Skoda Octavia Mk1 - 01 - Running Gear

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
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
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
DISTINGUISHING FEATURES OF THE ABS/EDL ITT MARK 20 IE AND THE ABS/EDL/ESP ITT MARK 20 IE
....................................................................................................................................................................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
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
Removing and installing parts of the ESP system..................................................................................415
Removing and installing as well as setting the brake light switch.........................................................422
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

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
CYLINDER ABS/EDL/TCS MARK 60.........................................................................................................443
ELECTRICAL TEST ABS/EDL/ TCS MARK 60............................................................................................445
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
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
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 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 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 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
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
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'
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'
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 -
supporting plate
t
Drum brake
Brake drum -
Brake drum - maximum diameter
Wheel-brake cylinder 1) -
Brake pad, width
Pad thickness without supporting shoe
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
S
13
1,9/74
-
1,9/96
-

Brake servo unit -
t
Front disc brake:
Front brake caliper
Front brake disc -
Minimum thickness without supporting
plate
t
Rear disc brake:
Rear brake disc -
plate
t
Drum brake
Brake drum -
Lining thickness
shoe
1)
2)
mm
23,81
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 with ABS
Engine
S = Manual gearbox
Brake servo unit -
t
Front disc brake:
Front brake caliper
Front brake disc -
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
FS-III 3)5)
54,0
280,0
22,0
mm
mm
mm
14
FN 3 4)
54,0
288,0
25,0

plate
t
Rear disc brake:
mm
mm
mm
Rear brake disc -
mm

plate
t
Drum brake
Brake drum -
Brake pad, width
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 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
Front bearing for track control arm
pressing in and pressing out Chapter
70 Nm + 90
Pendulum support
40 Nm + 90
20
t
10 40 Nm + 90
t
11 20 Nm + 90
t
12 Assembly carrier
t
t The repair of the thread for the screwed connection of the front track control arm is not permissible!
13 Self-locking nut
t
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
20 Rubber-metal bearing
t
21 Self-locking nut
t
22 100 Nm + 90
t
23 Rear bearing for track control arm
t
Fitting position Anchor
t
pressing in and pressing out Anchor
24 100 Nm + 90
t
25 70 Nm + 90
t
26 Lock washer
t
27 20 Nm + 90
t
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
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

t
Pressure plate -MP 3-406t
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

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).
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

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.
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

t
Pressure spindle -MP 3-448t
Counterholder -MP 6-410t
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
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
2Stop
3Suspension strut
t
t
repairing Chapter
4Drive shaft with inner CV joint
t
t
repairing Chapter
5Shim
6Fillister head screw with internal serrations
t
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 180
M10 = 50 Nm + 45
7Drive shaft with inner tripod joint
t
t
repairing Chapter
30

t
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 90
M10 = 50 Nm + 45
9Brake disc (FS-III)
t
without marking for axial run-out
t
with a fixing hole for the wheel hub
10 Wheel screw, 120 Nm
11 Self-locking twelve-point nut
t
slacken and tighten Chapter
t
12 4 Nm
13 Brake discs (FS-III)
t
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
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
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
19 Brake discs (FN-3)
t
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
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
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
29 Steering joint
t
check Chapter
t Inspect rubber bellows for damage, if necessary replace
t
30 Wheel-bearing housing
Including for vehicles with engine up to 92 kW.
t
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
32 Screw
t
33 8 Nm
34 ABS wheel speed sensor
t
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
36 Track rod with track rod end
t
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
40 Wheel hub without pulse rotor
t
only on vehicles without ABS
32
t
t
t
t
t
t
t
without marking for minimum axial run-out

press out Chapter
installing Chapter
Pull off the inner ring of the bearing Chapter
Repairing wheel bearing housing

t
Pipe section -MP 3-4012t
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
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

t
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

t
Spreader -VAS 3424t
Torque wrench, e.g. -V.A.G 1756t
Extractor Matra -V176Removing
Remove wheel and raise vehicle.

37
Note
Release screws -1-.

Note

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.


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
Attach the wheel.


wheel bearing.
mechanic required).

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!
60 Nm
90 Nm
20 Nm + 90
40
t
Use new nuts!
Brake caliper housing to wheel bearing housing
30 Nm
Repairing the suspension strut

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
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.
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
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.

Pay attention to the correct seating of the coil
spring in the adapter, e.g. -V.A.G 1752/4-arrow-.
42

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

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

t
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.
t
Assignment of the drive shaft and marking electronic catalogue of original parts.

Remove noise insulation Engine - Mechanics; Rep. gr.10.
Unscrew the drive shaft from the flange shaft/gearbox.
Note
Release screws -1-.

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.
Insert drive shaft.



Screw drive shaft onto flange shaft.
Screw the pendulum support to the assembly
carrier.
- Moisten the contact surface of the twelve-point

Install noise insulation Engine,
Attach the wheel.


wheel bearing.
mechanic required).

49

Tightening torque:
50 Nm + 60.
Note

Tightening torques:
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

t
Circlip pliers, e.g. -VW 161 At
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
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
3Shim
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
t
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
t
pressing out Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
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
10 Circlip
t
replace
t
remove with circlip pliers, e.g. -VW 161 A-,
11 Left drive shaft (solid shaft)
12 Open warm-type clamp
t
replace
t
tensioning Fig.
13 Joint boot for outer CV joint
t
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.
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
15 Disc spring
t
16 Thrust ring
t
17 Circlip
t
replace
t
insert into the groove at the shaft
18 Outer CV joint
52
t
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

t
Chapter
Note
t
t

Grease joint if necessary, when replacing the joint boot.
1Outer CV joint
t
t
removing Fig.
t
grease Anchor
t
check Chapter
2Circlip
t
replace
53
t
3Thrust ring
t
4Disc spring
t
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
t
t
t
replace
t
tensioning Fig.
8Drive shaft
9Joint boot for inner CV joint
t
Material: Arnitel (Polyelastomere)
t
t
t
t
replace
11 Cover
t
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
t
pressing out Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
13 Circlip
t
replace
t
remove with circlip pliers, e.g. -VW 161A-,
14 Fillister head screw with internal serrations
t
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
15 Shim
16 Gasket
54
t
replace
t Remove the protective foil from the gasket and stick it into the inner joint
17 Cover
t
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.

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

corners (-arrows B-) of the open warm-type
clamp.
-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

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

joint at the left and right shaft

joint at the left shaft

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-.
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

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

q
q
q
replace
q
tensioning Fig.
q
replace
q
tensioning Fig.
4Drive shaft
q
5Joint part
q
grease Anchor
q
q
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
7Rollers
8Tripod spider
q
Chamfer -arrow- points towards the drive shaft serration
9Circlip
q
replace
66
q
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
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
q
for tripod joint
q
always replace
14 Joint boot for tripod joint
q
q
for tripod joint
q
always replace
q
tensioning Anchor
16 Disc spring
q
17 Thrust ring
q
18 Circlip
q
replace
q
19 Outer CV joint
q
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

t
Chapter
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

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-.
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

t
Spacer sleeves -MP 3-458/2t
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)
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 On tripod joints only apply grease in the joint, never in the grease boot.

q
q
q
replace
q
tensioning Fig.
q
q initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 28 = 20 Nm + 90
q
4Shim
q
5Joint part
q
grease Anchor
q
6Tripod spider with rollers
q
Chamfer -arrow- points towards the drive shaft serration
7Circlip
q
replace
q
8O-ring seal
q
replace
9Cover
q
replace
73

q
for tripod joint
q
always replace
11 Joint boot for tripod joint
q
q
12 Drive shaft
q
q
replace
q
tensioning Fig.
14 Disc spring
q
15 Thrust ring
q
16 Circlip
q
replace
q
17 Outer CV joint
q
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
Disassembling and assembling the tripod joint AAR 2000

t
Chapter
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

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-.
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
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
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 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

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-.
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.
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
t
press off Fig.
t
inserting Fig.
5Self-locking twelve-point nut 70 Nm +40
t
6Wheel hub with wheel bearing and pulse rotor
t
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
7Wheel hub with wheel bearing without pulse rotor
t
t
t
t
850 Nm + 60
t
9Brake carrier with brake shoe
10 Holder for hand-brake cable
t
replace
11 Hand-brake cable
12 Self-locking nut
t
13 Self-locking screw, 30 Nm + 90
t
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
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
t
18 Socket nut
19 Brake-power regulator
t
t
testing and adjusting Chapter
20 20 Nm
21 16 Nm
22 20 Nm + 45
t
23 Balancing weight
24 Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
t
26 8 Nm
27 bottom base
28 Coil spring
t
t
83
t check for paint damage, if necessary eliminate paint damage

t only use helical springs of the same make on the rear axle
29 top base
t
installing Anchor
30 40 Nm + 90
t
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
t
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
t
t
t
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
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

t
Assembly device -MP5-400/1t
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.
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.

right vehicle side from the bearing bracket for
the axle.
Remove the bearing bracket from the axle.
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
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-.
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.

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.
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.
91
Screw in the screw -1-.

Inspecting or adjusting the brake-power
regulator Chapter.
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

attention to the correct fitting position
Chapter.
92
Hook hand brake cables into the holders

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

t
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:

93


vehicle sides).


