Volkswagen Polo Mk4 Brake System Technical Manual

Volkswagen Workshop Manuals
Polo Mk4
Running gear
Brake systems
Technical data
>>Technical data <<
Correspondence of PR numbers for the brake
Brake technical data
ABS, AR, TCS, !", !SP
Brake, brake mechanics
Brakes, hydraulics, regulator, ser#o
Running gear, a$les, steering
%heels, rim and tyre specifications
Body
!ngine
&ehicle electrics
Po'er transmission
(eating, #entilation, air conditioning
Clutch and gearbo$
Correspondence of PR numbers for the brake
The brake type installed in the #ehicle is gi#en on the #ehicle ) tag 'ith the respecti#e PR
number*
Brake systems > Technical data > Technical data > Correspondence of PR numbers for the brake > Example of a vehicle identification tag

Example of a vehicle identification
tag
In this example, the following
brake is installed in the vehicle:
t
-Arrow 1- Rear wheel brake (-
1!- "r#m brake$
t
-Arrow %- &ront wheel brake (-
1'(- "isc brake &) III$
*he vehicle I" label is located in
the spare wheel ho#sing and in
the +aintenance and ,arrant-
book.
*he table below shows the /R
n#mber codes and is important to
match brake caliper0disc0dr#m and
brake pads0linings.
t
1orrespondence 2 Electronic
/art 1atalog#e

+ront 'heel brakes
PR number +ront 'heel brake
,"- . ,"A . ,/0 +S )) 1,234
,"5 . ,/+ . ,/5 . ,"6 . ,/7 . ,"R . ,/R +S ))) 1,834
,"0 . ,/( C 98:)) 1,934
Rear 'heel disc brake
PR number Rear 'heel brake
,;; C 2<
,;T C 2<
,;S C 28
Rear 'heel drum brake
PR number Rear 'heel brake
,;B TB =>> ? 8> CR ,@ mm
,;- TB =>> ? 8> CR ,Amm
Brake technical data

Brake cylinder B in mm =>,C8
Brake cylinder B in mm ,A,>9 D 0ote
Ser#o brake B in inches <,9
Brake systems > Technical data > Technical data > Brake technical data > Front wheel brake FS II

&ront wheel brake &)
II

pos
.
/R n#mber 1'+ 0 1'A
(witho#t power
steering$
!rake c-linder 3
mm
14.56 witho#t A!)
)ervo brake 3 in 7,68899
1 !rake caliper &) II (1:;$
% !rake pad,
thickness
mm 1%
: !rake disc 3
mm
%:4
!rake disc,
thickness
mm 17
8 !rake caliper,
pl#nger
3
mm
87

Brake systems > Technical data > Technical data > Brake technical data > Front wheel brake FS III

&ront wheel brake &)
III

pos
.
/R n#mber 1'< 0 1=& 0 1=< 0 1'( 0 1=> 0
1'R 0 1=R
(with power steering$
!rake c-linder 3
mm
%5,?8
1 !rake caliper &) III (18;$
% !rake pad,
thickness
mm 18,1@
: !rake disc 3
mm
%6?
!rake disc,
thickness
mm %%
8 !rake caliper,
pl#nger
3
mm
68

Polo Mk4
Brake systems > Technical data > Technical data > Brake technical data > Front wheel brake C54-FN

&ront wheel brake 168-
&A :

pos
.
/R n#mber 1'A 0 1=B
(with power
steering$
!rake c-linder 3
mm
%5,?8
1 !rake caliper 168-&A: (16;$
% !rake pad,
thickness
mm 1:,?8
: !rake disc 3
mm
%77
!rake disc,
thickness
mm %6
8 !rake caliper,
pl#nger
3
mm
68

Brake systems > Technical data > Technical data > Brake technical data > !ear wheel di"c brake

Rear wheel disc
brake

pos
.
/R n#mber 1 0
1*
!rake c-linder 3
mm
%5,?8
1 !rake disc 3
mm
%:%
!rake disc,
thickness
mm 4
% !rake pad,
thickness
mm 11,8
: !rake caliper,
pl#nger
3
mm
:7
Brake systems > Technical data > Technical data > Brake technical data > !ear wheel dr#m brake witho#t $%S

Rear wheel dr#m brake witho#t
A!)

pos
.
/R n#mber 1! 0
1+
!rake c-linder 3
mm
%5,?8
14,56
1$
1 ,heel brake
c-linder
3
mm
1@,8?
14,56
% !rake shoe,
thickness
mm 6
!rake shoe, width mm :7.7
: !rake dr#m 3
mm
%55
Cnl- for vehicles with 1:D R#nning <ear witho#t
A!)

Brake systems > Technical data > Technical data > Brake technical data > !ear wheel dr#m brake with $%S

Rear wheel dr#m brake with
A!)

pos
.
/R n#mber 1! 0
1+
!rake c-linder 3
mm
%5,?8
1 ,heel brake
c-linder
3
mm
1@,8?
14,56
% !rake shoe,
thickness
mm 6
!rake shoe, width mm :7,7
: !rake dr#m 3
mm
%55

Brake systems > $%S& $'!& (CS& E')& ES* > +eneral information on the antilock braking ","tem -$%S.
<eneral information on the antilock braking s-stem
(A!)$
Brake systems > AB! A"R! TC! #"$! #P > %eneral information on the antilock braking system &AB' > $%S /0 12
A!) +
?5
*he A!) + ?5 s-stem is available in the following
versions:
t
A!
)
t
A!)0E")0A
)R
*he A!) brake s-stem is arranged diagonall-. *he braking power amplification is carried
o#t pne#maticall- thro#gh the vac##m servo brake.
Eehicles with A!) + ?5 do not have a mechanical braking power reg#lator. A special
software installed in the command #nit controls the distrib#tion of braking power to the rear
axle.
&a#lts in the A!) do not affect the brake s-stem and servo brake and the normal brake
s-stem also operates witho#t A!). A difference in the braking behavio#r is to be expected.
After the control lamp for A!) and the control lamp for the brake s-stem light #p, the rear
wheels ma- lock in advance d#ring braking.

A!)
location:
1 -
B-dra#lic #nit and command
#nit (8@ poles$.
% -
)ervo
brake

*he command #nit -1- (8@
poles$ and the h-dra#lic #nit
-%- form one single #nit.
)eparation is onl- possible
with components d#l-
disassembled. It is forbidden
to separate the h-dra#lic p#mp
-:- from the h-dra#lic s-stem
#nit. In the two connector
terminals there are two large
contacts with 8.7 mm of width
for each one.
Remove and install the
command #nit and the
h-dra#lic #nit 2 1hapter .

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > %eneral information on the antilock braking system &AB' > $%S %o"ch 534
A!) !osch
6.@
A!) !osch 6.@ is available in the following
versions:
t
A!
)
t
A!)0E")0A)R0
E)/
In case of complaints, the h-dra#lic #nit and the command #nit m#st be replaced
together.

A!)
location:
1 -
B-dra#lic #nit and command
#nit
% -
)ervo
brake

*he command #nit -1-
and the h-dra#lic #nit
-%- form one single
#nit. )eparation is onl-
possible with
components d#l-
disassembled. *he
h-dra#lic p#mp -8-
m#st not be separated
from the h-dra#lic
s-stem #nit (-:-!rake
press#re sensor 1 -
<%51-$.
Remove and install the
command #nit and the
h-dra#lic #nit
2 1hapter .

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > %eneral information on the antilock braking system &AB' > %o"ch 532 a" of 6ear7/odel 8225
!osch 7.5 as of Fear0+odel
%556
*he A!) !osch 7.5 in this vehicle has the following
config#ration:
t
A!
)
t
A!)0A)
R
t
A!)0E")0A)R0
E)/

A!)
location:
1 -
)ervo
brake
% -
B-dra#lic s-stem #nit and
command device
*he command device -1- and the
h-dra#lic s-stem #nit -%- form one
#nit. In case of damage, replace
both the command device and the
h-dra#lic s-stem together. It is
forbidden to separate the h-dra#lic
p#mp -:- from the h-dra#lic
s-stem #nit.

!osch 7.5 A!) and
A!)0A)R:
1ommand device and h-dra#lic
s-stem #nit 2 1hapter .

!osch 7.5
A!)0E")0A)R0E)/:
1ommand device and h-dra#lic
s-stem #nit 2 1hapter .

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > Information on $%S ","tem repair
Information on A!) s-stem
repair
of the GAssisted fa#lt diagnosis;.
t *he components removed m#st be placed on a clean s#rface and
covered over.
t
If the repair tasks are not carried o#t immediatel-, caref#ll- cover the open components or
place them in a proper location. (Hse the 1B5 ?47 :11 A repair set lid$
t
Hse lint-free
cloths.
t
Cnl- remove the replacement parts from their packages immediatel- before
assembl-.
t
Hse onl- parts in original
packaging.
t
"o not work with compressed air nor move the vehicle with the s-stem
open.
t
+ake s#re that no brake fl#id comes into contact with the
connectors.
t
"#ring painting, the command #nit ma- be momentaril- s#bmitted to a maxim#m
temperat#re of 46 I1, and for longer periods (approximatel- % ho#rs$ with the maxim#m of
76 I1.
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > Connect the 'iagno"i"& /ea"#rement and Information S,"tem 9$S 525:$ 758 and "elect the
f#nction"
1onnect the "iagnosis, +eas#rement and Information )-stem -EA) 6561A 06%-and select
the f#nctions
)pecial tools and workshop eJ#ipment
reJ#ired
t
"iagnosis, meas#rement and information s-stem -EA)
6561-

t
"iagnosis cable -EA) 656101- or
"iagnosis cable -EA) 65610:-
,ARAIA<
t
"#ring the test r#n, the
meas#rement and checking
eJ#ipment m#st be fastened to
the back seat of the vehicle.
t
"#ring the test drive, onl- the
passenger sho#ld operate this
eJ#ipment.

