracket (- Pos.9)
588

9-

Support

10 -

Nut

11 -

Support

Check the feed pressure of the vane pump


Vehicles with the vane pump located at the bottom or top
Special tools and workshop equipment required
t

Power-assisted steering testing device, e.g. -V.A.G 1402-

Adapter, e.g. -V.A.G 1402/1 A-

Adapter, e.g. -V.A.G 1402/2-

Adapter, e.g. -V.A.G 1402/3-

t
t

Hose from the adapter set, e.g. -V.A.G 1402/6Hose clamp -MP 7-602Note

If there is insufficient hydraulic oil in the reservoir always check the power-assisted
steering system for tightness Chapter.

If there is a leak on the power-steering gear first check the lines/line connections for
tightness, if necessary retighten and wipe dry.

Inspecting the gasket ring on the steering pinion and on the gear rack seal Chapter. If
there are leaks on the gasket ring or on the gear rack seal replace the power-steering gear.

Disposing of the power-steering gear Chapter.

Vehicles with vane pump located at the bottom

589

Pinch off the return line with the hose


clamp -MP 7-602-.

Remove the noise insulation in the


middle.

Place the catch pan under the vane


pump to collect escaping hydraulic oil.

Pinch off suction line -1- with hose clamp


-MP 7-602-.

Disconnect the plug connector from the


pressure switch on vehicles with pressure
switch.

Unscrew the pressure line -2- at the vane


pump.
Note

For reason of clarity the surrounding was


not shown in the fig.

Connect power-assisted steering testing device, e.g. -V.A.G 1402-

590

1-

Vane pump

2-

Sealing ring

t
345678t
910 t
11 t
12 t

replace after each removal


Adapter, e.g. -V.A.G 1402/1 AHose from the adapter set, e.g. -V.A.G 1402/6Adapter, e.g. -V.A.G 1402/3Power-assisted steering testing device, e.g. -V.A.G 1402Adapter, e.g. -V.A.G 1402/2Sealing ring
replace after each removal
Pressure line with banjo union
Hollow screw
for vane pump without pressure switch
Hollow screw
for vane pump with pressure switch
Sealing ring
for vane pump with pressure switch
591

13 -

Pressure switch

Vehicles with vane pump located at the top

If necessary, remove engine cover.

Pinch off the return line with the hose


clamp -MP 7-602-.

Pinch off the suction line with the hose


clamp -MP 7-602-.

Place the catch pan under the vane


pump to collect escaping hydraulic oil.

Unscrew the pressure line -1- at the vane


pump.
Note

For reason of clarity the surrounding was


not shown in the fig.

Connect power-assisted steering testing device, e.g. -V.A.G 1402592

1-

Vane pump

2-

Sealing ring

t
34567-

replace after each removal


Adapter, e.g. -V.A.G 1402/1 AHose from the adapter set, e.g. -V.A.G 1402/6Adapter, e.g. -V.A.G 1402/3Power-assisted steering testing device, e.g. -V.A.G 1402Adapter, e.g. -V.A.G 1402/2-

8t
9-

Sealing ring
replace after each removal
Pressure line with banjo union

10 -

Hollow screw

Test requirements:
l

V-belt/V-belt tension O.K.

Tightness of the system.


593

Hoses/lines are not buckled up or tied up.

Inspection:

Remove the hose clamp -MP 7-602- from the suction line and return line.
Open the shut-off valve at the manometer.

Start the engine and replenish the hydraulic oil level in the reservoir if so required.

Turn steering wheel 10 x from stop to stop.


Check feed pressure.

With the engine running at idling speed, close off the shut-off valve (no longer than 5
seconds), read off the pressure at max. steering angle and compare with the specified
value according to the following table.
Nominal pressure of the vane pump

Nominal value overpressure

Engine

MPa

bar

MPa

bar

Fuel engines

9,0

90

8,5 ... 9,5

85 ... 95

Diesel engines

9,0

90

8,5 ... 9,5

85 ... 95

Note

t If the specified value is exceeded or if it is not reached, replace the vane pump.
t

Remove and install the vane pump located at the top Chapter.

Remove and install the vane pump located at the bottom Chapter.

Disposing of the vane pump Chapter.


Switch off engine.

Pinch off the suction line and the return flow line with hose clamps -MP 7-602-.

Remove power-assisted steering testing device, e.g. -V.A.G 1402-.