Vehicles with ABS
94

Release screw -1-.


adapter.
outside

the axle.
inside
95

body.
Note
the axle.

the axle.
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

t
t
t
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-.
97

pump -VAS 6179--arrow B-.
While doing so, the hydraulic cylinder -VAS
6178- returns to the initial position.
assembly device (nut) -T10254/4-.

shown in the fig.
Installing:
98

1Rubber-metal bearing
2Axle body


99

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

stop into the axle body -2-.
bearing.


-G052 150 A2-.
outside
for the axle.
100


inside

vehicle side.
Note
Vehicles with ABS
101

regulator Chapter.


Note

Chapter.
102

Attach the wheels.
test drive.
Caution

Tightening torque:
t
t
Use new screws!
t
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm
Removing and installing shock absorber/spring

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

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).

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
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 -arrowmust be

positioned at the stop at the top of the base.
Tightening torques:
Chapter.
104
Disassembling and assembling shock absorber
1Shock absorber
t
t
t
t
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
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

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.
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-.
Note
When tightening the screw of the rubber-metal

t bearing, the axle body must be in the horizontal
position (unladen condition).
t attention to the correct fitting position
Chapter.
performed.
107
Note
After slackening or changing the mounting
bracket, check the overall track of the rear axle,
adjust if necessary.
Tightening torques:
t
Use new screws!
Rear suspension to bearing bracket
t
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
press off Chapter, - Pos. 5
drive in Chapter, - Pos. 5
109

t
t
t
t
t
730 Nm + 90
t
8Cover plate
9Holder for hand-brake cable
t
replace
10 Hand-brake cable
11 45 Nm + 90
t
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
t
t
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
13 Self-locking nut
t avoid slackening in order to remove the rear axle
t
17 20 Nm + 45
t
18 Balancing weight
t
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
t per rear axle only use helical springs of the same make
24 top base
t
installing Anchor
25 40 Nm + 90
t
t
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
t
t
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
27 Shock absorber
t
t
t
t
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
29 Axle stud
t
t
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
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


t
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:



vehicle sides).
113


Vehicles with ABS

Release screw -1-.


adapter.
outside
114

the axle.
inside

body.
Note
the axle.

the axle.
Position assembly devices, as shown, and pull

the rubber-metal bearing -1- out of the axle
body -2-.
Note
115

heard.
Pull out rubber-metal bearing by turning the

shown in the fig.
Installing:
116
Fasten rubber-metal bearing -1- with assembly

devices and nut -2- and insert into the axle
body -3-.

117
Insert the rubber-metal bearing -1- by turning

the nut -MP 5-401/3- up to the stop in the axle
body -2-.
bearing.
-G052 150 A2-.
outside
for the axle.


inside

vehicle side.
Note
Vehicles with ABS
118

regulator Chapter.


Note

Chapter.
119

Attach the wheels.
test drive.
Caution

Tightening torque:
t
t
Use new screws!
t
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm

t
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:

120


vehicle sides).


Vehicles with ABS
121

Release screw -1-.


adapter.
outside

the axle.
inside
122

body.
Note
the axle.

the axle.
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-.

Note
123

t
t
t
heard.

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

axle body -2-.
124


shown in the fig.
Installing:
125

2Axle body


126

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

stop into the axle body -2-.
bearing.


-G052 150 A2-.
outside
for the axle.
127


inside

vehicle side.
Note
Vehicles with ABS
128

regulator Chapter.


Note

Chapter.
129

Attach the wheels.
test drive.
Caution

Tightening torque:
t
t
Use new screws!
t
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm
Removing and installing shock absorber/spring

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
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).

Disconnect the plug connection of the wheel
speed sensor cable.
Release screw -2-.

Lower the gearbox jack and remove the helical
spring.
Install
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 -arrowmust be

positioned at the stop at the top of the base.
Disassembling and assembling shock absorber
131
1Shock absorber
t
t
t
t
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
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

t
Drive bushing -MP 3-427t
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
t
press off Fig. and Fig.
t
inserting Fig.
t
t
t
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
t
t
replace completely after each removal
Note
Item
7Axle stud
t
8Axle body
t
t
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

-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

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

t
Drive bushing -MP 3-427t
Hub cap extractor -MP 5-404t
Puller Kukko -20/2t
Puller Kukko -204/1-
137
1Brake disc, internally ventilated

2Wheel screw, 120 Nm
34 Nm
4Brake disc
5Cap
t
t
press off Fig. and Fig.
t
inserting Fig.
t
t
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
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
9Brake caliper
t
dismantling Fig.
10 Axle stud
t
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.

Remove the wheel bearing housing from the axle

stud
-20/2-.
Remove inner ring of the bearing from axle stud

-204/1-.
Note
Do not damage the ABS wheel speed sensor
when pulling off the inner ring of the bearing.
140

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.

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
t
7The wheel bearing
143
t
8Trailing arm
t
9Suspension arm
t
10 Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
t
11 Stop buffer
t
12 Coil spring
t
13 Propshaft
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
2Shock absorber bushing
3Pressurized shock absorber
t
t
check Chapter
t
t
4Anti-roll bar
5Self-locking nut 25 Nm
t
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
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
t
check colour coding
t
replace axle-wise
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

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

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.
Tightening torques:
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
152
t initially tighten crosswise to 10 Nm, then tighten crosswise to the recommended tightening torque
2Shim
3Assembly carrier
t
4Drive shaft with inner CV joint
t
t
repairing Chapter
570 Nm + 90
t
M12 x 1.5 x 80
t
6Screw
t
M12 x 1.5 x 75
t
7Top suspension arm
t
t different versions, assignment Electronic Catalogue of Original Parts
8Guide joint
t
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
13 4 Nm
14 Brake disc
15 Brake disc, internally ventilated
t
The pulse rotor is welded with the wheel hub
t
t
17 Circlip
t
t
pay attention to correct position
18 Wheel bearing
t
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
21 Bottom suspension arm
t
22 Guide joint
t
153
23 90 Nm
t
t
t
for trailing arm
t
25 Trailing arm
t
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
t the track can be corrected by moving the mounting bracket
28 Spacer
t
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
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

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-.
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,
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-.

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,
pump.

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

side of the wheel bearing housing.
Position hollow piston cylinder -1- with tie bolt
-5-, thrust piece -2- and special nut -4-.

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,
pump.

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-.

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,
1389 A/1-

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-.

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,
pump.

Then press in the wheel hub by pumping with
the foot pump.

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

t
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.

Pull out the rubber-metal bearing by turning
the spindle.
-A- Ring spanner
Insert rubber-metal bearing

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

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 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.

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.
wheel screw.
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.

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

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

t
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.

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-.
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

-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
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.
Tightening torques:
Mounting bracket to trailing arm
Bracket to body
Suspension arm to trailing arm
t
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 bottom suspension arm
Raise vehicle.
Remove wheel.
Unscrew bottom suspension arm from trailing

arm -arrow-.
the stop.

wheel screw.

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
The screws for the bottom suspension arm must
only be tightened when the vehicle is standing on
its wheels!
Chapter.
Tightening torques:
t
Suspension arm to assembly carrier
t
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-.

the stop.
wheel screw.
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

Install top suspension arm
The screws for the top suspension arm must only
be tightened when the vehicle is standing on its
wheels!
Chapter.
Tightening torques:
t
Suspension arm to assembly carrier
t
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
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
t Observe fitting position: ribbed side must point upwards
5110 Nm + 90
t
6Assembly carrier
t
7Support for final drive
840 Nm + 45
t
M10 x 40
t
940 Nm + 45
174
t
M10 x 55
t
10 Rear final drive
11 Self-locking nut, 25 Nm
t
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

t
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.

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-.
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

-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
Tighten the screws for the assembly carrier and
the mounting brackets on the marked fitting
position.
Chapter.
Tightening torques:
Bracket to body
t
Use new screws!
t
Use new screws!
Propshaft at final drive
t
Wheel bolt
Removing and installing rubber-metal bearing for assembly carrier

t
Assembly device -T10030Removing
Raise vehicle.
Remove wheels.

Remove assembly carrier with final drive Chapter.
179
75 Nm
110Nm +
90
60 Nm
110 Nm
14 Nm
120 Nm
Position the special tools.

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.
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.
Install assembly carrier with final drive
Chapter.
Chapter.
Tightening torques:
180
Bracket to body
t
Use new screws!
t
Use new screws!
t
Wheel bolt
Removing and installing rubber-metal bearing for final drive

t
Assembly device -T10030t
Assembly device -T30016
Raise vehicle.
Remove wheels.
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

the spindle.
Install
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.

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
Chapter.
Tightening torques:
Bracket to body
t
Use new screws!
t
Use new screws!
Anti-roll bar to assembly carrier
t
Cross member for final drive to assembly carrier
Support for final drive to assembly carrier
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

t
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.
t
Left and right drive shaft

Thus the wheel must still touch the ground.
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.
Note

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 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.

wheel bearing.
mechanic required) or pull on the handbrake.

release by one turn.