K

Engage the "iagnosis cable
-EA) 656101- or "iagnosis cable
-EA) 65610:- connector in the
diagnosis connector -arrow-.

K

1onnect the "iagnosis,
+eas#rement and Information
)-stem -EA) 6561A06%--arrow-,
and follow the instr#ctions on
the screen:
*he test eJ#ipment will be read-
when it displa-s the image
(pict#re$ of a vehicle.

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > Electrical7electronic component" and in"talling location"
Electrical0electronic components and installing
locations
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #lectrical(electronic components and installing locations > $%S /0 12 -$%S& $%S7E'S7$S!.

A!) + ?5 (A!),
A!)0E")0A)R$
1 -
B-dra#lic A!) #nit
-A66-
*he h-dra#lic #nit comprises the following
components:
J
A!) h-dra#lic p#mp
-E?8-
J
Ealve block (incl#des intake and exha#st
valves$
J
it can be checked with the "iagnosis, +eas#rement and Information )-stem -EA)
6561A06%-
J
*he A!) h-dra#lic p#mp -E?8- and the valve block ma- not be
separated
J remove and install
2 1hapter
% -
A!) control #nit
->158-
J

it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,
+eas#rement and Information )-stem -EA) 6561A06%-
J
do not disconnect the command #nit connector before the self-
diagnosis
J
remove and install
2 1hapter
: -
!rake pedal switch
-&8@-
J
Remove and install
2 1hapter
8 -
!rake pad wear control lamp
-:%-
J
Installation location: on the instr#ment
panel
&#nction:
2 1hapter
6 -
A!) control light
-8@-
J
panel
&#nction:
2 1hapter
? -
!rake s-stem control light -
117-
J
panel
&#nction:
2 1hapter
@ -
A)R control lamp
-7?-
J
panel
&#nction:
2 1hapter
7 -
"iagnosis
connector
J Installation location: 'ining on the driver9s side feet
area
4 -
e- for
A)R
J
Cnl- vehicles with
A!)0E")0A)R
J
panel
15 -
Right rear wheel speed sensor -<88- 0 'eft rear wheel speed
sensor -<8?-
J

+eas#rement and Information )-stem -EA) 6561A 06%-
J
"isc brake
2 1hapter
J
"r#m brake
2 1hapter
11 -
Right front wheel speed sensor -<86-0'eft front wheel speed sensor
-<8@-
J

J
replace
2 1hapter
1% -
,heel h#b0roller bearing
assembl-
J
the A!) sensor ring is assembled in the wheel roller
bearing
1: -
assembl-
J
bearing

"iagnosis
connector

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #lectrical(electronic components and installing locations > $%S %o"ch 534
-$%S7E'S7$S!7ES*.

A!) !osch 6.@
(A!)0E")0A)R0E)/$
1 -
B-dra#lic A!) #nit
-A66-
components:
J
A!) refl#x p#mp
-E:4-
J

+eas#rement and Information )-stem -EA) 6561A 06%- 2 1hapter
J
Ealve block (incl#des intake and exha#st
valves$
J
*he A!) refl#x p#mp -E:4- and the valve block m#st not be separated from
each other
J
remove and install
2 1hapter
% -
A!) control #nit
->158-
J it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,
J
diagnosis
J
remove and install
2 1hapter
: -
!rake press#re sensor 1
-<%51-
J

J
remove and install
2 1hapter
8 -
!rake light switch -&- and !rake pedal switch
-&8@-
J

J
remove and install
2 1hapter
6 -
-:%-
J
panel
&#nction:
2 1hapter
? -
A!) control light
-8@-
J
panel
&#nction:
2 1hapter
@ -
117-
J
panel
&#nction:
2 1hapter
7 -
A)R and E)/ control light
-166 -
J
panel
&#nction:
2 1hapter
4 -
"iagnosis
connector
J
Installation location: 'ining on the driver9s side feet
area
15 -
)teering angle sensor
-<76-
J

J
Installation location: on the steering col#mn, between the steering wheel and the steering
col#mn switch.
J
Cbserve the assembl- g#idelines
2 1hapter
11 -
'ateral acceleration sensor - <%55- and'ateral tilting intensit- sensor
-<%5%-
J

J
packed in a
case
J
Installation location: on the left transverse seat s#pport on the floor
plate
J
Cbserve the assembl-
g#idelines
2 1hapte
r
1% -
E)/
b#tton
J
panel
1: -
-<8@-
J

J
replace
2 1hapter
18 -
sensor -<8?-
J

J replace
2 1hapter
16 -
assembl-
J
bearing
1? -
assembl-
J
bearing

"iagnosis
connector

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #lectrical(electronic components and installing locations > $%S %o"ch 532 -$%S& $%S7$S!.

A!) !osch 7.5 (A!),
A!)0A)R$
1 -
B-dra#lic A!) #nit
-A66-
*he h-dra#lic #nit s-stem comprises the following
components:
J
A!) refl#x p#mp
-E:4-
J

J
valve block (incl#des intake and exha#st
valves$
J
*he A!) refl#x p#mp -E:4- and the valves m#st not be
separated.
J
remove and install
2 1hapter
% -
A!) control #nit
->158-
J
"o not disconnect the command #nit connector before the self-
diagnosis
J
remove and install
2 1hapter
: -
-&8@-
J
remove and install
2 1hapter
8 -
-:%-
J
installation location on instr#ment
panel
&#nction:
2 1hapter
6 -
A!) control light
-8@-
J
installing location: on the instr#ment
panel
&#nction:
2 1hapter
? -
117-
J
panel
&#nction:
2 1hapter
@ -
A)R control lamp
-7?-
J
in vehicles with A!)0A)R
onl-
J
panel
&#nction:
2 1hapter
7 -
"iagnosis
connector
J
installing location: on the foot compartment cover, on the driver9s
side
4 - )witch for A)R
-E1:%-
J
in vehicles with A!)0A)R
onl-
J
panel
15 -
sensor -<8?-
J

J
"isc brakes
2 1hapter
J
"r#m brake
2 1hapter
11 -
-<8@-
J

J
remove and install
2 1hapter
1% -
assembl-
J
bearing
1: -
assembl-
J
bearing
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #lectrical(electronic components and installing locations > $%S %o"ch 532
-$%S7E'S7$S!7ES*.

A!) !osch 7.5
(A!)0E")0A)R0E)/$
1 -
B-dra#lic A!) #nit
-A66-
components:
J
A!) refl#x p#mp
-E:4-
J

J
valve block (incl#des intake and exha#st
valves$
J
*he A!) refl#x p#mp -E:4- and the valves m#st not be
separated
J
remove and install
2 1hapter
% -
A!) control #nit
->158-
J
diagnosis
J
remove and install
2 1hapter
: -
-&8@-
J
remove and install
2 1hapter
8 -
-:%-
J
panel
&#nction:
2 1hapter
6 -
A!) control light
-8@-
J
panel
&#nction:
2 1hapter
? -
117-
J
panel
&#nction:
2 1hapter
@ -
-166 -
J
panel
&#nction:
2 1hapter
7 -
"iagnosis
connector
J
Installation location: 'ining on the driver9s side feet
area
4 -
)teering angle sensor
-<76-
J
Installation location: on the steering col#mn, between the steering wheel and the steering
col#mn switch
J
Cbserve the assembl-
g#idelines
2 1hapte
r
15 -
'ateral acceleration sensor - <%55- and'ateral tilting intensit- sensor
-<%5%-
J

J
packed in a
case
J
Installation location: on the left seat crossmember, on the floor
plate
J
Cbserve assembl-
g#idelines
J
remove and install
2 1hapter
11 -
)witch for the A)R 0 E)/ electronic stabilit- program
-E%6?-
J
panel
1% -
-<8@-
J

J
replace
2 1hapter
1: -
sensor -<8?-
J

J
replace
2 1hapter
18 -
assembl-
J
bearing
16 - ,heel h#b0roller bearing
assembl-
J
bearing

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > Fa#lt indication via control lamp"
&a#lt indication via control
lamps

1ontrol
lamps

pos
.
Aomenclat#re
1 !rake pad wear control lamp
-:%-
% A!) control light -8@-
: !rake s-stem control light
-117-
8 A)R control lamp -7?-
-166-
-:%-

t
If the 1ontrol light for brake pad
wear -:%--1- does not go off
after t#rning the ignition on and
after the inspection is over, or if
it lights #p while the vehicle is
moving, the fa#lt ma- have the
following ca#ses:
-a- the brake pads ma- be
worn.
1heck the front and rear brake
pads.
-b- an activation fail#re in the
1ontrol light for brake pad wear
-:%-. 2 Electrical diagrams,
diagnosis of electrical fa#lts and
installation locations.
A!) control light -
8@-

t
If the A!) control light -8@--%-
does not t#rn off after switching
the ignition on and after finishing
the check, the fa#lt ma- res#lt
from the following probable
ca#ses:
-a- the voltage s#ppl- is below 15
Eolt.
-b- there is a fa#lt in the
A!).
In the case of a fa#lt in the A!)
-b-, the antilock braking s-stem is
t#rned off, while the conventional
brake s-stem remains f#ll-
operational.
-c- there was a temporar- fa#lt in
the speed sensor from the the last
time the vehicle was started.
In case of speed sensor -c-, the
A!) control light -8@- will be
a#tomaticall- t#rned off after
starting the vehicle and at speeds
over %5 km0h.
-d- there is an interr#ption in the
connection between the
instr#ment panel and the A!)
control #nit ->158-. 2 Electrical
diagrams, diagnosis of electrical