594

Removing and installing vane pump


Note

Repairs on the vane pump are not foreseen. The cause of any problems which may be
t arising is determined by the pressure and tightness test. If there is a fault, replace the vane
pump.
The pumps supplied by the spare part storeroom are without oil. Therefore absolutely fill up
t with hydraulic oil before fitting -G 002 000- and turn by hand, otherwise noises or damage
to the pump could occur while driving.
t
t
t
t
t
t

Oil type: hydraulic oil -G 002 000Oil quantity in the system: 0.7 ... 0.9 ltr.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
Do not use drained hydraulic oil again.
Replace gasket rings.

Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation
t direction of an already used belt may destroy it. Pay attention to the correct position of the
V-ribbed belt in the belt pulley when installing it.
t

Disposal Chapter.

The version and the attachment of the vane pump as well as the bracket differ from the fig.
t according to the engine versions and thoses equipped with or without air conditioning
system.
Vehicles with 1.4/44 kW Engine:
t

Before removing, the fitting position of the belt pulley must be marked.

If the belt pulley of the vane pump is installed the wrong way round, it is displaced in
t relation to the other belt pulleys. The V-ribbed belt is damaged as a result of this
displacement.

Vehicles with vane pump located at the top


Special tools and workshop equipment required
t
t

Hose clamp -MP 7-602Pliers for spring strap clamps

t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Removing
595

The fig. shows the engine cover of the 1.9 Itr./66 kW (TDI) engine. The engine covers of the
other engine versions differ from the fig.

Remove engine cover.

1-

Plug

2-

Clamp

3-

Bolt

The fig. shows the guidance of the V-ribbed


belt on vehicles with air conditioning
system. Different routing of V-ribbed belt
on vehicles without air conditioning
system.
Note

Mark the rotation direction before removing


the V-ribbed belt. Reversing the rotation
direction of an already used belt may
destroy it. Pay attention to the correct
position of the V-ribbed belt in the belt
pulley when installing it.

Position flat ring spanner SW 16 at


hexagon of tensioning pulley.
Swing the the tensioning pulley in -the
direction of the arrow- detension the Vribbed belt.
Remove the V-ribbed belt.

The fig. shows the routing of the induction


pipe on the 1.9 ltr./66 kW TDI engine. The
following work steps must only be
performed on this engine version.

Open screw clamp -3-.

Unplug connector -4-.


596

Remove induction pipe -1-.

Valid for all engine versions with and


without air conditioning system.

Unscrew belt pulley, counterhold with Allan


key (SW 9 mm).
Valid for all vehicles with air conditioning
system and vane pump located at the top.

Pinch off the suction line - hydraulic oil


reservoir/vane pump - with the hose
clamp -MP 7-602-.
Open the spring strap clamp -1- with
pliers for spring strap clamps and detach
the suction line from the vane pump.
Unscrew pressure line (expansion hose)
-2-.

597

Screw out screws -1- and -2-.


Remove the vane pump from the
bracket.

Install
Note

The vane pumps supplied by the spare


part storeroom are without oil. Absolutely
fill up with hydraulic oil before fitting -G
t
002 000- and turn by hand, otherwise
noises or damage to the pump could
occur while driving.
The contact surfaces and the threads on
t both sides of the vane pump must be free
of paint.
t Do not use drained hydraulic oil again.
t

Replace gasket rings.

Fill the vane pump with hydraulic oil via


the induction pipe -arrow B-.
Turn the hub of the vane pump by hand
until hydraulic oil drains out of the
discharge nozzle -arrow A-.

598

Insert the vane pump in the bracket and


screw in screws -1- and -2-.

Tightening torque: 25 Nm

Screw the belt pulley to the vane pump


with Allan screws, counterhold with Allan
key (SW 9 mm).

Tightening torque: 25 Nm

Install V-ribbed belt Engine,


Mechanics; Rep. gr.13.
Note

Pay attention to the correct position of the


V-ribbed belt in the belt pulley when
installing it.

Install the induction pipe on the 1.9


ltr./66 kW TDI engine.
Note

Use new gasket rings to connect the


pressure line.
Install pressure line (expansion hose).
Tightening torque of the hollow screw: 38
Nm

599

Install spring strap clamp and suction


line as shown in the fig.
The longitudinal marking -A- on the
suction line must be flush with the mould
joint -C- on the vane pump.
Remove the hose clamp -MP 7-602- from
the suction line.
Top up with hydraulic oil and if necessary
bleed the power-assisted steering system
Chapter.
Check line connections for tightness
Chapter.
Install the engine cover.