Tightening torque:
50 Nm + 60
Note
186

Repairing drive shaft with CV joint

t
Circlip pliers, e.g. -VW 161 At
Tensioning pliers, e.g. -V.A.G 1682t
Workshop press, e.g. -V.A.G 1290 ANote
t
t
t

Grease joint if necessary, when replacing the joint boot.
Spread the grease mass evenly in the joint boot.
187
1Outer CV joint
t
t
removing Fig.
t
grease Chapter
t
check Chapter
2Circlip
t
replace
t
3Thrust ring
t
4Disc spring
t
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682- Fig.
6Joint boot
t
t
t
replace
t
tensioning Fig.
8Drive shaft (solid shaft)
939 Nm
t
M8 x 48
10 Shim
188

t
replace
t
tensioning Fig.
12 Joint boot for inner CV joint
t
t
t
remove with a drift
13 Disc spring
t
14 Inner CV joint
t
t
pressing off Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
15 Gasket
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
(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)

corners -arrows B- of the open warm-type
clamp.
ASpindle of tensioning pliers
B - Cutting edges of tensioning pliers
CTorque wrench
192
Tighten the open warm-type clamp on the inner

joint

corners -arrows B- of the open warm-type
clamp.
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:
t
Screw position -1t
Use new screws!
t
Screw position -2t
Use new screws!
100Nm + 90
100Nm + 90
198
Checking the camber on the rear axle
The camber cannot be 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
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
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 -arrowmust 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
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
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

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

t
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
->
Coding
13504
WSC
XXXXX
Vehicles with MK 60
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 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.
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
display -V.A.G
155200283
Front left wheel to earth or loose contact in the wiring
t
speed sensor
-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
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
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

Check the installation of the wheel speed

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

Performing actuator diagnosis Chapter.
Replace hydraulic unit -N55- Chapter.
The type of fault can only be detected as of 20 km/h (perform test drive).
Readout on
Rectifying fault
display -V.A.G
155200285
Front right
t
wheel speed
between wheel speed sensor -G45- and binder Current Flow Diagrams,
sensor -G45ABS control unit -J104Electrical Fault Finding and Fitting
Locations
t


00285
Front right

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.
speed sensor
-G45signal outside
the tolerance 1)

ABS control unit -J104-

Locations.


t


N.O.K.)
00285
Front right
speed sensor
N.O.K.)
-G45mechanical fault
1)
t
1)

-N55- defective



and 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-
Rectifying fault

between wheel speed sensor -G44- and binder Current Flow Diagrams,
ABS control unit -J104Electrical Fault Finding and Fitting
Locations.



Chapter.
00287
Rear right speed to earth or loose contact in the wiring
t
sensor -G44between wheel speed sensor -G44- and

signal outside
ABS control unit -J104Electrical Fault Finding and Fitting
1)
the tolerance
Locations.

222


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

-N55- defective



and Chapter.

Readout on
display -V.A.G
155200290
Speed sensor
t
rear left -G46between wheel speed sensor -G46- and
ABS control unit -J104-
Rectifying fault


Locations.
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the
speed sensor -G46pulse rotor for damage.

00290
Rear left wheel
t
speed sensor
-G46ABS control unit -J104signal outside
the tolerance 1)

Chapter.


Locations.


t
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the
speed sensor -G46pulse rotor for damage.

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


and Chapter.
mechanical fault
t
1)

1)

-N55- defective
Readout on
Rectifying fault
display -V.A.G
155200668
Open circuit, short-circuit to positive
t
Onboard
or earth
voltage tml. 30
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
the ABS control unit -J104- from
t
contact 3 to contact 14 interrupted or
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)
or earth
Fitting Locations.
Perform electrical test Chapter and
continue.
t
01276
Plug connection E-engine to control Performing actuator diagnosis Chapter.
t
ABS hydraulic
unit
pump -V64signal outside
the tolerance 1)
t
or earth
Fitting Locations.
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-.

1)
Readout on display
-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

Locations.
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
Locations
01315
Gearbox control
t BUS lines, short-circuit to to the current flow diagram binder Current Flow
unit 2)
no communication
Locations
01316
Brake control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow
no communication
Locations
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

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

t
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
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
XXXXX
Press key.
Vehicle system
Readout on display:
test
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.

t
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:
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:
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.

Enter display group number
XXX

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

There is also the possibility that the brake light switch is not correctly set Chapter.
Actuator diagnosis

t
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
- ->
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

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.
- ->
Readout on display:
Hydraulic
pump
ABS
-V64
Press the button within the next 60 seconds.
Readout on display:
- ->
Actuate brake pedal.
Operate brake
Press key.
Readout on display:
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.
- ->
The ABS hydraulic pump -V64- must run
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:
- ->
IFL: 0V OFL: VBAT Wheel FL
free
Press key.
ABS hydraulic pump -V64- no longer runs
Readout on display:
Press key.
- ->
Brake pedal must be felt to yield.
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:
- ->
locked
Press key.
- ->
Readout on display:
231
Take your foot off the brake pedal.

Release brake
Press key.
Readout on display:
- ->
Actuate brake pedal.
Release brake
Press key.
Readout on display:
Press key.
- ->
IFR: 0V OFR: 0V Wheel FR
locked
Readout on display:
Press key.
- ->
free
Readout on display:
- ->
locked
Press key.
Readout on display:
- ->
Release brake
Press key.
Readout on display:
- ->
Actuate brake pedal
Operate brake
Press key.
Readout on display:
- ->
IRL:0V ORL:0V
Wheel RL
locked
Press key.
Readout on display:
Press key.
- ->
IRL:VBAT ORL:0V
Wheel RL
locked
Readout on display:
- ->
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:
Press key.
- ->
IRL:VBAT ORL:0V
Wheel
RL free
Readout on display:
-
232
->

IRL:0V ORL:0V
Wheel RL
locked
Press key.
Readout on display:
- ->
Release brake
Press key.
Readout on display:
- ->
Actuate brake pedal
Operate brake
Press key.
Readout on display:
- ->
IRR:0V ORR:0V
Wheel RR
locked
Press key.
Readout on display:
Press key.
- ->
The ABS hydraulic pump -V64- must not run.
IRR:VBAT ORR:0V
Wheel RR
locked
Readout on display:
- ->
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:
Press key.
- ->
IRR:VBAT ORR:0V
Wheel
RR free
Readout on display:
- ->
IRR:0V ORR:0V
Wheel RR
locked
Press key.
Readout on display:
- ->
Release brake
Press key.
Read-out on display: (for vehicles with EDL)
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

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
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:
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:
Please wait . . . (10 sec.)
Readout on display:
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
3
Readout on display:
Release pedal;FR+FL bleeder screws OPEN
Press button.
Readout on display:
2
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
5
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
Readout on display:
6
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
7
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
Readout on display:
8
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
9
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
Readout on display:
10
Readout on display:
Actuate pedal 10x; Bleeder screws CLOSED
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
235
10
11

11
Readout on display:
Press button.
Readout on display:
12
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
Readout on display:
14
14

15

Readout on display:
16
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
12

13

Readout on display:
14
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
t
Pedal yields.
t
Pedal moves back.
Readout on display:
12

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
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

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
Jumper to contact -144
Voltage supply terminal -155
Rear left wheel speed sensor -G466
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

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

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
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

k
sensor -G47-.
Test the wiring according to the current
Fitting Locations
241

contact).

7
22 + 23
Resistance of the
rear right speed
sensor -G44-

k
sensor -G44-.
Fitting Locations
contact).
5+6
Resistance of the
rear left speed
sensor -G46-

k
sensor -G46-.
Fitting Locations
contact).
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
of the front left l Ignition off
speed sensor
rotor.
-G47Turn front left Alternating
voltage min.
wheel to
65 mV
approx. 1 1/s
001.
11
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

rotor.

001.
rotor.
Alternating
voltage min.
190 mV


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.

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-.
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
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
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

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

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
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
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

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
2t
t
t
3t
4-
Hydraulic control unit
1)
Fitting position: in left of engine compartment

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-
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)
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)
Pulse rotor for front wheel speed sensor
check Chapter
247
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.
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
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.
Connect battery Electrical

System; Rep. gr.27.
Interrogate the fault memory Chapter.
Erasing fault memory Chapter.
Removing and installing bracket

Removing
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

t
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
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
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.


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
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.
System; Rep. gr.27.
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
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

Release screw -2-.

Take the wheel speed sensor -G44- /
-G46- out of the axle stud.
Install
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.

(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:
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:

out the coding,
set clock,

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.

266

-arrows-.
Note

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

Attach the wheel.
System; Rep. gr.27.
Removing and installing as well as adjusting brake light switch up to model year 1999
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

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
Retaining pin
Master brake cylinder
cannot be repaired, replace completely in the event of faults
8t
only for vehicles with 74 kW, 92 kW and 110 kW engine
270
9t
Heat shield
10 -
Cap nut, 25 Nm
11 12 13 -
8 Nm
Dampening rubber
Support
14 -
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
Hydraulic unit to wheel cylinder/rear left brake caliper
20 -
Hydraulic unit to wheel cylinder/rear right brake caliper
19 t

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).

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
272
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
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,

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,

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

Chapter
Check longitudinal acceleration sender -G251Reading measured value block Chapter.