fa#lts and installation locations.
A!) control light -8@- and !rake
s-stem control light -117-
t
goes off, b#t the control lamp
!rake s-stem control light
-117--:- remains on, the fa#lt
ma- have the following ca#ses:
-a- the handbrake is
on.
-b- the brake fl#id level is too
low.
-c- there is a fa#lt in the activation
of the !rake s-stem control light
-117- 2 Electrical diagrams,
installation locations.
t
and !rake s-stem control light
-117--:- are t#rned on, this
means that the A!) and E!E
(electronic braking power
distrib#tion$ have failed.
,ARAIA<
,hen the A!) control light - 8@-
and !rake s-stem control light
-117-t#rn on, the rear wheels
ma- block in advance d#ring
braking.
A)R control lamp -
7?-

t
If the A)R control light -7?--8-
does not go off when the ignition
is switched on and after
completing the check, the
ca#ses for the fa#lt ma- be:
-a- short circ#it to positive in the
A)R E%6? b#tton.
-b-A)R control lamp -7?-
activation fail#re. 2 Electrical
diagrams, diagnosis of electrical
fa#lts and installation locations.
-c- the A)R s-stem has been
t#rned off via )witch for the
A)R0E)/ electronic stabilit-
program - E%6?-.
*here is a fa#lt excl#sivel- related
to the A)R safet- s-stem. *he
A!)0E") and E!" vehicle safet-
s-stems remain f#ll- operational.
If the A)R control light -7?-
blinks while the vehicle is moving,
this means the A)R s-stem is in
adL#sting mode.
-166-

t
If the E)/ and A)R control lamp
-166 - for the A)R0E)/
stabiliMation program -8- does
not go off after the ignition is
switched on and after the
inspection ends, the fa#lt ma-
have the following ca#ses:
-a- )hort circ#it to positive in the
A)R0E)/ - E%6? b#tton.
-b- a fa#lt in switching the control
lamp E)/ and A)R control light
-166- 2 Electrical diagrams,
installation locations
-c- the A)R0E)/ s-stem was
t#rned off b- the )witch for the
A)R0E)/ electronic stabilit-
program -E%6?-.
*here is a fa#lt excl#sivel- related
to the A)R0E)/. *he vehicle9s
A!)0E") and E!E safet-

s-stems remain f#ll- operational N
Refer to the fa#lt memor-.
If the E)/ and A)R control light
-166- for the A)R0E)/
stabiliMation program blinks d#ring
the drive, then the A)R or E)/
s-stem is in adL#stment mode.
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > ;,dra#lic #nit& "ervo brake7brake c,linder - a""embl, overview
Hydraulic unit, servo brake/brake cylinder - assembly
overview
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > $%S /0 12
A!) +
?5
*he brake c-linder and the servo brake ma- be independentl-
replaced.
,ARAIA<
Alwa-s replace self-locking n#ts and screws s#bLect to ang#lar
torJ#e

1 -
!rake pipe
connection
J
!rake c-linder0press#re pl#nger loop to the h-dra#lic
#nit
J
Identification in the h-dra#lic #nit
-"-
% -
!rake pipe
connection
J
B-dra#lic #nit for left front brake
caliper
J
-E'-
: -
!rake pipe
connection
J
B-dra#lic #nit for right front brake
caliper
J Identification in the h-dra#lic #nit
-ER-
8 -
!rake pipe
connection
J
!rake c-linder0floating pl#nger loop for the h-dra#lic
#nit
J
-)-
6 -
!rake fl#id
reservoir
? -
/l#
g
@ -
)ealing
pl#g
J
moisten with brake fl#id and press in the brake
c-linder
7 -
)ervo
brake
J
Cn gasoline engines, the vac##m reJ#ired is removed from the intake
manifold.
J
1heck the
operation
J

/ress the brake pedal several times #ntil the end with the engine stopped (*his eliminates
an- remaining vac##m inside the device$.
J

Aow, keep the brake pedal pressed in the braking position with medi#m force and start the
engine. ,hen the servo brake is working properl-, this can be felt with a foot on the brake
pedal (the amplification is active$.
J
in case of fa#lts, replace
completel-
J
1heck valve (in the vac##m hose$
2 1hapter
J
separate from the brake pedal
2 1hapter
J
remove and install
2 1hapter
4 -
)ealin
g
J
to servo
brake
15 -
)elf-locking hex head
n#t
J
replac
e
J
%5
Am
11 -
!rake
c-linder
J
cannot be repaired. In case of fa#lts, replace
completel-.
J
remove and install
2 1hapter
1% -
Retaining pin for the brake fl#id
reservoir
J
insert thro#gh the brake
c-linder
1: -
)ealing
pl#g
J
1onnection for vac##m
hose
18 -
)ealing
ring
J
replac
e
16 -
n#t
J
replac
e
J
%7
Am
1? -
)crew
s
J
7
Am
1@ -
n#t
J
replac
e
J
%5
Am
17 -
)#ppor
t
14 -
)t#
d
J
)t#d welded to the
bod-
%5 -
n#t
J
replac
e
J
%5
Am
%1 -
)#ppor
t
%% -
!rake pipe
connection
J
B-dra#lic #nit for the left rear brake caliper 0 wheel
c-linder
J
-B'-
%: -
!rake pipe
connection
J
B-dra#lic #nit for the right rear brake caliper 0 wheel
c-linder
J
-BR-
%8 -
)t#
d
J
)t#d welded to the
bod-
%6 -
A!) h-dra#lic #nit -A66- with A!) control #nit -
>158-.
J

In the h-dra#lic #nit the A!) h-dra#lic p#mp -E?8- and the intake and exha#st valves are
checked thro#gh self-diagnosis
J
separated
J
remove and
install
J
,hen replacing the h-dra#lic #nit, seal the old part with the pl#gs from the repair set
n#mber E* 1B5 ?47 :11 A
J
Remove and install A!) control #nit ->158-
2 1hapter .

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB M, -. > Connect the
brake pipe" and the brake c,linder pipe" to the h,dra#lic #nit
1onnect the brake pipes and the brake c-linder pipes to the
h-dra#lic #nit

Eehicles with A!) and
A!)0E")0A)R
A -
&loating pl#nger
loop
-
Identification in the h-dra#lic
#nit -)-
! -
/ress#re pl#nger
loop
-
#nit -"-
1 -
B-dra#lic #nit for left front
brake caliper
-
#nit -E'-
% -
B-dra#lic #nit for right front
brake caliper
-
#nit -ER-
: -
B-dra#lic #nit to wheel
c-linder0 right rear brake
caliper
-
#nit -BR-
8 -
B-dra#lic #nit to wheel
c-linder0 left rear brake caliper
-
#nit -B'-

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB M, -. > Command
#nit and h,dra#lic #nit - remove and in"tall

1ommand #nit and h-dra#lic #nit - remove and
install
reJ#ired
t
D*orJ#e wrench - 6 to 65 Am (enc. 10%D$D -EA<
1::1-
t
*orJ#e wrench - 8 to %5Am (enc. :07D$ -EA<
1815 -
t
!rake pedal pressing device -EA<
17?40%-

/l#g repair set 1B5 ?47
:11 A
After disconnecting the command
device from the h-dra#lic #nit,
alwa-s place the valve t#be
transport protection in the
h-dra#lic #nit
B-dra#lic #nits witho#t the
transport protection are not
covered b- warrant-.
1 -
Ealve t#be transport
protection
% -
/l#gs +
15
: -
/l#gs +
1%
Remov
e
Installation
location:
*he command #nit is screwed to
the h-dra#lic s-stem #nit and is
fo#nd in the right side of the
engine compartment.
,ARAIA<
*he brake pipes in the h-dra#lic
#nit area m#st not be bent.
K

Aote the coding in vehicles with
code radio eJ#ipment, reJ#est
s#ch coding if necessar-.
K

"isconnect the batter-
2 Electrical s-stemO Rep. <r.%@ .
: c-linders, inLection
engine:
K

"isconnect the vac##m hoses
from the #pper air filter case
section.

K
Remove the cover b- the points
marked with -arrows-.
8 c-linders, inLection
engine:
K

/#ll the hose from the oil
separator and the check valve
on the #pper air filter case
section.

K
marked with-arrows-.
:-c-linder diesel
engine:
K
/#ll the engine cover #p and
awa- from the fittings.

K
Remove the intake hose
-1-.
8-c-linder diesel engine with
inLector p#mp #nit:
K

K

Remove hose -1- and intake
t#be -%- 2 EngineO Rep. <r.%: .
or:

K

Remove the flexible aspiration
t#be-1- and +otor for intake
manifold valve -E16@--%-
2 EngineO Rep. <r.%: .
8 c-linders, diesel engine with
distrib#tion inLector p#mp:
K

K
Remove the escape gas ret#rn
valve -1-.
1ontin#ation for all
vehicles:

K

Hnlock and disconnect -arrow 1-
the connector from command
#nit -arrow %-.
K
/lace the !rake pedal pressing
device -EA< 17?40%-.
K

/lace the ventilation hose of the
ventilation reservoir over the left
front and left rear brake caliper
pl#gs and open the pl#gs.
K

/ress brake pedal at least ?5
mm with the !rake pedal
pressing device -EA< 17?40%-.
K
1lose the left front and left rear
bleeding pl#gs.
K

"o not remove the !rake pedal
pressing device -EA< 17?40%-
K

/#t an adeJ#ate n#mber of lint-
free cloths #nder the command
#nit and the h-dra#lic #nit.
+ake s#re that no brake fl#id
reaches the contacts.

K

Hnscrew the h-dra#lic #nit pipes
-:- connected to the brake
c-linder.
K
Release the remaining h-dra#lic
#nit brake pipes.
K

1lose the brake pipes and
threaded holes with pl#gs from
the repair set n#mber
1B5 ?47 :11 A.