Vehicles with vane pump located at the bottom


t
t

Hose clamp -MP 7-602Pliers for spring strap clamps

t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Removing
Note

Mark the rotation direction before removing the V-ribbed belt. Pay attention to the correct
position of the V-ribbed belt in the belt pulley when installing it.

600

Swivel the tensioning pulley with an


open-end wrench in -direction of arrow-.
Remove the V-ribbed belt.

The fig. shows the middle and left noise


insulation on vehicles with petrol engines.

Remove middle and right noise insulation


-arrows-.

Valid for all petrol engines without air


conditioning system.
Vehicles with 1.4/44 kW Engine:

Before removing, the fitting position of


the belt pulley must be marked.
Note

If the belt pulley of the vane pump is


installed the wrong way round, it is
displaced in relation to the other belt
pulleys. The V-ribbed belt is damaged as a
result of this displacement.
Continued for all vehicles

601

Unscrew belt pulley, counterhold with


Allan key (SW 9 mm).

Pinch off the suction line - hydraulic oil


reservoir/vane pump - with the hose
clamp -MP 7-602-.
Open the spring strap clamp -3- with
pliers for spring strap clamps and detach
the suction line from the vane pump.

Vehicles without pressure switch (fig.)

Unscrew hollow screw -2- and remove


pressure line (expansion hose).

Vehicles with pressure switch (without fig.)


Disconnect plug from pressure switch.

Unscrew pressure switch and remove


pressure line (expansion hose).

Vehicles without and with pressure switch.

Screw out screws -1- and -4-.

Remove vane pump -5- from bracket.


Install
Note

The vane pumps supplied by the spare


part storeroom are without oil. Absolutely
fill up with hydraulic oil before fitting -G
t
002 000- and turn by hand, otherwise
noises or damage to the pump could
occur while driving.
t The contact surfaces and the threads on
both sides of the vane pump must be free
602

of paint.
t Do not use drained hydraulic oil again.
t

Replace gasket rings.

Fill the vane pump with hydraulic oil via


the induction pipe -arrow B-.
Turn the hub of the vane pump by hand
until hydraulic oil drains out of the
discharge nozzle -arrow A-.

Insert the vane pump in the bracket and


screw in screws -1- and -2-.

Tightening torque: 25 Nm
Vehicles with 1.4/44 kW Engine:

603

Screw the belt pulley to the vane pump


with Allan screws according to the made
marking, counterhold with Allan key (SW
9 mm).
Tightening torque: 25 Nm
Note

If the belt pulley of the vane pump is


installed the wrong way round, it is
displaced in relation to the other belt
pulleys. The V-ribbed belt is damaged as a
result of this displacement.
Continued for all vehicles

Screw the belt pulley to the vane pump


with Allan screws, counterhold with Allan
key (SW 9 mm).

Tightening torque: 25 Nm

Install V-ribbed belt Engine,


Mechanics; Rep. gr.13.
Note

Pay attention to the correct position of


t the V-ribbed belt in the belt pulley when
installing it.
t

Use new gasket rings to connect the


pressure line.

Install pressure line (expansion hose).


Tightening torque of the hollow screw or
the pressure switch: 38 Nm

Install spring strap clamp and suction


line as shown in the fig.
joint -C- on the vane pump.

Top up with hydraulic oil and if necessary


bleed the power-assisted steering system
604

Chapter.

Check line connections for tightness


Chapter.

Install middle and right noise insulation.

Disposing
of the
pumpequipment required
Special
tools
andvane
workshop

Note

The oils used in the vane pump do not contain any harmful substances. These oils may be
disposed of together with the drained engine and gearbox oil.

t Dispose of used oils in compliance with the applicable environmental regulations.


Used oils (this concept refers to used engine and gear oils including ATF as well as mineral
t hydraulic oils), suitable for preparation must never be mixed with brake fluid, antifreeze
agent, artificial resin or thinners, chemicals etc.
t
t

After "draining" the used parts must be allowed to drip adequately.


When disposing of used parts comply with the legal specifications as there are minor
residual amounts of hydraulic oil in the power-steering gears.
Remove the vane pump.

Vehicles with the vane pump located at the top Chapter

Vehicles with the vane pump located at the bottom Chapter

Hold the vane pump over a catch pan


and fully drain the hydraulic oil by
turning it repeatedly or by turning the
pump.
The line connections arrows -A- and -Bmust not be shut off.

Disposing of the vane pump.

605