Display group 006
Readout on display:
Enter 006 display group number 006 and confirm with Enter display group number XXX
key Q.
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.
Readout on display:

Enter display group number XXX
275
Enter 125 for display group number 125 and confirm

entry with key Q.
Readout on display:
Display field

->
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
no connection
Data BUS to automatic gearbox control unit

3
t
t
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-.
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:
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)
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
13
Longitudinal acceleration sender -G251-
15
Longitudinal acceleration sender -G251278
17
Longitudinal acceleration sender -G251-
Overview of test steps (test steps Chapter)

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

1598/21-
max.
Check the cables between
the multi-pin connector of the 1.5
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
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
binder Current Flow

Locations
Electric/electronic components and fitting locations (four-wheel drive)

12t
t
t
3t
4t
t
1)
Brake master cylinder brake servo unit

1)

repairing Chapter
ABS warning light -K47Fitting location: in the dash panel insert, function:
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:

Chapter
6-

Rear right and left wheel speed sensors -G44- / -G46- 1)
check Chapter
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
8-
Front right and left wheel speed sensors -G45- / -G47- 1)
Pulse rotor for the wheel speed sensor at the front on the right and left
check Chapter
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

order.
Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - fourwheel drive
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 550 V
t
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
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-.

(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:
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.

coding.
re-set clock

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

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.

speed sensor cable/wheel speed sensor
-1- and close cover -2-.
-arrows-.
Note

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

Attach the wheel.
System; Rep. gr.27.
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.
t
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
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

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

2Hydraulic unit
3unit

2Hydraulic unit
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-
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
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
-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,
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.
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
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
-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.
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
t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) -3- remains lit, the
control unit is not yet coded.
296
Vehicle fitted with ABS/EDL/ESP - EDL does not operate

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

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

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.

Note
All unlisted contacts are not yet assigned and must under no circumstances be connected to
other components!
299

-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

-T47a- wiring loom/ABS control unit -J104-
Conta
ct
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
Jumper to contact 18
Lateral acceleration sender -G200- (earth lead)
10
Brake pressure sender 2 -G214-
11
Yaw rate sender -G202- (earth lead)
12
13
Brake detection switch of the ESP -F83-1)
14
not assigned
15
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
23
24
TCS/ESP button -E256- / voltage supply relay for warning light -K155-
25
Lateral acceleration sender -G200- (voltage line)
26
27
Yaw rate sender -G202- (voltage line)
28
29
30
not assigned
31
Brake light suppression relay -J508-
32
33
34
Front left speed sensor -G47-
35
Control unit with display unit for radio and navigation (only for navigation system)
36
37
38
not assigned
39
Plug connection -T16a/7-, -K- cable
40
Lateral acceleration sender -G200- (signal line)
41
42
Yaw rate sender -G202- (signal line)
43
44
Voltage supply terminal 15 via S 13
45
not assigned
46
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-.

Voltage supply of the ABS hydraulic pump -V64-
- Perform test step 1
Voltage supply of the valves in the hydraulic unit
Voltage supply of the control unit -J104-
Function of the brake light switch -F-
Brake light suppression relay -J508-
Jumper
Resistance of the front right speed sensor -G45-
Resistance of the front left speed sensor -G47-
Resistance of the rear right speed sensor -G44-
Resistance of the rear left speed sensor -G46-
Voltage signal of the front right speed sensor -G45-
302
Voltage signal of the front left speed sensor -G47-
Voltage signal of the rear right speed sensor -G44-
Voltage signal of the rear left speed sensor -G46-
Function of the ABS warning light -K47-
Function of the hand brake/brake fluid level warning light -K14/33-
Function of the ESP warning light -K155-
Function of the ESP button -E256-
Actuation of the steering angle sender -G85-
Actuation of the lateral acceleration sender -G200-
Actuation of the yaw rate sender -G202-
Actuation of the brake pressure sender -1--G201-
Actuation of the solenoid coil for brake pressure -N247-
Actuation of the brake detection switch -F83-1)
Test of the data BUS cable
Voltage supply for -V.A.G 1551-, plug connection -T16a-
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
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
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-
14.5V
-T47a/16- via fuse -S162- to
battery positive.
Ignition
off
Test wiring of contact

-T47a/15- to earth binder

Fitting Locations

304
Fitting Locations
3
44 + 46 Voltage supply of the ABS Ignition

l
control unit -J104on
(terminal 15)
14.5V
-T47a/44- via fuse S13 and
ignition starter switch.

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


connector -T47a- from
the ABS control unit
-J104-
max.1.5
Test wiring for open

circuit

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

Test -V.A.G
Test covers
step 1598 Abushes
23 + 46 Brake light
suppression
relay -J508-

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

flow diagram for open circuit and short
circuit binder Current Flow Diagrams,
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

Test -V.A.G
step 1598 Abushes
3+4
Test covers

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

Locations
33 + 34 Resistance of the
Ignition
l
front left speed
off
sensor -G47-
Replace wheel speed sensor -G45 Chapter
1,0 ...
1.3 k
sensor.

flow diagram.

Locations
7+6
Resistance of the
Ignition
l
rear right speed
off
sensor -G44-
1,0 ...
1.3 k
sensor.

flow diagram.

Locations
307
10
Ignition
l
rear left speed
off
sensor -G46-
1,0 ...
1.3 k
sensor.

flow diagram.

Locations
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

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
65 mV
pulse rotor.
13
Alternating
190 mV
pulse rotor.

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

group number 001

308
group number 001

of the rear
l Ignition off
left speed
sensor -G46Turn rear left
wheel by
approx. 1 turn
per sec.
Alternating
190 mV
pulse rotor.

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

nominal value
If the ABS warning light does not

light up for approx. 2 seconds:
-T47a/22- (control unit) to
contact -T32a/19- (dash panel
insert) for short-circuit to

earth. Binder Current Flow
Check dash panel insert, fault

in the dash panel insert
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

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

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
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
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
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-

earth.
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

contact -T32b/14- (dash panel
insert) for open circuit and
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
Replace TCS/ESP button


test step 19a
ste 1598 Ap
bushes
19
l Test conditions
additional works

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

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

fuse S13 for open circuit
binder Current Flow
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
binder Current Flow

Check cables for

short-circuit to

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

-J104 Connect test box
-V.A.G 1598 A- with
adapter -V.A.G
313

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)

1.5
Repair the wiring according
to the current flow diagram
binder Current Flow
Finding and Fitting
Locations
Wiring of contact
-T3n/2- (lateral
Wiring of contact
-T3n/3- (lateral
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
Test V.A.G
Test
step 1598 A covers
bushes
21
Test conditions
additional works

Cables for l
Ignition off
yaw rate
Measuring range 200
sender
l
set
-G202Pull out the multi-pin
-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)
max.
1.5
Wiring of contact
-T3m/2- (yaw rate
Wiring of contact
-T3m/3- (yaw rate
l
Measuring range
20 M set
Remove fuse S13

earth
315

binder Current Flow


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

Ignition off
Measuring range 200
set
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
via plug connection

via plug connection

l
Measuring range 20 M
set
Check cables for short316

max.
1.5

binder Current Flow
Finding and Fitting
Locations
circuit to positive or to
earth

ste 1598 A
p
bushes
23
Cables for
brake
pressure
sender 2
-G214-
l
l
Test conditions
additional works

Ignition off
Measuring range 200
set
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-

circuit:
Wiring of contact -T3p/1- max.

(brake pressure sender 2) 1.5
via plug connection

Wiring of contact -T3p/2(brake pressure sender 2)
via plug connection

Wiring of contact -T3p/3(brake pressure sender)
via plug connection

317

binder Current Flow
Finding and Fitting
Locations
set
Remove fuse S13
Check cables for short circuit to positive or to

earth

ste 1598 A
p
bushes
24
Test conditions
additional works

Cables for
l
Ignition off
solenoid coil
for brake
pressure
-N247connector -T47a- from the


1598 A- with adapter -V.A.G
1598/33Disconnect plug connection
T6x at brake servo unit

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

circuit.

binder Current Flow
Finding and Fitting
Locations
Remove fuse S13

earth
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-

Test -V.A.G Test
ste 1598 A- covers
p
bushes
25

Test conditions
additional works
Brake
l
Ignition off
detection
switch
-F83Pull out the multi-pin

Connect test box -V.A.G 1598

1598/33Disconnect plug connection
-T6x- at brake servo unit

circuit:
Wiring of contact -T6x/1(brake detection switch
-F83-) via plug connection
-T47a/13- (ABS control unit
-J104-)
319

-J104-)

binder Current Flow
Finding and Fitting
Locations

-J104-).
Remove fuse S13


Test -V.A.G Test
l
ste 1598 A- covers
p
bushes

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-

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

1.5
(steering angle sender -G85-)

binder Current Flow
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
1)
Remove fuse S13

Check cables for short-circuit to
Only on vehicles with automatic gearbox

ste 1598 Ap
bushes
27
Test conditions
additional works

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)

earth.
Test wiring of -T16a/1- via

-S5-.
Repair the wiring

according to the current
flow diagram binder
Electrical Fault Finding
Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter

321

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

max.
Test wiring of contact -T16a/7
1.5
to contact -T47a/39-
Remove fuse S13

binder Current Flow

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
322

binder Current Flow

Electric/electronic components and fitting locations ABS/EDL/ESP Mark 20
1-
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
3-
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
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
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-
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 -

t
Rear right and rear left wheel speed sensors -G44/G46-
t
t

check Chapter
Chapter and Chapter
13 t
Front right and front left wheel speed sensors -G45/G47- 1)

check Chapter
Chapter
14 t
Voltage supply relay for warning light -K155--J535Fitting location: additional relay carrier, space 7
15 t
16 t
Brake light switch -Fis open in off position
17 -
Control unit for ABS/EDL/ESP -J104325
Fitting location: at the hydraulic unit in left of engine compartment
t
t
t
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
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
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
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
9-
10 -
Support
11 -
Dowel screw, 8 Nm
12 -
Cap nut, 25 Nm

Note
coding.
set clock,
Disconnect battery.
Note
328

filter.



brake pedal load, e.g. -V.A.G 1238/B- or
-V.A.G 1869/2-.

screw.

fluid flowed out.

bleeder screw.
Release the multi-pin connector -1- (arrow a-) and disconnect it from the
hydraulic control unit (-arrow b-).
Note

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.
reservoir.

the hydraulic unit.