K

Hnscrew the hexagonal n#ts -1-
from the command #nit0h-dra#lic
#nit.
K
Remove the h-dra#lic #nit with
the command #nit.
Install
t
Cnl- remove the pl#gs from the
new h-dra#lic #nit when the
respective brake pipe is
assembled.
t
If the pl#gs were alread-
removed from the h-dra#lic #nit,
the brake fl#id ma- leak to the
point that proper bleeding and
filling can no longer be ens#red.
,hen Loining the command #nit
with the h-dra#lic #nit, be caref#l
not to bend the h-dra#lic #nit valve
towers with the magnetic coils of
the command #nit.
K

)crew the command #nit to the
h-dra#lic #nit with the new
screws. +ake s#re that the
maxim#m tightening torJ#e is 8
Am.
K
)crew the A!) #nit to the
s#pport.

"o not tighten hexagonal n#ts
completel- -%-. *his makes
screwing each brake pipe -1- to
the h-dra#lic #nit easier.
)eJ#ence of brake pipes in the
h-dra#lic #nit 2 1hapter
K

After screwing the brake pipes,
screw the h-dra#lic #nit.
K

*he rest of the installation
process is carried o#t in reverse
order to removal.
K
Remove the !rake pedal
K
!leed the brake s-stem
2 1hapter
K
1ode A!) control #nit
->158-.
)-stem -EA) 6561A 06%-and
select the f#nction 2 1hapter .
K
1ode the
radio.

*ightening torJ#es:
1ommand #nit in the h-dra#lic #nit max. 6.6
Am
Bexagonal head screw to h-dra#lic #nit on the
s#pport
7 Am
Bexagonal n#t on the bod- %5 Am
!rake pipes in the A!) set:
*hreads + 15 x 1 18 Am
*hreads + 1% x 1 18 Am

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB M, -. > )oo"en the
command #nit from the h,dra#lic #nit
'oosen the command #nit from the h-dra#lic
#nit
K /osition the h-dra#lic #nit and the command #nit down and on a clean and flat
s#rface.
K

'oosen the internal *orx E6
screws -arrows- on the h-dra#lic
#nit.
,ARAIA<
It is forbidden to separate the
h-dra#lic p#mp from the h-dra#lic
s-stem #nit.
K

1aref#ll- separate, #pwards, the
h-dra#lic #nit with the h-dra#lic
p#mp in the separation point -1-
from the command #nit.

,hile p#lling the command #nit,
be caref#l not to bend the
h-dra#lic #nit valve towers with
the magnetic coils of the
command #nit.
1over the command #nit magnetic
coils with a lint-free cloth.
After separating the command #nit
from the h-dra#lic #nit, #se the
transport protection for the valve
towers.
*he tower -%- s#pplied as
replacement part for the command
#nit ma- onl- be connected once
and then separated again.

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB M, -. > In"tall a new
command device
Install a new command
device
,ARAIA<
)trong oscillations (for example, falls and shocks$ ma- damage the command device
irreversabl-. *he command device will be rendered #n#sable.
l
!efore assembling the new command device, it is necessar- to insert the p#mp engine
adapter #p to the stop and fit it. *he adapter g#ide ma- not be damaged
l
*he adapter s#pplied as replacement part ma- be fit onl- onceO after that, it is not possible
to remove it.
l
*he white p#tt- located on the command device base ma- not be
removed
l
*he contact s#rfaces of the adapter, press#re sensor and command device, as well as the
silicone-based gel and sealing elements ma- not be to#ched, soiled or damaged man#all-
or with an- other obLects.
K
Install the adapter #p to the stop, on the respective g#ide and
co#ple it.
K
Install the command device, to the right, in the h-dra#lic command
#nit
K
*ighten the h-dra#lic s-stem #nit and command device with the bolts s#pplied in
the set.
Aote
t
A new command eJ#ipment ma- onl- be assembled two times on the same h-dra#lic #nit.
Ctherwise, the seals will lose their sealing properties
t
A new command device that has alread- been #sed in normal traffic conditions ma- not
be assembled again
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > $%S %o"ch 534
A!) !osch
6.@
replaced.
,ARAIA<
torJ#e

1 -
A!) control #nit
->158-
J
Remove and install
2 1hapter
% -
B-dra#lic A!) #nit
-A66-
J

In the h-dra#lic #nit the A!) h-dra#lic p#mp -E?8- and the intake and exha#st valves are
checked thro#gh self-diagnosis
J
separated
J
n#mber E* 1B5 ?47 :11 A
J
Remove and install
2 1hapter
: -
External
screw
J
:
Am
8 -
-<%51-
J
remove and install
2 1hapter
6 - !rake pipe
connection
J
caliper
J
-E'-
? -
!rake pipe
connection
J
caliper
J
-ER-
@ -
!rake pipe
connection
J
#nit
J
-B=%-
7 -
!rake pipe
connection
J
!rake c-linder0press#re pl#nger loop to the h-dra#lic
#nit
J
-B=1-
4 -
!rake pipe
connection
J
for the left rear brake
caliper
J
-B'-
15 -
!rake pipe
connection
J
for the right rear brake
caliper
J
-BR-
11 -
)ervo
brake
J
manifold.
J Cn diesel engines, a vac##m p#mp is installed to create
vac##m.
J
1heck the
operation
J

J

engine. ,hen the servo brake is working properl-, this can be felt with a foot on the brake
J
In case of fa#lts, replace
completel-
J
1heck valve (in the vac##m hose$
2 1hapter
J
2 1hapter
J
remove and install
2 1hapter
1% -
)ealin
g
J
to servo
brake
1: -
n#t
J
replac
e
J
%7
Am
18 -
)ealing
ring
J
replac
e
16 -
n#t
J
replac
e
J
%5
Am
1? -
!rake
c-linder
J
cannot be repaired. ,here fa#lts occ#r, replace
completel-.
J
remove and install
2 1hapter
1@ -
reservoir
J
c-linder
17 -
)ealing
pl#g
J
c-linder
14 -
)ealing
pl#g
J
1onnection for vac##m
hose
%5 -
!rake fl#id
reservoir
%1 -
/l#
g
%% -
n#t
J
replac
e
J
%5
Am
%: -
)#ppor
t
%8 -
)t#
d
J
)t#d welded to the
bod-
%6 -
)crew
s
J
7
Am
%? -
)#ppor
t
%@ -
)crew
s
J
7
Am
%7 -
n#t
J
replac
e
J
%5
Am
%4 -
)t#
d
J
)t#d welded to the
bod-

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > Connect
the brake pipe" and the brake c,linder pipe" to the h,dra#lic #nit

1onnect the brake pipes and the
brake c-linder pipes to the
h-dra#lic #nit
- Identification in the h-dra#lic
#nit -BR-
8 -
B-dra#lic #nit to left rear brake
caliper
-
#nit -B'-
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > Command
#nit for h,dra#lic #nit - remove and in"tall
1ommand #nit for h-dra#lic #nit - remove and
install
reJ#ired

t
D*orJ#e wrench - 6 to 65 Am
(enc. 10%D$D -EA< 1::1-

t
!rake pedal pressing device
-EA< 17?40%-

:11 A
h-dra#lic #nit
1 -
protection
% -
/l#gs +
15
: -
/l#gs +
1%
Remov
e
Installation
location:
engine compartment.
,ARAIA<
#nit area m#st not be bentP
K

K

engine:
K

section.

K
engine:
K

section.

K
:-c-linder diesel
engine:
K

K
-1-.
inLector p#mp #nit:
K

K

or:

K

K

K
valve -1-.
vehicles:
K

"isengage !rake press#re
sensor 1 -<%51- connector -%-.

K

Hnlock -arrow 1- and disengage
-%- the A!) h-dra#lic #nit -A66-
connector.
K
K
/ress the brake pedal with the
act#ator.
K

/lace the venting hose of the
venting reservoir over the left
front brake caliper pl#g and
open the pl#g.
K
1lose the left front venting
pl#g.
K


K

'oosen and hang the h-dra#lic
#nit brake pipes -1- to the brake
c-linder.
K
#nit brake pipes.
K

1B5 ?47 :11 A.
K

from the command
#nit0h-dra#lic #nit.
K
Remove the h-dra#lic #nit with
the command #nit.
K

Hnscrew the hexagonal n#ts -%-
and -8- and remove the
command #nit0h-dra#lic #nit
s#pport.
Install
t
assembled.
t If the pl#gs were alread-

point that proper venting and
K

Installation is performed in the
reverse seJ#ence of the
removal.
K
2 1hapter
K
->158-.
K
1ode the
radio.
*ightening torJ#es:
1ommand device to h-dra#lic #nit
t
Hse new
screwsP
: Am
*hreads + 15 x 1 18
Am
*hreads + 1% x 1 18
Am
Bexagonal n#t on the bod- %5
Am
s#pport
7 Am

Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > Command
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > !emove
the h,dra#lic #nit command device
Remove the h-dra#lic #nit command
device
h-dra#lic #nit and replace onl- the command device.
t If the h-dra#lic #nit is damaged, replace it along with the
command #nit
A!)0E")0A)R0E)/
!osch 6.@
1 -
1ommand
device
% -
B-dra#lic
#nit
: -
!rake press#re
sensor
8 -
Refl#x
p#mp

K

Remove the external *orx E6
screws -1 to ?- from the
h-dra#lic #nit.
*he *orx screws m#st not be
re#sed.
,ARAIA<
It is forbidden to separate the
refl#x p#mp from the h-dra#lic
#nit.
K

1aref#ll- remove the command
p#lling it #pwards.