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

Note
The third fixing screw for the hydraulic

control unit is covered by the hydraulic
pump -V64-.
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.

bracket.
Note

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-.


System; Rep. gr.27.
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
Initiate basic setting and perform null

balance Chapter.
Erasing fault memory Chapter
Removing and installing bracket

Removing

Chapter.
332
Unscrew nuts -1- and cap nut -3-.
Remove holder -2-.
Install
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

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
Contact assignment 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).
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 Vt
Removing and installing wheel speed sensor

Chapter
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.

coding.
set clock,

Removing
Disconnect battery.
Note

air filter.

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.

arrow-.

-T47a- wiring loom/ABS control unit -J104-
Contact
3+4

33 + 34
6+7
36 + 37
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

Connect wheel speed sensor cable to wheel speed sensor.

-arrows-.
Note

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.

lock (purple).
Lock the secondary lock (purple) with a

arrow-.
Position the cap on the multi-pin

connector.

control unit -J104- and lock.

System; Rep. gr.27.
340
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

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
coding.
set clock,

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.

System; Rep. gr.27.
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
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.

centre position:

-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.

System; Rep. gr.27.
Perform the basic setting of the steering

angle sender -G85- Chapter.
347
Removing and installing as well as setting the brake light switch

up to MY 1999 Chapter
as of MY 2000 Chapter
for vehicles with ABS/EDL/ESP Mark 20
Note
t
Repairing Chapter.
t
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.
348
1-
Brake servo unit
check 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
7-
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
t
13 t
t
14 t
Retaining pin
fit through the master brake cylinder
12 t
Plugs

Brake pressure sender -1--G201in the floating piston circuit
Brake pressure sender -2--G214in the push rod piston circuit
349
15 t
Connector
Connection wiring loom dash panel/engine compartment
16 -
Wiring loom
17 -
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 -
24 -
Control unit for ABS/EDL/ESP
25 -
Hydraulic unit for ABS/EDL/ESP
26 -
Brake line connection, 14 Nm
27 t
28 t

30 -
Brake line, 14 Nm
31 t
29 -
Brake line, 14 Nm
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.
t
ABS Self-study programme
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

1)
352
1-
2t
t
t
3t
4t
t
1)

repairing Chapter
ABS warning light -K47Fitting location: in the dash panel insert, function:
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-
The hand brake/brake fluid level warning light comes on:
353

Chapter
6-

Rear right and rear left wheel speed sensors -G44/G46- 1)
check Chapter
Chapter and Chapter
7t
Brake light switch -Fis open in off position
8t

check Chapter
Chapter
Removing and installing the hydraulic control unit and the bracket
Note
354
t
Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
Brake pedal load, e.g. -V.A.G 1238/B-
Brake filling and bleeding device, e.g. -VAS 5234-
Extraction bottle (commercially available)
Brake fluid Chapter
1t
the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
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
6t
Brake line, 14 Nm
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
9-
Brake line, 14 Nm
10 t
Brake line, 14 Nm
between master brake cylinder/floating piston circuit and hydraulic unit
11 t
Brake line, 14 Nm

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:
set clock,
Disconnect battery.
Note
356

filter.



brake pedal load, e.g. -V.A.G 1238/B-.

screw.

fluid flowed out.

bleeder screw.

remove it from the control unit -arrows-.
Note

contacts.
In order to collect the brake fluid,

position an absorption fleece under the
Note
Do not bend the brake lines around the

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.
reservoir -arrows-.

the hydraulic unit.
the screw plugs from the repair set.
Unclip the cable for clutch control -arrow

A-.
Unscrew the screws -arrows B- on the


Note
Only then remove plugs from the hydraulic

unit when the relevant brake line is
installed.

bracket.
Note

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


System; Rep. gr.27.
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
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.
Chapter.
Removing and installing the wheel speed sensor cables
Removing
Note
t
t
t
It is prohibited to repair shielded ABS cables.

coding.
After connecting the battery, check the vehicle equipment:
set clock,
initialise power windows on vehicles fitted with power windows.
Disconnect battery.
Note

air filter.

361

remove it from the control unit -arrows-.
Unclip the cap of the multi-pin connector

using a screwdriver -arrows- and remove
it.

arrow-.
362

wiring loom/ABS control unit -J104-
Contact
Wiring to component
33 + 34
45 + 46
42 + 43
36 + 37
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

Connect wheel speed sensor cable to wheel speed sensor.
363

-arrows-.
Note

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.

lock and position the cap of the multi-pin
connector.
System; Rep. gr.27.
Chapter.
ABS/EDL/TCS Mark 60
Note
t
Repairing Chapter.
364
1t
Brake servo unit

check Chapter
2t
3t
4-
Sealing ring
replace
Screw cap
with integrated brake fluid level warning contact -F34Brake fluid reservoir
5t
6-
Plugs
Retaining pin
7-
8-
t
9t
replace
Brake line
Master brake cylinder/push rod piston circuit THV to hydraulic unit
365
10 t
Brake line
11 t
only fitted on certain models
replace
12 t
Heat shield
only fitted on certain models
13 t

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

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

-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

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
- Perform test step

4
- Perform test step

5
- Perform test step

6
- Perform test step

7
- Perform test step

8
- Perform test step

9
- Perform test step

10
- Perform test step

11
- Perform test step

12
- Perform test step

13
- Perform test step

14
Function of the TCS button -E132-
- Perform test step

15
- Perform test step

369
16
- 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
Fault Finding and Fitting Locations.
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Test -V.A.G
step 1598 Abushes
Test covers
Test
conditions
Specified
value

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


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


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.

Fitting Locations.
approx.
Check brake light switch -F
battery
Chapter.
voltage
Brake
pedal
actuated

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

nominal value
Check wiring according to

current flow diagram.
Throughout the test, do not

move cables binder Current
Flow Diagrams, Electrical Fault
If the lines are not found to be
faulty:
the front left
speed sensor
-G47-
t Ignition off
1.0...1.3 k


faulty:
Replace speed sensor -G47371
Chapter.
the rear right
speed sensor
-G44-
t Ignition off
1.0...1.3 k


faulty:
the rear left
speed sensor
-G46-
t Ignition off
1.0...1.3 k


faulty:
9 33 + 34 Voltage signal
of the front
right speed
sensor -G45-
l Vehicle raised
l Ignition off

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
per sec.
group number 001.
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
l Vehicle raised
l Ignition off
372

the rotor.
-G47- to ensure it is correctly
group number 001
the rotor.
sensor -G44-
Turn rear right Alternating

voltage min.
wheel by
190mV
approx. 1 turn
per sec.

group number 001.
of the rear left

speed sensor l Ignition off
-G46Alternating
Turn rear left
voltage min.
wheel by
190mV
approx. 1 turn
per sec.

the rotor.
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

nominal value
The warning light

-K47- lights up for current flow diagram binder
approx. 2 seconds Current Flow Diagrams, Electrical

Switch on and goes out
ignition
Locations.
l
Ignition
off
Fault in the dash panel insert.

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

nominal value
The warning light

-K86- lights up for
approx. 2 seconds
and goes out
TCS warning light
-K86- lights up


Fitting Locations.
Operate TCS TCS warning light

Replace TCS button -E132
button -E132- -K86- goes out
Body Work; Rep. gr.70
once again

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
control units connected to
a data BUS line:
Connect -V.A.G 1598 Awith adapter -V.A.G
374

nominal value
1598/36
Check the data BUS cable

for open circuit
Set measuring range

20 M

earth
max.
1.5


Locations.


Locations.

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
1552-, plug
multimeter -V.A.G 1526connection
1)
with the measuring tool
-T16aset -V.A.G 1594- to the
plug connection -T16a-1)

d value
nominal value
10.0 14,5V
Test the wiring according

binder Current Flow
Finding and Fitting
Locations.
Contact assignment of the diagnostic connector Chapter.

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

d value
from nominal value
plug
connection
-T16a-1)
unit -J104Connect -V.A.G 1598 A- with

adapter -V.A.G 1598/36-

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
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
binder Current Flow

Fault Finding and
Fitting Locations.