,hile removing the command
device, ens#re that the valve
t#bes -1- from the h-dra#lic #nit
-b- are not bent with the
electromagnetic coils -%- of the
command device -a-.
K

1over the command #nit
electromagnetic coils with a lint-
free cloth.
K

1heck the sealing s#rfaces of
the h-dra#lic s-stem #nit for
cleanlinessO if necessar-, clean
with eth-l alcohol #sing a lint-
free cloth.
,hile working on the h-dra#lic
s-stem #nit sealing s#rfaces, do
not #se files, metal scrapers,

sandpapers or similar tools.
If the h-dra#lic #nit sealing s#rface
is damaged (scratches or wear
signs$, replace the brake s-stem
h-dra#lic #nit.
K

1heck the contact springs -1- in
the h-dra#lic #nit (refl#x p#mp$
for an- b#rnt or oxidiMed spots.
Ao grinding or cleaning operations
are permitted on the contact
springs, and the h-dra#lic #nit
m#st be replaced along with the
command device.
K

/rotect the open h-dra#lic
s-stem #nit against damage to
the valve t#bes, and cover the
#nit with a lint-free cloth.

Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > !emove
the h,dra#lic #nit command device
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > In"tall the
command device to the h,dra#lic #nit
Install the command device to the h-dra#lic
#nit

,hile installing the command
device -a- on the h-dra#lic #nit -b-,
ens#re that the valve t#bes -1- are
not bent with the electromagnetic
coils -%-.
K
Install the command device to
the h-dra#lic #nit.
K

/ress the command device on
the h-dra#lic s-stem seating
s#rface #ntil it fits completel-
with the h-dra#lic #nit rib and
remains in this position.
K

Alternatel- tighten the central
screws -1- and -%-, #ntil the
command device is fastened to
the h-dra#lic #nit.

Hse the new *orx screws provided
with the set.
K

Install screws -:- to -?- and
tighten the screws #ntil the
command device is f#ll- seated.
K
*hen, alternatel- tighten the
crews.
K

*ighten the screws in the
seJ#ence from -1- to -?- to :
Am.
*he h-dra#lic #nit threads #sed to
fasten the command device m#st
not be damaged. If the thread is
damaged (tro#ble in tightening the
screws man#all- or screws not
tightened to the specified torJ#e$,
replace the h-dra#lic s-stem #nit.

K

Identif- with a p#nch, in the
traced area -arrow-, each
assembl- of the h-dra#lic #nit
with a command device.
Aote
*he h-dra#lic #nit s#pports onl- 6
assemblies in the command #nit.
After 6 assemblies in the
command #nit, it m#st be
replaced.

Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > In"tall the
command device to the h,dra#lic #nit
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > %rake
pre""#re "en"or : +82:
-<%51-
Remov
e
"epending on engine version, remove the air filter or the engine
cover:

t
: c-linders, inLection engine
2 Anchor
t
8 c-linders, inLection engine
2 Anchor
t
:-c-linder diesel engine
2 Anchor
t
8-c-linder diesel engine with inLector p#mp #nit
2 Anchor
t
8 c-linders, diesel engine with distrib#tion inLector p#mp
2 Anchor
vehicles:
K

"isconnect the connector -:- of
braking press#re sensor -%-.
K

K

"isconnect the brake pipes -1-
from the h-dra#lic #nit.
K

1B5 ?47 :11 A.
K
Remove the braking press#re
sensor.
Install
K

Installation is performed in the
reverse seJ#ence of the
removal.

*ightening torJ#e:
!raking press#re
sensor
%5
Am
K
2 1hapter

Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > %rake
pre""#re "en"or : +82:
Polo Mk4
A!) !osch
7.5
replaced.
,ARAIA<
torJ#e

1 -
A!) control #nit
->158-
J
remove and install the A!) h-dra#lic #nit -A66- with theA!) control #nit ->158 -
2 1hapter .
% -
B-dra#lic A!) #nit
-A66-
J
*heA!) refl#x p#mp -E:4- and the co#pled valves m#st not be
separated.
J
n#mber E* 1B5 ?47 :11 A
J
remove and install the A!) h-dra#lic #nit -A66- with theA!) control #nit ->158 -
2 1hapter .
: -
!rake pipe
connection
J
caliper
J
-ER-
8 -
!rake pipe
connection
J
for the left rear brake
caliper
J
-B'-
6 -
!rake pipe
connection
J
for the right rear brake
caliper
J
-BR-
? -
!rake pipe
connection
J
caliper
J
-E'-
@ -
!rake c-linder
connection
J
#nit
J
-B=1-
7 -
!rake c-linder
connection
J
#nit
J
-B=%--
4 -
)ealin
g
J
to servo
brake
15 -
)ervo
brake
J
manifold.
J
Cn diesel engines, a vac##m p#mp is installed to create
vac##m
J
Cperation
checking:
K
K

engine. ,hen the servo brake is working correctl-, it can be felt with a foot on the brake
J
In case of fa#lts, replace
completel-
J
1heck valve (in the flexible vac##m t#be$
2 1hapter
J
2 1hapter .
J
disassemble and assemble
2 1hapter
11 -
n#t
J
replac
e
J
%7
Am
1% -
)ealing
ring
J
replac
e
1: -
n#t
J
replac
e
J %5
Am
18 -
!rake
c-linder
J
cannot be repaired. ,here fa#lts occ#r, replace
completel-.
J
remove and install
2 1hapter
16 -
reservoir
J
c-linder
1? -
)ealing
pl#g
J
c-linder
1@ -
)ealing
pl#g
J
connection to flexible vac##m
t#be
17 -
!rake fl#id
reservoir
14 -
/l#
g
%5 -
)crew
s
J
7
Am
%1 -
n#t
J
replac
e
J
%5
Am
%% -
)#ppor
t
%: -
)t#
d
J
)t#d welded to the
bod-
%8 - )elf-locking hex head
n#t
J
replac
e
J
%5
Am
%6 -
)t#
d
J
)t#d welded to the
bod-
%? -
)#ppor
t

Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Connect
1onnect the brake pipes and the brake c-linder pipes to the
h-dra#lic #nit

1onnect the brake pipes and the
brake c-linder pipes to the
h-dra#lic #nit:
A -
B-dra#lic #nit to the brake
c-linder press#re pl#nger loop
! -
c-linder floating press#re
pl#nger loop
1 -
brake caliper
: -
caliper
8 -
B-dra#lic #nit to right rear
brake caliper

Cn the h-dra#lic s-stem
#nit:
A -
c-linder press#re pl#nger loop
-
#nit -B=1-
! -
c-linder floating press#re
pl#nger loop
-
#nit -B=%-
1 -
B-dra#lic #nit for right front
brake caliper
-
#nit -ER-
% -
caliper
-
#nit -B'-
: -
B-dra#lic #nit to right rear
brake caliper
-
#nit -BR-
8 -
brake caliper
-
#nit -E'-

Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Connect
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Command
1ommand #nit for h-dra#lic #nit - remove and
install
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
-EA< 17?40%-

:11 A
h-dra#lic #nit.
1 -
protection
% -
/l#gs +
15
: -
/l#gs +
1%
Remov
e
Installation
location:
engine compartment.
,ARAIA<
#nit area m#st not be bent.
K

K

engine:
K

section.

K
engine:
K

section.

K
:-c-linder diesel
engine:
K

K
-1-.
inLector p#mp #nit:
K

K

or:

K

K

K
valve -1-.
1ontin#ed for all
vehiclesO

K
/#sh the connector safet- lock
-arrow- downwards.

K

Release the connector from the
command device -arrow- and
remove b- p#lling it forward.
K
K
/ress the brake pedal with the
act#ator.
K

/lace the bleeding hose of the
bleeding reservoir over the left
front brake caliper pl#g and
open the pl#g.
K
1lose the left front venting
pl#g.
K


K

'oosen and hang the h-dra#lic
#nit brake pipes -:- to the brake
c-linder.
K

1B5 ?47 :11 A.
K
#nit brake pipes.

K

from the command device0
h-dra#lic #nit s#pport.
K

Remove the h-dra#lic #nit along
with the command #nit, p#lling it
#pward.
K
Remove the command device 0
h-dra#lic #nit s#pport.
Install
t
assembled.
t
If the pl#gs were alread-
point that proper venting and
K
Install the A!) #nit on the
s#pport.
K

*he rest of the installation is
processed in the reverse order
from removal.
K
K
2 1hapter .
K
->158-.

K
1ode the
radio.
*ightening torJ#es:
*hreads + 15 x 1 18
Am
*hreads + 1% x 1 18
Am
Bexagonal n#t on the bod- %5
Am
s#pport
7 Am

Brake systems > AB! A"R! TC! #"$! #P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Command
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > $%S ","tem component" on the front and rear axle" - remove and in"tall
A!) s-stem components on the front and rear axles - remove and
install
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > AB system components on the front and rear a3les + remo*e and install > !emove and in"tall
the front axle $%S ","tem component"

Remove and install the front axle A!) s-stem
components
1 -
,heel roller bearing
case
% -
Internal hex head
screw
J
7
Am
: -
A!) speed
sensor
J
is checked thro#gh self-
diagnosis
J

before inserting the sensor, -o# m#st clean the internal hole s#rface and coat with
'#bricating p#tt- -< 555 ?65-. Refer to the 2 1hemicals +an#al
J
remove and install
2 1hapter
8 -
1over
plate
6 - Bexagonal head
screw
J
15
Am
? -
,heel h#b with roller
bearing
J
the A!) sensor ring is assembled in the
wheel h#b
J
remove and install 2 R#nning gear, axle, steeringO Rep.
<r.85
@ -
!rake
disc
7 -
1ross-slotted
screw
J
8
Am

Brake systems > AB! A"R! TC! #"$! #P > AB system components on the front and rear a3les + remo*e and install > !emove and in"tall
the front axle $%S ","tem component"
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > AB system components on the front and rear a3les + remo*e and install > Remo*e and
install the front a3le AB system components > Front axle "peed "en"or - remove and in"tall
&ront axle speed sensor - remove and
install
Remov
e
K
'ift the
vehicle.

K
"isengage the speed sensor
cable connector -%-.
K

Remove the screw -1- from the
wheel roller bearing case.
K

Remove the A!) speed sensor
from the wheel roller bearing
case.
&or easier viewing, the brake disc
is represented as removed.
Install
K

!efore installing the speed
sensor, clean the internal
s#rface of the hole and appl-
'#bricating /#tt- -< 555 ?65 -
aro#nd the sensor. )ee
2 1hemical +aterials +an#al .
K

/lace the speed sensor in the
wheel roller bearing case and
tighten the screw to 7 Am.
K
1onnect the speed sensor with
the speed sensor cable.
K

*#rn the steering wheel
completel- to the left and to the
right and control the space
available for the speed sensor
cable.

install the front a3le AB system components > Front axle "peed "en"or - remove and in"tall
Polo Mk4
install the front a3le AB system components > /0 12 front "peed "en"or cable" - remove and in"tall
+ ?5 front speed sensor cables - remove and
install
reJ#ired

t
,iring harness repair set -EA)
14@7 -
e
K

K

K

Hnlock and disconnect the
command #nit -arrow 1- and p#ll
it -arrow %-.

K

Release the m#ltiple connector
cover cap with a screwdriver
and remove it.

K

Hnlock the secondar- lock
(p#rple$ with a small screwdriver
in the arrow direction.

A!)0E")0A)R0E)/ + ?5,
connector -*8@-
/ino#t for connector -*8@- of
harness0A!) control #nit ->158-.
2 Electrical diagrams, diagnosis
of electrical fa#lts and installation
locations.

K

,ith an extractor from the
Barness repair set - EA) 14@7-,
extract the respective contacts.
K

"isconnect the connector from
the speed sensor cable and the
speed sensor.

K

Also disconnect the connector
-1- on vehicles with the brake
pad wear indicator.
K
"isengage the s#pport cable
-%-.
K

Remove the defective speed
sensor cable and replace with a
new cable.
Install
K

K

&asten the
speed
sensor
cable-
arrows-.

,ARAIA<
Ens#re that
the speed
sensor cable
at point A
passes
behind the
h-dra#lic
brake t#bing,
and the cable
at point !
passes in
front of the
h-dra#lic
brake t#bing.
K

/lace the
brake pad
wear
indicator
connector
on the
s#spension
s#pport.
K

Insert the
contact in
the pl#g.

K

/#sh the individ#al cable
ins#lation to the stop with
Barness repair set -EA) 14@7-.
K

'ock the contacts with the
secondar- lock and place the
m#ltiple connector cover cap.

install the front a3le AB system components > /0 12 front "peed "en"or cable" - remove and in"tall
Polo Mk4
install the front a3le AB system components > %o"ch 534 front "peed "en"or cable" - remove and in"tall
!osch 6.@ front speed sensor cables - remove and
install
reJ#ired

t
Barness repair set -EA)
14@7-
Remov
e
K

Cbserve coding in vehicles
eJ#ipped with code radio. If
necessar-, reJ#est coding.
K


K

Hnlock and disconnect the
command #nit -arrow 1- and p#ll
it -arrow %-.

K

cover cap with a screwdriver
and remove it.

K

Hnlock the secondar- lock
(p#rple$ with a small screwdriver
in the arrow direction.

A!)0E")0A)R0E)/ !osch 6.@
connector -*8%-
/ino#t for connector -*8%- of
harness0A!) control #nit ->158-.
2 Electrical diagrams, diagnosis
of electrical fa#lts and installation
locations

K

Barness repair set -EA) 14@7-,
K

speed sensor.
K

pad wear indicator.
K
-%-.
K

new cable.
Install
K

K

&asten the
speed
sensor
cable-
arrows-.

,ARAIA<
Ens#re that
the speed
sensor cable
at point A
passes
behind the
h-dra#lic
brake t#bing,
and the cable
at point !
passes in
front of the
h-dra#lic
brake t#bing.
K

/lace the
brake pad
wear
indicator
connector
on the
s#spension
s#pport.
K

Insert the
contact in
the pl#g.

K

/#sh the individ#al cable
ins#lation to the stop with
Barness repair set -EA) 14@7-.
K


Polo Mk4
!osch 7.5 front speed sensor cables - remove and
install
reJ#ired

t
14@7 -
Remov
e
K

K


K

Hnlock the command #nit
connector b- p#shing -arrow-.

K

Release the connector from the
command device -arrow- and
remove b- p#lling it forward
K

cover cap with a screwdriver and
remove it.
Role of contacts of :7-pin
connector -*:7-
harness0command #nit A!)
control #nit ->158- 2 Electrical
plans, diagnosis of electrical fa#lts
and installing locations.
K

Barness repair set -EA) 14@7-,
K

"isengage the connector from
own speed sensor.

K

pad wear indicator.
K
-%-.
K

new cable.
Install
K

K
&asten the speed sensor cable-
arrows-.
,hen installing the speed sensor
cable, make s#re the cable is not
twisted in the wheel ho#sing.
K

/lace the brake pad wear
indicator connector on the
s#spension s#pport.
K
Insert the contact in the
pl#g.
K


Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > AB system components on the front and rear a3les + remo*e and install > $%S ","tem
component" on rear axle -vehicle" with dr#m brake". - remove and in"tall
A!) s-stem components on rear axle (vehicles with dr#m brakes$ - remove
and install
,ARAIA<
torJ#e

1 -
Axle
bod-
% -
Internal hex head
screw
J
7
Am
: -
A!) speed
sensor
J
is checked thro#gh self-
diagnosis
J

before installing the sensor, clean the internal s#rface of the hole and appl- '#bricating
/#tt- -< 555 ?65- aro#nd the sensor. Refer to the 2 1hemicals +an#al
J
"r#m brake
2 1hapter
8 -
!rake
t#be
6 - Axle
end
? -
Bandbrake
cable
@ -
Bexagonal head
screw
J
with dish
spring
7 -
1ross-slotted
screw
4 -
!rake
dr#m
J
!rake dr#m diameter, %55
mm
J
,ear limit %51.6
mm
J
!efore removing the brake dr#m, -o# m#st p#ll the brake back
2 1hapter
J
1lean caref#ll- and check for event#al wear, damages, dimensional acc#rac- and
#ndamaged braking s#rface.
15 -
1a
p
J
remove and install 2 R#nning gear, axles, steeringO Rep.
<r.8%.
11 -
)elf-locking grooved
n#t
J
replac
e
1% -
,heel h#b with wheel roller bearing and
rotor
J
alwa-s replace
completel-
J
<r.8%.
1: -
1aliper bod- with brake
shoes
J
before removing the brake dr#m, p#ll the brake back
2 1hapter

http:00workshop-man#als.com0volkswagen0polo-
mk80brakeQs-stems0absQadrQtcsQedlQesp0absQs-stemQcomponentsQonQtheQfrontQandQrear
QaxlesQremoveQandQinstall0absQs-stemQcomponentsQonQrearQaxleQ
R%7vehiclesQwithQdr#mQbrakesR%4QremoveQandQinstall0
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > AB system components on the front and rear a3les + remo*e and install > AB system
components on rear a3le &*ehicles with drum brakes' + remo*e and install > Speed "en"or on rear axle -dr#m brake. - remove and
in"tall
)peed sensor on rear axle (dr#m brake$ - remove and
install
Remov
e
K
'ift the
vehicle.

K

"isconnect the connector -1-
from the speed sensor cable and
also from the speed sensor.
K
Release the screw -%- from the
axle end.
K
"isconnect the speed sensor
from the axle end.
Install
K

'#bricating /#tt- -< 555 ?65 -
aro#nd the sensor. )ee
2 1hemical +aterials +an#al .
K

axle end hole and tighten the
screw to 7 Am.
K
1onnect the speed sensor and
respective cable

components on rear a3le &*ehicles with drum brakes' + remo*e and install > Speed "en"or on rear axle -dr#m brake. - remove and
in"tall
Polo Mk4
components on rear a3le &*ehicles with drum brakes' + remo*e and install > !ear "peed "en"or cable" - remove and in"tall
Rear speed sensor cables - remove and
install
reJ#ired

t
14@7 -
Remov
e
K

Cbserve coding in vehicles
eJ#ipped with code radio. If
necessar-, reJ#est coding.
K

K

speed sensor.
K
Remove the back door sill
lining.
K

+ove the carpet awa- from the
seat area 2 <eneral bod-
repairs, interiorO Rep. <r.@5 .

K

Remove the r#bber bellows -1-
and p#ll the speed sensor cable
-%- inside the internal
compartment.

K

1#t the speed sensor cable
between -arrows--A- and -!-,
#sing the ins#lating pliers from
the Barness repair set -EA)
14@7 -, and remove the
defective section -%- from the
cable.
Install
K
Insert the new speed sensor
cable.

K

)trip 16 mm of the cable tip with
the ins#lating pliers and t#rn the
stripped cable halfwa-.
K

1onnect the speed sensor cable
with the help of a cable fastener
from the Barness repair set -
EA) 14@7-.
K

1onnect the speed sensor to its
corresponding cable connector.