Test -V.A.G
step 1598 Abushes
19
Test covers
Specifie
Test
conditions d value

value
additional
works
14 + 38 Jumper for
Ignition
t
ABS/EDL/TCS
off
0.0 - 1.0 Test the wiring according to the current

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

t
t

Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02

1)
377
1-
Brake servo unit
with master brake cylinder and brake fluid reservoir
Remove and install brake servo unit Chapter
2t
3t
Lateral acceleration sender -G200-1)

Fitting location: next to the steering column under the dash panel
4t
Yaw rate sender -G202-1)

5t
Brake pressure sender -1--G201-1)
Steering angle sender -G85-1)
column switch
6-
ABS warning light -K47378
function Chapter
7-
function Chapter
8-
function Chapter
9t


check Chapter
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
11 t
12 t
Brake light switch -F-1)

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-

379
t
t
t
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
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
15 t

check Chapter
Chapter
16 t
t
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

1)
380
1-
Brake servo unit
with master brake cylinder and brake fluid reservoir
Remove and install brake servo unit Chapter
2t
3t
4-
Steering angle sender -G85-1)
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-
function Chapter
7-
function Chapter
8-

check Chapter
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
10 t
11 t
Brake light switch -F-1)

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-

382
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
when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104 Chapter
14 t

check Chapter
Chapter
15 t

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

Chapter
Fitting position ABS/EDL/TCS/ESP Mark 60

2Hydraulic unit
3unit

2Hydraulic unit
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
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
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
reached.
-d- the connection from the ABS control
unit -J104- to the dash panel insert -J218- is
interrupted binder Current Flow
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
Fitting Locations
t light (-K14/33-) -2- light up, then the ABS
system and the EBD (Electronic Brake
pressure Distribution) have failed.
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
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
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.
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
t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) remains lit, the
control unit is not yet coded.
Electrical test ABS/EDL/TCS/ESP Mark 60

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

air filter.
Connect test box -V.A.G 1598 A- with

adapter -V.A.G 1598/36 Chapter

Contact assignment of the plug connection -T16a- (diagnostic connection) with the vehicle
system tester -V.A.G1552389
Chapter
-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
6-
Lateral acceleration sender -G200(signal)
Voltage supply of the longitudinal

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
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

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
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

391
Voltage supply of the ABS hydraulic pump -V64-
Voltage supply of the valves in the hydraulic unit
Voltage supply of the control unit -J104-
Jumpers
Function of the ESP warning light -K155-
Function of the TCS/ESP button -E256-
Actuation of the steering angle sender -G85-
Actuation of the lateral acceleration sender -G200-
Actuation of the yaw rate sender -G202-
Actuation of the longitudinal acceleration sender -G251-
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
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
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-

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
393

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

nominal value
If necessary set brake light switch

Chapter.
Replace brake light switch

Chapter.

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
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

circuit

41 (control unit) to
contact 1 (brake light
switch)
l
Set measuring range

20 M
Remove fuse S13

earth
394

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

Test -V.A.G
step 1598 Abushes
Test covers

Test
value
conditions d value
additional
works
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
Ignition
l
front left speed
off
sensor -G47-
k
sensor.

flow diagram.

395
locations
Switch on measuring range: resistance measurement (2k)

Test -V.A.G
step 1598 Abushes
Test covers

Test
value
conditions d value
additional
works
Ignition
l
rear right speed
off
sensor -G44-
k
sensor.

flow diagram.

locations
Ignition
l
rear left speed
off
sensor -G46-
k
sensor.

flow diagram.

locations
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

nominal value
10 33 + 34 Voltage signal l Vehicle raised Alternating

of the front
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

group number 001.
of the front
l Ignition off
left speed
sensor -G47Turn front left
wheel by
approx. 1 turn
per sec.
Alternating

65 mV
pulse rotor.

of the rear
l Ignition off
right speed
sensor -G44Turn rear right
wheel by
approx. 1 turn
per sec.
Alternating

190 mV
pulse rotor.

of the rear
l Ignition off
left speed
sensor -G46Turn rear left
wheel by
approx. 1 turn
per sec.
Alternating

190 mV
pulse rotor.

group number 001.

group number 001.
Functional test: ABS warning light -K47397

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
approx. 2
seconds and
goes out
Ignition off
The multi-pin
connector is inserted
l
on the control unit
-J104- and locked

from nominal value
If the ABS warning light

does not light up:

Electrical fault finding
and Fitting locations
Check dash panel insert,
fault in the dash panel
insert Electrical
System; Rep. gr.90
Switch on ignition
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

from nominal value
Check the brake fluid

level warning contact
-F34- in the screw cap of
the brake fluid reservoir.

Fitting locations
insert Electrical
System; Rep. gr.90
Switch on
ignition
Functional test: ESP warning light -K155Test -V.A.G Test covers l Test conditions
398
bushes
16

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
insert.
Check ESP button -E256-.
Test voltage supply relay for
warning light -K155-.

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
p bushes
17

the
The function of
TCS/ESP
the ESP warning
button
l
light -K155- was
-E256tested with test
step 17
Specified value
The warning
approx. 2
seconds and
goes out
Multi-pin
connector
l inserted on
control unit -J104and locked
Switch on
ignition
399

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.

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

earth.
Test voltage supply of contact

-T4f/1- (ESP button) via fuse
S13 for open circuit Current

Replace ESP button
Electrical System; Rep.
gr.96

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

d value
nominal value
steering angle
sender -G85-
-T47a- from the

control unit -J104-
fuse S15 for open circuit.

Repair wiring according to

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

10.0- fuse S13 for open circuit
14.5V
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

Wiring of contact
-T6w/2- (steering
angle sender) with

Wiring of contact
-T6w/1- to earth
Measuring range 20
MQ set
401

1.5

Fitting locations
Remove fuse S15
Check cables for

short-circuit to

Test -V.A.G
ste 1598 Ap bushes
19
Test covers
Test conditions
additional works

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

1598/36-
Disconnect the plug

connection -T3n- from
the lateral acceleration
sender

circuit
Wiring of contact
-T3n/1- (lateral

1.5

Fitting locations
Wiring of contact
-T3n/2- (lateral
Wiring of contact
402
max.
1.5
-T3n/3- (lateral
l
set
earth

Test V.A.G
step 1598 A
bushes
20
Test covers
Cables for
lateral
acceleration
sender -G200-
Test conditions
additional works
Ignition off

d value
nominal value
Measuring range
200 set

-J104
Connect -V.A.G 1598

1598/36-
Disconnect the plug

connection -T3mfrom the yaw rate
sender

circuit
Wiring of contact
-T3m/1- (yaw rate
Wiring of contact
-T3m/2- (yaw rate
-T47a/24- (control
403

max.
1.5


Fitting locations
unit)
Wiring of contact
-T3m/3- (yaw rate

-T47a/26- (control
unit)
Measuring range
20 M set
Check cables for

short-circuit to

Test -V.A.G
Test covers
step 1598 Abushes
21 -
Cables for
brake
pressure
sender -1-G201-
Test conditions
additional works
Ignition off

Measuring range 200

set

-J104

1598/36-
Disconnect the plug

connection -T30- from
the brake pressure
sender -1--G201

circuit
Wiring of contact
-T30/1- (brake pressure
Wiring of contact
404

max.
1.5
Fitting locations

Wiring of contact
l
set
earth

Test -V.A.G
ste 1598
p
Abushes
22
Test covers
Test conditions
additional works

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
sender -G251

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
flow diagram binder
sender -G251- and the multiCurrent Flow Diagrams,
pin connector of the control
Electrical Fault Finding
unit -J104- for open circuit

405
Check wiring according

to the current flow
diagram Current flow

diagrams, Electrical
fault finding and Fitting
locations

Test -V.A.G
Test l
step 1598 A- covers
bushes
11 + 15
23
Specifie
d value
Test conditions
additional works

nominal value
Data l
Ignition off
BUS
cables l Measuring range 200 set
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

406

current flow diagram Current

earth
1)
Only on vehicles with automatic gearbox.

Test -V.A.G
ste 1598 Ap bushes
24
Test covers
Test conditions
additional works
Specifie
d value

from nominal value
Voltage supply for l

10.0Ignition on
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

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.

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

d value
nominal value
max.
1.5

-T16a/7- to contact
-T47a/39-.

Fitting locations
1598/33Test wiring
between contact
-T16a/7- and
contact -T47a/39l
Measuring range
20 M set
Check cables for
short-circuit to
408


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

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
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Inspect thickness BookletOctavia

always replace axle-wise
410
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
5t
Guide bolt, 30 Nm
67t
Cap
Brake hose with banjo union and hollow screw
cannot be disassembled, must be fully replaced
8-
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
Circlip
411
15 t
Wheel hub with pulse rotor

16 t
Wheel hub without pulse rotor

Removing and installing brake pads/brake caliper (FS III)

t
t
t
t
Piston jig -MP 9-403Brake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid 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

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
Note
position.
t
mouth via a hose!
t
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
t
t

t
t
3-

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

416
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
Inspect thickness BookletOctavia
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:
Unscrew brake hose -Pos. 10- from brake caliper.
Installing:
t
t
8-
Screw brake hose -Pos. 10- to brake caliper.

repairing Chapter
Guide bolt, 30 Nm
417
removing and installing -Pos. 4
9-
Cap
10 t

must be replaced completely, do not dismantle
11 t
124 Nm
Clean ribbing on the underside
12 -
13 14 t
8 Nm
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste).
15 -
Cover plate
16 17 t
10 Nm
Wheel bearing
18 19 t
Circlip
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

Removing and installing brake pads/brake caliper FN 3

t
t
Piston jig -MP 9-403Brake filling and bleeding device, e.g. -VAS 5234418
t
t
Bleeding bottle (commercially available)

Brake fluid Chapter

Removing
Remove wheels.
Note
t
t
Note
Remove caps -arrows-.
Disconnect the plug connection for the

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.

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

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.
Connect the plug connection for the

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.
t brake pads, if necessary top up with
brake fluid.
422
Removing and installing brake discs (FN 3)

Note
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
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.

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.
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

t
Measuring tool for brake drum -MP 5-407-
Dial gauge (measuring range 0 -10 mm)
t
t
Brake fluid Chapter

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.
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.
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
5-
Wheel hub with wheel bearing and pulse rotor

426
6-
Wheel hub with wheel bearing without pulse rotor
7t
Self-locking screw, 50 Nm + 60
8t
Brake carrier with brake shoe

removing:
Resetting brake Chapter.
Remove the brake drum.
Unscrew brake pipe.
Remove brake carrier.
Installing:
Install brake carrier.
Screw on brake hose.
Install the brake drum.
Bleeding Brake System Chapter
repairing Chapter.
910 -
Axle body
Axle stud
11 12 t
t
8 Nm
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

t
Hook (commercially available)
Plastic wedge 3409
Brake fluid Chapter

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:
Unscrew brake hose.
Remove wheel-brake cylinder.

Installing:
429
Install wheel-brake cylinder.
Screw on brake pipe.
7-
8 Nm
8-
Tensioning sleeve
9-
Brake carrier
10 t
remove to check brake pad thickness Fig.
11 t

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
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

t
t
Hook (commercially available)

Removing
Remove wheels.
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 -arrowmust 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.
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.
Remove ashtray in centre console.
Release Phillips head screws.

remove Body Work; Rep. gr.68.
1-
Handbrake cable
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



t
t
t
Brake fluid Chapter

Note
position.
mouth via a hose!
t
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
4-
Cap
press off Chapter
inserting Chapter
5-
Self-locking twelve-point nut, 70 Nm + 40
6-
Wheel hub with wheel bearing and pulse rotor

437
7-
30 Nm + 90
8-
Cover plate
9-
Axle stud
10 -
Hand-brake cable
11 -
Axle body
12 -
13 -
8 Nm
14 -
30 Nm + 30
15 -
Brake carrier with guide bolts and protective caps
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)
16 -
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
removing

438
Unscrew brake hose -Pos. 16- at brake caliper.
Installing:
t
t
repairing 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
19 -
Brake pads
Thickness 17 mm (including the support plate)
Wear limit: 7.5 mm (including supporting plate)
Check thickness: BookletOctavia
t
t

20 t
t
Pad retaining spring

always replace when changing the brake pads
Removing and installing brake pads

t
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
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 pads and the pad

retaining springs.
Note

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.
to damage if brake fluid was added in the
meantime.
WARNING

440

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.

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.
Attach the wheels.
Note
t After each brake pad replacement,

441

t brake pads, if necessary top up with brake
fluid.
Setting the hand-brake (disc brake)

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.

1-
Handbrake cable
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.

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
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


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
order.
Note
When installing the hand brake cables,

t pay attention to the correct fitting
position 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

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



t
t
t
Brake fluid Chapter

Note
position.
mouth via a hose!
t
449
12-
80 Nm
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)
3-
always replace
4-
Tightening torque of the hollow screw: 35 Nm
t
5t
t
Brake caliper
removing:
450
Unscrew brake hose -Pos. 4- at brake caliper.
Installing:
repairing Chapter
t
t

one must first adjust the hand-brake after undertaking repair or replacement work, the foot
brake must not be applied beforehand!
6-
Brake pads
Thickness 17 mm (including the support plate)
Wear limit: 7.5 mm (including supporting plate)
Check thickness: BookletOctavia
t
t

7-
t
t
always replace when changing the brake pads

8-
Cover plate
910 t
t
10 Nm
Self-locking twelve-point nut
tighten Chapter
11 12 -
4 Nm
Brake disc, internally ventilated
Diameter 256 mm
Thickness 22 mm
Wear limit 20 mm

451
13 -
Brake disc
Diameter 232 mm
Thickness 9 mm
Wear limit 7 mm
14 t

15 t
Circlip
16 t
Wheel bearing
17 18 -
Trailing arm
Hand-brake cable
19 t
20 21 t
8 Nm
Drive shaft
Removing and installing brake pads

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
as otherwise this may cause uneven braking.
Removing


Raise vehicle.
Remove wheels.

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 pads and pad

retaining springs -arrows-.
Note

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.
to damage if brake fluid was added in the
meantime.
WARNING

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.
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

the right into the brake caliper.
Insert the new pad retaining springs

-arrows- and brake pads in the brake
carrier.

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

-direction of the arrow- and hook on the
hand-brake cable -3-.
Fit clip -1-.
Attach the wheels.
Lower the vehicle.

Note
After each brake pad replacement,

t
t

brake pads.
Setting the hand-brake

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.

456

1-
Handbrake cable
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


Raise vehicle.
458

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
order.
Note

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
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
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
4t
Accelerator pedal
removing and installing: Engine, Mechanics; Rep. gr.20
5-
6t
t
Brake pedal
separate from the brake servo unit 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
When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
461
1t
2t
Bearing bracket
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
45-
Screw
Brake pedal
separate from the brake servo unit Chapter

6789-
Cap
Bushing
Bearing bolt
10 11 -
Strut
Separating the brake pedal from the brake servo unit and clipping
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-.
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.
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

t
t
Release tool -T10159AGrease MoS2 (molykote grease)
Removing
Release screws -2-.

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.
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.
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.
order.

Tightening torques:
Brake pedal to bracket
t

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
with ABS, ABS/EDL Mark 20 - LHD vehicles
Note
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
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
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
3-
locked with lateral catches in the retaining pin
4t
Plugs
5-
Retaining pin
6t
two brake pressure senders (-G201- and -G214-) are additionally installed on vehicles with
ABS/EDL/ESP
Check tightness Chapter
7t
8t
Heat shield
9t
10 -
replace
Sealing ring
470
replace
11 -
Plugs
12 -
Vacuum hose
13 -
Gasket
between brake servo unit and bulkhead
14 t
replace
with ABS, ABS/EDL Mark 20 - RHD vehicles
Note
one another.
471
1t
t
Brake servo unit with mechanical brake assistance

all vehicles without ABS
Right-hand drive vehicles with ABS, ABS/EDL

472
t
t
mechanical brake assistance integrated in the brake servo unit

unit
t
t

The brake assistance cannot be repaired, replace the brake servo unit completely when
handling a fault Chapter

t
check Chapter
t
2t
Screw cap
3-
with lateral catches for locking screw
4-
Plugs
5-
Plugs
t moisten with brake fluid and press expansion reservoir into the sealing surfaces
6-
7-
8-
Locking screw for brake fluid reservoir, 10 Nm
9t
Sealing ring
replace
10 t
t
Gasket
473
replace
11 -
replace
Removing and installing the master brake cylinder - LHD vehicles

t
t
t
t
Hose clamp -MP 7-602Extraction bottle (commercially available)

Brake fluid Chapter
Repair set SP.-no. -1H0 698 311 ANote
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

filter.
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
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.
Bleed clutch system (manual gearbox) Manual Gearbox; Rep. gr.30.
Repairing the clutch control BookletOctavia.
Initiate the basic setting on vehicles with EDL Chapter.
Removing and installing the master brake cylinder - RHD vehicles

t
t
t
t

Brake fluid Chapter
475
coding.
Removing
Vehicles with TDI turbocharger engines

Remove top charge air pipe with connecting hose Engine, Mechanics; Rep. gr.21.
Disconnect plug -3- from brake fluid level

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
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

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.
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

t
Hose clamp -MP 7-602-
Brake pedal load, e.g. -V.A.G 1238 B-
Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
t
t
t
t
Release tool -T10159AExtraction bottle (commercially available)

Repair set SP.-no. -1H0 698 311 ABrake fluid Chapter
478
Note
coding.
Removing
Remove the hydraulic control unit Chapter.


clamp -MP 7-602-.

Remove vacuum hose from the brake
servo unit.
Release screws -2-.

holders.

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.

Fill up with new brake fluid Chapter.

System; Rep. gr.27.

out the coding.
Re-set clock.
BookletOctavia.
480
Bleed clutch system (manual gearbox)

Manual Gearbox; Rep. gr.30.
Repairing the clutch control

BookletOctavia.
Initiate the basic setting on vehicles with

EDL Chapter.
Removing and installing the brake servo unit - RHD vehicles

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)
Note
coding.
Removing
Remove engine cover Engine, Mechanics; Rep. gr.10.

Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Lay sufficient non-fluffing cloths around the engine.

481
Remove master brake cylinder with brake fluid reservoir Chapter.
Release screws -2-.

holders.

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

unit.


System; Rep. gr.27.
On vehicles with radio encoding, carry

out the coding.
Set clock.
Initialise power windows on vehicles
BookletOctavia.


BookletOctavia.

EDL 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
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
8t
t
Piston
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

t
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.

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.

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
t
Brake fluid Chapter
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.
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

insert with both ends into the bores in the brake caliper
9-
Sealing ring
10 t
t
Piston
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

t
Brake fluid Chapter
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.

purpose.
Note
When removing, make sure that the

cylinder surface is not damaged.
Install


-G 052 150 A2-.
Insert new gasket ring in the groove of

the brake caliper.
491


protective cap with a plastic wedge in the
groove of the cylinder.

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
t
Resetting tool -T10165-
t
t
t

Brake fluid Chapter
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.
1t
t
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-
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
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

t
Resetting tool -T10165-
t
t
t

Brake fluid Chapter
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

the left.
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:


-G 052 150 A2-.
Insert new gasket ring in the brake

caliper.