K
&asten the r#bber bellows
-1-.
K
/#t the carpet in the seat area
again.
K

Install the rear door sill lining
2 <eneral bod- repairs,
interiorO Rep. <r.@5 .

components on rear a3le &*ehicles with drum brakes' + remo*e and install > !ear "peed "en"or cable" - remove and in"tall
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > AB system components on the front and rear a3les + remo*e and install > $%S ","tem
component" on rear axle -vehicle" with di"c brake". - remove and in"tall
A!) s-stem components on rear axle (vehicles with disc brakes$ - remove
and install
,ARAIA<
torJ#e

1 -
Axle
bod-
% -
!rake
t#be
: -
Bandbrake
cable
8 -
1ross-slotted
screw
J
8
Am
6 -
!rake
disc
? -
1a
p
J
<r.8%.
@ -
)elf-locking grooved
n#t
J
replac
e
7 -
,heel h#b with wheel roller bearing and
rotor
J
alwa-s replace
completel-
J
<r.8%.
4 -
Bexagonal head
screw
J
with dish
spring
15 -
1over
plate
11 -
Axle
end
1% -
A!) speed
sensor
J

1: -
Internal hex head
screw
J
7
Am
Polo Mk4
components on rear a3le &*ehicles with disc brakes' + remo*e and install > Speed "en"or on rear axle - remove and in"tall
)peed sensor on rear axle - remove and
install
Remov
e
K
'ift the
vehicle.
K

"isengage connector -1- from
the speed sensor cable and from
the own speed sensor.
K
Release the screw -%- from the
axle end.
K
"isconnect the speed sensor
from the axle end.
Install
K

'#bricating /#tt- -< 555 ?65-
aro#nd the sensor. Refer to the
2 1hemicals +an#al
K

axle end hole and tighten the
screw to 7 Am.
K

components on rear a3le &*ehicles with disc brakes' + remo*e and install > Speed "en"or on rear axle - remove and in"tall
Polo Mk4
components on rear a3le &*ehicles with disc brakes' + remo*e and install > !ear "peed "en"or cable" - remove and in"tall
Rear speed sensor cables - remove and
install
reJ#ired

t
14@7 -
Remov
e
K

K

K

speed sensor.
K
Remove the back door sill
lining.
K

+ove the carpet awa- from the
seat area 2 <eneral bod-
repairs, interiorO Rep. <r.@5 .

K

Remove the r#bber bellows -1-
and p#ll the speed sensor cable
-%- inside the internal
compartment.

K

1#t the speed sensor cable
between -arrows--A- and -!-,
#sing the ins#lating pliers from
the Barness repair set -EA)
14@7 -, and remove the
defective section -%- from the
cable.
Install
K
Insert the new speed sensor
cable.

K

)trip 16 mm of the cable tip with
the ins#lating pliers and t#rn the
stripped cable halfwa-.
K

1onnect the speed sensor cable
with the help of a cable fastener
from the Barness repair set -
EA) 14@7-.
K

1onnect the speed sensor to its
corresponding cable connector.

K
&asten the r#bber bellows
-1-.
K
/#t the carpet in the seat area
again.
K

Install the rear door sill lining
2 <eneral bod- repairs,
interiorO Rep. <r.@5 .

components on rear a3le &*ehicles with disc brakes' + remo*e and install > !ear "peed "en"or cable" - remove and in"tall
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > ES* ","tem component" - a""emble and di"a""emble
E)/ s-stem components - assemble and
disassemble
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #P system components + assemble and disassemble > Steering angle "en"or +55 - remove and
in"tall
)teering angle sensor - <76- - remove and
install
*he steering angle sensor is installed between the steering wheel and the steering col#mn
switch.
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #P system components + assemble and disassemble > teering angle sensor %2/ + remo*e
and install > !emove
Remov
e
K
/osition the wheels in a straight
angle.
K
Remove the Airbag #nit, if fitted, and the steering wheel. 2 1hassis, axles,
steeringO Rep. <r.87 .
K
Remove the )teering angle sensor -<76- on the central
position.
Polo Mk4
Brake systems > AB! A"R! TC! #"$! #P > #P system components + assemble and disassemble > teering angle sensor %2/ + remo*e
and install > In"tall
Install
K
Install the )teering angle sensor -<76-, and carr- o#t the basic
adL#stment.
K
1arr- o#t basic adL#stment with the "iagnosis, +eas#rement and Information )-stem
-EA) 6561A 06%- in the f#nction GAssisted tro#bleshooting;.
K
1onnect the "iagnosis, +eas#rement and Information )-stem -EA) 6561A 06%-, and
advance #ntil the G&#nction0component selection; is displa-ed.
K
Install the Airbag #nit, if fitted, and the steering wheel. 2 1hassis, axles,
steeringO Rep. <r.87 .
Polo Mk4
Brake systems > %rake& brake mechanic" > Front wheel brake - repair
&ront wheel brake -
repair
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > !epair front brake"& FS II di"c brake c,linder
Repair front brakes, &) II disc brake
c-linder
Aote
t After replacing the brake pads, press the brake pedal repeatedl- for proper pad

seating
t
*o aspirate the brake fl#id from the brake fl#id reservoir, #se the !rake filling and
bleeding eJ#ipment -EA) 6%:8- or !rake filling and bleeding eJ#ipment -E.A.< 17?4-.
t
!efore removing the brake caliper or a brake caliper hose, -o# m#st place the !rake
pedal pressing device -EA< 17?40%-.
1 -
!rake
disc
J
!rake disc thickness: 17
mm
J
,ear limit: 1?
mm
J
alwa-s replace the pads from the same
axle
J
to remove, first release the brake
caliper
J

"o not remove the brake discs from the wheel h#b with with excessive force, #se a r#st
remover if necessar-, otherwise the discs ma- be damaged.
J
+axim#m disc beating 5.5:
mm
J
+axim#m disc S roller bearing beating 5.1%8
mm
on brake discs with vis#al check s-stem, refer to
2 1hapter
% -
)cre
w
J
8
Am
: -
!rake
pads
J
with wear
indication
J
when the corresponding wear is reached (limit: % to : mm$, a control lamp t#rns on in the
instr#ment panel
J
*hickness 1% mm, the pad with largest packing area is installed on the
o#tside
J
,ear limit: @ mm with the rear
plate
J
1heck thickness
2 !ooklet
J
alwa-s replace from the same
axle
J
remove and install
2 1hapter
8 -
!rake
caliper
J
repair
2 1hapter
J
remove and install
2 1hapter
6 -
'ower
sleeve
? -
'ower
b#shing
@ -
'ower spacer
sleeve
7 -
'ower internal hex head
screw
J
%6
Am
4 - Air d#ct
15 -
Bexagonal head
screw
J
15
Am
11 -
'ower internal hex head
screw
J
%6
Am
1% -
Hpper spacer
sleeve
1: -
Hpper
b#shing
18 -
Hpper
sleeve
16 -
&astening
sleeve
1? -
!rake hose with ann#lar noMMle and hollow
screw
J
:6
Am
1@ -
,heel
h#b
J
<r.85
17 -
Bexagonal head
screw
J
15
Am
14 -
1over
plate
%5 -
case
%1 -
A!) speed
sensor
J before installing the sensor, clean the internal s#rface of the hole and appl- '#bricating
%% -
Internal hex head
screw
J
7
Am
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > %rake pad"& FS II brake caliper - remove and in"tall
!rake pads, &) II brake caliper - remove and
install
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
/l#nger spacer -*
15186-

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > %rake pad"& FS II brake caliper - remove and in"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 55 brake caliper + remo*e and install > !emove
Remov
e
K
Remove the
wheels.

K

&or vehicles with brake pad
wear indicator, disconnect the
connector -1-.
K
Remove the cover
caps.

K

'oosen the two screws -arrows-
of the brake caliper and remove
them.
K

Remove the brake c-linder and
fasten it with wire so that the
brake caliper weight does not
stress and damage the brake
flexible t#be.
K
Remove the brake
pads.
&or cleaning the brake c-linder
-o# m#st onl- #se alcohol.

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 55 brake caliper + remo*e and install > !emove
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 55 brake caliper + remo*e and install > In"tall
Install
!efore installing new brake pads, press the pl#ngers in the c-linder with the refitter device.

!efore pressing the pl#ngers, collect the reservoir brake fl#id in a container. Ctherwise, if
brake fl#id recirc#lates d#ring this interval it ma- leak and ca#se damage.
K
Reposition the
pl#ngers.
K
Install the brake
pads.

K
*he larger brake pad is installed
on the o#tside.

K

Assemble the brake c-linder
with the pads in the wheel roller
bearing case.
K
&irst, place the brake c-linder
#nderneath -arrow-.
K

*he brake c-linder pin m#st be
behind the wheel roller bearing
case g#ide.
K

Install the screw on the wheel
roller bearing case and tighten
to %6 Am 2 Item .
K
1o#ple the brake pad wear
indicator connector.
K
Install the
wheels.

*ightening torJ#es 2 R#nning
gear, axles, steeringO Rep. <r.88 .
Aote
t
After replacing each brake pad,
press the brake pedal
repeatedl- and strongl- with the
vehicle stopped so that the
brake pads are perfectl- seated
for operation.
t
After replacing the brake pads,
check the brake fl#id level.
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 55 brake caliper + remo*e and install > In"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > FS II brake caliper - remove and in"tall
&) II brake caliper - remove and
install
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
-EA< 17?40%-

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > FS II brake caliper - remove and in"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > 4 55 brake caliper + remo*e and install > !emove
Remov
e
*he following seJ#ence is related onl- to brake caliper replacement or
repair tasks
Remove the
wheels.
"isconnect the brake pad wear
connector.
Insert a flexible t#be in the caliper bleeder valve, and then
open it.
Install the !rake pedal pressing device -EA<
17?40%-.
1lose the bleeder valve and remove the bleeder
container.
Remove the brake flexible
t#be.
Remove the brake caliper g#ide
pins.
Remove the caliper from the brake
s#pport.
Remove the brake pads from the brake
caliper.
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > 4 55 brake caliper + remo*e and install > In"tall
Install
l
Retracted
pl#nger
K
Install the pads on the caliper c#p and
pl#nger.

/ads with larger dimensions are
seated on the o#tside.
K

Assemble the brake caliper with
the pads in the wheel roller
bearing case.