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.

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
Tension spring
16 Nm
Socket nut
8t
Screw
Inspecting and adjusting the brake-power regulator

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.
Bleed brake system, vehicles with or without ABS or ABS/EDL Mark 20 and Mark 60
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.
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.
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.

Mark 20 Chapter.

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
t
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
t
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-
4-
Bleeding sequence for vehicles with Mark 60

1-
2-
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

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.

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

t Brake-power regulator or brake system tester, e. g. -V.A.G 1310- or -V.A.G 1310 At
Brake fluid Chapter
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
one another.
1t
Brake servo unit

check Chapter

508
t
Functional test
Against the direction of the arrow the valve must be closed.
2-
replace
3-
Gasket
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
7-
8-
Sealing ring
replace
9-
Retaining bracket
for fixing the wiring loom -Pos. 16-
10 t
Plugs
11 -
Retaining pin
509
12 t
13 -
replace
14 t
Heat shield
15 t
Brake pressure sender -1--G201in the floating piston circuit
16 17 t
Wiring loom
Brake pressure sender -2--G214in the push rod piston circuit
18 t
Connector
Connection wiring loom dash panel/engine compartment
19 -
Plugs
20 t
t
Vacuum hose
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
re-set clock

Removing
Disconnect battery.

filter.

Lay sufficient non-fluffing cloths around

the plenum chamber, the engine and the
gearbox.

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-
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
order.

System; Rep. gr.27.
Only fill up with new brake fluid after

installing.

Perform basic setting of brake pressure

sender -G202- and -G214- Chapter.
Tightening torques:
Brake pressure sender -1-
25 Nm
Brake pressure sender -2-
25 Nm
Removing and installing the master brake cylinder - LHD vehicles

t
t
t
t

Brake fluid Chapter
Repair set SP.-no. -1 HO 698 311 A512
Note
coding.
set clock,

Removing
Disconnect battery.

filter.


gearbox.

brake fluid reservoir -5-.

clamp -MP 7-602-.

34-

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
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.

installing.

System; Rep. gr.27.

Tightening torque:
Master brake cylinder to brake servo unit
20 Nm
Removing and installing the master brake cylinder - RHD vehicles

t
t
t

Brake fluid Chapter
514
coding.
Removing



clamp -MP 7-602-.

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
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.

installing Chapter.

System; Rep. gr.27.
Note
After reconnecting the battery, a few

additional operations must be carried out


BookletOctavia.

EDL Chapter.
516

Chapter
Removing and installing the brake servo unit - LHD vehicles

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
coding.
After connecting the battery check the vehicle equipment:
set clock,

Removing
Disconnect battery.
517

filter.


gearbox.
Remove hydraulic control unit -1 Chapter.


clamp -MP 7-602-.

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-.

holders.

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

unit Chapter.


System; Rep. gr.27.
Tightening torque:
Brake servo unit to foot controls
28 Nm
Removing and installing the brake servo unit - RHD vehicles

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)
Note
520
coding.
Removing
Remove engine cover Engine, Mechanics; Rep. gr.10.

Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Lay sufficient non-fluffing cloths around the engine.

Remove master brake cylinder with brake fluid reservoir Chapter.
Release screws -2-.

holders.

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-.

unit.



System; Rep. gr.27.
On vehicles with radio encoding, carry

out the coding.
Set clock.
Initialise power windows on vehicles
BookletOctavia.


BookletOctavia.

EDL 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
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
t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 as of model year 2002
t
unit
The brake assistance cannot be repaired, replace the brake servo unit completely when
handling a fault LHD vehicles Chapter, RHD vehicles Chapter

t
check Chapter
t removing and installing LHD vehicles Chapter, RHD vehicles Chapter

t
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
Functional test
2t
3t
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
4t
5t
6t
7-
Plugs
moistened with brake fluid, press in expansion reservoir
Retaining pin
Retaining bracket
524
serves to fix the wiring loom
8-
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
13 t
t
t
14 -
Gasket
always replace
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 master brake cylinder

LHD vehicles Chapter.
RHD vehicles Chapter.

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
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

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.

coding.
set clock,

Removing
Disconnect battery.
Put the wheels in straight-ahead position.
Release screws -2-.

holders.
Remove the airbag on the driver's side

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.
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).

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.

centre position:

-1-.
The markings -arrows- must be flush.

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.
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-.
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-.
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 -arrowsuntil 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.
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-.
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:

-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

Install footwell covering on driver's side

Install steering wheel Body work; Rep.

gr.69.
Install the airbag on the driver's side

WARNING
Nobody should be in the vehicle when the

battery is being connected!

System; Rep. gr.27.
Vehicles without ESP:

Vehicles with ESP:

angle sender Chapter.
Removing and installing the ignition lock housing with the steering column mounted
541
Note
coding.
re-set clock

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

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!

System; Rep. gr.27.
Vehicles without ESP

Vehicles with ESP

angle sender -G85- 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

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
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
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
100 Nm + 90
100 Nm + 90
20 Nm + 90
545
19 -
Pendulum support
20 t
40 Nm + 90
21 t
20 Nm + 90
22 t
20 Nm + 90
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 hydraulic oil reservoir

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
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

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 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.
Slacken the Allan screw of the clamping
ring -2- so far until the universal joint can
be removed from the steering gear
pinion.

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

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.

pinion and tighten with new screw; 30
Nm.
Tighten the Allan screw of the clamping

ring to 17 Nm.
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

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
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

replace
tensioning Anchor
Track rod
Tightening torque on steering rack: 75 Nm
left and right track rod adjustable

7-
8-
Power-steering gear
t
t
t
t
9-
no provision made for repairs

adjust Chapter
Inspecting centre position Anchor
Left track rod end
557
t
t
check Anchor
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

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
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

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
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.

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.

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

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
6-
Hollow screw, 38 Nm
M14 x 1.5
7-
Nut, 23 Nm
8-
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
Assembly carrier
20 Nm + 90
20 Nm + 90
20 Nm + 90
40 Nm + 90
Pendulum support
20 Nm + 90
100 Nm + 90
573
18 t
100 Nm + 90
19 t
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
26 t
Hollow screw, 45 Nm
Sealing sleeve
Pay attention to installation instructions Chapter
28 t
29 -
20 Nm + 90
Steering column universal joint
Removing and installing hydraulic oil reservoir

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
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
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

575
t
t
t

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.
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.

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.

carrier.
Lower assembly carrier.
Unscrew the pressure line -1- (expansion

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
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

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

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.

pinion and tighten with new screw; 30
Nm.
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

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
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

583
check Anchor

2-
Counternut, 50 Nm
3-
replace
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

replace
tensioning Anchor
Track rod
Tightening torque on steering rack: 75 Nm
left and right track rod adjustable

7t
t
t
t
Power-steering gear
no provision made for repairs
adjust Chapter
Inspecting centre position Anchor
8-
9-
Left track rod end

584
t
t
t
check Anchor
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
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
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

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
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-

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
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.
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

t
t
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

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
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-.
Screw the belt pulley to the vane pump

with Allan screws, counterhold with Allan
key (SW 9 mm).
Install V-ribbed belt Engine,

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
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.
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.
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.
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
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-.
603

with Allan screws according to the made
marking, counterhold with Allan key (SW
9 mm).
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.

with Allan screws, counterhold with Allan
key (SW 9 mm).
Install V-ribbed belt Engine,

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

Skoda Octavia Mk1 - 01 - Running Gear

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Skoda Octavia Mk1 - 01 - Running Gear

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SKODA OCTAVIA

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

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

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

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

Nominal values front axle

Overall track -adjustableCamber4)

Max. difference of the caster angles between left and

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

Toe difference angle on turns of 20 of inside wheel

Max. difference between left and right side

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

Values are also valid for Octavia 4x4 vehicles

Rough road suspension

Max. difference between

Example of a vehicle data sticker

Filling weight (g)

Hydraulic oil amount in the system (I)

Vehicles without ABS

Master brake cylinder -

Vehicles without ABS

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

Brake disc, minimum thickness

Rear brake disc -

Brake disc, thickness

Vehicles without ABS

Change brake fluid

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

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

1.9 ltr./66 kW TDI

1.9 Itr./74 kW PDi

1.9 ltr./81 kW TDI

1.9 Itr./96 kW PDi

Tyre inflation pressures BookletOctavia

Load rating-indexes (Load index):

Front suspension, drive shafts

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

track control arm

Removing and installing the track control arm

Special tools and workshop equipment required

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

Slacken twelve-point nut.

Raise vehicle and remove wheel.

Release twelve-point nut.

Insert supporting device -MP 9-200- and

Mark installation position of bolts -1-, otherwise

Release screws -1-.

Push out the drive shaft. To do so position the

While pushing out the drive shaft make sure there

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

Release the screw -1- downwards by slightly

serration of the wheel hub.

with the new screws in the former positions.

track control arm or with the suspension strut.

the outer joint rests in the wheel bearing.

Mechanics; Rep. gr.10.

Attach the wheel.

wheels do not yet touch the ground.

release by 1/2 a turn.

The torque wrench is recommended e.g. for

Special tools and workshop equipment required

Press off front bearing for track control arm

Press in front bearing for track control arm

Fitting position of rear bearing for track control