K

)tart placing the caliper
#nderneath -arrow- close to the
brake s#pport.
K

*he brake caliper tear m#st be
positioned behind the brake
s#pport g#ide.
K
)crew the flexible t#be on the
brake caliper.
K
act#ator -E.A.< 17?40% -.
K
Engage the brake pad wear
K
!leed the brake
s-stem.
Install the
wheels.
gear, Axles, )teeringO Rep. <r.88 .

Aote
t
Repeatedl- and strongl- press
the brake pedal so that the pads
seat properl- according to their
normal operational condition
t
1heck the brake oil
level
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Front wheel brake - FS II brake caliper - repair
&ront wheel brake - &) II brake caliper -
repair
Aote
t
After replacing the brake pads, press the brake pedal repeatedl- for proper pad
seating
t
*o aspirate the brake fl#id from the brake fl#id reservoir, #se the !rake filling and
t

1 -
!rake
disc
J
vented, 3 %6?
mm
J
*hickness: %%
mm
J
,ear limit: 14
mm
J
alwa-s replace the pads from the same
axle
J
caliper
J

J
mm
J +axim#m disc S roller bearing beating 5.1:1
mm
2 1hapter
% -
)cre
w
J
8
Am
: -
!rake
pads
J
with wear
indication
J
when the corresponding wear is reached (limit: approx. 8 mm$ a control lamp is t#rned on
in the instr#ment panel
J
*hickness 18
mm
J
,ear limit: @ mm with the rear
plate
J
1heck thickness
2 !ooklet
J
axle
J
remove and install
2 1hapter
8 -
!rake
caliper
J
for brake pad replacement, do not remove the brake flexible
t#be
J
repair
2 1hapter
J
remove and install
2 1hapter
6 -
<#ide
pin
J
:5
Am
? -
1over
cap
J
remov
e
@ - &astening
sleeve
7 -
screw
J
:6
Am
4 -
,heel
h#b
J
extract and press 2 R#nning gear, axles, steeringO Rep.
<r.85
15 -
Bexagonal head
screw
J
15
Am
11 -
1over
plate
1% -
case
1: -
A!) speed
sensor
J

18 -
Internal hex head
screw
J
7
Am
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > %rake pad"& FS III di"c brake c,linder - remove and in"tall
!rake pads, &) III disc brake c-linder - remove and
install
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
/l#nger spacer -*
15186-

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > %rake pad"& FS III di"c brake c,linder - remove and in"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 555 disc brake cylinder + remo*e and install >
!emove
Remov
e
K
Remove the
wheels.

K

&or vehicles with brake pad
wear indicator, disconnect the
connector -1-.
K
Remove the cover
caps.

K

'oosen the two g#ide pins
-arrows- from the brake caliper
and remove them.
K

Remove the brake c-linder and
fasten it with wire so that the
brake caliper weight does not
stress and damage the brake
flexible t#be.
K
Remove the pads from the
brake c-linder.
&or cleaning the brake caliper
case, #se alcohol onl-.

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 555 disc brake cylinder + remo*e and install >
!emove
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 555 disc brake cylinder + remo*e and install > In"tall
Install

K
/ress the pl#ngers
back.
K
/lace the pads in the brake
caliper case

K

Assemble the brake caliper case
with the pads in the wheel roller
bearing case.
K
&irst place the brake c-linder
#nderneath -arrow-
K

*he brake c-linder pin m#st be
behind the wheel roller bearing
case g#ide.
K

*ighten the brake caliper case
with two g#ide pins on the brake
s#pport to :5 Am 2 Item .
K
1o#ple the brake pad wear
K
Install the
wheels.
t
After replacing each brake pad,
press the brake pedal repeatedl-
and strongl- with the vehicle
stopped so that the brake pads
are perfectl- seated for
operation.
t

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Brake pads! 4 555 disc brake cylinder + remo*e and install > In"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > FS III brake caliper - remove and in"tall
&) III brake caliper - remove and
install
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
-EA< 17?40%-

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > FS III brake caliper - remove and in"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > 4 555 brake caliper + remo*e and install > !emove
Remov
e
repair tasks
Remove the
wheels.
connector.
open it.
Install the !rake pedal pressing device -EA<
17?40%-.
container.
t#be.
Remove the two cover caps from the brake caliper fastening
sleeves.
Remove the brake caliper g#ide
pins.
s#pport.
Remove the brake pads from the brake
caliper.
Polo Mk4
Install
l
Retracted
pl#nger
K
Install the pads in the caliper
bod-.
K
Assemble the brake caliper with the pads in the wheel roller bearing
case.

K

)tart placing the caliper
#nderneath -arrow- close to the
brake s#pport.
K

*he brake caliper tear m#st be
positioned behind the brake
s#pport g#ide.
K
Assemble the two protection
covers.
K
)crew the flexible t#be on the
brake caliper.
K
K
Engage the brake pad wear
K
!leed the brake
s-stem.
Install the
wheels.
Aote
t
Repeatedl- and strongl- press
the brake pedal so that the pads
seat properl- according to their
normal operational condition
t
1heck the brake oil
level

Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Front wheel brake - C 54-ll brake caliper - repair
&ront wheel brake - 1 68-ll brake caliper -
repair
Aote
t
After replacing the brake pads, press the brake pedal repeatedl- for proper pad
seating
t *o aspirate the brake fl#id from the brake fl#id reservoir, #se the !rake filling and

t
1 -
!rake
disc
J
vented, 3 %77
mm
J
*hickness %6
mm
J
,ear limit: %%
mm
J
axle
J
caliper
J

J
mm
J
+axim#m disc S roller bearing beating 5.188
mm
2 1hapter
% -
)cre
w
J
8
Am
: -
/late for pad
s#pport
8 -
!rake
pads
J
with wear
indication
J
when the corresponding wear is reached (limit: approx. 8 mm$ a control lamp is t#rned on
in the instr#ment panel
J
*hickness 1:
mm
J
,ear limit: % mm witho#t the rear
plate
J
1heck thickness
2 !ooklet
J
axle
J
remove and install
2 1hapter
6 -
!rake
s#pport
J
&asten to wheel roller bearing
case
J
it is s#pplied as replacement part containing l#bricating
p#tt-
J
in case of damages to the protection covers or g#ide pins, assemble the
repair set
? -
/rotection
cover
@ -
<#ide
pin
7 -
*hermal protection
plate
4 -
!rake
caliper
J
for brake pad replacement, do not remove the brake flexible
t#be
J
repair
2 1hapter
J
remove and install
2 1hapter
15 -
<#ide
pin
J
:5
Am
11 -
&astening
sleeve
1% -
screw
J
:6
Am
1: -
)cre
w
J
1lean in case of
re#se
J
1%6
Am
18 -
Internal hex head
screw
J
7
Am
16 -
A!) speed
sensor
J

1? -
case
1@ -
1over
plate
17 -
Bexagonal head
screw
J
15
Am
14 -
,heel
h#b
J
extract and press 2 R#nning gear, axles, steeringO Rep.
<r.85
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > !emove and in"tall brake pad"& C 54-ll di"c brake c,linder
Remove and install brake pads, 1 68-ll disc brake
c-linder
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
/l#nger spacer -*
15186-

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > !emove and in"tall brake pad"& C 54-ll di"c brake c,linder
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Remo*e and install brake pads! C /6+ll disc brake cylinder >
!emove
Remov
e
"#ring removal, identif- the brake pads that will be re#sed. Install the same pads on the
same placeO otherwise, brake behavio#r will be irreg#lar
K
Remove the
wheels

K

&or vehicles with brake wear
indicator, disconnect the
connector -1-.

K
Remove bolts
-arrows-
K

Remove brake caliper and
fasten it correctl- with a wire not
to damage the flexible t#be

K
Remove the protection plate
-%-
-1-.
K

/#ll the o#ter brake pad -8-
towards -arrow A- direction from
the s#pport and remove it in
-arrow !- direction.
K
Remove protection plate -:- and
-6- from s#pport.
K

1lean seating s#rface of the pad
s#pport plate on brake s#pport.
&or cleaning the brake caliper
case, #se alcohol onl-.
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Remo*e and install brake pads! C /6+ll disc brake cylinder > In"tall
Install

K
/ress the pl#ngers
back.
K
Install the new thermal
protection plate.
*he thermal protection plate edge
m#st seat with brake caliper
opening.
K
Install pad s#pport plates on
brake s#pport.
K
Assemble brake pads on the
s#pport.
K
Install brake caliper on the
brake s#pport.
K
1o#ple the connector for the
brake pad wear sensor.
K
Install the
wheels.
t After replacing each brake pad,
press the brake pedal
repeatedl- and strongl- with the
vehicle stopped so that the
brake pads are perfectl- seated

for operation.
t
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > Remo*e and install brake pads! C /6+ll disc brake cylinder > In"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > C 54 II brake caliper - remove and in"tall
1 68 II brake caliper - remove and
install
reJ#ired

t
(enc. 10%D$D -EA< 1::1-

t
!rake pedal act#ator -E.A.<
17?40%-

Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > C 54 II brake caliper - remove and in"tall
Polo Mk4
Brake systems > Brake! brake mechanics > 4ront wheel brake + repair > C /6 55 brake caliper + remo*e and install > !emove
Remov
e
repair tasks
Remove the
wheels.
connector.
open it.
Install the !rake pedal act#ator -E.A.<
17?40% -.
container.
t#be.
Remove the hexagonal head
screws.
s#pport.
http:00workshop-man#als.com0volkswagen0polo-
mk80brakeQs-stems0brakeQbrakeQmechanics0frontQwheelQbrakeQrepair0cQ68QiiQbrakeQcalip
erQremoveQandQinstall0remove0

Volkswagen Polo Mk4 Brake System Technical Manual

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Volkswagen Polo Mk4 Brake System Technical Manual

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